Safegate Group SL-HF-I User manual

Airfield Lighting
Manual
8” SafeLED Omnidirectional Inset Light
(SL-HF-I; SL-HT-I)
Final Approach and Take Off area
Touchdown and Lift Off area
Aiming Point

Note: This page is blank for convenient double-sided printing.

Airfield Lighting Safegate Group
Manual Date: September 2014
Ref: SL-HF-I; SL-HT-I Version: 1.3
Page 1 of 16
MANUAL
8” SAFELED OMNIDIRECTIONAL INSET LIGHT
(SL-HF-I; SL-HT-I)
CONTENTS
Section Description Page No.
1. INTRODUCTION ...........................................................................................................3
1.1 SAFETY INSTRUCTIONS................................................................................3
1.1.1 Product Safety............................................................................................3
1.1.2 Electrical Maintenance..............................................................................3
1.1.3 Mechanical Maintenance...........................................................................3
1.2 DESCRIPTION OF THE FITTING....................................................................4
1.2.1 Dimension of the Fitting and the Base ....................................................4
1.3 DELIVERY OF THE FITTING...........................................................................4
2. INSTALLATION.............................................................................................................5
2.1 INSTALLING/ REMOVING THE FITTING........................................................6
2.2 ELECTRICAL CONNECTIONS........................................................................7
2.2.1 Cable Grounding........................................................................................8
3. MAINTENANCE ............................................................................................................9
3.1 BASIC MAINTENANCE PROGRAMME...........................................................9
3.2 WORKSHOP MAINTENANCE .......................................................................10
3.2.1 Disassembling/ Assembling the Fitting.................................................10
3.2.2 Replacing a LED Assembly with Holder................................................11
3.2.3 Replacing the Prism and its Gasket.......................................................12
4. SUPPORT....................................................................................................................13
4.1 SAFEGATE GROUP WEBSITE .....................................................................13
4.2 RE-CYCLING..................................................................................................13
4.2.1 Local Authority Re-cycling .....................................................................13
4.2.2 Safegate Group Re-cycling.....................................................................13
4.3 SPARE PARTS...............................................................................................14

Airfield Lighting Safegate Group
Manual Date: September 2014
Ref: SL-HF-I; SL-HT-I Version: 1.3
Page 2 of 16
Documentation
This document includes Airfield Lighting information with a focus on safety, installation
and maintenance procedures.
For more information, see www.safegate.com.
Note: It is very important to read this document before any work is started.
Copyright
© Copyright 2012 by Safegate Group. All rights reserved. This item and the
information contained herein are the property of Safegate Group. No part of this
document may be reproduced, transmitted, transcribed, stored in a retrieval system,
or translated into any language or computer language in any form or by any means
otherwise, without the expressed written permission of Safegate Group,
Djurhagegatan 19, SE-213 76 Malmö, Sweden.
History
Version Date Description
1.0 August 2012 First Release
1.1 December 2012 Second Release
1.2 March 2014 Third Release
1.3 August 2014 Fourth Release
Note: This page is to be updated with every authorised change to the document.
Abbreviations and Terms
This document may include abbreviations and terms.
Abbreviation
Term
ICAO
International Civil Aviation Organization
IEC
International Electrotechnical Committee
LED
Light Emitting Diode
STAC
Service Technique de l'Aviation Civile (France)
FAA
Federal Aviation Administration
FATO
Final Approach and Take Off area
TLOF
Touchdown and Lift Off Area
LED
Light Emitting Diode

