OCEM LHI Instruction manual

Document UT-MT-0693_EN Page 1 of 33
Via della Solidarietà, 2/1
40056 Valsamoggia Loc. Crespellano
BOLOGNA ITALY
Edition 15/01/2020 Supersedes edition 08/01/2019
Via Farini, 6 –40124 Bologna - Italy
THIS COPY IS NOT SIGNED SINCE IT IS FILED AND DELIVERED BY MEANS OF THE AUTOMATIC KNOWLEDGE MANAGEMENT SYSTEM (IT CAN BE SIGNED ON REQUEST). THIS DOCUMENT AND THE DATA CONTAINED HERE IN, IS
PROPRIETARY PROPERTY AND SHALL NOT BE DUPLICATED, USED OR DISCLOSED –IN WHOLE OR IN PART –FOR ANY PURPOSE WITHOUT WRITTEN CONSENT OF OCEM.
LED INSET HELIPORT LIGHT
LHI
INSTRUCTION MANUAL FOR USE, INSTALLATION
AND MAINTENANCE
Compiled by: Nicola Marabini
Approved by: Piero Scaramagli
N° Attachments: 1
Copy n°:

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LED INSET HELIPORT LIGHT LHI
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
06/22/2012
First issue
10/25/2013
Power consumption updating
11/03/2014
New address of the Company
General revision
Deleted § “List of the recommended spare parts” and added relevant
attachment
09/01/2019
15/01/2020
Added monitoring and cage options
Added § “List of the recommended spare parts”
REVISIONS
Index
Date
Description
Edited by
Approved by
LIST OF EFFECTIVE PAGES
From page 1 to page 33

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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
LIST OF ATTACHMENTS ..................................................................................................................... 6
1GENERAL.........................................................................................................................7
2MAIN FEATURES .............................................................................................................7
2.1 REMOVABLE LIGHT UNIT................................................................................................ 7
2.1.1 Dome..................................................................................................................... 7
2.1.2 Optical Assembly................................................................................................... 8
2.1.3 Power Supply/Control Board ................................................................................ 8
2.1.4 Lower Cover .......................................................................................................... 8
2.2 SHALLOW BASE ............................................................................................................ 13
3INSTALLATION .............................................................................................................. 15
3.1 PAVEMENT BORING AND SAWCUTTING...................................................................... 15
3.2 INSTALLING THE SHALLOW BASE ................................................................................. 16
3.3 SECONDARY WIRING.................................................................................................... 22
4MAINTENANCE ............................................................................................................. 22
4.1 REMOVING AND OPENING THE LIGHT UNIT FROM THE BASE .................................... 22
4.1.1 Removing the fixture .......................................................................................... 22
4.1.2 Opening the fixture............................................................................................. 23
4.1.3 How to Access Lens Assembly ............................................................................ 23
4.1.4 Closing the fixture............................................................................................... 23
4.1.5 Leakage test ........................................................................................................ 24
4.1.6 Reinstalling the fixture........................................................................................ 24
4.2 LENS CLEANING ............................................................................................................ 25
4.2.1 Lens outside cleaning.......................................................................................... 25
4.2.2 Lens inside cleaning ............................................................................................ 25
4.3 LENS REPLACEMENT..................................................................................................... 26
4.3.1 Removing the Lens.............................................................................................. 26
4.3.2 Installing the New Lens....................................................................................... 26
4.4 LED MODULE REPLACEMENT....................................................................................... 27
4.5 ELECTRONICS REPLACEMENT....................................................................................... 27
4.6 GASKETS ....................................................................................................................... 28
4.6.1 Gasket examination ............................................................................................ 28
4.6.2 O-Ring replacement............................................................................................ 29
4.7 CABLE LEAD WITH PLUG............................................................................................... 29

