UEL Manual

Instruction Manual AM.02.
630e
Edition 1.3
High Intensity Unidirectional Elevated Light

for Approach, Threshold and Runway End and for Sequenced Flashing Lights (SFLS) or Runway Threshold Identification (RTILS) Systems
Type UEL
AM.02.630e edition 1
Record of Changes AM.02.630e
Revision 1.0 New manual
Description
Editor Checked BUG MR
Date 03/04
1.1
Addition of some spare parts
MR
BUG
05/04
1.2
Position of the clear front glass
BUG
MR
05/04
1.3
Code number spare parts
EV
MR
04/05
Safety Instructions
Safety precautions
Operating and maintenance personnel should refer to ICAO Airport Services Manual Part 9, Airport Maintenance Practices and to FAA Advisory Circular AC 150/5340-26 "Maintenance of Airport Visual Aid Facilities" for instructions on safety precautions. Personnel must always observe the safety regulations. The equipment has been designed and manufactured to allow safe and secure operation, however, the following rules must be strictly observed.
Keep away from Operating and maintenance personnel must always observe all safety regulations. live circuits Do not change lamps or components or make adjustments to equipment when the light circuit is switched on. See FAA Advisory Circular AC 150/5340-26 concerning safety.
Resuscitation
Operating and maintenance personnel should get acquainted with the resuscitation techniques described in the First Aid Instruction Manual as issued by the Red Cross Organisation or similar.
Use Restriction Notice and Warranty
Use restriction notice
The content of this Instruction Manual is the property of n.v. ADB s.a. 585, Leuvensesteenweg B-1930 Zaventem - Belgium Tel. 32 2 722 17 11 Fax 32 2 722 17 64
E-mail: adb-air@adb.be Internet: http://www.adb-air.com This manual or parts thereof may not be reproduced, stored in a retrieval system or transmitted, in any form or by any means, electronic, mechanical, photocopying, recording or otherwise, without ADB's prior written consent.
Warranty
N.V. ADB S.A. guarantees that the performance of the products described in this manual, when sold by ADB or its licensed representatives, meets the requirements of ICAO Annex 14, Volume 1, and FAA specification AC 150/5345-46. Any defect in design, material or workmanship, which may occur during proper and normal use over a period of one (1) year from date of shipment, will be repaired or replaced by ADB free of charge, ex works. Operational failure resulting from lamp burnt out, improper maintenance or installation, damage due to runway maintenance equipment, snow ploughs or aircraft arresting gear hooks is not considered a result of proper use and is beyond the scope of the warranty. Warranty does not cover natural wear and tear nor damage arising after delivery owing to faulty or negligent handling, excessive strain, unsuitable materials for operation, deficient civil engineering work, unsuitable soil conditions, and such chemical, electrochemical or electrical influences as were not assumed at the time of the contract. All liability for consequences of any inexpert alterations or repairs carried out by Purchaser or a third party shall be waived. N.V. ADB S.A. shall in no event be liable to Purchaser for any further claims, particularly claims for damages not affecting the goods themselves. The above constitutes the limits of ADBs liabilities in connection with the products covered by this manual.
Information about this Manual
Chapter Overview Using Icons
Each chapter starts with an overview of the topics treated in that chapter.
Icons are used to attract the attention of the reader to specific information. The meaning of each icon is described in the table below: Type of information Description A note provides information that is not indispensable, but may nevertheless be valuable to the reader, such as hints and tips. A caution is used when there is danger that the reader, through incorrect manipulation, may damage equipment, get an unexpected result or has to restart (part of) a procedure. A warning is used when there is danger of personal injury. A reference guides the reader to other places in this manual, where he/she will find additional information on a specific topic.
Icon
Note Caution
Warning Reference
Parts identification
Parts identification symbols (1, 2, 3, 4, ) appearing in the text refer to the Exploded views page 38.
Comments and This manual has been compiled with all possible care and in view of providing a valuable and practical tool to the Airport Maintenance personnel. proposals We encourage customers to address us their comments and proposals for improving further the contents of this manual. Communications should be addressed to the After Sales department of ADB: n.v. ADB s.a. 585, Leuvensesteenweg B-1930 Zaventem - Belgium Tel. 32 2 722 17 11 Fax 32 2 722 17 64
E-mail: adb-air@adb.be Internet: http://www.adb-air.com
Table of Contents
Safety Instructions Use Restriction Notice and Warranty Information about this Manual Chapter 1: General Information and Requirements General information Product data Chapter 2: Installation General recommendations Equipment required for installation How to mount the UEL at ground level How to mount the UEL on a 60mm O.D. conduit How to mount the UEL on a safety approach mast Chapter 3: Orientation and elevation settings Standard levelling device Electronic levelling device Commissioning Chapter 4: Maintenance Preventive maintenance How to replace the lamp How to dismantle the optical assembly Chapter 5: Troubleshooting Chapter 6: Assemblies and Exploded Views Assemblies Exploded views
2 3 4 6 7 8 10 11 12 13 16 20 22 23 25 27 28 29 30 32 33 34 35 38
Chapter 1: General Information and Requirements Overview
Introduction
In this chapter you will find general information about the UEL lights.
Contents
This chapter contains the following topics. Topic General information Product data See Page 7 8
Chapter 1: General Information and Requirements
General information
UEL
The UEL-1-150 steady burning lights are used for: Precision Approach lighting in Cat. I, II and III in white and red light, Threshold and Threshold wingbar lighting in Cat. I, II and III in green light, Runway end lighting in Cat. I, II and III in red light, Supplementary elevated stopbar lights. The UEL-1-120 flashing lights are used for: Sequence Flashing Lights (SFLS) or Runway Threshold Identification Lights (RTILS), using a low voltage (400V) Xenon flash lamp.
Model definition
The UEL-1-150 is a steady burning unidirectional elevated light. The UEL-1-120 is a flashing unidirectional elevated light used in a flashing system in combination with the ADB control cabinets FCU. Refer to the exploded views, starting from page 38.
Installation
They are shipped ready for installation and can be mounted in three different ways, on any support with a 60mm outer diameter mounting interface: At ground level, On a 60mm O.D. conduit, On a safety approach mast.
Purpose of this manual
This manual describes the procedures for installation, maintenance and troubleshooting of the ADB type UEL lights.
Scope of this manual
This manual covers the light fixtures suitable for use in systems described in ICAO Annex 14, Attachment A, Section 11. The light construction is in compliance with FAA E 982 specification for the general functional constructional requirements, and with AC150/5345-46B for mechanical & environmental properties. This light also complies with NATO STANAG 3316. Operation beyond the limitations mentioned in those specifications may result in degradation of performance, damage or failure of components or hazardous conditions.
Product data
Equipment supplied
UEL units are either packed individually in a durable, cushioned and corrugated cardboard box, labelled with ADB and ordering numbers, or on pallet boxes in larger quantities. Depending on the ordered code number, the fittings are supplied:

