Ut MT 0428 - RCLF

O.C.E.M. S.p.A.
Document UT-MT- 0428 Pagina 1 di 39

Edition 11/11/04
Supersede the edition 01/22/04

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QUESTO DOCUMENTO E DI PROPRIETA DELLA O.C.E.M. S.p.A. IL SUO CONTENUTO NON PUO ESSERE DIVULGATO NE MODIFICATO SENZA IL CONSENSO SCRITTO DELLA O.C.E.M. S.p.A.
THIS DOCUMENT BELONGS TO O.C.E.M. S.p.A. ITS CONTENT CANNOT BE DIVULGED OR MODIFIED WITHOUT WRITTEN APPROVAL OF O.C.E.M. S.p.A.

SEMI-FLUSH
RUNWAY CENTRELINE LIGHT

RCLF

INSTRUCTION MANUAL FOR USE,
INSTALLATION AND MAINTENANCE

Compiled by: N. Marabini Approved by: Ing. P. Scaramagli

Via 2 Agosto 1980 n11
40016 SAN GIORGIO DI PIANO
BOLOGNA ITALY
N appendices

Copia N
O.C.E.M. S.p.A. Document UT-MT-0428 Pagina 2 di 39

Edition 11/11/04
SEMI-FLUSH RUNWAY CENTRELINE LIGHT RCLF
INSTRUCTION MANUAL FOR USE, INSTALLATION AND MAINTENANCE

R E V I S I O N S

REV DESCRIPTION DATE COMP APP


Edition 11/11/04

L I S T O F E F F E C T I V E P A G E S

PAGE REV PAGE REV

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11 33

12 34

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16 38

17 39

18

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22

Edition 11/11/04

LIMITED PRODUCT WARRANTY

THE FOLLOWING WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL OTHER
WARRANTIES, WHETHER EXPRESS, IMPLIED OR STATUTORY, INCLUDING, BUT
NOT BY WAY OF LIMITATION, ANY WARRANTY OF MERCHANTABILITY OR FITNESS
FOR ANY PARTICULAR PURPOSE.

OCEM warrants to each original Buyer of Products manufactured by the Company that
such Products are, at the time of delivery to the Buyer, free of material and workmanship
defects, provided that no warranty is made with respect to:

(a) any Product which has been repaired or altered in such a way, in Companys
judgement, as to affect the Product adversely;

(b) any Product which has, in Companys judgement, been subject to negligence, accident
or improper storage;

(c) any Product which has not been operated and maintained in accordance with normal
practice and in conformity with recommendations and published specification of Company;
and,

(d) any Product, component parts or accessories manufactured by others but supplied by
Company (any claims should be submitted directly to the manufacturer thereof).

OCEMs obligation under this warranty is limited to use reasonable efforts to repair or, at
its option, replace, during normal business hours at the facility of the Company, any
Product which in its judgement proved not to be as warranted within the applicable
warranty period. All costs of transportation of Products claimed not to be warranted and of
repaired or replacement Products to or from the facility of the Company shall be borne by
Purchaser. Company may require the return of any Product claimed not to be as
warranted to its facility, transportation prepaid by Purchaser, to establish a claim under this
warranty. The cost of labour for installing a repaired or replacement Product shall be borne
by Purchaser. Replacement parts provided under the terms of this warranty are warranted
for the remainder of the warranty period of the Products upon which they are installed to
the same extent as if such parts were original components thereof. Warranty services
provided under the Agreement do not assure uninterrupted operations of Products;
Company does not assume any liability for damages caused by any delays involving
warranty service. The warranty period for the Products is 24 months from date of shipment
or 12 months from date of first use, whichever occurs first.

Edition 11/11/04

SAFETY NOTICES

This equipment is normally used or connected to circuits that may employ voltages which
are dangerous and may fatal if accidentally contacted by operating or maintenance
personnel. Extreme caution should be exercised when working with this equipment. While
practical safety precautions have been incorporated in this equipment, the following rules
must be strictly observed:

KEEP AWAY FROM LIVE CIRCUITS

Every time operating and maintenance personnel must observe all safety regulations. Do
not perform maintenance on internal components or re-lamp with power ON.

RESUSCITATION

Maintenance personnel should familiarize themselves with the technique for resuscitation
found in widely published manuals of first aid instructions.

CE CERTIFICATE

This equipment complies with the requirements of the EEC directives 73/23/EEC
and 93/68EEC with regard to Electromagnetic Compatibility.

PLACING OUT OF SERVICE

In case of dismantling, placing out of service, scrapping, the user shall follow all the
required precautions for component and material elimination, according to local rules.


Edition 11/11/04

TABLE OF CONTENTS

Cover 1
Revisions 2
List of Effective Pages 3
Limited Product Warranty 4
Safety Notices 5
Tble of Contents 6
List of Figures 7

1.0 General 9

2.0 Main Features 9

2.1 Removable Light Unit 9
2.2 Shallow Base 18

3.0 Installation 21

3.1 Installing shallow base with thru-feed system (mounting
system B) with cable leads to be laid in wireways 21
3.2 Installing shallow base (suitable for conduit system) with
cable leads to be laid into cable ducts 27
3.3 Installing light unit on L-868 base, size B 30
3.4 Coloured Filter 32

4.0 Maintenance 32

4.1 Removing light unit from the base and opening light unit 32
4.2 Cleaning glass prism and filter 33
4.3 Replacing prism 33
4.4 Relamping 34
4.5 O-ring 35
4.6 Cable lead with plug and bush 35
4.7 Vibration-damping block 36
4.8 Pressure valve 36
4.9 Cleanliness and workmanship 37
4.10 Maintenance program 37

