Hali-Brite L-801H Manual

Installation and Maintenance Manual
Hali-Brite®
L-801H(L) LED Heliport Rotating Beacon
Copyright © 2020 Hali-Brite®Inc., Brainerd, MN, U.S.A. Printed in U.S.A. Rev 1

2Hali-Brite® L-801H(L) Installation and Maintenance Manual
Table of Contents
1Introduction................................................................................................................. 3
1.1 About this Manual............................................................................................... 3
1.2 Model Configurations......................................................................................... 3
1.3 Warranty ............................................................................................................. 3
1.4 Disclaimers ......................................................................................................... 4
2Safety Precautions....................................................................................................... 5
2.1 Safety Statements................................................................................................ 5
2.2 General Practices ................................................................................................ 5
2.3 Electrical Practices.............................................................................................. 6
2.4 Qualified Personnel............................................................................................. 7
2.5 Proper Usage....................................................................................................... 7
3Specifications.............................................................................................................. 8
3.1 Electrical and Optical Specifications.................................................................. 8
3.2 Physical Specifications ....................................................................................... 8
3.3 Environmental Specifications............................................................................. 8
4Installation................................................................................................................... 9
4.1 Unpacking........................................................................................................... 9
4.2 Tools and Supplies Needed................................................................................. 9
4.3 Installation........................................................................................................... 9
5Maintenance.............................................................................................................. 12
5.1 Maintenance Schedule ...................................................................................... 12
5.2 Maintenance Procedures................................................................................... 12
6Repair........................................................................................................................ 14
6.1 Timing Belt....................................................................................................... 14
6.4 Mercotac rotary electrical connector ................................................................ 14
6.5 Lamp Power Supply.......................................................................................... 15
6.6 Motor and Gearhead ......................................................................................... 15
7Troubleshooting Chart, Replacement Parts and Wiring Diagrams........................... 17

Hali-Brite® L-801H(L) Installation and Maintenance Manual 3
1Introduction
1.1 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 L801A(L)
Airport Rotating Beacon. This manual also includes installation and maintenance
instructions for all equipment sold as options to the basic unit.
1.2 Model Configurations
L801HL116: 120 VAC, 60 Hz, Class I (-30C to +55C)
L801HL125: 220-240 VAC, 50 Hz, Class I (-30C to +55C)
L801HL126: 220-240 VAC, 60 Hz, Class I (-30C to +55C)
L801HL216: 120 VAC, 60 Hz, Class II (-55C to +55C)
L801HL225: 220-240 VAC, 50 Hz, Class II (-55C to +55C)
L801HL226: 220-240 VAC, 60 Hz, Class II (-55C to +55C)
1.3 Warranty
Hali-Brite®products are guaranteed against mechanical, electrical, and physical
defects for a period of one year (four years for LED lamps) 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. 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, 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

4Hali-Brite® L-801H(L) Installation and Maintenance Manual
than those made expressly herein. All such warranties being expressly
disclaimed. Details and values given in this manual are average values and have
been compiled 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
information 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 buyers
from making their own experiments and tests.
1.4 Disclaimers
This manual is published for informational purposes only and the information
provided should not be considered as all-inclusive or covering all contingencies.
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 particular
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, indirect
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.

Hali-Brite® L-801H(L) Installation and Maintenance Manual 5
2Safety 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 performing
any procedure. Failure to do so may result in personal injury, property damage, or
possible death.
2.1 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 that could result in minor
personal injury, product, or property damage.
WARNING: Indicates hazards or unsafe practices that could result in severe
personal injury or death.
DANGER: Indicates immediate hazards that will result in severe personal
injury or death.
2.2 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 installation
and maintenance.
• Use proper hand and eye protection as needed when installing or maintaining
this equipment.
• Make sure you have adequate first aid supplies available when installing this
equipment.

