OCEM LERA Instruction manual

Document UT-MT-0812_ENG Page 1 of 28
Via della Solidariet n°2/1
40056 Valsamoggia Loc. Crespellano
BOLOGNA ITALY
Edition 19/05/2016 Suspended edition 18/12/2014
Via della Solidariet , 2/1 – 40056 Valsamoggia - Italy
QUESTA COPIA NON E’ FIRMATA PERCHE’ REGISTRATA E DISTRIBUITA TRAMITE SISTEMA AUTOMATICO DI GESTIONE DEL PATRIMONIO INFORMATIVO (PUO’ ESSERE FIRMATA A RICHIESTA). QUESTO DOCUMENTO E’ PROPRIETA’
RISERVATA DI OCEM; IL SUO CONTENUTO NON PUO’ ESSERE DIVULGATO NE’ MODIFICATO SENZA IL CONSENSO SCRITTO DI OCEM.
ELEVATED LEDs APPROACH, THRESHOLD,
THRESHOLD WING BAR, RUNWAY END
AND STOP BAR
LERA
INSTRUCTION MANUAL FOR USE, INSTALLATION
AND MAINTENANCE
Compiled by: M. ROMAGNOLI Approved by: M. MAZZOTTI
N° Attachments: Copy n°:

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INSTRUCTION MANUAL FOR USE, INSTALLATION AND MAINTENANCE
LIMITED PRODUCT WARRANTY
THE FOLLOWING WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL OTHER WARRANTIES, WHETHER
EXPRESS, IMPLIED OR STATUTORY, INCLUDING, BUT NOT BY WAY OF LIMITATION, ANY
WARRANTY OF MERCHANTABILITY OR FITNESS FOR ANY PARTICULAR PURPOSE.
OCEM - ENERGY TECHNOLOGY warrants to each original Buyer of Products manufactured by the Company
that such Products are at the time of delivery to the Buyer, free of material and workmanship defects,
provided that no warranty is made with respect to:
(a) any Product, which has been repaired or altered in such a way, in Company’s judgement, as to affect
the Product adversely;
(b) any Product which has, in Company’s judgement, been subject to negligence, accident or improper
storage;
(c) any Product which has not been operated and maintained in accordance with normal practice and in
conformity with recommendations and published specification of Company;
(d) the breaking of the warranty seals, if present, determines the immediate termination of the warranty;
and,
OCEM - ENERGY TECHNOLOGY’s obligation under this warranty is limited to use reasonable efforts to
repair or, at its option, replace, during normal working hours at the facility of the Company, any Product
which in its judgement proved not to be as warranted within the applicable warranty period. All costs of
transportation of Products claimed not to be warranted and of those repaired or replaced, to or from the
facility of the Company shall be borne by Purchaser. Company may require the return of any Product
claimed not to be as warranted to its facility, transportation prepaid by Purchaser, to establish a claim
under this warranty. The cost of labour for the installation of a repaired or replaced Product shall be
borne by Purchaser. Replacement parts provided under the terms of this warranty are warranted for the
remainder of the warranty period of the Products upon which they are installed to the same extent as if
such parts were original components thereof. Warranty services provided under the Agreement do not
assure uninterrupted operations of Products; Company does not assume any liability for damages caused
by any delays involving warranty service.
IMPORTANT: READ THIS DOCUMENT
Before proceeding to the operations of installation, commissioning, operation, maintenance or disposal,
carefully read the entire document.
SAFETY INFORMATION
Extreme caution should be exercised when working with this equipment; it is normally used or connected
to circuits that operate at dangerous voltages and can be fatal.
The following section contains important safety information that you must follow when installing and
using the apparatus.
Misuse of the equipment or lack of care in applying safety procedures and prescriptions specified in this
document, may result in a hazard.
Avoid contact with voltage or current sources.
For no reason the protections and the safety devices must be removed.

