TKH 921 User manual

Runway Guard Lights - type 921
Installation and Maintenance Instructions
LED AGL
Airfield Ground Lighting
03-71087
V2.0

Please read carefully and understand the contents of this manual.
Failure to read the manual may result in serious injury or even death, or serious damage to
equipment.
Make sure this manual is always accessible for all users and ensure you have read and
understood the contents.
Copyright ©TKH Airport Solutions 2022
All rights reserved for TKH Airport Solutions. No part of this publication may be reproduced, modified, stored in a retrieval system, or
transmitted, by any means or in any form without the written permission of the copyright owner.
The content of this document is property of TKH Airport Solutions. Proprietary rights of TKH Airport Solutions B.V. or its affiliated
companies include the following: The specified (product) information herein and all related data and information are proprietary and
confidential to TKH Airport Solutions B.V. and are the subject of trade secrets and copy licensed from TKH Airport Solutions B.V. The
related data and information are provided in confidence, and all use, disclosure, copying, transfer and storage, except as authorized in
the written License Agreement from TKH Airport Solutions B.V. to the user, is strictly prohibited.
The English version of this document is the original version; this language version is verified by the manufacturer. All other language
versions are translations of the original English language version.

Contents
1 About this Manual........................................................................................................................4
1.1 Limitations of the Document................................................................................................................. 4
1.2 Liability and Warranty............................................................................................................................4
1.3 Storing the Manual................................................................................................................................4
1.4 Terms and Abbreviations...................................................................................................................... 5
1.5 Manufacturer Details............................................................................................................................. 5
1.6 Document Information........................................................................................................................... 5
2 Safety Instructions.......................................................................................................................6
2.1 Safety.....................................................................................................................................................6
2.2 Qualified Personnel...............................................................................................................................6
2.3 Intended use..........................................................................................................................................6
2.4 Installation..............................................................................................................................................7
2.5 Operation...............................................................................................................................................7
2.6 Action in the event of a system or component malfunction..................................................................8
3 About the Runway Guard Lights - type 921............................................................................. 9
3.1 Electronics............................................................................................................................................. 9
3.2 Light Output Performance.....................................................................................................................9
3.3 Configurations......................................................................................................................................10
3.4 Accessories..........................................................................................................................................11
3.5 RGL-921 Spare Parts..........................................................................................................................11
4 General Recommendations.......................................................................................................13
4.1 Receiving, Storage and Unpacking.....................................................................................................13
4.2 Electrical Connection...........................................................................................................................13
4.3 Base Earthing......................................................................................................................................13
5 Installation...................................................................................................................................14
5.1 Unpacking the RGL-921......................................................................................................................14
5.2 Installation in the Field........................................................................................................................14
6 Maintenance................................................................................................................................15
6.1 Warranty Limitation..............................................................................................................................15
6.2 Maintenance in the Field.....................................................................................................................15
6.3 Maintenance in the Workshop............................................................................................................ 15
6.3.1 Changing the Front Glass...........................................................................................................16
6.3.2 Replacing the Complete LED Light Unit.....................................................................................17
7 Adjustment..................................................................................................................................19
7.1 Aligning the Fixtures............................................................................................................................19
7.1.1 Directional Alignment of Elevated Fixtures.................................................................................20
7.1.2 Operation.....................................................................................................................................22
7.1.3 Storage........................................................................................................................................24
Installation and Maintenance Instructions - LED AGL Runway Guard Lights - type 921
©TKH Airport Solutions 2022. All rights reserved. 3

1 About this Manual
This manual contains information about the installation and maintenance of the LED AGL Runway Guard
Lights - type 921 (RGL-921 ).
1.1 Limitations of the Document
TKH Airport Solutions reserves the right to revise this document without notification.
The data provided in this document is based on the most recent information at the time of publication. TKH
Airport Solutions is continually seeking to ensure that its products are developed to the latest technological
standards. As a result, it is possible that there may be some differences between the product and the
information in this manual.
For further information regarding adjustment, maintenance or repair which is not described in this document,
please contact the Customer Service department of TKH Airport Solutions.
The information in this document concentrates solely on use of the products as intended by the
manufacturer.