Airfield Lighting Safegate Group
Manual Date: September 2014
Ref: SL-HF-I; SL-HT-I Version: 1.3
Page 3 of 16
1. INTRODUCTION
In this section you can find a general description and safety instructions related to the
installation and usage of the fitting.
SafeLED heliport inset light is an omnidirectional, LED-based light fixture. It is a robust
construction designed for harsh weather environments with encapsulated electronics.
The housing is IP67 protected. The protrusion above ground is only 9 mm for minimal
risk of external mechanical impact. It can be mounted in shallow bases with a total
depth of only 100 mm. The SafeLED heliport inset light comes with a cable in order to
make the installation easy and safe.
1.1 SAFETY INSTRUCTIONS
Make sure you read this section and are familiar with safety precautions before any
work is started.
1.1.1 Product Safety
Airfield lighting fixtures in a constant current circuits are connected in a circuit via
isolating transformers with currents between 2.0 –6.6A in the primary circuits. The
primary voltages, depending on the circuitry, are usually several kilovolts and
therefore lethal. Although the open circuit voltages of the isolating transformers are
much lower, the peak voltage while opening the secondary circuit under current is
also hazardous. So it is vitally important to follow all the safety regulations with
adequate circumspection.
In the design of this equipment all the practical safety aspects have been taken into
account. It is also important to strictly follow existing international or national
regulations, the instructions established by civil aviation authority or airport operator
and the following instructions.
1.1.2 Electrical Maintenance
Valid safety regulations must always be followed. Never carry out any maintenance or
maintenance measures before the current is confirmed as safely disconnected. Use
extreme caution when disconnecting or connecting high voltage primary connectors.
WARNING! PRIOR TO THE COMMENCEMENT OF WORK ALL ELECTRICAL
SERVICES MUST BE ISOLATED FROM THE SUPPLY AND CONNECTED TO
EARTH. FULL DETAILS OF THE WORK INVOLVED MUST BE GIVEN TO THE
AUTHORISED PERSON RESPONSIBLE FOR THE ELECTRICAL ENGINEERING
SERVICES AT THE AIRPORT WITH REGARD TO THE DURATION OF THE WORK
AND SO ON. IT IS RECOMMENDED THAT PRIOR TO STARTING ANY CUTTING
WORK, THE NATURE AND LOCATION OF SERVICES SUCH AS CABLE DUCTS
AND THE LIKE SHOULD BE IDENTIFIED. ANY INSTALLATION OR MAINTENANCE
WORK SHOULD ONLY BE CARRIED OUT BY TRAINED AND EXPERIENCED
PERSONNEL. ALSO, WHEN WORKING ON CIRCUITS USING AIRFIELD SMART
POWER SYSTEM (ASP) THE SCM MUST BE TUNED OFF.
1.1.3 Mechanical Maintenance
When maintaining mechanical components, it is important to follow the instructions for
electrical maintenance.

Airfield Lighting Safegate Group
Manual Date: September 2014
Ref: SL-HF-I; SL-HT-I Version: 1.3
Page 4 of 16
1.2 DESCRIPTION OF THE FITTING
The SafeLED Heliport inset light is an 8” omnidirectional low projection LED light
fixture provided with optional green or white LED.
The light fixture is designed for parallel VAC circuits, 230V 50Hz.
1.2.1 Dimension of the Fitting and the Base
FIGURE 1 –HORIZONTAL
FIGURE 2 –VERTICAL
FIGURE 3 –DIMENSIONS FOR BASE
1.3 DELIVERY OF THE FITTING
The fitting comes ready for installation, each unit supplied completely assembled,
tested and sealed.

Airfield Lighting Safegate Group
Manual Date: September 2014
Ref: SL-HF-I; SL-HT-I Version: 1.3
Page 5 of 16
2. INSTALLATION
In this section you can find a description of the different steps for successful
installation of the fitting. Before you start, make sure you have read and understand
§1.1 Safety Instructions.
The SafeLED Heliport fitting can be installed in one of following:
a 8 inch shallow base, minimum height 100 mm with side or bottom entry for the
cable. The fitting is fixed with two M10 lock nuts
a 12 inch base with side or bottom entry. The fitting shall be installed together with
an AFL adapter ring 12”-8” with two M10 studs
an FAA L-868B deep base using adapter ring
The following tools are recommended for installation and removal of the fitting:
Box spanner (16mm)
Torque wrench (16mm)
Two big flat screwdrivers (for removal)
One brush or cloth
Note: Provided that the receiving base has been properly installed, no other tools are
required.
Typically, the installation steps refer to:
1. Installing/ removing the fitting
2. Electrical connections