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INSTRUCTION MANUAL FOR USE, INSTALLATION AND MAINTENANCE
OPERATION ON THE EQUIPMENT - SKILLS
Operation on the equipment and access to its internal parts shall be done by experienced personnel,
adequately trained and aware of the risks related to electricity and high voltages.
Safety rules shall be adopted when operating on the equipment, or on cables and other apparatus
connected to the it
DO NOT OPERATE ON ENERGIZED CIRCUITS
Do not carry out any operation on the converter or on apparatus connected to it when the circuits are
energized.
WHEN HANDLING AND SERVICING THIS EQUIPMENT, OBSERVE PRECAUTIONS FOR HIGH VOLTAGE
EQUIPMENT
Before any access, inspection or intervention, be sure to have switched-off the unit, opened the main
circuit breaker and removed the supply to the unit (by opening the circuit breaker/switch on the
distribution board at the beginning of the supply line).
Then wait discharge time (at least 5 minutes), ground carefully the system, and check for voltage
presence before accessing..
REANIMATION
The maintenance staff must be aware of the risks related to electricity, criteria to prevent the risk of
electric shock and resuscitation techniques
CE MARK
This equipment complies with the requirements of European regulations for the CE mark.The
user has to respect all prescriptions reported in this document.
This equipment complies with the requirements of the EEC directives 2004/108/EEC and
2006/95/EEC with regard to “Electromagnetic Compatibility” and “Low Voltage Electrical
Apparatus” respectively.
OUT OF SERVICE
In case of dismantling, decommissioning, destruction, disposal, the user shall follow all the required
precautions for component and material elimination, according to local rules and applicable law.

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INSTRUCTION MANUAL FOR USE, INSTALLATION AND MAINTENANCE
EDITIONS
Date
18/12/2014 First issue
19/05/2016 Correct translation errors
REVISIONS
Index Date Des ription Edited by Approved by
LIST OF EFFECTIVE PAGES
From page 1 to page 28

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INSTRUCTION MANUAL FOR USE, INSTALLATION AND MAINTENANCE
INDEX
LIMITED PRODUCT WARRANTY ......................................................................................................... 2
SAFETY INFORMATION ...................................................................................................................... 2
EDITIONS ........................................................................................................................................... 4
REVISIONS .......................................................................................................................................... 4
LIST OF EFFECTIVE PAGES .................................................................................................................. 4
INDEX ................................................................................................................................................. 5
INDEX OF FIGURES ............................................................................................................................. 6
INDEX OF TABLES ............................................................................................................................... 6
LIST OF ATTACHMENTS ..................................................................................................................... 6
1 GENERAL ......................................................................................................................... 7
2 MAIN FEATURES ............................................................................................................. 7
2.1 MAIN COMPONENTS 7
2.2 POWER SUPPLY 7
2.3 OPERATING CONDITIONS 8
3 INSTALLATION INSTRUCTIONS ....................................................................................... 12
3.1 FIXTURE INSTALLATION 12
3.2 CIVIL WORKS 14
3.3 EXTERNAL WIRING OF THE TWO-POLE CABLE LEAD WITH L-823 PLUG 15
3.4 INSTALLING THE LIGH UNIT ON THE PIPE ELBOW AND ELECTRICAL CONNECTION 19
4 MAINTENANCE ............................................................................................................. 20
4.1 MAINTENANCE PROGRAM 20
4.1.1 Periodical Checks ................................................................................................ 20
4.1.2 Snowplow Operations ......................................................................................... 20
4.2 FIELD INTERVENTIONS: REMOVING AND OPENING THE FIXTURE 21
4.3 MAINTENANCE CENTER INTERVENTIONS 22
4.3.1 Replacing of the cover with resin embedded electronic .................................... 22
4.3.2 Replacing of the led module ............................................................................... 23
4.3.3 Replacing of the cable lead with plug ................................................................. 24
4.4 M ONITORING ................................................................................................................ 27
4.5 TROUBLESHOOTING ..................................................................................................... 28

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INSTRUCTION MANUAL FOR USE, INSTALLATION AND MAINTENANCE
INDEX OF FIGURES
Figure 1: o erall dimensions .............................................................................................................. 8
Figure 2: exploded iew ..................................................................................................................... 9
Figure 3: P/N identification ............................................................................................................. 11
Figure 4: direct mounting ................................................................................................................ 12
Figure 5: mounting on supporting pole ........................................................................................... 13
Figure 6: mounting on frangible and lowering mast ..……………………………………………………………….13
Figure 7: ci il works … … ………………………………………………………………………………………………………..……14
Figure 8: nut and body of the bulkhead connector disassembled ….. …………………………………………..15
Figure 9: cable lead insertion……………………………………………………………..………………………………………15
Figure 10: fit-in wires of the cable lead …...… ……………………………………………………………………………..16
Figure 11: wires cutting ……………………………………………………………………………………………………………..16
Figure 12: support with ertical aiming adjusting de ice …………………………………………………….…….17
Figure 13: tightening torque ………………………………………………………………………………………………………17
Figure 14: bush with screw .............................................................................................................. 18
Figure 15: final mechanical assembly ............................................................................................. 18
Figure 16: grounding wiring for fixture equipped with two-pole cable lead with plug .................. 19
Figure 17: bulkhead connector electrical connection ...................................................................... 21
Figure 18: electronic co er-LED support assembly t be remo ed in bold ........................................ 22
Figure 19: power supply 14 LED module and 7 LED module ........................................................... 22
Figure 20: co er with resin embedded electronic to be replaced ................................................... 23
Figure 21: 7 LED module .................................................................................................................. 23
Figure 22: 14 LED module ................................................................................................................ 24
Figure 23: bulkhead connector internal body and nut ………………………………………………………………..25
Figure 24: wires pulled through the grommet ................................................................................ 25
Figure 25: grommet placed inside the internal body ...................................................................... 25
Figure 26: wires fitted-in ................................................................................................................. 26
Figure 27: wires fitte-in – top iew .................................................................................................. 26
Figure 28: wires cutting ................................................................................................................... 26
Figure 29: tightening torque ........................................................................................................... 27
Figure 30: monitoring restoring ………………………………………………………………………………………………27
INDEX OF TABLES
Table 1: Use and power consumption ............................................................................................... 8
LIST OF ATTACHMENTS
UC-PU-0315 - LIST OF THE RECOMMENDED SPARE PARTS