1.2 Liability and Warranty
TKH Airport Solutions cannot be held responsible for injuries or damage resulting from non-standard,
unintended use, faulty or improper installation of its equipment, or failure to follow the instructions and safety
guidelines in this manual. The safety of any system incorporating the LED AGL Runway Guard Lights - type
921 is the responsibility of any site installation, commissioning, maintenance, and operational personnel
using the system.
Disregarding the safety instructions in this manual will result in the loss of warranty in
case of damage.
Refer to the general TKH Airport Solutions Terms and Conditions document supplied with your sales order
contract for a complete liability and warranty description.
1.3 Storing the Manual
This Installation and Maintenance Instructions is a part of your product. Store the manual in a location that
can be easily accessed by personnel working on the product.
It is the responsibility of the company operating this equipment to ensure that its personnel is provided with a
copy of this manual.
4Installation and Maintenance Instructions - LED AGL Runway Guard Lights - type 921
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1.4 Terms and Abbreviations
AGL Airfield Ground Lighting
EASA European Aviation Safety Agency
ICAO International Civil Aviation Organization
IEC International Electrotechnical Committee
LED Light Emitting Diode
1.5 Manufacturer Details
TKH Airport Solutions
Elektrostraat 17 P.O. Box 236 Telephone: [phone]
7483 PG Haaksbergen 7480 AE Haaksbergen [email protected]
The Netherlands The Netherlands http://www.tkh-airportsolutions.com
For service requests, please contact the TKH Airport Solutions Customer Service department service@tkh-
airportsolutions.com
1.6 Document Information
Name : 05_LED-AGL_Runway_Guard_Lights_921_03-71087
Version : V2.0
Language : English (Original manual)
For the latest version of this document see https://www.tkh-airportsolutions.com/airfield-products/ or scan:
Installation and Maintenance Instructions - LED AGL Runway Guard Lights - type 921
©TKH Airport Solutions 2022. All rights reserved. 5

2 Safety Instructions
2.1 Safety
This section contains general safety instructions for using your TKH Airport Solutions equipment. Some
safety instructions may not apply to the equipment in this manual. Note all warnings and follow all
instructions carefully. Failure to do so may result in personal injury, death, or property damage.
To use this equipment safely,
• Refer to the International Standard IEC 61820, Electrical installation for lighting and beaconing of
aerodromes - Constant current series circuits for aeronautical ground lighting - System design and
installation requirements, and to the International Standard IEC 61821, Electrical installations for lighting
and beaconing of aerodromes - Maintenance of aeronautical ground lighting constant current series
circuits for instructions on safety precautions.
• Observe all safety regulations. To avoid injuries, always remove power prior to making any wire
connections and touching any live part. Refer to the International Standards IEC 61820 & IEC 61821.
• Read and become familiar with the general safety instructions provided in this section of the manual
before installing, operating, maintaining, or repairing this equipment.
• Read and carefully follow the instructions given throughout this manual for performing specific tasks and
working with specific equipment.
• Store this manual within easy reach of personnel installing, operating, maintaining, or repairing this
equipment.
• Follow all applicable safety procedures required by your company, industry standards, and government or
other regulatory agencies.
2.2 Qualified Personnel
The term "qualified personnel" is defined here as an individual who thoroughly understands the equipment
and its safe installation, operation, maintenance, and repair. Qualified personnel are physically capable of
performing the required tasks, familiar with all relevant safety rules and regulations, and have been trained
to safely install, operate, maintain, and repair the equipment. It is the responsibility of the company installing,
operating or maintaining this equipment to ensure that its personnel meet these requirements.
2.3 Intended use
Use of this equipment in ways other than described in the datasheet and this manual may result in personal
injury, death, or property damage. TKH Airport Solutions cannot be held responsible for injuries or damage
resulting from non-standard, unintended application 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 use. Unintended use may result from taking the following actions:
• making changes to equipment that have not been recommended or described in this manual or using
parts that are not genuine TKH Airport Solutions replacement parts or accessories
• using materials or auxiliary equipment that are inappropriate or incompatible with your TKH Airport
Solutions equipment
• allowing unqualified personnel to perform any task
6Installation and Maintenance Instructions - LED AGL Runway Guard Lights - type 921
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2.4 Installation
Read the safety and installation sections of all system component manuals before installing your equipment.