6Hali-Brite® L-801H(L) Installation and Maintenance Manual
• Do not modify this equipment as this could create a safety hazard and void your
Hali-Brite®warranty.
• Use only 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 equipment is rated and approved for the 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.
2.3 Electrical Practices
• Do not attempt to make electrical connections with the power on.
•Disconnect and lock out electrical power before touching any electrical
connections.
• 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 moving equipment will
not damage it.
• Protect equipment with safety devices as specified by applicable safety
regulations.
• 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.

Hali-Brite® L-801H(L) Installation and Maintenance Manual 7
2.4 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®equipment
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.
2.5 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 make any modifications that have 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
nonstandard, 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.

8Hali-Brite® L-801H(L) Installation and Maintenance Manual
3Specifications
3.1 Electrical and Optical Specifications
FAA Type ......................................................L-801H(L)
Input Voltage..................................................120 or 220-240VAC, +/-10%, 50/60
Hz
Power Consumption.......................................116W (Class I), 516W (Class II)
Lamps...........................................................One white, one green, one amber
Rated Average Lamp Life ...................50,000 hours
Beam Intensity ....................................12,500 min. effective candelas from
+1° to +2° vertical and from +8° to +10° vertical, 25,000 min. effective
candelas from +3° to +7
Rotation Speed ..............................................12 RPM (Produces 36 flashes per
minute)
3.2 Physical Specifications
Dimensions ....................................................Height: 28.25 inches (717.55 mm)
........................................................................Width: 18.25 inches (463.55 mm)
Mounting Dimensions.....................................Four ½ inch (12.7 mm) holes in a
rectangular pattern: (4"x 16") (101.6 x 406.4 mm)
Product Weight...............................................75 lb. (34 kg)
Shipping Weight ............................................118 lb. (53.52 kg)
3.3 Environmental Specifications
Operating Temperature (Class I) ...................-30C (-22F) to +55C (+131F)
Operating Temperature (Class I) ...................-55C (-67F) to +55C (+131F)
Heater (Class II only) .....................................400W (heating element)
Turns On .............................................Below 0°C (+32°F)
Humidity .........................................................0% to 100%
Altitude ...........................................................Sea level to 10,000 feet (3000 m)
Wind................................................................Velocities to 100 mph (161 km/h)

Hali-Brite® L-801H(L) Installation and Maintenance Manual 9
4Installation
WARNING: Allow only qualified personnel to perform the following tasks.
Observe and follow the safety instructions in this document and all other
related documentation.
4.1 Unpacking
Handle equipment very carefully to prevent component damage. Note any exterior
damage to the carton/crate that might lead to detection of equipment damage.
Open the top of the carton/crate. Remove foam packing from the top of the box.
Carefully lift the unit out of the box.
CAUTION: Do not lift the unit by the head. Failure to observe this warning
may result in equipment damage.
Unpack the carton/crate upon receipt and check the contents and their condition.
If you note any damage to any equipment, file a claim with the carrier
immediately. The carrier may need to inspect the equipment.
4.2 Tools and Supplies Needed
Equipment Required But Not Supplied
Wrenches
Set of Screwdrivers
Set of Pliers
Voltmeter
Insulation Tester
Level
Lightning Rod
Ground Wire (for lightning rod)
Liquid Glass Cleaner
S0-3 Cable, AWG 12, liquid-tight conduit and connectors
4.3 Installation
The HBM 150/2 rotating beacon comes completely assembled except for
installation of a customer-supplied AWG 12, S0-3 power cord.
4.3.1 Mounting
Open the front door on the cabinet. Inspect the interior to make sure all parts are
tight and have not been loosened in shipment. Close the door and tighten the
latches.