5.0 List of Recommended Spare Parts 39

Edition 11/11/04

LIST OF FIGURES

FIGURE 1a - SEMI-FLUSH RUNWAY CENTRELINE LIGHT RCLF -
REMOVABLE LIGHT UNIT EXPLODED VIEW 10

FIGURE 1b - SEMI-FLUSH RUNWAY CENTRELINE LIGHT RCLF -
REMOVABLE LIGHT UNIT PARTS LIST 11

FIGURE 2 - SEMI-FLUSH RUNWAY CENTRELINE LIGHT RCLF -
DOME OUTSIDE VIEW 12

LOWER COVER WITH ONE ENTRY AND
INSULATING STRIPS INSIDE VIEW 12

FIGURA 4 - SEMI-FLUSH RUNWAY CENTRELINE LIGHT RCLF -
ELECTRONIC RELAYS INSIDE VIEW 13

LOWER COVER WITH TWO ENTRIES AND
INSULATING STRIPS INSIDE VIEW 13

LOWER COVER WITH TWO ENTRIES AND

LOWER COVER - OUTSIDE VIEW 14

COMPLITE P/N IDENTIFICATION 17

STANDARD SHALLOW BASE (MOUNTING SYSTEM B)
ONE ENTRY 19

TWO ENTRIES 20

EXAMPLE OF LIGHT CONFIGURATION (ONE
TRANSFORMER PER EACH LIGHT) 22


Edition 11/11/04

RETILS CONFIGURATION 23

PAVEMENT BORING, SAWCUTTING AND J OINT
INTERSECTION DETAILS 24

SHALLOW BASE MOUTING DETAILS 26

SHALLOW BASE FOR SIDE CONDUIT -
MOUNTIG DETAILS 29

SHALLOW BASE FOR BOTTOM CONDUIT
MOUNTING DETAILS 30

LIGHT UNIT WITH ADAPTOR RING
(MOUTING SYSTEM R) 31

Edition 11/11/04

1.0 GENERAL

RCLF semi-flush runway centreline light is high intensity, bidirectional, inset, steady
burning type; and provide photometric performances in compliace with ICAO Specs -
Annex 14, STANAG 3316, IEC TS 61827 (style 4) and FAA AC 150/5345-46 specification.
Fixtures described in this manual are manufactured to be powered through isolating
transformers by series circuits, fed by constant current regulators.
Characteristics and location of the fixtures shall be in compliance with ICAO Specs -
Annex 14, STANAG 3316 and FAA.

2.0 MAIN FEATURES

Each light assembly mainly consists of a removable light unit and a shallow base
receptacle (mounting system B). The light assembly is waterproof and designed to
withstand aircraft impact and roll-over loads without damage.
On request, a suitable adaptor ring (base mounted, option R) is available to allow the
installation on shallow base, 12 diameter, or on deep base, type L-868, size B, as per
FAA AC 150/5345-42, thereby permitting replacement of any inset fixture without removing
the deep base from the pavement.

2.1 REMOVABLE LIGHT UNIT

The removable light unit mainly consists of a dome, a lower cover and the optical
assembly (fig. 1a-b/2/3/4/5/6/7).

The dome is made by treated drop-forged aluminium and includes two windows to seat
the prisms. In correspondence of the windows, the dome is outside provided with
identification letters A and B.
The dome is provided with two through holes for fastening the light unit to the base and
two dead holes for matching two studs mounted on the base, so to prevent the rotation of
the light unit due to aircraft wheel impact/roll over.
It is also provided with two suitable slots, in opposite position, to make easy the light unit
removal by using suitable lifting tools (available on request, P/N 332.4140 or P/N
332.4230). As alternative, two screwdrivers can be used.
An O-ring (separately supplied) shall be mounted outside around the dome, to avoid dirt
deposits between dome and shallow base.


Edition 11/11/04

REMOVABLE LIGHT UNIT EXPLODED VIEW
12
11
27
13
10
9
7
6
25
1
3
21
26
24
23
12
22
8
4
5
2
24
17
19 18
14
20
16
15

Edition 11/11/04

N Description Qt.
1 Complete lower cover see also Fig. 3/4/5/6 1
2 RCLF dome 1
3 HSFH M5x12 inox screw 3
4 O-Ring 4600 silicone 1
7 Lampholder 1
8 Lamp 2
9 Spacer 4
10 Vibration-damping block 4
11 HSCH M5x16 inox screw 4
12 Dia. 5 inox grower washer 4
13 Dia.5,3x13x1,5 teflon washer 8
14 Optical assembly mounting plate 2
15 Filter-holder box 2
16 Filter 1
17 HSFH M5x12 inox screw 3
18 Teflon prism-holder 2
19 Prism 2
20 Prism gasket 2
21 Cable lead with plug L-823 and terminal bush (*)
22 Grounding cable L=250mm 1
23 Dia.5x10x1 inox washer 1
24 CH M5x10 inox screw 3
25 Fuse cutout (*)
26 O-Ring 2056 Viton (*)
27 Dia. 7x14x1,6 inox washer 4