A thorough understanding of system components and their requirements will help you install the system
safely and efficiently. Failure to follow these safety procedures can result in personal injury or death.
• Allow only qualified personnel to install TKH Airport Solutions and auxiliary equipment. Use only approved
equipment. Using unapproved equipment in an approved system may void agency approvals and will void
the warranty.
• 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.
• Do not hold / carry the light assemblies by the cables.
• Install all electrical connections to local codes provided they are not in contradiction with the general
rules.
• Use only electrical wire of sufficient gauge and insulation to handle the rated current and voltage demand.
All wiring must meet local codes.
• Route electrical wiring along a protected path. Make sure the wires will not be damaged by moving
equipment and animals (e.g. rodents).
• Protect components from damage, wear, and harsh environmental conditions.
• Allow sufficient room for maintenance, panel accessibility (power products), and cover removal (power
products).
• 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.
2.5 Operation
Only qualified personnel (see Qualified Personnel on page 6) should operate this equipment. Read
all system component manuals before operating this equipment. A thorough understanding of system
components and their operation will help you operate the system safely and efficiently.
• Before starting this equipment, check all safety interlocks, fire-detection systems, and protective devices
such as panels and covers. Make sure all devices are fully functional. Do not operate the system if these
devices are not working properly. Do not deactivate or bypass automatic safety interlocks or locked-out
electrical disconnects or pneumatic valves.
• Never operate equipment with a known malfunction.
• Do not attempt to operate or service electrical equipment if standing water is present.
• Use this equipment only in the environments for which it is rated. Do not operate this equipment in humid,
flammable, or explosive environments unless it has been rated for safe operation in these environments.
• Never touch exposed electrical connections on equipment while the power is ON.
• Never look directly in the light source while the power is ON.
Installation and Maintenance Instructions - LED AGL Runway Guard Lights - type 921
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2.6 Action in the event of a system or component malfunction
Do not operate a system that contains malfunctioning components. If a component malfunctions, turn the
system OFF immediately.
• Disconnect and lock out electrical power.
• Allow only qualified personnel to make repairs. Repair or replace the malfunctioning component
according to instructions provided in its manual. Allow only qualified personnel to perform maintenance,
troubleshooting, and repair tasks. Only persons who are properly trained and familiar with TKH Airport
Solutions equipment are permitted to service this equipment.
• Follow the recommended maintenance procedures in your equipment manuals.
• Connect all disconnected equipment ground cables and wires after servicing equipment. Ground all
conductive equipment.
• Use only approved TKH Airport Solutions replacement parts. Using unapproved parts or making
unapproved modifications to equipment may void agency approvals, impair specified performance and
create safety hazards.
• Check interlock systems periodically to ensure their effectiveness.
• Do not attempt to service electrical equipment if standing water is present. Use caution when servicing
electrical equipment in a high-humidity environment.
• Use tools with insulated handles when working with electrical equipment.
8Installation and Maintenance Instructions - LED AGL Runway Guard Lights - type 921
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3 About the Runway Guard Lights - type 921
TKH Airport Solutions RGL-921 light fixtures are constructed mainly by using standard components from
TKH Airport Solutions standard program of elevated fixtures.
Each light assembly has two LED light fixtures. Each light fixture is a unidirectional, yellow light.
Each light fixture can be individually aligned (see Adjustment on page 19). The light assembly has a
breakable coupling designed for 2” (60 mm) stake mounting (Type C) or with 2” thread stub (Type A).
3.1 Electronics
The driver electronics for the LED modules are identical to the electronics used in TKH Airport Solutions
unidirectional LED light fixture type 792.
The electronics will transfer the RMS value of the 6.6 A series circuit current into the necessary LED current.
The electronics is informed about the LED current needed from the EPROM memory on the LED module.
The electronics also have a built-in facility for flashing the LEDs, and automatically synchronizing to the AC
input when switched on. One of the two light units is programmed to start OFF and the other to start ON, and
the two lights stay synchronized by means of counting the half waves on the power supply. The RGL units
can be ordered with or without activated internal flasher.
3.2 Light Output Performance
Three parameters are essential for the correct light output.