10 Hali-Brite® L-801H(L) Installation and Maintenance Manual
Determine the beacon mounting location, and drill four ½” holes in the platform,
spaced as shown in Figure 1.
Figure 1
If the surface is not level, spacers or shims will be needed. Place a level on top of
the weather cap and use shims as necessary under the four corners to bring the
beacon to level. Install and tighten the mounting bolts, four each #1/2-13 bolts,
length as required.
4.3.2 Wiring
See Figure 2 to locate the power connection point. The power cord enters the
beacon chassis through the hole in the base, and attaches to the white terminal
block in the lower right corner.
Figure 2
Power
Terminal
Block

Hali-Brite® L-801H(L) Installation and Maintenance Manual 11
To install power cord, perform the following procedure:
1. Unscrew the two door latches and open the chassis door.
2. Route the cable through the hole in the bottom of the chassis. Install a ½”
liquid-tight conduit fitting in the chassis hole.
3. Connect the power cord at the terminal strip as follows: Attach the black
wire (120 VAC) to the terminal marked , the white wire (neutral) to the
terminal marked N, and the green wire (ground) to the terminal marked G.
4.3.3 Optional Heater Wiring
The optional heater assembly consists of a 400-watt heating element and
thermostat. The heater assembly should be connected through a power cord to a
separate circuit breaker, so that it may remain operable when the beacon is
turned off. The circuit breaker should be switched off during the summer months.
When the temperature drops below +32°F (0°C), the thermostat activates the
heater, which is attached to the motor gearbox. The gearbox lubricant is warmed
and this facilitates rotation of the beacon when it is energized.
The power connections for the heater are located on the same terminal block as
the main beacon power connections. Attach the black wire (120 VAC) to the
terminal marked C, the white wire (neutral) to the terminal marked N, and the
green wire (ground) to the terminal marked G.
4.3.4 Beam Angle Adjustment
All beacons are shipped from the factory preset at an elevation angle of 5
degrees, per FAA requirements. To adjust to a different angle, refer to Section
5.2.2.

12 Hali-Brite® L-801H(L) Installation and Maintenance Manual
5Maintenance
5.1 Maintenance Schedule
Interval Task
Daily Inspect for lamp failure and proper rotation.
Bi-monthly Inspect cleanliness of glass. Clean as necessary.
Annually Inspect all electrical connections.
Replace beacon lamps at 50,000 hours.
5.2 Maintenance Procedures
5.2.1 Lamp Replacement
1. Disconnect and lock out power to the beacon.
2. Remove the four ¼ - 20 bolts that mount the lamp to the rain cap.
3. Locate the electrical hub in the center of the rain cap.
4. Remove ½” conduit cover and gasket.
5. Remove the appropriate wire nuts.
6. Remove the cord strain relief from the electrical hub.
7. The lamp now is free to be removed.
8. Repeat above steps in reverse order to install replacement lamp.
5.2.2 Beam Angle Adjustment
All beacons are shipped from the factory preset at an elevation angle of 5
degrees, per FAA requirements.
To adjust the beacon beam to a different angle, perform the following procedure:
1. The beacon head has four screws that secure the lamp to the lamp support
brackets. Loosen these four screws. This will allow the head to pivot on
the top mounting bolts. (See figure 3)
2. Locate the beam elevation label on the right side of the beacon head. (See
figure 3)
3. Locate the sight window at the bottom of the right support bracket. (See
figure 3)

Hali-Brite® L-801H(L) Installation and Maintenance Manual 13
4. Adjust the beam angle by gently pressing on the bottom of the beacon
head until the front edge of the sight window aligns with the desired
elevation on the elevation label.
5. While holding the head in this position, tighten the four screws that secure
the lamp to the lamp support brackets.
6. Repeat Steps 1-6 for the other head.
Figure 3
5.2.3 Lens Cleaning
Clean lenses periodically with alcohol or glass cleaner and soft cloth. Wipe
dry with a clean soft cloth.
5.2.4 Lubrication
All moving parts are permanently lubricated and will not require further
attention.
Beam
elevation
label
Sight
Window