(*) 1 or 2 depending on the power supply mode

REMOVABLE LIGHT UNIT PARTS LIST


Edition 11/11/04

DOME OUTSIDE VIEW

LOWER COVER WITH ONE ENTRY AND INSULATING STRIPS
INSIDE VIEW
1 - Bush of the cable
leads with plug and
bush
2 - Plug-insulating
strips cables
3 - Insulating strip-
insulating strip
cable
4 - Insulating strip
5 - Insulating strip
fastening screws
6 - Leak test valve
7 - Letter A for
cable lead
identification
1 - Dome
2 - Slot for dome removal
3 - Letter "A" to identify the
beam
4 - Through hole for light unit
fastening


Edition 11/11/04


LOWER COVER WITH TWO ENTRIES AND INSULATING STRIPS
INSIDE VIEW
1 - Cable lead with
plug and bush
2 - Plug-relay wire
3 Relay-relay wire
4 - Electronic cutout
relay
5 - Relay fastening
screws
6 - Leak test valve
7 - Letter A for cable
lead identification

1 - Cable leads
with plug and
bush
2 - Bush-isulatin
strip wires
3 - Insulating trips
4 - Insulatin strips
screws
5 - Leak test valve
6 - Letter A and
B for cable
leads
identification


Edition 11/11/04

LOWER COVER WITH TWO ENTRIES AND ELECTRONIC RELAYS
INSIDE VIEW

LOWER COVER OUTSIDE VIEW
1 - Lower cover
2 - Identification label
3 - Grounding cable hole
4 - Letter A and B for
cable leads indication
5 - Seat for cable leads
bush

7 - Cable leads
with plug and
bush
8 - Bush-relay
wires
9 - Electronic
relays
10 - Electronic
relays screws
11 - Leak test valve
12 - Letter A and
B for cable
leads
identification

Edition 11/11/04

The lower cover consists of a treated aluminium casting; it is fastened to the dome by
means of three screws HSFH M5x12 (Fig. 1 - n 3). An O-ring is provided between dome
and lower cover too.
Inside the lower cover the lamps, on the lampholders, are connected to the insulating
strips or the electronic relays.
The cover is outside provided with one or two cable leads with plug L-823 and bush, a
grounding screw with yellow-green cable lead (with male faston terminal) and a valve (with
removable cap) for leak test.

The optical assembly consists of two prisms, two lamp and two coloured filters.
The prisms are mechanically clamped into the light dome by means of a mounting plate
with a gasket; the mounting plate is fixed by means of three screws HSFH M5x12 (Fig. 1 -
n 17). An additional teflon gasket is placed between the mounting plate and the prisms, to
avoid glass-metal direct contact. The prisms replacement is quick and easy and doesnt
require any sealing.
The lamps are of tungsten-halogen type, 48 W, 6,6 A, 1000 hour rated life, with dichroic
reflector and cable leads (with male faston terminals); they are mounted on a suitable plate
surely fastened to a mounting by means of a spring for easy and quick relamping. Plate,
mounting and sping are stainless steel.

J ust one optical assembly is available for this fixture (P/N 152.1700), infact RCLF hasnt
particular beam toes, in compliance with FAA 150/5345-46.
The lamps plate assembly, with a identification label, are always secured in a fixed position
on the lower cover, attached by means of four vibration-damping blocks.
One dichroic filter is placed in the rear side of the prism. The filter holder box is fixed to the
dome by means of two screws CH M5x10 (Fig. 1 - n 24).
Lamps, prisms and coloured filters are factory assembled; they may be field replaced if so
desired (parr. 3.4 - 4.3 - 4.4).

The light unit is supplied with one or two cable lead with plug and bush; it consists of two
single-pole teflon leads, size 2.5 sqmm, 0.500 m long, which end with a threaded bush
including two rounded male faston terminals. The plug is in compliance with FAA L-823 for
very quick coupling with the receptacle mounted on the shallow base.
If light unit is equipped with one cable lead with plug, both the lamps will work
simultaneously; If it is necessary to operate independently the two lamps, then two cable
leads with plug are necessary.

Bidirectional fixtures - one cable lead with plug and bush
The bush of the unique cable lead is screwed to the lower cover in correspondence to the
entry "A" (Figg. 4/6).
Each lamp is connected by means faston terminals to the relevant insulating strip, which is
fixed to the lower cover (one of the lamp male fastons is connected to one of the insulating
strip female ones). The insulating strips are connected to the bush of the unique cable lead
by means a pair of wires (one cable for each insulating strip) equipped at one end with
two female rounded terminals for connection to the bush male fastons and at the other end
with two female terminals for connection to the strip male fastons (Figg. 3/4 - n 2). A
third wire realizes the series connection between the insulating strips (Figg. 4/6 - n 3).

Edition 11/11/04

Each strip is suitable to seat a fuse cutout (option F), which on request can be supplied to
allow the series of more light fixtures on the secondary of one isolating transformer .
As alternative each insulated strip can be replaced by an electronic cutout relay (option
E) directly fixed to the lower cover (Fig. 4). In this case the lamp male terminals are
connected to the relay female faston, while the relay male fastons are connected to the
rounded cable lead male faston through the above described pair of wires. The third wire
realizes the series connection between the relays.

Bidirectional fixtures - two cable leads with plug and bush
Both the cable entries of the lower cover are used: the bush of the lamp A cable lead is
screwed to the lower cover in correspondence to the entry "A" and the bush of the lamp
B cable lead is screwed to the lower cover in correspondence to the entry "B" (Figg.
5/6).
Each lamp is connected by means faston terminals to the relevant insulating strip, which is
fixed to the lower cover (the lamp male fastons are connected to the insulating strip female
ones). The insulating strip is connected to the bush of the relevant cable lead by means a
pair of wires equipped at one end with two female rounded terminals for connection to the
bush male fastons and at the other end with two female terminals for connection to the
strip male fastons.
Each strip is suitable to seat a fuse cutout (option F), which on request can be supplied to
allow the series of more light fixtures on the secondary of one isolating transformer .
As alternative each insulated strip can be replaced by an electronic cutout relay (option
E) directly fixed to the lower cover (Fig. 6). In this case the male terminals of each lamp
are connected to the female faston of the relevant relay, while the male fastons of the relay
are connected to the rounded male faston of the relevant cable lead through the above
described pair of wires.