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INSTRUCTION MANUAL FOR USE, INSTALLATION AND MAINTENANCE
4.7.1 Removing the cable lead with plug..................................................................... 29
4.7.2 Installing the new cable lead with plug .............................................................. 30
4.8 PRESSURE VALVE.......................................................................................................... 30
5TROUBLESHOOTING ....................................................................................................311
6LIST OF THE RECOMMENDED SPARE PARTS.................................................................312
INDEX OF FIGURES
Figure 1 –8” Dome outside view ...................................................................................................... 8
Figure 2 –Lower Cover Outside View ............................................................................................... 9
Figure 3 –Lower Cover Inside View .................................................................................................. 9
Figure 4 –Wiring Diagram............................................................................................................... 10
Figure 5 –Exploded View ................................................................................................................ 11
Figure 6 –Part List........................................................................................................................... 12
Figure 7 - Complete P/N identification............................................................................................ 12
Figure 8 –Gasket of 8” fixture for 8” shallow base......................................................................... 14
Figure 9 –Standard 8“-12” shallow base........................................................................................ 14
Figure 10 –Pavement Boring, Sawcutting and Joint Intersection Details ...................................... 15
Figure 11 –Gaskets for 8” shallow base ......................................................................................... 18
Figure 12 –Gaskets for 12” shallow base ....................................................................................... 19
Figure 13 –8” shallow base for side or bottom ducts (method “B”).............................................. 20
Figure 14 –12” shallow base for side or bottom ducts (method “B”)............................................ 20
Figure 15 –Shallow base installation details .................................................................................. 21
Figure 16 –Optical device (refer to the manual UT-MT-0485 for further information) ................ 21
Figure 17 –Removing the Aluminium Ring..................................................................................... 23
Figure 18 - Lower Cover Fixing Screws............................................................................................ 24
Figure 19 - Lower Cover with Pressure Valve.................................................................................. 24
Figure 20 –Fixture Gaskets ............................................................................................................. 25
Figure 21 –Lens Surface to be Cleaned .......................................................................................... 26
Figure 22 - Lens Replacement ......................................................................................................... 27
Figure 23 - LED Module Replacement............................................................................................. 27
Figure 24–Fixture Gaskets.............................................................................................................. 28
Figure 25 –Lens Gasket................................................................................................................... 29
Figure 26 - Cable Lead With Plug..................................................................................................... 30
Figure 27 - Lower Cover with Pressure Valve.................................................................................. 31
LIST OF ATTACHMENTS

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LED INSET HELIPORT LIGHT LHI
INSTRUCTION MANUAL FOR USE, INSTALLATION AND MAINTENANCE
1GENERAL
LHI inset LED heliports light is low intensity, omnidirectional, 8” steady burning type.
These fixtures are intended for use as helipad area lighting.
LHI lights are in compliance with ICAO Annex 14 Vol.2, IEC TS 61827 (Style 4) and
NATO-STANAG 3619.
The fixtures described in this manual are designed to be connected to series circuit or
parallel circuits.
Location of these fittings shall be in compliance with ICAO - Annex 14 or STANAG
Specs
2MAIN FEATURES
Each light assembly consists of a removable fixture and a shallow base receptacle.
The fixture is waterproof and designed to withstand aircraft impact and roll-over
loads without damage.
On request a suitable adaptor ring (base mounted) is available to allow the
installation on shallow base, 12” diameter, or on deep base, type L-868, size B, as per
FAA AC 150/5345-42, thereby permitting replacement of any inset fixture without
removing the deep base from the pavement.
Power consumption 20 or 12 VA (series circuits white or green/yellow respectively)
and 42 or 21 VA (parallel circuits white or green/yellow respectively).
2.1 REMOVABLE LIGHT UNIT
The removable fixture mainly consists of a dome, an optical assembly and a lower
cover.
2.1.1 Dome
The dome is made of treated drop-forged aluminium and includes one cavity to seat
the lens, complete with gasket, kept in the proper position by means of an aluminium
ring fixed with HSCS M5x16 screws.
The dome is provided with two through holes for fastening the light unit to the base
and two dead holes for matching two studs mounted on the base, so to prevent the
rotation of the light unit due to aircraft wheel impact/roll over
It is also provided with two suitable slots, in opposite position, to make easy the
fixture removal by using two suitable lifting tools (available on request, P/N 332.4140
or 332.4230). As alternative, two screwdrivers can be used.
A silicone O-Ring (separately supplied) has to be mounted outside around the dome,
to avoid dirt deposits between dome and shallow base.