14 Hali-Brite® L-801H(L) Installation and Maintenance Manual
6Repair
6.1 Timing Belt
To replace the timing belt:
1. Disconnect and lock out power to the beacon.
2. Disconnect the two lamp wires from the control panel. Refer to Section 7
for the wiring diagram.
3. Loosen the four screws on the motor, with a 5/32” Allen wrench and 3/8”
wrench.
4. Slide the motor to the right and remove the old belt.
5. Install the new belt.
6. Tighten the belt by sliding the motor to the left. The belt should have 1/8”
deflection. Do not over tighten the belt.
7. Reconnect the two lamp wires to the control panel.
8. Reconnect power to the beacon.
6.2 Mercotac rotary electrical connector
Perform the following steps to replace the mercotac rotary electrical connector:
1. Disconnect and lock out power to the beacon.
2. Disconnect the two lamp wires from the control panel. Refer to Section 7
for the wiring diagram.
3. Remove the two wires from the bottom of the coupling.
4. Loosen the cap screw in torque arm, and remove the torque arm.
5. Loosen the setscrew in the bottom of the main shaft, and remove the
mercotac rotary electrical connector.
6. Remove the two wires from the top of the mercotac rotary electrical
connector.
7. Place the black wire on the center tab of the new mercotac rotary electrical
connector, and place the white wire on the outer tab of the new mercotac
rotary electrical connector.
8. Reinsert the mercotac rotary electrical connector in the shaft, and tighten
the setscrew. (NOTE: Do not over tighten.)
9. Reinstall the torque arm, and tighten the cap screw. (NOTE: Do not over
tighten.)
10.Place the black wire on the center tab of the mercotac rotary electrical
connector, and the white wire on outer tab of the mercotac rotary electrical
connector.
11.Connect the two wires to the control panel. Make sure they are connected
to the original terminals. (NOTE: The black wire connects to the upper
terminal, and white wire connects to the lower terminal.)

Hali-Brite® L-801H(L) Installation and Maintenance Manual 15
12.Reconnect power to the beacon.
13.The Mercotac rotary electrical connector contains a small amount of
mercury. It should be returned to the manufacturer for recycling, using the
form located at the back of this manual.
6.3 Lamp Power Supply
To replace a lamp power supply, perform the following steps:
1. Disconnect and lock out power to beacon.
2. Open the cabinet door.
3. Refer to the wiring diagrams in Section 7 to locate the connections.
Disconnect the power supply input power leads at the terminal block.
4. Remove the power supply output wires at the terminal block.
5. Remove the two 8-32 screws and nuts attaching the power supply to the
beacon ballast plate, and remove the old power supply.
6. Place the new power supply into position on the beacon ballast plate.
7. Replace the two 8-32 screws and nuts to attach the power supply to the
beacon ballast plate.
8. Reconnect the power supply input power wires to the terminal block.
9. Reconnect the power supply output wires to the terminal block.
10.Reconnect the power to the beacon.
6.4 Motor and Gearhead
1. Disconnect and lock out power to the beacon.
2. Refer to the wiring diagrams in Section 7 for component connections.
3. Loosen the four cap screws that hold the motor in place, and slide the
motor to the right.
4. Remove the timing belt.
5. Remove the setscrews in the motor gear, and remove the gear. (NOTE:
There are two setscrews in each hole.)
6. Disconnect the motor black wire from control panel.
7. Disconnect the wires from the capacitor.
8. Remove the nuts from the four motor cap screws.
9. Remove the motor and gearbox.
10.If replacing only the motor, separate the old motor from the gearbox, and
replace with the new motor.
11.If replacing only the gearbox, separate the gearbox from the motor, and
replace with the new gearbox.
12.Install the new motor and gearbox back on to motor plate with the four cap
screws and nuts.
a. (NOTE 1: Make sure the shaft of the gearbox is to the right.)
b. (NOTE 2: Make sure the wires of the motor are facing out.)
13.Reinstall the gear on the shaft of the gearbox, and tighten the setscrews.