The light assembly unit is 203 mm in diameter and 90 mm (+18,5 mm for plugs) high; the
protrusion above the ground is 6 mm.

An identification data label is externally applied over the lower cover (Fig. 7). Moreover, to
identify quickly the beam colour, the letters A and B of the dome in front of the windows
is painted in the same colour of the filter.
The same colour painting is provided outside on the lower cover.
See Fig. 8 for complete P/N informations.
All hardware is made of stainless steel.


Edition 11/11/04

COMPLETE P/N IDENTIFICATION
Type:
Compliance:
F =FAA
I =ICAO Cat. III
S =STANAG and ICAO Cat. I - II
T =Taxiway ("Y" and "G" - ICAO only)
R =RETILs ("Y", unidirectional dome only)
Colour(Side A)/Colour(Side B):
C =Clear
R =Red
Y =Yellow
G =Green
X =Blank
M =Aperture not finished (unidirectional dome)
Lamp:
045 =1x48W 6,6A Reflectorized
090 =2x48W 6,6A Reflectorized
Electrical System:
1P =One Plug
2P =Two Plugs
Mounting Assembly:
B =Standard Shallow Base, 8" dia.
R =Adaptor Ring, 8"-12" dia.
O =No Mounting Assembly
Options:
F =Fuse Cutout
E =Electronic Cutout Relay
R C F L 0 F R C 9 0 P 2 O F

Edition 11/11/04

2.2 SHALLOW BASE

The shallow base (mounting system B) (Fig. 7) consists of a treated aluminium casting
containing an electrical feed-thru system to connect the power cables, consisting of one or
two cable leads with receptacle incoming inside the base through one or two cable glands.
The cable lead with receptacle consists of two single-pole teflonleads, size 2.5 sqmm,
0.770 m long, with FAA L-823 receptacle.
The letters "A" and B are printed inside the base for cable leads identification.
The base is equipped with an internal grounding screw with yellow-green cable lead, size
2.5 sqmm, 0.250 m long, with female faston terminal for quick connection to the
corresponding of the light unit. An additional external grounding screw is provided close to
the cable entry.
The shallow base is designed for cementing in place in a hole drilled in the pavement.
The light unit has to be fastened to the base by means of two screws. Each locking screw
is complete with external lockwasher and nylon washer (not to lose the previous one). Two
studs are provided in the base to prevent rotation of the light unit due to aircraft wheel
impact/roll over.
An O-ring (separately supplied) must be placed between base and light unit for
watertightness.
The shallow base is 214 mm in diameter and 125 mm high.
On request, special bases without cable leads can be supplied, provided with holes
suitable for conduit connections.
Inside the base two suitable holders (Fig. 9/10 - n 9) are provided to properly sustain the
secondary power cable, in case of this cable is inside incoming through a conduit.


Edition 11/11/04

1 - Standard shallow base
2 Cable gland for cable entry
3 - Two-pole receptacle with teflon cables
4 - Grounding cable with female faston
5 - Internal grounding screw
6 - External grounding screw
7 - Threaded inserts for light unit fastening by screws
8 - Stud to prevent light unit rotation
9 - Secondary power cable holder
10 - Letter A for calbe lead identification

ONE ENTRY -
1
5
4
6
2
10
3
9
8
7

Edition 11/11/04

1 - Standard shallow base
2 Cable glands for cable entry
3 - Two-pole receptacle with teflon cables
4 - Grounding cable with female faston
5 - Internal grounding screw
6 - External grounding screw
7 - Threaded inserts for light unit fastening by screws
8 - Stud to prevent light unit rotation
9 - Secondary power cable holder
10 - Letters A and B for calbe leads identification

TWO ENTRIES -
8
9
7
1
2 6
5
10

Edition 11/11/04

3.0 INSTALLATION

3.0.1 Using the scheme as shown in example of light configuration FIGURE 11a/b, drill
each recess in pavement as illustrated in FIGURE 12. Make sure the recess size
and depth are maintained within the specified limits. The recess side walls must be
perpendicular to the pavement surface. The bottom surface must be flat or slightly
concave to assure that the shallow base rest securely and in true position. The
recess can best be drilled using a diamond-faced core drill in a sturdy, stable drill
rig.

3.0.2. Before installing the shallow base, be sure all surfaces of the recess are clean and
dry. If any of these surfaces is damp, it is desirable that it be dried and blown clean
with a compressed air blast.

3.0.3 Mark on the pavement surface the aiming direction of the light by chalk, nails or
other devices.

NOTE 1: For further information about location and connection circuit of the fixtures see
FAA AC 150/5340-30 specification.

3.1 INSTALLING SHALLOW BASE WITH THRU-FEED SYSTEM (MOUNTING
SYSTEM B) WITH CABLE LEADS TO BE LAID IN WIREWAYS

The wireways should be sawed using a diamond-faced saw, as shown in Figg. 11/12.
When wireways cross construction joints, the sawcuts should extend at least 25 mm below
the existing joint for a distance of 15 cm each side of the joint. In this case, the top 25 mm
of the wireway will have to be filled with an appropriate joint sealing filler. Before installing
the shallow base, be sure all surfaces of the wireways are clean and dry. If any of these
surfaces are damp, it is desirable that they are dried and blown with a compressed air
blast.