with lamp (packed separately), with or without power supply cable cable (packed separately), with or without top light (see page 38).
Unless contractually specified differently, one instruction manual is delivered per order.
UEL dimensions
170
145
The illustration below gives you the outside dimensions of the UEL light, in mm.
Technical data
The table below lists technical data of the UEL. Type Input Rated lamp life Temperature range Humidity Protection class Altitude Wind Weight UEL-1-150 6.6 A 1000 hours - 55C to + 55C up to 100% IP 44 Sea level to 3000 m Velocities up to 560 km/hr Approx. 1.7 kg UEL-1-120 400 V (through FCU cabinet) 3.600.000 flashes - 55C to + 55C up to 100% IP 44 Sea level to 3000 m Velocities up to 560 km/hr Approx. 2,0 kg
270
AM.02.630e edition 1 Ordering codes and reference data pertinent to the product are listed in the tables References on page 36.
Chapter 2: Installation Overview
Introduction
This chapter instructs you on how to install the UEL lights. Generally, the installation complies with the applicable sections in the ICAO Aerodrome Design Manual, part 4, FAA Advisory Circulars and, if applicable, other National Codes or local rules.
Mounting methods
The UEL can be mounted in three different ways, on any support with a 60mm outer diameter mounting interface: At ground level, On a 60mm O.D. conduit, On a safety approach mast.
Contents
This chapter contains the following topics. Topic General recommendations Equipment required for installation How to mount the UEL at ground level How to mount the UEL on a 60mm O.D. conduit How to mount the UEL on a safety approach mast See Page 11 12 13 16 20
Chapter 2: Installation
10
General recommendations
Receiving, storage and unpacking
1. Upon receipt of goods at the site store, check all packings for visible damage. Every damaged box should be opened and its content inspected for damage. If equipment is damaged, a claim form shall be filed 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 packing 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.
Electrical connection
The UEL-1-150 light assemblies are designed for connection to 6.6 or 20 Amps series circuits via one FAA L-830 or L-831 isolation transformer (type ADB : RST), with a nominal secondary current of 6,6A. Refer to ADB cat. leaflet A.06.110 or Instruction manual AM.06.110 for more information on isolation transformers. The isolation transformers are to be ordered separately. The UEL-1-120 light assemblies are designed for connection to a FCU control cabinet by means of a 5-core cable. Refer to ADB Instruction Manual A.02.6200 for more information on the connection to the FCU control cabinet and the type of cable to use. The FCU control cabinets are to be ordered separately.
Elevation and azimuth setting angles
Elevation and azimuth setting angles according to the specific use and location of the light can be found in ICAO Annex 14, Appendix 2, Fig. 2.1 to 2.4 and 2.8.
Refer to Chapter 3: Orientation and elevation settings, page 22 of this manual, for instructions about how to set the elevation angle.
Elevation angle
11
Equipment required for installation
Equipment required, but not supplied
In the table below you will find a list of the equipment required for installation, but not supplied with the lights:
Description L-867 base plate assembly and gasket (if base mounted) L-867 deep base (if base mounted) Conduit elbow (if mounted on conduit elbow) Breakable coupling MR/F2 for mounting on 60mm O.D. conduit Breakable coupling for ground mounting 2-core cable with factory-moulded FAA L-823 plug Primary connector kit, 1-pole Secondary connector kit, 2-pole Natural hydraulic vacuum silicone grease Scotch N 33 electrical tape Standard levelling device Electronic levelling device CN A/R * = Order Number = As requested = supplied with some versions of the UEL
CN see cat.leaf. see cat.leaf. 1409.00.012 1409.05.027 1409.06.020 7850.42.210 7637.55.123 1570.05.410 1570.05.400
Quantity A/R A/R A/R A/R A/R 1/light* 1/light 1/light A/R A/R A/R A/R
12
How to mount the UEL at ground level