16 Hali-Brite® L-801H(L) Installation and Maintenance Manual
14.Reinstall the belt on the two gears, and tighten the belt by sliding the motor
to the left, and tighten the cap screws and nuts. (NOTE: Adjust the timing
belt for no more than 1/8” deflection.)
15.Reconnect the wires to the motor capacitor. Red wire on the left side, and
the two white wires on the right side.
16.Reconnect the black wire to the neutral on control panel.
17.Reconnect the power to the beacon.

Hali-Brite® L-801H(L) Installation and Maintenance Manual 17
7 Troubleshooting Chart,
Replacement Parts and
Wiring Diagrams
Beacon Troubleshooting Chart
This chart will help you to locate over 99% of beacon problems. Detailed repair
procedures are located in chapter 6 of this manual.
If you are still unable to solve the problem, call Hali-Brite at 800-553-6269.
No Yes
No
Yes
Yes
No
No
No
No
Start
Beacon rotates?
Lamps operate?
Lamp and motor
switches off, or no
power from source
Motor switch off?
Timing belt broken?
Replace motor
Both lamps failed?
Lamp
switch off
Replace lamp.
Does it work?
Replace lamp
power supply

18 Hali-Brite® L-801H(L) Installation and Maintenance Manual
Replacement Parts
Ref
Part Number
Description
1
0100-3944
Surge Protector
2
0200-0030
70 W Power Supply
3
0200-0032
150 W Power Supply
4
0600-0003
Drive Belt
5
4100-0000-1A
Motor 120VAC
6
4100-0006-2
Motor 230VAC
7
5000-0003
Pulley, Main Shaft
8
5000-0004
Pulley, Motor
9
9100-0015
1/2 in CONDUIT Cover & Gasket
10
9200-0049
Head Assembly, White
11
9200-0050
Head Assembly, Green
12
9200-0051
Head Assembly, Amber
1
2
3
4
5
11
10
6
9
8
7
12

MERCOTAC CONNECTOR RECYCLING
Thank you for returning your used Mercotac connectors for recycling and not disposing them in the trash or landfill. The
used connectors will be sent to a licensed mercury recycling facility where the liquid mercury is retrieved for future use
through an environmentally safe distillation process.
HOW TO RETURN MERCOTAC CONNECTORS:
Used Mercotac connectors should be returned to Mercotac Inc. by UPS Ground shipping only. Do not send Mercotac
connectors through the U.S. Mail. Mercotac Inc. provides free shipping within the 48 contiguous United States. Please
contact Mercotac, Inc. for these shipping instructions. The used Mercotac connectors should be shipped to:
Mercotac Inc.
Attn: Returns
6195 Corte Del Cedro
Carlsbad, CA 92011
HOW TO PACKAGE:
The Mercotac connectors should be tightly sealed in a plastic bag using twist ties or a similar closure and then packaged
with cushioning in a sturdy box. This completed Recycling Form must be included in the box with the shipment.
RETURNED CONNECTORS: (PACKING LIST)
Model QTY. Model QTY.
__________ _____ ___________ _____
__________ _____ ___________ _____
__________ _____ ___________ _____
__________ _____ ___________ _____
__________ _____ ___________ _____
FROM:
Company: _______________________________ FOR MERCOTAC USE
Contact: _______________________________ Received by: _______________________________
Address: _______________________________ Date received: _______________________________
_______________________________ Date Faxed: _______________________________
Telephone #: _______________________________
Y N
Do you require a receipt? 1) Verify information on form and complete above.
2) Place used Mercotac connectors in Recycling container.
Fax receipt to ( ) _____________________ 3) If required Fax receipt .
4) File competed form in Recycle File Folder,Engineering
6195 Corte Del Cedro, Carlsbad California 92011
Telephone [phone] •
••
•Fax [phone]
Email: [e-mail]