Airfield Lighting Safegate Group
Manual Date: September 2014
Ref: SL-HF-I; SL-HT-I Version: 1.3
Page 6 of 16
2.1 INSTALLING/ REMOVING THE FITTING
Install
(a) Open the box and verify that the
characteristics of the fitting correspond to
your design requirements (type, colour etc.).
(b) Control the label on the fitting for product
information.
(c) Carefully clean all contact surfaces on the
fitting and the base (and if necessary on the
adaptor ring).
(d) Place the O-ring gasket on the fitting.
(e) Check that the fitting corresponds to the
actual installation position (colour, direction).
(f) Connect the fitting connector(s) to the base
supply cable(s).
(g) Place the connector under the fitting and
install on the base.
(h) For an installation on bases use a torque
limiting box spanner of 16 mm, install and
tighten the two M10 lock nuts to a torque of
35 Nm (= 3.5 kg m). For other base
manufacturers refer to their specifications.
(i) After installation, check that each fitting
works properly.
FIGURE 4 –INSTALLATION
Remove
WARNING! WHEN A FITTING HAS BEEN REMOVED, THE BASE MUST
BE FITTED WITH A COVER DESIGN FOR THIS PURPOSE OR WITH A
SPARE LIGHT FIXTURE.
(a) When removing the fitting, it is recommended to change the lock nuts each time
the fitting is dismounted.
(b) Remove the fitting from the base using two large flat blade screwdrivers.
(c) Disconnect the secondary supply connector.
(d) Remove the O-ring gasket. It is recommended to change the gasket each time the
fitting is removed from the base.

Airfield Lighting Safegate Group
Manual Date: September 2014
Ref: SL-HF-I; SL-HT-I Version: 1.3
Page 7 of 16
2.2 ELECTRICAL CONNECTIONS
The fittings for the heliport are power supplied with 230 Vac, 50Hz.
The design of the electrical circuits can include junction boxes, allowing connection in
parallel of the fittings. The drawing below shows an example of connections.
(A= Fitting, B= Junction Box and C= Sealed coupling)
FIGURE 5 –CONNECTIONS
Depending on the base used, the fitting can be connected in several ways:
directly to the junction box, with a connection cable (preferred)
to a cable connected to the junction box, with a sealed coupling (C in fig. 6.
Connections).
to a cable connected to the junction box, with terminals and heat shrinkable
sleeves. For this type of electrical connection, follow the general description
below:

Airfield Lighting Safegate Group
Manual Date: September 2014
Ref: SL-HF-I; SL-HT-I Version: 1.3
Page 8 of 16
FIGURE 6 –TERMINALS AND HEAD SHRINKABLE SLEEVES
2.2.1 Cable Grounding
For safety reasons the fitting shall be grounded with the protective earth (PE) ground
wire (green/yellow wire). It is recommended to use a separate fuse and a residual
current device on the circuit. For calculation of the fuse size, calculate with the given
power consumption for used fitting. The mains cable is a standard 3x1.0mm2cable
and has a length of 1 m.