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INSTRUCTION MANUAL FOR USE, INSTALLATION AND MAINTENANCE
1GENERAL
LERA elevated LED light is high intensity, bidirectional or unidirectional steady burning type.
These fixtures are intended for use as approach (centreline and crossbars), approach side row barrettes,
threshold, threshold wing bar and stopbar, in order to provide a visual aid to landing and taxiing aircrafts.
LERA lights are in compliance with:
ICAO Annex 14 Vol.1
FAA AC 150/5345-46 and Engineering Brief No67
IEC TS 61827
NATO-STANAG 3316.
The fixtures described in this manual are designed to be connected to series circuit, replacing those
equipped with incandescent lamps, fed through standard isolation transformers connected to CCR with
variable current from 2.8 A to 6.6 A.
Location of these fittings shall be in compliance with ICAO - Annex 14, STANAG 3316 and FAA.
2MAIN FEATURES
2.1 MAIN COMPONENTS
The fixture consists of:
body balanced on a special support for proper and accurate horizontal and vertical aiming. The
support allows the direct mounting on the breakable coupling or on the top of 60 mm dia
supporting pole
anodized aluminum LED support
cover to house the LED power supply electronic
LED power supply electronic resin-embedded inside the cover
LED module and lens array, housed inside the relevant support
aluminum breakable coupling, 2” GAS threaded (only for direct mounting)
cable lead with FAA L-823 plug
yellow-green wire for grounding purpose.
All hardware is made of stainless steel.
See “Complete P/N identification” figure for P/N information.
2.2 POWER SUPPLY
Through 6.6 A series circuit.

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INSTRUCTION MANUAL FOR USE, INSTALLATION AND MAINTENANCE
CODE USE COLOUR CONSUMPTION
AC Approach centreline and
crossbars
White 38VA
AR Approach side row Red 26VA
TG Threshold Green 30VA
WG Threshold Wing Bar Green 30VA
ER Runway end Red 20VA
SB FAA L-862S Stop bar Red 20VA
BA ICAO Stop bar Red 17VA
Table 1: Use and power consumption
2.3 OPERATING CONDITIONS
Temperature: - 55°C to +55°C (- 67°F to +131°F)
Humidity: 0 to 100%
Figure 1: o erall dimensions

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Figure 2: exploded iew

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INSTRUCTION MANUAL FOR USE, INSTALLATION AND MAINTENANCE
Nr. Des ription Qty
1 Cover with resin-embedded electronic .............................................................................................. 1
2 Cover gasket ....................................................................................................................................... 1
3 LED module support ........................................................................................................................... 1
4 LED module support gasket ................................................................................................................ 1
5 LED module (*) ................................................................................................................................... 1
6 Lens array for LED module (*) ............................................................................................................ 2
7 Body .................................................................................................................................................... 1
8 Transparent front protection gasket .................................................................................................. 1
9 Transparent front protection ............................................................................................................. 1
10 Transparent front protection holder plate (in the colour of the emitted light) ................................. 1
11 Vertical aiming adjusting device ......................................................................................................... 1
12 Special support ................................................................................................................................... 1
13 FAA L-823 plug .................................................................................................................................... 1
14 Breakable coupling ............................................................................................................................. 1
(*) three different versions of the LED modules are available: for stopbar 7 LED module with integrated
lenses, for runway end 7 LED module and independent lens array, for the other ones 14 LED module and
independent lens array