ATTENTION: do not handle the fixture by the lead wires.

3.1.1 Remove the light unit from the base, by unscrewing the two locking screws
complete with washers. Raise the light unit, by using the two lifting tools (or two
screwdrivers) inserted in the suitable slots provided on the dome.

3.1.2 Before placing the shallow base in the drilled hole, all external surfaces which will
be bonded to the pavement (except the feed-thru zone) should be slightly
sandblasted and must be cleaned with solvent to assure an adequate bond
between base and sealer. Do not handle the base by the lead wires.


Edition 11/11/04

EXAMPLE OF LIGHT CONFIGURATION (ONE TRANSFORMER
PER EACH LIGHT)

Edition 11/11/04

RETILS CONFIGURATION


Edition 11/11/04

PAVEMENT BORING, SAWCUTTING AND J OINT
INTERSECTION DETAILS

Edition 11/11/04

3.1.3 Connect an insulated grounding wire of suitable length to the grounding screw
externally provided on the wall of the base, close to the feed-thru system.

3.1.4 Unwind the light base leads and splice them to the power cables using solderless
squeeze connectors, crimped with the proper tool. The splices to the light base
leads should be made at staggered locations.
Insulate each splice carefully using either heat shrinkable insulating tubing properly
applied or three layers of plastic electrical insulating tape applied with half overlap.
Connect also the grounding wire to the main grounding network by using a suitable
clamping lug.

3.1.5 A positioning jig (P/N 332.4200). should be used to install and align the base. Mount
the jig on the base by screwing the two spacers in the threaded holes of the base
(Fig. 10); notche in the jig, corresponding to those in the base, is then to be used to
align the fixture with the properly surveyed markings.

3.1.6 Properly arrange the leads in the wireways; if necessary, small wads of plastic
insulating tape may be used to wedge the leads in the bottom of the wireways.

3.1.7 With the jig attached to the base, completely cover the bottom of the base with
sealer material. Apply a thin coat of sealer to the bottom of the drilled hole to assure
a bond between the bottom of the light base and the drilled hole. Use temporary
plugs so as to block the wireways entrances into the drilled hole. The plugs will
retain the sealer while it begins to dry up.

ATTENTION: avoid starting the installation when the ambient temperature is
below 10 C (86F), unless the sealer used is designed for curing at a
lower temperature.

3.1.8 Push the base into the recess until its upper side is at the level of the pavement
surface; during this operation the sealer will be forced upwards in the interstice
between base and recess. Make sure the sealer doesnt flow inside the base.
At the same time align the light base by sighting the two notches of the jig with the
markings on the pavement surface.
.


Edition 11/11/04

SHALLOW BASE MOUNTING DETAILS

Edition 11/11/04

3.1.9 Place the two linear levels (P/N 738.2001) crosswise on the jig; then level the jig by
operating the four levelling screws. If necessary, a weight may be placed on the jig
to hold the light base in position.
The remainder of the space between the sides of the shallow base and the drilled
hole should be filled with sealer. Fill to a level even with the top of the base or up to
approx 25 mm from the pavement, according to the local needs.
In this last case, fill the remaining 25 mm with a suitable joint sealing filler.

3.1.10 The jig should be left in place until the sealer dries up. But if any voids are present
around the shallow base, just as possible remove the jig for complete visibility and
refill.

3.1.11 When the shallow base installation is finished, install the removable light unit. The
light unit is shipped complete (including the lamp) and ready for installation as
received, except the lower cover outside O-ring and the dome outside O-ring
separately supplied (Fig. 1 - n 5/6). Be sure that inside of the shallow base is dry
and clean. Place properly the first O-ring in the outside groove of the lower cover
and the second one in the outside groove of the dome.
Connect the plugs of the cable leads of the light unit to the receptacle in the shallow
base. Connect the grounding wire of the light unit to the grounding wire of the
shallow base (faston connection). Then press the light unit firmly and evenly by
hand onto the shallow base.
The light unit is subject to mechanical damage and/or optical misalignment if not
properly seated on the base flange.

3.1.12 Secure the inset light fixture to the shallow base using the two locking screws
complete with washers. One drop of anaerobic adhesive, medium type (e.g. Loctite
243) should be applied to the screws before installation; tightening torque is 31 Nm.

3.1.13 Fill the wireways completely with a suitable approved sealer and let cure for at least
24 hours before disturbing, unless otherwise specified.

3.2 INSTALLING SHALLOW BASE (SUITABLE FOR CONDUIT SYSTEM) WITH
CABLE LEADS TO BE LAID INTO CABLE DUCTS

The cable ducts will be laid inside suitable wireways, which should be sawed using a
diamond-faced saw. The realization of the cable duct is depending on the local conditions,
therefore no suggestion are herebelow provided.

ATTENTION: do not handle the fixture by the lead wires.

3.2.1 Remove the light unit from the base, by unscrewing the two locking screws
complete with washers. Raise the light unit by using the two lifting tools (or two
screwdrivers) inserted in the suitable slots provided on the dome.


Edition 11/11/04

3.2.2 Before placing the shallow base in the drilled hole, all external surfaces which will
be bonded to the pavement should be slightly sandblasted and must be cleaned
with solvent to assure an adequate bond between base and sealer. Do not handle
the base by the lead wires.