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1. Dome
2. Slot for dome removal
3. Through hole for light unit
fastening
Figure 1 –8” Dome outside view
2.1.2 Optical Assembly
The optical assembly consists of one lens (Figure 5 - n°5) with relevant gasket (Figure
5 - n°4) and one LED module complete with collector lens (Figure 5 - n°12) kept into
the proper position by its support.
LED module, complete with collector lens, consists of six LEDs mounted on a metal
core PCB, coupled with the support through thermo conductive material.
All the optical assembly parts are factory assembled; they may be field-replaced if
necessary.
2.1.3 Power Supply/Control Board
The power supply/control board is encapsulated into waterproof and heat
conductive silicon resin.
The PCB powers and controls the LEDs and it’s available in two versions: series
circuits or voltage power supply.
2.1.4 Lower Cover
The lower cover consists of a treated aluminium casting; it is fastened to the dome
by means of three screws HSFH M5x10. An O-Ring is provided between dome and
lower cover.
The cover is provided with one threaded hole for cable entry and external grounding
screw with yellow-green cable lead, size 2.5 mm2, 0.250 m long, with male faston
terminal. A suitable valve is outside mounted for the leakage test.
Watertightness between fixture and shallow base is ensured by means of a gasket
(separately supplied) to be placed on the relevant groove around the lower cover.
The fixture is supplied with one cable lead with L-823 plug; it consists of two single-
pole teflon leads, size 2.1 mm2 (#14 AWG), 0.700 m long. The plug is in compliance

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with FAA AC 150/5345-26 for very quick coupling with the receptacle mounted on the
shallow base.
The fixture is 203 mm in diameter and 85 mm (+ 18.5 mm for plugs) high; the
protrusion above the ground is less than 6.35 mm.
An identification data label is externally applied over the lower cover (Figure 2 –n°2).
Moreover, to identify quickly the beam colour, the letter “A” of the dome in front of
the window is painted in the same colour of the light beam.
1. Lower cover
2. Identification label
3. Grounding cable hole
4. Letter “A” and “B” for
cable lead identification
5. Cable lead entry
Figure 2 –Lower Cover Outside View
The same colour painting is provided outside on the lower cover.
See “Complete P/N identification” figure for P/N information.
All hardware is made of stainless steel.
1. Cable lead with plug
2. Leak test valve
3. Letter “A” and “B” for
cable lead identification
Figure 3 –Lower Cover Inside View

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POWER
SUPPLY
LED
1 In 1 Out
Figure 4 –Wiring Diagram

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8
9
12
11
1
2
3
4
5
6
7
10
Figure 5 –Exploded View

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No. Description Qty
1 Aluminium lens holder.........................................................................................1
2 O-Ring for aluminium lens holder........................................................................1
3 Lens ......................................................................................................................1
4 Lens gasket...........................................................................................................1
5 Dome....................................................................................................................1
6 O-Ring for dome...................................................................................................1
7 O-Ring for lower cover ........................................................................................1
8 Lower cover..........................................................................................................1
9 Valve for watertightness test...............................................................................1
10 LED module with accessories...............................................................................1
11 Lower cover gasket ..............................................................................................1
12 FAA L-823 plug .....................................................................................................1
Figure 6 –Part List
LHI - I - C - D - O - 0 - 0
Basic P/N:
Compliance:
I = ICAO - IEC
S = STANAG
Colour:
W = White
G = Green
Y = Yellow
Mode:
S = Series Circuit
D = Parallel Circuit 48 V
Monitoring system :
O = No monitoring system
M= Monitoring* (only S mode)
Arctic Kit:
0 = Without Arctic Kit
Cage:
0 = Without cage
C=With cage
Colour Selection
SPECS
USE
COLOUR
WHIT
E
GREE
N
YELLO
W
ICAO
FATO and Aiming
Point
X
ICAO
TLOF Heliport Edge
X
STANAG
TLOF Heliport Edge
X
STANAG
Landing Direction
X
Figure 7 - Complete P/N identification