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INSTRUCTION MANUAL FOR USE, INSTALLATION AND MAINTENANCE
LERA – AC – P-001 – M – 0
Basi P/N:
Use Code:
(Refer to table A)
Configuration:
P-001 = Fixture complete with breakable coupling
C-050 = Fixture with special support and cable lead (L= 0.5 m)(*)
C-250 = Semi-assembled fixture (AC and AR only)(*) (**)
C-000 = Fixture without cable lead (*)
Monitoring:
0 = Without Monitoring
M = With Monitoring
Ar ti kit:
0= Without Arctic Kit
(*) Supporting pole and breakable coupling must be ordered separately
(**) This configuration is provided with special support and cable lead (L = 2.5 m) not assembled
Figure 3: P/N identification
TABLE A
CODE
USE
COLOUR
AC
Approach centreline and crossbars
White
AR
Approach side row
Red
TG
Threshold
Green
WG
Threshold wing bar
Green
ER
Runway end
Red
SB
FAA Stop bar
Red
BA
ICAO Stop bar
Red

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3INSTALLATION INSTRUCTIONS
3.1 FIXTURE INSTALLATION
Three different installation modalities are provided for LEA lights.
Direct installation on the breakable coupling, normally for threshold, threshold wing bar and
runway end lighting. In this case the fixture is supplied completely assembled with breakable
coupling and FAA L-823 plug.
Figure 4: direct mounting
On the top of a supporting pole with breakable coupling, normally for approach (centreline and
crossbars), approach side row barrettes and stop bars.
In this case the fixture is supplied without supporting pole and breakable coupling, which must be
ordered separately.
The aluminum pole, dia 60 mm, is available of length not exceeding 2 m (four standard lengths
are available: 50 cm - 1 m - 1.5 m - 2 m) and must be on-site cut at the proper length depending
on the approach profile design.
The fixture can be supplied assembled complete with FAA L-823 plug (two-single pole wires, 50
cm long), and grounding wire for installation on poles of length not exceeding 30 cm, or semi-
assembled, that is two-pole cable lead with FAA L-823 plug, 2.50 m long, not wired to the fixture.
The cable lead must be on-site cut at the proper length and then wired to the fixture by means of
the special bulkhead connector.
NOTE: the fixture must not be opened to wire the able lead with FAA L-823 plug.

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INSTRUCTION MANUAL FOR USE, INSTALLATION AND MAINTENANCE
Figure 5: mounting on supporting pole
On the top of a frangible and lowering mast, normally for approach (centreline and crossbars) and
approach side row barrettes.
In this case the frangible and lowering mast must be ordered separately and the fixture is
supplied assembled complete with FAA L-823 plug (two-single pole wires, 50 cm long), and
grounding wire.
On request the fixture can be supplied without cable lead with plug and grounding wire, which
have to be separately purchased of the proper length.
Figure 6: mounting on frangible and lowering mast

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Take as reference para. 3.3 which provides the instructions to realize the external wiring of the two-pole
cable lead with FAA L-823 plug.
3.2 CIVIL WORKS
Each light is usually installed on a suitable concrete block, into which a pipe elbows is cemented.
The isolating transformer is housed into a separate concrete pit which is normally placed close
the above concrete block (Figure 7).
The pit can be placed far from the concrete block too , but in this case a suitable cable duct has to be
provided between the pit and the pipe elbow for passing the secondary cable.
As alternative the assembly pit-pipe elbow can be replaced by a steel sheet base, which can be
used to house the isolating transformer, complete with an upper steel plate with a threaded
sleeve.
A suitable concrete block has to be provided in case of installation on frangible and lowering mast. To
house the isolatin transformer follow the suggestions given before.
Figure 7: ci il works

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INSTRUCTION MANUAL FOR USE, INSTALLATION AND MAINTENANCE
3.3 EXTERNAL WIRING OF THE TWO-POLE CABLE LEAD WITH L-823 PLUG
When the LERA fixtures are supplied “semi-assembled”, it is necessary to wire the cable lead with L-823
plug, once cut at the proper length, to the fixture by means of the bulkhead connector and then complete
the mechanical assembly.
•Unscrew the external nut of the bulkhead connector from the internal body, provided to fasten
the wires, and cut the cable sheath for a length of approx. 40 mm (fig. 8)
Figure 8: nut and body of the bulkhead connector disassembled
• Insert the cable through the nut and then the gasket of the bulkhead connector body (fig. 9)
Figure 9: cable lead insertion
Wires
L=40 mm
ATTENTION
Installation and starting must be carried out by skilled personnel only and following the
specific local rules!
The cable can be wired only when the fixture is not powered!
The bulkhead connector can be reused for a maximum of ten times using the same conductor
size.
The two wires of the cable lead must be connected exclusively to the terminals 1 and 2. The
numbers
re stamped on the wall of the internal body of the bulkhead connector
.