3.1.6 A positioning jig (P/N 332.4200). should be used to install and align the base. Mount
the jig on the base by screwing the two spacers in the threaded holes of the base
(Fig. 10); notche in the jig corresponding to those in the base is then to be used to
align the fixture with the properly surveyed markings.

3.2.4 With the jig attached to the base, completely cover the bottom of the base with
sealer material. Apply a thin coat of sealer to the bottom of the drilled hole to assure
a bond between the bottom of the light base and the drilled hole. It may be
necessary to place temporary plugs so as to block the wireways entrances into the
drilled hole. The plugs will retain the sealer while it begins to dry up.

ATTENTION: avoid starting the installation when the ambient temperature is
below 10C (86F), unless the sealer used is designed to dry up at a
lower temperature.

3.2.5 Push the base into the recess until its upper side is at the level of the pavement
surface; during this operation the sealer will be forced up the side of the light base:
take care no sealer flowing inside the base.
At the same time align the light base by sighting the two notches of the jig with the
markings on the pavement surface.

3.2.6 Place the two linear levels (P/N 738.2001) crosswise on the jig; then level the jig by
operating the four levelling screws. If necessary, a weight may be placed on the jig
to hold the light base in position.
When the shallow base is in its final position, the conduit(s) must be properly jointed
to the hole(s) provided on the shallow base. This(these) hole(s) can be provided
either on the wall either on the bottom, the number and the dimensions according to
customer requirements (Figg. 14 - 15).
The remainder of the space between the sides of the shallow base and the drilled
hole should be filled with sealer. Fill to a level even with the top of the base or up to
approx 25 mm from the pavement, according to the local needs.
In this last case, fill the remaining 25 mm with a suitable joint sealing filler.

3.2.7 The jig should be left in place until the sealer dries up. But if any voids are present
around the shallow base, just as possible remove the jig for complete visibility and
refill.

3.2.8 Lay the secondary power cable and the grounding wire inside the cable duct from
the isolating transformer to inside the base. The secondary power cable must be
equipped with a suitable two-pole receptacle kit and the grounding wire must be
connected to the grounding screw inside the shallow base.

Edition 11/11/04

3.2.9 The light unit is shipped complete (including the lamp) and ready for installation as
received, except the lower cover outside O-ring and the dome outside O-ring
separately supplied (Fig. 1 - n 5/6).
Be sure that inside of the shallow base is dry and clean. Place properly the first O-
ring in the outside groove of the lower cover and the second one in the outside
groove of the dome.
Connect the plug of the cable lead of the light unit to the receptacle in the shallow
base. Connect the grounding wire of the light unit to the grounding wire of the
shallow base (faston connection). Then press the light unit firmly and evenly by
hand onto the shallow base.
The light unit is subject to mechanical damage and/or optical misalignment if not
properly seated on the base flange.

3.2.10 Secure the inset light fixture to the shallow base by using the two locking screws
complete with washers. One drop of anaerobic adhesive, medium type (e.g. Loctite
243) should be applied to the screws before installation; tightening torque is 31 Nm.

SHALLOW BASE FOR SIDE CONDUIT
MOUNTING DETAILS


Edition 11/11/04

SHALLOW BASE FOR BOTTOM CONDUIT
MOUNTING DETAILS

3.3 INSTALLING LIGHT UNIT ON L-868 BASE, SIZE B

Install L-868 light base in compliance with FAA AC 150/5340-30.
The light unit is shipped complete fastened to the adaptor ring (base mounted, option R)
(Fig. 16), including the lamp, and is ready for installation as received.
Be sure the flange on the transformer housing is clean and the O-ring (if used) is in place
in the O-ring groove.
Connect the plug of the light unit to the receptacle of the isolating transformer inside the
deep base. Connect the grounding wire of the light unit to the grounding wire of the deep
base (faston connection). Then press the light unit firmly and evenly by hand onto the base
flange. Secure the light unit to the base by using the six locking screws complete with
washers, supplied with the base. One drop of anaerobic adhesive, medium type (e.g.
Loctite 243) should be applied to the screws before installation; tightening torque is 25 Nm.
For intallation on 12 OCEM shallow base one drop of screw past (e.g. Dow Corning
Molycote 1000) should be applied to the screw before intallation; tightening torque is 25
Nm.
The light unit is subject to optical misalignment and/or mechanical damage if not properly
seated.


Edition 11/11/04

LIGHT UNIT WITH ADAPTOR RING (MOUNTING SYSTEM R)
1 - Adaptor ring (mounting system R)
2 - Removable light unit
3 - Hardware to fasten the light unit to the adaptor ring
4 - Hardware to fasten the adaptor ring to the 12 base

Edition 11/11/04

3.4 COLOURED FILTER

Any changes necessary for operational needs must be done after installation acceptance.
If the light unit is open before acceptance, the warranty is void.

If it is necessary to add, remove or replace the filter, operate as follows.
Remove the light unit from the base, by unscrewing the two locking screws complete with
washers. Raise the light unit by using the two lifting tools (or two screwdrivers) inserted in
the suitable slots provided on the dome.
Remove the lower cover assembly by unscrewing the three fixing screws HSFH M5x12
(Fig. 1 - n 3). Remove the filter complete with support by unscrewing the relevant screws.
Before installing new filter, make sure it is clean, of the proper colour and free of
scratches. Install the new filter complete with support, by using the two relevant screws CH
M5x10 (Fig. 1 - n 24). Tightening torque is 3.8 Nm.
Check the O-ring (between dome and lower cover) (Fig. 1 - n 4) is properly placed in the
relevant seat. Re-assembly the lower cover to the dome by using anaerobic adhesive, light
type (e.g. LOXEAL 24-18) on the three fixing screws HSFH M5x12 (Fig. 1 - n 3);
tightening torque is 3.8 Nm.
Check the O-ring (Fig. 1 - n 5) is properly placed outside around the dome.
Check the O-ring (Fig. 1 - n 6) is properly placed outside around the lower cover.
Return the light unit to runway for installation.