Introduction
The UEL is mounted on a breakable coupling which is screwed into a mounting device such as a conduit elbow or a deep base with cover.
Procedure
1. UEL-1-150 steady burning light The following table instructs you on how to install the UEL-1-150 at ground level: Step 1 Action Before installing the light, connect the plug of the two-core cable to the receptacle of the cable coming from the transformer. The transformer receptacle rests in the upper part of the conduit elbow or the cover plate. Do not tape the plug/receptacle assembly in order to allow for quick disconnection in case of impact. 2 3 Screw the breakable coupling in the conduit elbow or cover plate. Remove the optical cartridge (1) by hinging it down and lifting it out of the hinge. Insert the two-core cable through the housing (3), and install the light without optical cartridge on the breakable coupling, without tightening the bracing clamp (5). Clamp the cable into the stress reliever (6). In case of a top light, the two cables should be clamped into the cable stress reliever. 5 Cut the two-core cable in the light fitting to the right length, maintaining sufficient slack to easily connect it to the lamp with the cartridge hinged down. Crimp the "fast-on" connectors on the cores of the cable. Slip the insulation sleeves over the cores of the cable. 6 7 8 Adjust the position of the light unit as described in chapter Orientation and elevation settings Once the position of the light is correct, put the optical cartridge back in place. Connect the lamp to the "fast-on" connectors. Do not forget to slip the insulation sleeves over the "fast-on" connectors to avoid short-circuits. 9 Close the light fitting. Continued on next page
13
How to mount the UEL at ground level, continued
2. UEL-1-120 flashing light The following table instructs you on how to install the UEL-1-120 at ground level: Step 1 Action Before installing the light, make sure that a sufficent length of of 5-core cable coming from the FCU cabinet is available above the conduit elbow or the cover plate. Install the breakable coupling on the conduit elbow or cover plate. Remove the optical cartridge (1) by hinging it down, disconnecting the lamp connector and lifting the cartridge out of the hinge. Insert the cable through the housing (3), and install the light without optical cartridge on the breakable coupling, without tightening the bracing clamp (5). Clamp the cable into the stress reliever (6). Cut the cable in the light fitting to the right length, maintaining sufficient slack to easily connect the cable to the connector. Connect the cable to the connector. 6 7 8 9 Adjust the position of the light unit as described in chapter Orientation and elevation settings. Once the position of the light is correct, put the optical cartridge back in place. Insert the lamp connector back in place. Close the light fitting. Continued on next page
2 3
4 5
14
How to mount the UEL at ground level, continued
Illustration
The illustration below gives an overview of the procedure described above.
3 6
UEL
Breakable coupling Base plate T300/3 Gasket Receptacle clamp UEL
L-867 base, 12 Dia. Rubber grommet Breakable coupling
305
In situ poured concrete block
25
305
PVC pipe
525
550 x 550
15
375 55
How to mount the UEL on a 60mm O.D. conduit