Airfield Lighting Safegate Group
Manual Date: September 2014
Ref: SL-HF-I; SL-HT-I Version: 1.3
Page 9 of 16
3. MAINTENANCE
In this section you can find a description of the different steps for the maintenance of
the fitting.
Before you start, make sure you have read and understand §1.1 Safety Instructions.
Find out the location of the light unit that needs maintenance. If the purpose is to
replace an existing light unit with new one, make sure that corresponding unit is
available.
WARNING! WHEN A FITTING HAS BEEN REMOVED FROM ITS BASE, THE
BASE MUST BE EITHER FITTED WITH A COVER OR A RESERVE FITTING PUT
IN ITS PLACE.
IT IS RECOMMENDED THAT ONLY AUTORIZED PERSONNEL DISASSEMBLE
FITTINGS WITH PRIOR AGREEMENT FROM SAFEGATE.
The following tools and accessories are required for maintenance actions:
One angled socket spanner of 16 mm
One Torque limiting spanner with 16 mm and 5 mm adaptors
One Allen key of 5 mm
Two large flat blade screwdrivers (for removal of the fitting from its base)
Silicone grease (for housing screws)
One angled socket spanner of 12 mm (for the valve)
Sealing compound (for the valve)
One brush or cloth (general cleaning)
A compressor (or a manual car tyre pump) equipped with a manometer (for
the water tightness test)
3.1 BASIC MAINTENANCE PROGRAMME
There are recommended maintenance tasks to ensure that the equipment is in correct
operating condition.
Maintenance tasks
Weekly
Visual inspection of the fitting.
Removal of dust from external surfaces of the fitting.
Monthly
Check of the optical window, check for mechanical damage.
Check for proper fixing of the fitting in its base.
Yearly
Detailed inspection of the fitting.
Check of the body resistance, check for mechanical damage
(for example cracks around prism windows).
Clean of the optical windows.
Note: The basic maintenance program is intended for fittings at a standard Heliport
site in normal operating conditions.
It is recommended to verify that the fitting is water tight, after disassembly/ assembly,
before installation in the field (see § 3.2.1 Disassembling/ Assembling the Fitting).
A daily function check is referred to in the document:
ICAO, Airport Services Manual Part 9, Airport Maintenance Practice and FAA AC
150/5340-26A, Maintenance of airport visual aids facilities.

Airfield Lighting Safegate Group
Manual Date: September 2014
Ref: SL-HF-I; SL-HT-I Version: 1.3
Page 10 of 16
The light is designed for outdoor operation, however storing the light outside without
using it is a risk for damage to light components. For a longer storage time (more than
a week), it is recommended to store the light indoors in a dry and dust free
environment and at room temperature. Proper storage ensures trouble free
replacement procedures. It is strongly recommended not to store any electrical
equipment outside.
3.2 WORKSHOP MAINTENANCE
It is important to always make sure that the fitting is depressurized before disassembly
for maintenance work.
Before you start, make sure you have read and understand §1.1 Safety Instructions.
Note: Only the most common maintenance procedures are instructed in following
paragraphs. Construction of the luminaire allows a full disassembling and replacement
of all the parts if required.
The workshop maintenance refers to following actions:
1. Disassembling/ assembling the fitting
2. Replacing a LED assembly with holder
3. Replacing the prism and its gasket
3.2.1 Disassembling/ Assembling the Fitting
Disassemble
(a) Untighten the two housing screws using a
5 mm Allen key.
(b) Lift up the bottom cover and disconnect the
LED-board cable.
(c) Remove the O-ring gasket from the bottom
cover.
FIGURE 7 –DISASSEMBLY
Assemble
Carefully clean all contact surfaces of the fitting
and the cover.
(a) Place a new O-ring gasket in the track in the
bottom cover.
Note: The O-ring gasket must be changed
each time the fitting is opened.
(b) Connect the LED-board to the converter.
(c) Put the bottom cover back in place and
tighten the two screws using a torque
limiting spanner with a torque of 8 N m
(equivalent to 0.8 kg m or 8 g cm).