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•Screw, only one turn, the nut to the body. Fit-in the wires of the cable lead into the terminals 1 and
2 (fig. 10).
Figure 10: fit-in wires of the cable lead
•Cut the wires, flush with the body of the bulkhead connector (fig. 11).
Figure 11: wires cutting

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Insert the bulkhead connector nut-body assembly through the special support with vertical aiming
adjusting device (Fig. 12).
Figure 12: support with ertical aiming adjusting de ice
Tighten the nut-body assembly to the fixed section of the bulkhead connector mounted on the
fixture body, in this way providing the electrical connection (tightening torque: 5 Nm) (Fig. 13). Use
special tubular wrench 22 mm for bulkhead connector tightening (P/N. 798.0006).
Figure 13: tightening torque
Complete the mechanical assembly of the fixture. Unscrew from the body the bush with screw,
provided for the vertical aiming adjusting device (fig. 14).

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Figure 14: bush with screw
Assembly the support with vertical aiming adjusting device to the body by means of the two
screws with washer, which act as fulcrum; fasten the vertical aiming adjusting device to the body
by means the bush with screw before removed. Tighten the two screws with a torque of 5 Nm
and the bush screw with a torque of 3 Nm (fig. 15).
Figure 15: final mechanical assembly

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Provide the grounding wiring by means of the suitable external screw, placed at the bottom of the
body (fig. 16).
Figure 16: grounding wiring for fixture equipped with two-pole cable lead with plug
3.4 INSTALLING THE LIGH UNIT ON THE PIPE ELBOW AND ELECTRICAL CONNECTION
For the installation of the light with breakable coupling and eventual supporting pole, the
following steps are suggested:
pass together the secondary cable lead with receptacle and a suitable length of grounding wire
(grounded inside the pit) through the pipe elbow (or base plate)
 place the receptacle into the upper threaded section of the pipe elbow (or base plate), by
holding it between the two plastic rings, and pass the grounding wire through the rings
(in correspondence of break point provided on the rings)
insert the cable lead with plug plus the yellow-green wire through the breakable coupling and the
supporting pole, if provided
 connect the fixture grounding wire to the grounding wire coming from the pit (or from the
base): splice both the wires and connect them together by using a crimping connector
connect the light plug to the secondary receptacle inside the pipe elbow (or base plate)
tighten the breakable coupling into pipe elbow (or the base plate) until coupling bottoms
out. Push any extra cable length into the breakable coupling or the breakable
coupling+supporting pole, if provided
set the body on the breakable coupling or on the supporting pole top, if provided, and
tighten it by means of the four locking screws
to aim the fixture in the horizontal and vertical planes, see the document UT-MT-0810.
NOTE
To aim the fixture mounted on a frangible and lowering mast, see the document UT-MT-0811.

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4MAINTENANCE
WARNING
BEFORE ANY MAINTENANCE INTERVENTION, MAKE SURE THE
POWER SUPPLY BE SWITCHED OFF.
DO NOT OPERATE ON LIVE PARTS!!!
LED lighting fixtures do not require frequent maintenance. With well-run installations and handling
fixture carefully, avoiding excessive falls or collisions, the only maintenance work to be carried out
on the field is to clean the glass or equivalent components.
4.1 MAINTENANCE PROGRAM
In order to ensure maximum light fixture life, the installed units should be subject to a maintenance
program in accordance with the following instructions and taking as reference the Airport Service
Manual ICAO - Part 9 - Airport Maintenance Practices or FAA AC 150 5340-30.
4.1.1 Periodi al Che ks
Monthly
Cleaning of the transparent front protections
Correct setting of the lights
Annual
Stability of the civil works
Stability and assembly of lights
Electrical connections and insulation degree
Luminous
efficiency of luminous sources
Condition of all the gaskets
Uns heduled
After unusual atmospheric precipitation, check the light
condition and remove any luminous beam obstructions
4.1.2 Snowplow Operations
Snowplow operators should exercise extra care not to strike the light fixtures with snowplow
blades. After snow removal operations, inspect all light fixtures to locate and replace, if necessary,
any damaged light assemblies.
Recommended snow removal techniques are described in Airport Service Manual ICAO - Part 9 -
Airport Maintenance Practices or FAA AC 150/5200-30.