Introduction
The UEL is mounted on a piece of aluminium conduit with 60 mm O.D, with a maximum length of 2 m. The conduit is fastened in a breakable coupling, which in turn is screwed into a conduit elbow or on a base cover.
Procedure
1. UEL-1-150 steady burning light The following table instructs you on how to install the UEL-1-150 on a 60 mm O.D. conduit: Step 1 Action Before installing the light, prepare a two-core cable with plug, making sure that a sufficent length of cable is available above the conduit elbow or cover plate. Connect the plug of the two-core cable to the receptacle of the cable coming from the transformer. The transformer receptacle rests in the upper part of the conduit elbow or the cover plate. Do not tape the plug/receptacle assembly in order to allow for quick disconnection in case of impact. 2 Install the breakable coupling on the conduit elbow or cover plate, and the conduit on the breakable coupling. Make sure that the conduit is perfectly vertical, using the screws of the breakable coupling for adjustment. Tighten the counter-nuts. 3 Remove the optical cartridge (1) by hinging it down and lifting it out of the hinge. Insert the two-core cable through the housing (3), and install the light without optical cartridge on the conduit, without tightening the bracing clamp (5). Clamp the cable into the stress reliever (6). In case of a top light, the two cables should be clamped into the cable stress reliever. 5 Cut the two-core cable in the light fitting to the right length, maintaining sufficient slack to easily connect it to the lamp with the cartridge hinged down. Crimp the "fast-on" connectors on the cores of the cable. Slip the insulation sleeves over the cores of the cable. 6 7 8 Adjust the position of the light unit as described in chapter Orientation and elevation settings Once the position of the light is correct, put the optical cartridge back in place. Connect the lamp to the "fast-on" connectors. Do not forget to slip the insulation sleeves over the "fast-on" connectors to avoid short-circuits. 9 Close the light fitting.
16
AM.02.630e edition 1 Continued on next page
17
How to mount the UEL on a 60mm O.D. conduit, continued
2. UEL-1-120 flashing light The following table instructs you on how to install the UEL-1-120 on a 60 mm O.D. conduit: Step 1 2 Action Before installing the light, make sure that a sufficent length of 5-core cable coming from the FCU cabinet is available above the conduit elbow. Install the breakable coupling on the conduit elbow or cover plate, and the conduit on the breakable coupling. The conduit must be perfectly vertical, using the screws of the breakable coupling for adjustment. Tighten the counter-nuts. 3 Remove the optical cartridge (1) by hinging it down, disconnecting the lamp connector and lifting the cartridge out of the hinge. Insert the cable through the housing (3), and install the light without optical cartridge on the conduit, without tightening the bracing clamp (5). Clamp the cable into the stress reliever (6). Cut the cable in the light fitting to the right length, maintaining sufficient slack to easily connect the cable to the connector. Connect the cable to the connector. 6 7 8 9 Adjust the position of the light unit as described in chapter Orientation and elevation settings. Once the position of the light is correct, put the optical cartridge back in place. Insert the lamp connector back in place. Close the light fitting. Continued on next page
4 5
18
How to mount the UEL on a 60mm O.D. conduit, continued
Illustration
The illustration below gives an overview of the procedure described above. 3 6
5 UEL
Breakable coupling MR/F2
25
2000 max
Aluminium conduit 60 mm O.D. Max. length 2 m
525
550 x 550
55
375
19
How to mount the UEL on a safety approach mast
Introduction
When the UEL has to be installed at more than 2 m (6.7 feet) above ground level, a safety approach mast with a 60mm O.D. top piece must be used.
Procedure
1. UEL-1-150 steady burning light The following table instructs you on how to install the UEL-1-150 on a safety approach mast: Step 1 Action Before installing the light, install a two-core secondary cable from the transformer to the top of the mast, according to the instructions of the manufacturer of the mast. Make sure to provide sufficient slack in the cable so as to cope with possible height adjustment of the mast. 2 Lower the mast. Remove the optical cartridge by hinging it down and lifting it out of the hinge. Insert the two-core cable through the housing (3), and install the light without optical cartridge on top of the mast, without tightening the bracing clamp. 3 Clamp the cable into the stress reliever. In case of a top light, the two cables should be clamped into the cable stress reliever. 4 Cut the two-core cable in the light fitting to the right length, maintaining sufficient slack to easily connect it to the lamp with the cartridge hinged down. Crimp the "fast-on" connectors on the cores of the cable. Slip the insulation sleeves over the cores of the cable. 5 6 7 Adjust the position of the light unit as described in chapter Orientation and elevation settings. Once the position of the light is correct, put the optical cartridge back in place. Connect the lamp to the "fast-on" connectors. Do not forget to slip the insulation sleeves over the "fast-on" connectors to avoid short-circuits. 8 Close the light fitting. Continued on next page
20
How to mount the UEL on a safety approach mast, continued
2. UEL-1-120 flashing light The following table instructs you on how to install the UEL-1-120 on a safety approach mast: Step 1 Action Before installing the light, install a 5-core cable coming from the FCU cabinet to the top of the mast, according to the instructions of the manufacturer of the mast. Make sure to provide sufficient slack in the cable so as to cope with possible height adjustment of the mast. Lower the mast. Remove the optical cartridge (1) by hinging it down, disconnecting the lamp connector and lifting the cartridge out of the hinge. Insert the cable through the housing (3), and install the light without optical cartridge on top of the mast, without tightening the bracing clamp (5). 3 4 Clamp the cable into the stress reliever (6). Cut the cable in the light fitting to the right length, maintaining sufficient slack to easily connect the cable to the connector. Connect the cable to the connector. 5 6 7 8 Adjust the position of the light unit as described in chapter Orientation and elevation settings. Once the position of the light is correct, put the optical cartridge back in place. Insert the lamp connector back in place. Close the light fitting.
21
Chapter 3: Orientation and elevation settings Overview
Introduction
In this chapter the orientation and elevation settings for an UEL light are described.
Contents
This chapter contains the following topics. Topic Standard levelling device Electronic levelling device Commissioning See Page 23 25 27
Chapter 3: Orientation and elevation settings
22
Standard levelling device
Introduction