Airfield Lighting Safegate Group
Manual Date: September 2014
Ref: SL-HF-I; SL-HT-I Version: 1.3
Page 11 of 16
Water tightness check
It is recommended to verify that the fitting is
water tight:
(a) Remove the water tightness test valve cap.
(b) Fill up the fitting with compressed air (test
pressure = 140 kPa or 20 psi).
(c) Put the fitting in water, wait 3 minutes and
check if air bubbles leave the fitting.
If that is the case, the fitting is not water
tight. Disassemble the fitting once again to
check/clean all contact surfaces and check
gaskets. Replace if necessary.
3.2.2 Replacing a LED Assembly with Holder
Remove
(a) Disassemble the fitting (see § 3.2.1
Disassembling/ Assembling the Fitting).
(b) Using a 5 mm Allen key, unscrew and
remove the fixing screws of the prism
holder.
(c) Remove the LED assembly.
FIGURE 8 –LED
Replace
(a) Connect cable from the converter to the
LED-board
(b) Place a new LED assembly on the fitting.
(c) Fasten the LED holder assembly using the 6
M6x20 mm fixing screws with a torque
limiting spanner with a torque of 6,5 N m,
(see fig 10 –Fixing screw order).
(d) Assemble the fitting (see § 3.2.1
Disassembling/ Assembling the Fitting).
FIGURE 9 –FIXING SCREW ORDER

Airfield Lighting Safegate Group
Manual Date: September 2014
Ref: SL-HF-I; SL-HT-I Version: 1.3
Page 12 of 16
3.2.3 Replacing the Prism and its Gasket
Remove
(a) Disassemble the fitting (see § 3.2.1
Disassembling/ Assembling the Fitting).
(b) Using a 5 mm Allen key, untighten and
remove the 6 fixing screws of the LED
assembly.
(c) Remove the LED assembly and protection
washer.
(d) From outside the fitting body, push out the
prism.
(e) Remove the prism and gasket from the
fitting body.
(f) Clean the contact surfaces of the window on
the fitting body.
FIGURE 10 –PRISM
Replace
(a) Mount the new gasket in the fitting body.
Note: It is recommended to change the
gasket each time a prism is removed.
(b) Insert the prism in the gasket in the fitting
body window.
(c) Install the plastic washer and LED holder
assembly.
(d) Install and tighten the prism holder and LED
assembly screws.
(e) Assemble the fitting (see § 3.2.1
Disassembling/ Assembling the Fitting).

Airfield Lighting Safegate Group
Manual Date: September 2014
Ref: SL-HF-I; SL-HT-I Version: 1.3
Page 13 of 16
4. SUPPORT
Our experienced engineers are available for support and service at all times,
24 hour/7 days a week. They are part of a dynamic organization making sure the
entire Safegate Group is committed to minimal disturbance for airport operations.
Safegate Group Support
Safegate Group knows that our equipment is used
in one of the busiest industries in the world, where
down-time costs money and creates delays for
airlines and their passengers. As one of the world’s
leading suppliers of airport systems, Safegate
Group is committed to ensuring that our customers
are able to get the most out of your equipment,
regardless of the location or the time of day. For
this reason, Safegate Group has established the
Safegate Group Support service.
Safegate Group Support is a unique service
provided by Safegate Group to our customers, free
of charge during the warranty period or as a
service contract. Any time of day, any day of the
year, a Safegate Group engineer is on standby to
answer questions and assist with any problems
that may arise. Qualified technical assistance is
just a phone call or an e-mail away,
24-7 worldwide.
[e-mail]
[phone]
4.1 SAFEGATE GROUP WEBSITE
The Safegate Group Website, www.safegate.com, offers information regarding our
airport solutions, products, company, news, links, downloads, references, contacts
and more.
Note: There is also a Client/Partner login area for the latest information and
updates, if available.
4.2 RE-CYCLING
4.2.1 Local Authority Re-cycling
The disposal of Safegate Group products is to be made at an applicable collection
point for the recycling of electrical and electronic equipment. The correct disposal of
equipment prevents any potential negative consequences for the environment and
human health, which could otherwise be caused by inappropriate waste handling. The
recycling of materials helps to conserve natural resources. For more detailed
information about recycling of products, contact your local authority city office.
4.2.2 Safegate Group Re-cycling
Safegate Group is fully committed to environmentally-conscious manufacturing with
strict monitoring of our own processes as well as supplier components and sub-
contractor operations. Safegate Group offers a re-cycling program for our products to
all customers worldwide, whether or not the products were sold within the EU.