CAUTION: the filters are fragile and susceptible to scratches.

4.0 MAINTENANCE

The preferred method of maintaining these lights is to replace each light unit periodically
and systematically and return it to the maintenance shop for renovation.

As an alternative, the light unit can be serviced in the field. However, it is recommended
that field servicing is limited to cleaning the prisms and to replacing the lamp.

4.1 REMOVING LIGHT UNIT FROM THE BASE AND OPENING LIGHT UNIT

Remove the light unit from the base by unscrewing the two locking screws complete with
washers. Raise the light unit by using the two lifting tools (P/N 332.4140 or P/N 332.4230)
inserted in the suitable slots provided on the dome. As an alternative, two screwdrivers
can be used.
Open the light unit by unscrewing the three locking screws HSFH M5x12 (Fig. 1 - n 3).
Every time the light unit is removed from the base receptacle and opened, inspect the
following:
a) prism and filter if clean or damaged and take provision as necessary, as described at
paragraphs 4.2 - 4.3;
b) O-ring between base and light unit and replace it, if necessary, as described at
paragraph 4.5;
c) cable lead with plug for damage and replace it, if necessary, as described at paragraph
4.6.

Edition 11/11/04

4.2 CLEANING PRISMS AND COLOURED FILTERS

4.2.1 Cleaning prism outside

Removing the light unit is not necessary to clean the outer surface of the prism.
With a compressed air blast or suitable brushes, remove all accumulated debris from the
light channels. Clean the outer surface of the prism with a detergent solution. If the prism
Is coated with a substance impervious to the detergent, a suitable solvent should be
sparingly applied with a wad of cotton or a patch of cloth on the end of a wood splint. After
the solvent has acted, the remaining solvent and softened coating should be removed with
a clean piece of cotton or cloth without scratching the glass. Avoid excessive contact
between the solvent and the prism gasket. Remove all remaining solvent from prism and,
just as possible, from the gasket. A gentle air blast may be used.

4.2.2 Cleaning prism inside and filter

Normallly prisms and coloured filters cleaning operations are not necessary because light
unit is watertight . Whenever it is necessary , remember the following rules.
Remove the light unit from the base and open it following instructions of par. 4.1.
Prism and filter surfaces are now accessible. Remove the filter complete with support by
unscrewing the relevant screws. Polish prism and filter surfaces with propylic alcohol or
similar non abrasive product; dry them carefully. Reinstall the filter complete with support,
by using the two relevant screws CH M5x10 (Fig. 1 - n 24); tightening torque is 3.8 Nm.

Final check before light unit re-assembling.
Verify the correct position of O-ring between dome and lower cover (Fig. 1 - n 4).
Mount the lower cover on the dome and fasten it by means the three screws HSFH M5x12
(Fig. 1 - n 3). One drop of anaerobic adhesive lower type (per esempio LOXEAL 24-18
should be applied to the screws before installation; tightening torque is 3,8 Nm.
Verify the correct positioning of the O-ring around the dome (Fig. 1 - n 5) and of the O-
ring around the lower cover (Fig. 1 - n 6). Return the light unit to taxiway for installation.
Light unit is ready to be field installed.

4.3 REPLACING PRISM

If the prism is broken, leaks, is badly pitted or scarred, it must be replaced. The prism can
be replaced as described below. It is highly recommended to do a complete overhaul of
the light unit. Contact OCEM for any suggestion.

4.3.1 Removing prism

Remove the light unit from the base and open the light unit, as described at paragraph 4.1.
Clean out possible pieces of the old prism and all accumulated debris from the inside.
Unscrew the three screws HSFH M5x12 (Fig. 1 - n 17) which lock the prism retainer.
Remove the retainer and the teflon prism-holder. Then remove the old prism (or the
remaining part of it) and the gasket (or part of it) eventually left in the prism seat.

Edition 11/11/04

Carefully clean the prism seat by scraping and taking care not to damage the relevant
walls.

4.3.2 Installing new prism

Place a new gasket in the prism cavity on the dome, then position and press by hand the
prism in the relevant seat.
Then mount a new teflon prism-holder. Insert the above assembly completely in the seat
by working with two strong screwdrivers, set in the prism retainer seat. Fasten the retainer
with the three relevant screws HSFH M5x12 (Fig. 1 - n 17); Tightening torque is 3.8 Nm.
Inspect all components inside the light unit for damages or signs of corrosion. Replace all
necessary components.

Reassembly the fixture following instructions of par 4.2.

4.3.3 Pressure test

The assembly should be given a 1,4 atm air pressure test. This can be done by connecting
an external air pressure line to the valve provided on the lower cover. Immerge the
assembly under water, so air loss will be easily viewed if some part is damaged or
assembling is wrong.
If there is no air loss then test is passed succesfully.
Return the light unit to taxiway for installation.Light unit is ready to be field installed.

4.4 RELAMPING

Removal of the lamps from the optical assembly mounting plate is very simple: disconnect
the faston terminals of the lamp wires from the insulating strips or from the electronic
cutout relays and slide each lamp from its seat by forcing the elastic holder.