This system is suited for ground mounted lights or pole mounted lights up to 2 m. It consists of a support, which is secured on the light unit, in the place of the optical cartridge, and which is equipped with a elevation angle setting device, a sighting device (both with a graduated scale) and a spirit level. The elevation angle setting device is graduated from 0 to 25. For the azimuthal setting, the system can be rotated around a vertical axis, and has 4 set positions that allow aiming at reference points (generally other lights) in a direction parallel or perpendicular to the centre line. The sighting device is graduated from -4 to +4 to allow for toe-in angles. Two additional set positions at -15 and +15 permit the setting of RTILS lights.
Procedure
The following table instructs you on how to work with the device: Step 1 2 3 Assemble the system. Remove the optical cartridge and install the levelling device in its place. Tighten the securing screw. Set the elevation angle on the setting device and the azimuth (toe-in) angle on the sighting device. Refer to ICAO Annex 14 to know the correct elevation and toe-in angles in function of the light and its position. 4 5 Level the light approximately to allow the azimuth orientation of the light. Set the light in the correct direction using the sighting device, aiming at the next or former light in the same alignment. For lights in a barrette, a side row or a wing bar, aiming laterally at another light is possible. For this purpose release the two locking levers, turn the system by 90 until a distinct click can be felt, and retighten the locking levers. If there is no light in the same alignment, use a reference pole. 6 7 Secure the bracing clamp of the light. Use the spirit level to set the light at the correct elevation by unscrewing/ tightening slightly the two opposite screws. Tighten the screws sufficiently to avoid any play, but do not overtighten them. Once this is done, secure the two counter-nuts. Remove the device. Put the optical cartridge back in place, without forgetting to connect the lamp. Continued on next page Action
23
Standard levelling device, continued
Illustration
The drawing below illustrates the procedure described above:
Elevation angle setting device Sighting device Spirit level
Securing screw
Locking levers
Elevation angle adjustment screws
Bracing clamp
24
Electronic levelling device
Introduction
This system is suited for fittings mounted on safety approach masts, when it is not possible to get access to the top of the mast in its standing position.
Composition
The system consists of a support similar to the one used with the standard simplified levelling device (see page 23). However, the support is equipped with a sensor activated with a switch, with a 10 m long cable. The operator can then operate the sensor from the ground, and read the elevation angle measurement when the mast is tilted to the ground.
Procedure
The following table instructs you on how to work with the device: Step 1 Lower the mast. See instruction manual of the supplied masts. 2 If the mast has been correctly installed, i.e. its tilting axis is perpendicular to the centre line, a light with 0 toe-in will have its front surface fully horizontal when the mast is tilted over 90 (down to the horizontal). With the mast in this position, adjust the light by turning it around the tube, and then tighten the bracing clamp. For lights with a toe-in, first adjust the light for 0 toe-in. Make a reference mark on the tube just below the zero mark at the bottom of the slip fitter. Using the graduated scale, turn the light around the tube to the desired toe-in, and tighten the bracing clamp. 3 4 5 6 Remove the optical cartridge and install the levelling device in its place. Tighten the securing screw. Raise the mast. Operate the switch to take a measurement. Lower the mast and read the angle indicated on the digital display. Calculate the difference between the real angle and the required one. If necessary, adjust the elevation angle by unscrewing/tightening slightly the two opposite screws. Tighten the screws sufficiently to avoid any play, but do not overtighten them. Once this is done, secure the two counternuts. While doing the correction, two measurements means are useable: - The elevation scale on the side of the light body (coarse measurement); - The levelling device itself, by taking a measurement before and after correction (fine measurement). Raise the mast and repeat the operation 6 until the adjustment is correct. Lower the mast and remove the device. Put the optical cartridge back in place, without forgetting to connect the lamp. Action
7 8 Note:
During the installation of the approach line, a quicker method is to use a platform at the light level for an easy initial adjustment. Continued on next page
25
Electronic levelling device, continued
Illustration
The drawing below illustrates the procedure described above:
Digital display
Securing screw
Graduated scale (elevation) Measurement switch Elevation angle adjustment screws
Bracing clamp
Graduated scale (azimuth)
26
Commissioning
Final check
A flight check shall be performed to detect gross misalignment in the approach and runway threshold lighting system. Errors shall be corrected and the system shall not be put in operation until it has been found satisfactory during the flight test.
27
Chapter 4: Maintenance Overview
Introduction
In this chapter, maintenance of the UEL light is described as well as the procedures of how to replace the lamp and the optical cartridge. Preventive maintenance of the light fixtures should be performed as listed in the table on the next page. Maintenance frequency depends on the conditions under which the runway is used (i.e. climate, traffic, etc.). The recommended practices for maintenance are described in the FAA Advisory Circular no. AC 150/5340-26. For the numbering of the components mentioned in this chapter, refer to the exploded view on page 38.
Contents
This chapter contains the following topics. Topic Preventive maintenance How to replace the lamp How to dismantle the optical assembly See Page 29 30 32
Chapter 4: Maintenance
28
Preventive maintenance
Preventive maintenance tasks
In the table below you will find a checklist of preventive maintenance tasks. Before attempting to service, de-energize and lockout the circuit or the regulator so that the fixture can not be energized by remote means. Check Lamp failure Dimly burning lamp Broken lens Replace lamp. Replace lamp if discoloured, blackened or distorted. Replace optical cartridge. Action
Interval Daily
Weekly
Obtrusion of the light beam by 1. Remove vegetation. vegetation 2. Use weed killer. Dirty lens Clean with glass cleaner. Straighten level and align fixture. Inspection of the light: check drain holes and status of the lens and gaskets. Paint anew. Repair or replace. Clean when system is deactivated. Tighten loose connections. Mark location of low mounted fixtures (use red flags or sticks) to facilitate snow removal and lessen the risk of damage to the fixtures by snow removal equipment.