The color of the LED output together with the yellow front glass defines the correct color.
The LED light output together with the lens on each LED defines the correct light distribution.
Installation and Maintenance Instructions - LED AGL Runway Guard Lights - type 921
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3.3 Configurations
Configura-
tion RGL Types (A or C breakable coupling) Drawing Description
A921880 (A)
921885 (B)
Standard installation:
• No Fail-Open
• One FAA plug
• Automatic synchronization and
flashing
B921890 (A)
921895 (B)
Standard installation:
• Built-in Fail-Open
• One FAA plug
• Automatic synchronization and
flashing
Failure in one lamp will activate Fail-
Open and both lamps are switched
off.
C921900 (A)
921905 (B)
Installation for external flasher:
• No Fail-Open
• Two FAA plugs
• No synchronization and flashing;
programmed for steady burning
D921910 (A)
921915 (B)
Installation for external flasher:
• Two Fail-Open relays
• Two FAA plugs
• No synchronization and flashing;
programmed for steady burning
Failure in one lamp will activate the
respective Fail-Open relays, and the
other lamp will continue to work.
E921935 (A)
921940 (B)
230 V installation:
• Special 230 V RGL trafo is needed
(Type K921920)
• Output options 15%, 30% and
100% light intensity
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3.4 Accessories
Optional:
• 792.119 - Adjustment kit for alignment
3.5 RGL-921 Spare Parts
Installation and Maintenance Instructions - LED AGL Runway Guard Lights - type 921
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Pos. Name Type Number
per
Light
1 Front glass, yellow P-382305 2
2 Spring for front glass 792006/1 2
3 Alu-housing 792011 2
4 Sun shade 792060 2
5a1RGL LED spare light unit, complete, STEADY 792883 0/2
5b1RGL LED spare light unit, complete, ON 792886 0/1
5c1RGL LED spare light unit, complete, ON with FO 792886-FO 0/1
5d1RGL LED spare light unit, complete, OFF 792887 0/1
5e1RGL LED spare light unit, complete, OFF with FO 792887-FO 0/1
5f1RGL LED spare light unit, complete, 230 V 792896.206
6 Housing group with electronics 190.774-257 2
7 Flat Gasket 8-inch 190.779-007 2
8 O-ring gasket 792014/2 2
9 Stainless lock P-855506 4
10a Breakable coupling type C 790901/2 0/1
10b Breakable coupling type A 790518/2 0/1
11 Cable with FAA plug style 1 P-510.064 1/2
12 Y-tube with box 921205/1 1
13 PVC plug P-850.150 2
14 PVC roundel P-855.001 2
15 Adjustment fixing assembly 790021+790022+P-902.841 2
16 Electrical assembling box P-411.240 1
17 Grommet P-850.056 1
18 Flat-band cable 182.780-00 2
19 Trafo for 230 V RGL K-921920 0/1
1Label at position 6 indicates program version or type of Flash operation.
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4 General Recommendations
4.1 Receiving, Storage and Unpacking
1. Upon receipt of goods at the site store, check all packaging for visible damage. Every damaged box
should be opened and its contents inspected for damage. If equipment is damaged, a claim form shall
be filled with the carrier immediately. It may then be necessary for the carrier to inspect the equipment.
2. Store the light assembly preferably in its original packaging in a protected area. When stored unpacked,
please take care not to damage the cable insulation.
3. Unpack the light assembly at the installation site to avoid damage during transportation and handling.
4.2 Electrical Connection
The light assemblies covered by this manual are designed for connection to 6.6 or 20-A series circuits via
one or two L-830 or L-831 series transformers. The current to the light should not exceed 6.6 A + 5%. The
series transformers are to be ordered separately.
4.3 Base Earthing
Whatever the chosen installation method, it is strongly recommended to earth the base, especially in
locations presenting a risk of lightning strikes. Failure to earth the base correctly will void the warranty for all
damages occurring as a result of voltage surges.
Installation and Maintenance Instructions - LED AGL Runway Guard Lights - type 921
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5 Installation
5.1 Unpacking the RGL-921
Unpack the equipment and make sure that nothing is broken before starting installation.
The RGL-921 light fixtures are not pre-adjusted in the factory and must be adjusted before taking into
operation.