Airfield Lighting Safegate Group
Manual Date: September 2014
Ref: SL-HF-I; SL-HT-I Version: 1.3
Page 14 of 16
Safegate Group products and/or specific electrical and electronic component parts
which are fully removed/separated from any customer equipment and returned will be
accepted for our recycling program.
All items returned must be clearly labelled as follows:
For ROHS/WEEE Re-cycling.
Sender contact information (Name, Business Address, Phone number).
Main Unit Serial Number.
Safegate Group will continue to monitor and update according for any future
requirements for EU directives as and when EU member states implement new
regulations and or amendments. It is our aim to maintain our compliance plan and
assist our customers.
Note: For more information, see www.safegate.com, or contact Safegate Group
Support via email at [e-mail] or phone [phone].
4.3 SPARE PARTS
Spare parts are available for Airfield Lighting fittings. For more information see the
Spare Parts List document.
Note: Contact Safegate Group for assistance with ordering spare parts.

Airfield Lighting Safegate Group
Manual Date: September 2014
Ref: SL-HF-I; SL-HT-I Version: 1.3
Page 15 of 16
Note: This page is blank for convenient double-sided printing.

Airfield Lighting Safegate Group
Manual Date: September 2014
Ref: SL-HF-I; SL-HT-I Version: 1.3
Page 16 of 16
Check in to the future
How many aircraft can your
airport handle today?
Can this number be increased
without adverse effects on the
airport’s safety level?
It is a known fact that traffic
volume will rise in the foreseeable
future. More movements will
demand monitoring of the entire
airport. Requirements will be
sharpened and the development
of an integrated system
controlling not only ground
movements but also air traffic
close to the airport is of the
highest interest.
The International Civil Aviation
Organization (ICAO) already
describes A-SMGCS, Advanced
Surface Movement Guidance and
Control System, as the answer to
the future modern airport need to
control the entire airport space in
one superior system.
To a larger extent than today’s
systems, A-SMGCS will rely on
automated processes to give both
pilots and traffic controllers exact
information about positions and
directions. Safegate Group
delivers complete A-SMGCS
solutions already, as well as all
vital parts relating to it.
Safegate Group can check your
airport into the future
–today!
www.safegate.com
Safegate Group offers solutions for increased safety, efficiency and environmental benefits to airports worldwide. The company was founded in 1973 and has its
headquarters in Malmö, Sweden. Safegate Group has more than 70 partners around the globe in order to be close to its customers.
Earlier members of Safegate Group include Thorn AFL and Idman, who both have over 40 years of experience in airfield lighting solutions for airports and
heliports. The latest member of Safegate Group is Avibit, a leading provider of next generation software applications and integration of efficient air traffic control
systems. Safegate Group’s complete range of products and services, a “one-stop shop”, provides solutions to customers and airborne travellers around the globe.
Safegate Group HQ
Djurhagegatan 19
SE-213 76 Malmö, Sweden
Phone: [phone]
Fax: [phone]
E-mail: [e-mail]
Australia
[e-mail]
[phone]
Austria
[e-mail]
[phone]
Brazil
[e-mail]
[phone]
China
[e-mail]
[phone]
Dubai
[e-mail]
[phone]
Finland
[e-mail]
[phone]
France
[e-mail]
[phone]
Germany
[e-mail]
[phone]
India
[e-mail]
[phone]
Malaysia
[e-mail]
[phone]
Qatar
[e-mail]
[phone]
Russia
[e-mail]
[phone]
Singapore
[e-mail]
[phone]
Spain
[e-mail]
[phone]
UK
[email protected]
[phone]
USA
[e-mail]
[phone]