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2.2 SHALLOW BASE
The shallow base (
Figure 9) consists of a treated aluminium casting containing an electrical feed-thru
system to connect the power cables, consisting of one cable lead with receptacle
incoming inside the base through one cable gland. The cable lead with receptacle
consists of two single-pole leads, size 2.5 mm2, 1.00 m long, with FAA L-823
receptacle.
The letters "A" and “B” are printed inside the base for cable leads identification.
The base is equipped with an internal grounding screw with yellow-green cable lead,
size 2.5 mm2, 0.250 m long, with female faston terminal for quick connection to the
corresponding of the fixture. An additional external grounding screw is provided
close to the cable entry.
The shallow base is designed for cementing in place by means of epoxy-resin in a hole
drilled in the pavement.
The fixture has to be fastened to the base by means of two or six M10x30 stainless
steel hex cap screws (8” or 12” shallow base resp.). If the base has American
threaded holes, UNC 3/8-16 screws can be used. Each locking screw is complete with
special sealed external silicon-coated lock-washer.
A gasket (separately supplied) must be placed between base and fixture for
watertightness: for 8” fixtures (
Figure 8 - n°1) around the lower cover, for 12” fixtures (
Figure 9 - n°9) placed in the relevant shallow base groove.
The 12” shallow base is 320 mm in diameter and 150 mm high, while the 8” one is
214 mm in diameter and 125 mm high.
On request, special bases without cable leads can be supplied, provided with holes
suitable for conduit connections.
Inside the base two suitable holders (
Figure 9 - n°7) are provided to properly sustain the secondary power cable, in case of
this cable is inside incoming through a conduit.

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INSTRUCTION MANUAL FOR USE, INSTALLATION AND MAINTENANCE
Figure 8 –Gasket of 8” fixture for 8” shallow base
1. Cable gland for cable
entry
2. External grounding screw
3. Cable leads with socket
4. Internal grounding screw
5. Grounding cable with
female faston terminal
6. Letters “A” for cable lead
identification
7. Power cable holders
8. Threaded holes for fixture
fastening by bolts
9. O-Ring between fixture
and base
Figure 9 –Standard 8“-12” shallow base

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3INSTALLATION
3.1 PAVEMENT BORING AND SAWCUTTING
Drill each recess in pavement following the instruction in Figure 10.
Figure 10 –Pavement Boring, Sawcutting and Joint Intersection Details
Make sure the recess size and depth are maintained within the specified limits. All
surfaces of the recess must be clean and dry. If any of these surfaces is damp, it is
desirable that it be dried and blown clean with a compressed air blast. The recess
side walls must be perpendicular to the pavement surface. The bottom surface must
be flat or slightly concave to assure that the shallow base rest securely and in true
position. The recess can best be drilled using a diamond-faced core drill in a sturdy,
stable drill rig.
Mark on the pavement surface the aiming direction of the light by chalk, nails or
other devices.

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3.2 INSTALLING THE SHALLOW BASE
Two different installations are possible:
Method “A” – cable leads to be laid in wireways
Method “B” – cable leads to be laid in cable ducts (Figure 14)
Proceed as follow to realize a proper installation.
STEP
A
B
ACTIVITY DESCRIPTION
1


Take the base from the shipping box.
2


To assure an adequate bond between base and hole all external surfaces of
the base should be sandblasted and must be cleaned with solvent. TAKE CARE
NOT TO DAMAGE THE ELECTRICAL SYSTEM.
3

/
Connect an insulated G/Y grounding wire of suitable length to the grounding
screw externally provided on the wall of the base.
4