5.2 Installation in the Field
1. Connect the pre-adjusted light fixture electrically.
2. Mount the light fixture in the breakable coupling without tightening the screws in the coupling.
3. Turn the pylon until it is perpendicular to a line towards a point in the middle of the taxiway, 100 m away
from the RGL line.
4. Tighten the screws in the breakable coupling to the torque shown below using a torque wrench.
14 Installation and Maintenance Instructions - LED AGL Runway Guard Lights - type 921
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6 Maintenance
6.1 Warranty Limitation
The light assemblies are delivered fully tested and sealed. In case of malfunctioning during the warranty
period, the defective light shall be shipped back to TKH Airport Solutions without opening it. Any attempt to
open the light during the warranty period will void the warranty.
The front glasses are not included in the warranty.
6.2 Maintenance in the Field
It is recommended to limit field maintenance to cleaning the front glasses. The light fixtures should be
replaced at regular intervals and overhauled in the maintenance workshop.
• Every 6 months:
• Check the alignment of light fixtures and adjust if necessary (See Adjustment on page 19.)
• Regularly:
• Clean the front glass if necessary.
• Perform a visual check that both light fixtures display a similar light output.
6.3 Maintenance in the Workshop
The pictures in the steps below may differ from your model. The actions described are,
however, the same for all models.
Installation and Maintenance Instructions - LED AGL Runway Guard Lights - type 921
©TKH Airport Solutions 2022. All rights reserved. 15

6.3.1 Changing the Front Glass
To exchange the front glass, follow the instructions below:
1. Use a small screwdriver to press out the spring through the hole at the base of the housing.
2. Remove the spring and front glass.
3. Check the rubber gasket thoroughly, and replace with a new one if necessary.
4. Place the new front glass.
5. Remount the spring with the open part pointing downwards towards the fixture foot. Make sure the
spring is pushed firmly into the slot.
The hole in the rim (a) must be covered by the spring (b).
16 Installation and Maintenance Instructions - LED AGL Runway Guard Lights - type 921
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6. Use slip-joint pliers to pinch around the rim of the unit, to ensure that the metal spring is pushed all the
way into the slot in the housing. Wrap tape around the jaws of the pliers to avoid scratching the paint.
6.3.2 Replacing the Complete LED Light Unit
To de-install the light unit and install a new unit, follow the instructions below:
1. De-install the LED light unit:
a. Open the 2 spring locks on each side of the unit and lift the LED light unit out of the yellow
housing.
b. Unplug the power supply cable from the LED light unit.
c. Disconnect the earth wire from the LED light unit.
Installation and Maintenance Instructions - LED AGL Runway Guard Lights - type 921
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2. Install the new LED light unit
a. Reconnect the earth wire to the new LED light unit.
b. Reconnect the power supply cable to the new LED light unit. Either use long-nose pliers, or
remove the front glass to ease access. Follow the instructions in Changing the Front Glass on
page 16 to remove and remount the front glass.
If a black plastic cover is mounted on the power cable, make sure the
cover is firmly pressed down onto the black ball joint.
2.a 2.b
c. Insert the new LED light unit into the yellow housing.
d. Close the spring locks.
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7 Adjustment
7.1 Aligning the Fixtures
The following tools enable you to make precise in-line alignment of groups of light fixtures, or of an individual
fixture in relation to a fixed point:
• Adjustment kit 792.119, consisting of:
1. Adjustment tool 792.116
2. Alignment telescope tool kit 792.118 (including mounting accessories)
Never look at the sun through the optical sights - it may permanently damage your eyes.
Installation and Maintenance Instructions - LED AGL Runway Guard Lights - type 921
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7.1.1 Directional Alignment of Elevated Fixtures
To set up the adjustment tool and alignment telescope, follow the instructions below:
1. Mount the adjustment tool onto the light fixture:
a. Ensure that the pins are in the right position.
b. Tighten the screw.
2. Adjust the elevation by inserting the upper blue cable pin into the hole for the required vertical angle.
3. Mount the telescope kit:
20 Installation and Maintenance Instructions - LED AGL Runway Guard Lights - type 921
©TKH Airport Solutions 2022. All rights reserved.