* More frequently during rainy seasons.
Monthly Semi-annually *
Fixture misalignment Presence of water in optical cartridge Paint flaking off
Annually
Cracks, corrosion, shorts Dirty contacts Loose connections
In prediction of heavy snowfall
29
How to replace the lamp
Procedure
Lamp replacement can be performed preferably in the maintenance base, or on site, at the location of installation. The following table instructs you on how to replace a lamp in the maintenance base: Step 1 2 Action Open the fitting by hinging down the optical cartridge (1). (UEL-1-150): Slide the insulating sleeves away from the "fast-on" connectors and disconnect the lamp (2) from the cable wires. (UEL-1-120): Disconnect the cable from the lamp (2). 3 Remove the optical cartridge and replace it by another one of the same model, in overhauled condition. If damaged, replace the insulation sleeves. (UEL-1-150): Reconnect the lamp. Apply a light coat of silicone grease on the fast-on connectors. Slide the insulating sleeves back in place over the fast - on connectors (UEL-1-150): Re-connect the lamp cable 5 6 Close the optical cartridge. Back in the maintenance base: 1- Remove the lamp (on the UEL-1-120, by unscrewing the four fixation screws) 2- Clean the cartridge and especially the front glass (1b), check the condition of the reflector (1c), the gaskets (1a and 1d) and the spring (7), and replace if needed. 3- Carefully install the new lamp in the keyed aperture at the rear of the optical cartridge (on the UEL-1-120, retighten the four screws). The optical cartridge is now ready to be used again.
1. In case of relamping executed in the field, the lamp can be changed without removing the optical cartridge from the light. The quality of the result can be affected, most of all in case of night work, rain or cold conditions. 2. Touching the quartz bulb with bare fingers may seriously shorten the lamps life. If the bulb has been touched, wipe it carefully with a piece of lens cleaning tissue or similar material moistened with alcohol. Continued on next page
30
How to replace the lamp, continued
Illustration
The illustration below clarifies the procedure described above.
UEL-1-150
UEL-1-120
31
How to dismantle the optical assembly
Procedure
The following table instructs you on how to dismantle the optical assembly (to be done in the maintenance base): Step 1 2 3 4 Action Remove the optical cartridge (1) from the light. Remove the lamp (2). Slide the front gasket (1a) around the front of the cartridge. This releases the reflector (1c) and the front glass (1b). Reassembly is done in the opposite order.
As the reflector used in the optical assembly is not symetrical, correct positioning is necessary and will be obtained when the hole in the reflector corresponds with the positioning pin of the optical cartridge. The clear front glass has a structure spreading the light, created by lines on the internal surface. Therefore, it is important that those lines be positioned vertically and not horizontally.
Illustration
The illustrations below clarifiy the procedure described above.
32
Chapter 5: Troubleshooting
Troubleshooting In the table below, a number of problems are listed in the first column. In the second column, you will find the possible causes of the problem and in the third table column the solution: Before attempting to service, de-energize and lockout the serie circuit or the regulator so that the fixture can not be energized by remote means. Problem Lamp does not energize. Possible cause Lamp defective Loose or broken contact or connector Moisture present in fixture Replace lamp. Tighten or replace the contacts or connector. Open up and dry, inspect lens for cracks. Check the gaskets. Check that the drainage hole, in the bottom of the optical cartridge, is not obstructed. Deteriorated wire insulation Defective isolation transformer Short lamp life (UEL-1-150): Too high current (lamp will have black burns) Replace wires. Check transformer secondary current (in short-circuit) with true RMS Ammeter. Check output current of isolating transformer at full brightness. Current should not exceed 6.7 A. Replace transformer if defective; if not, adjust CCR output current. Moisture in assembly Open up and dry, inspect lens for cracks. Check the gaskets. Check that the drainage hole, in the bottom of the optical cartridge, is not obstructed. Defective lamp or lamp bulb touched with bare fingers (lamp interior will have a yellow-white powdery appearance if air has entered through a hole or crack) Replace lamp. Solution
Chapter 5: Troubleshooting
33
Chapter 6: Assemblies and Exploded Views Overview
Introduction
This chapter gives an overview of the main and sub-assemblies and the exploded views of the UEL lights.
Contents
This chapter contains the following topics. Topic Assemblies Exploded views See Page 35 38
Chapter 6: Assemblies and Exploded Views
34
Assemblies
Spare parts
It is recommended to create a sufficiently large stock of spare parts to maintain the fittings. It will mainly consist of consumables like lamps, gaskets, etc. Other components that may need replacement, such as front glasses, hardware and sub-assemblies should be stocked in smaller quantities. The stock should also contain some optical cartridges and complete fittings of each type.
Ordering code UEL
UEL - 1 - 150 - C - 2 - Y - 0 - S
Unidirectional = 1 Lamp power 120 W (Flash light) = 120 45 W (Suppl. stop bar) = 045 100 W (Runway end) = 100 150 W (Other applications) = 150 Beam colour White = C Green = G Red = R For mounting on Ground (with second. cable) =0 Pole or mast (without cable) =2 Colour (aluminium) Aviation yellow = Y Low intensity top light Without = 0 With = 1 Special requirements to be specified in full text (Complete or modify as necessary)
Accessories
Adjustment tools (elevation and azimuth) With electronic clinometer Without electronic clinometer 1570.05.400 1570.05.410
Note: Extension cables, conduits, connector kits, breakable couplings, frangible masts, ... need to be ordered separately. For assistance, please contact ADB.
Continued on next page
35
Assemblies, continued
Table 1
In the table below you will find all parts of the UEL-1-150 and UEL-1-120 lights.
References related to exploded view Complete fitting (with or without L.I. top light) 1 Optical front cartridge assy. (aviation yellow) Optical front cartridge for
Appr. side rows Rwy end Suppl stop bars
UEL White
UEL Red
UEL Green
UEL flash
Order quantit y (per) (*) 1
(*) 4072.00.920
(*)
(*) 4072.00.970
(*) 4072.00.980
4072.00.950 4072.04.940 4072.04.950 4071.95.941 1408.20.201 1408.20.211 1408.20.240 1408.20.250 4071.99.450 4071.95.953 4071.99.450 4071.95.953 4071.99.450 4071.95.953 4071.98.151 4071.95.953 2990.48.330 2990.48.325 2990.48.340 6120.00.010 7100.08.593 2990.48.340 6120.00.010 7100.08.593 2990.48.340 6120.00.010 7100.08.593 4071.99.540 159.03.511 7100.08.593 10 1 100 4071.95.941 4071.95.941 1408.20.220 4071.95.941 1408.20.230 10 1 1 1 1 1 10 1 1 1 1
1a 1b
Lens / reflector seal Front glass or lens