/
Splice the light base leads to the power cables using solderless squeeze
connectors, as shown in the figure, crimped with the proper tool. Connect also
the grounding wire to the main grounding network by using a suitable
clamping lug.
ATTENTION: Insulate each splice carefully using either heat shrinkable
insulating tubing properly applied or at least three layers of plastic electrical
insulating tape applied with half overlap.
5


Mount the positioning jig (P/N 332.4301) on the base as shown in Figure 15.
An optical device for proper fixture orientation is available (P/N 332.4351 Figure
16).
6

/
Properly arrange the leads in the wireways using small pieces of insulating
tape if necessary.
7


Completely cover the bottom of the base with sealer material, apply a thin
coat of sealer to the bottom of the drilled hole to assure a bond between the
bottom of the light base and the drilled hole. It may be necessary to place
temporary plugs so as to block the wireways entrances into the drilled hole
(METHOD “A”) or the cable ducts entrance (METHOD “B”). The plugs will retain

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STEP
A
B
ACTIVITY DESCRIPTION
the sealer while it begins to dry up.
ATTENTION: avoid starting the installation when the ambient temperature is
below 10°C (86°F), unless the sealer used is designed to dry up at a lower
temperature.
8


Push the base into the recess until its upper side is at the level of the
pavement surface; take care no sealer flowing inside the base. Align the notch
of the base with the markings on the pavement surface.
9

/
Observing the circular level fixed on the jig, level the jig by operating the three
leveling lobe knobs (Figure 15). If necessary, a weight may be placed on the jig
to hold the light base in position.
The remainder of the space between the sides of the shallow base and the
drilled hole should be filled with sealer up to approx 25 mm from the
pavement, according to the local needs.
Fill the remaining 25 mm with a suitable joint sealing filler.
10
/

Observing the circular level fixed on the jig, level the jig by operating the three
leveling lobe knobs (Figure 15). If necessary, a weight may be placed on the jig
to hold the light base in position.
When the shallow base is in its final position, the conduit(s) must be properly
jointed to the hole(s) provided on the shallow base. This(these) hole(s) can be
provided either on the wall either on the bottom, the number and the
dimensions according to customer requirements (Figure 13 and Figure 14).
The remainder of the space between the sides of the shallow base and the
drilled hole should be filled with sealer up to approx 25 mm from the
pavement, according to the local needs.
Fill the remaining 25 mm with a suitable joint sealing filler.
11
/

Lay the secondary power cable, equipped with a suitable two-pole receptacle
kit, and the grounding wire inside the cable duct.

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INSTRUCTION MANUAL FOR USE, INSTALLATION AND MAINTENANCE
STEP
A
B
ACTIVITY DESCRIPTION
12


To install a 8” fixture place the O-Ring around the dome (Figure 11- n°1) and
between fixture and base (Figure 11- n°2), for 8” fixtures with adaptor ring
place the O-Ring between fixture and base (Figure 12- n°3).
To install a 12” fixture place the O-Ring around the dome (Figure 12- n°1) and
between fixture and base (Figure 12- n°3).
Connect the plug and the grounding wire of the fixture with the receptacle and
the grounding wire of the base; press the fixture by hand onto the base and
secure it using the six (12” base) locking screws complete with washer, one
drop of screw paste (e.g. Dow Corning Molycote 1000) should be applied to
the screws before installation; two screws are used for 8” base, one drop of
anaerobic adhesive, medium type (e.g. Loctite 243) should be applied.
Tightening torque is 35 Nm.
ATTENTION: The fixture is subject to mechanical damage and/or optical
misalignment if not properly seated on the base flange.
1. O-Ring around
the dome
2. O-Ring between
fixture and base
Figure 11 –Gaskets for 8” shallow base

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1. O-Ring around
the dome
2. 12” shallow
base
3. O-Ring between
fixture and base
Figure 12 –Gaskets for 12” shallow base

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Ø100
125 125
Ø214 Ø214
Figure 13 –8” shallow base for side or bottom ducts (method “B”)
Ø320 Ø320
Ø100
150 150
Figure 14 –12” shallow base for side or bottom ducts (method “B”)