Approach (150W) End (100W) Suppl. Stop bar
(45W) 1c 1d 2 Reflector Front cartridge gasket Lamp PK30D

Halogen 45W-6.6A Halogen 100W-6.6A Halogen 150W-6.6A
Flashing lamp 400V 60J Lamp Connection kit Flasher Trigger PCB 4a Levelling screw M6 x 40 Stainless steel DIN 933 4b M6 Nut for levelling screw Stainless steel Cable clamp 5 Bracing clamp with screw
7150.53.220 4071.95.992 1409.07.100
7150.53.220 4071.95.992 1409.07.100
7150.53.220 4071.95.992 1409.07.100
7150.53.220 4071.95.992 1409.07.100
100 10 10
(*) See ordering codes, previous page. Continued on next page
36
Assemblies, continued
Optional items
UEL-1-150
Order quantity (each) 1
Secondary cable with moulded-on L823 style 1 2-pole connector, 0,5m for ground mounting
1MC3DA050 C01
Red lens assy, for LI top 1480.03.315 light Clear lens assy, for LI top light Lamp for L.I. top light Gy 9.5 45W 6.6A Lamp socket for L.I. top light 6-pole plug with leads for UEL with top light 1480.03.295 2990.40.820 6114.00.080 6104.40.200
1 1 1 1 1
37
Exploded views
UEL-1-150
The illustration below shows the exploded view of the UEL-1-150.

1 2 7 3
Herebelow the execution with low intensity top light.
1a
1b
1c
1d
4a 4b
Continued on next page
38
Exploded views, continued
UEL-1-120
The illustration below shows the exploded views of the UEL1-120.
2 7 3
1a
1b
1c
1d
4a 4b
39
N.V. ADB S.A. Leuvensesteenweg, 585 B 1930 Zaventem Belgium Tel. : 32/2/722.17.11 Fax : 32/2/722.17.64 Companies in France, U.K. and U.S.A. Agents all over the world
40

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Instruction Manual AM.02.

High Intensity Unidirectional Elevated Light

Record of Changes AM.02.630e

Revision 1.0 New manual

Editor Checked BUG MR

Addition of some spare parts

Position of the clear front glass

Code number spare parts

Use Restriction Notice and Warranty

Use restriction notice

Information about this Manual

Chapter Overview Using Icons

E-mail: adb-air@adb.be Internet: http://www.adb-air.com

Chapter 1: General Information and Requirements Overview

Chapter 1: General Information and Requirements

Purpose of this manual

Scope of this manual

Chapter 1: General Information and Requirements

Chapter 1: General Information and Requirements

Chapter 1: General Information and Requirements

Chapter 2: Installation Overview

Receiving, storage and unpacking

Elevation and azimuth setting angles

Equipment required for installation

Equipment required, but not supplied

How to mount the UEL at ground level

How to mount the UEL at ground level, continued

How to mount the UEL at ground level, continued

The illustration below gives an overview of the procedure described above.

Breakable coupling Base plate T300/3 Gasket Receptacle clamp UEL

L-867 base, 12 Dia. Rubber grommet Breakable coupling

In situ poured concrete block

How to mount the UEL on a 60mm O.D. conduit

AM.02.630e edition 1 Continued on next page

How to mount the UEL on a 60mm O.D. conduit, continued

How to mount the UEL on a 60mm O.D. conduit, continued

The illustration below gives an overview of the procedure described above. 3 6

Breakable coupling MR/F2

Aluminium conduit 60 mm O.D. Max. length 2 m

How to mount the UEL on a safety approach mast

How to mount the UEL on a safety approach mast, continued

Chapter 3: Orientation and elevation settings Overview

Chapter 3: Orientation and elevation settings

Standard levelling device

Chapter 3: Orientation and elevation settings

Standard levelling device, continued

The drawing below illustrates the procedure described above:

Elevation angle setting device Sighting device Spirit level

Elevation angle adjustment screws

Chapter 3: Orientation and elevation settings

Electronic levelling device

Chapter 3: Orientation and elevation settings

Electronic levelling device, continued

The drawing below illustrates the procedure described above:

Graduated scale (elevation) Measurement switch Elevation angle adjustment screws

Graduated scale (azimuth)

Chapter 3: Orientation and elevation settings

Chapter 3: Orientation and elevation settings

Chapter 4: Maintenance Overview

Preventive maintenance tasks