CAUTION: touching the quartz bulb with bare fingers may seriously shorten the
lamp life. If the quartz bulb has been touched, wipe it clean with a piece
of lens cleaning tissue or similar material moistened with isopropyl
alcohol.

Insert the new lamp in fixed position on its seat (with the UP mark, printed on the lamp,
in upward position), so lock it with the spring. Connect the cable leads of the new lamp to
the insulating strip fixed on the lower cover assembly. Otherwise the lamp cable leads
must be connected to the cable leads of the electronic cutout relay, if provided.
Reassembly the lower cover to the dome; carry out the final check described in par 4.2.



Edition 11/11/04

4.5 O-RINGS

4.5.1 O-ring examination

Every time an O-ring sealed assembly is taken apart, any O-ring must be closely
examined as described below and replaced if necessary.
Any O-ring that is stretched, torn, has a permanent set or some other defect, which would
prevent it from forming a water-tight seal must be replaced with a new O-ring.
Light assembly is equipped with the following gaskets:
one O-ring in the lower part of the dome (between dome and lower cover)] (Fig. 1 - n
4);
one O-ring externally mounted around the dome (Fig. 1 - n 5)
one O-ring externally mounted around the lower cover (Fig. 1 - n 6)
one prism gasket mounted between prism and the dome (Fig. 1 - n 20). As much as
regards prism gasket replacement see par 4.3.

4.5.2 O-ring replacement

Remove the old O-ring from the groove and clean the flange mating surfaces and the
groove, scraping carefully. Take care not to damage the mating surface and the bottom
and sides of the groove. Position it in the centre of its groove and push it inside.

NOTA 1: Make sure that the proper O-ring is re-inserted into the groove.

NOTA 2: The groove is so designed to provide room for displacement of the O-ring when
compressed between the mating surfaces. Properly tightened screws are
important in obtaining a complete seal.

4.6 CABLE LEAD WITH PLUG AND BUSH

4.6.1 Removing the cable lead with plug and bush

Inside the lower cover, disconnect the pair of wires with faston terminals from the bush of
the damaged cable lead with plug. Outside the lower cover, remove the damaged cable
lead with plug by unscrewing the threaded bush.

Tightening torque:
lower cover HSCH screw: 3.8 Nm
light unit locking screw: 31 Nm (for shallow base)
25 Nm (for L-868 base, size B)

Edition 11/11/04

4.6.2 Installing the new cable lead with plug and bush

Be sure that threaded hole surface is perfectly clean. Place the O-Ring (Fig. 1 n 26)
around the bush. Put a drop of anaerobic adhesive lower type (e.g. LOXEAL 24-18) on the
threaded surface of the bush of the new cable lead with plug. Tighten externally the bush
and restore internally the electrical connections.
Verify the correct position of O-ring between dome and lower cover (Fig. 1 - n 4).
Reconnect the faston terminale of the insulating strip to the new bush.
Mount the lower cover on the dome and fasten it by means the three screws HSFH M5x12
(Fig. 1 - n 3). One drop of anaerobic adhesive lower type (e.g. LOXEAL 24-18) should be
applied to the screws before installation; tightening torque is 3,8 Nm.

4.6.3 Pressure test

The assembly should be given a 1.4 atm air pressure test.

WARNING: pressure test must be carried out at least 15 minutes after putting
anaerobic adhesive to let it work correctly.

See par 4.3.3.

4.7 VIBRATION-DAMPING BLOCK

If it is necessary to replace the vibration-damping block for aging or damaging , see the
following instructions after removing light unit from the base and after opening it as
described in par. 4.1.
It is recommended to replace all the four vibration-damping blocks.
Remove the lampholder complete with lamp, by unscrewing the four screws HSCH M5x16
(Fig. 1 - n 11).
Remove the brass spacers and then the vibration-damping blocks.
Disconnect the male faston of the lamp from the insulating strip.
Mount the new vibration-damping blocks in their seats and insert the new brass spacers.
Reassembly the lampholder, by tightening the four screws HSCH M5x16 (Fig. 1 - n 11);
tightening torque is 1.9 Nm. Reconnect the male faston of the lamp to the insulating strip.


4.8 PRESSURE VALVE

If a leakage is found through the pressure valve during an air pressure test, check carefully
where the leakage happens. If the leakage is between the valve and the lower cover,
check the tightening of the valve body to the lower cover from the inside of the light unit.
If the leakage is between the valve core and body, remove the valve cap and check the
tightening of the valve core to the body from the outside of the light unit by means of
pointed pliers.

Edition 11/11/04

In case the pressure valve needs replacing, operate as follows, considering the light unit
already open, as described at paragraph 4.1. Remove the valve cap. Unscrew the valve
body with gasket from the inside of the lower cover by clamping the hexagonal end section
of the valve body. Screw the new valve on the lower cover; tightening torque is 0.35 Nm.
Check the valve core is tightened to the valve body and then screw its cap.

4.9 CLEANING AND WORKMANSHIP

Service life depends upon the entire assembly being waterproof. All surfaces must be
clean, dry and free of all foreign matter if the light fixture is to operate for an extended
period without requiring maintenance.

NOTE: see par 5.0 for recommended spare parts list

4.10 MAINTENANCE PROGRAM

In order to ensure maximum light fixture life, the installed units should be subject to a
maintenance program in accordance with the following instructions and taking as
reference the ICAO suggestions provided by the Airport Services Manual - Part 9 - Airport
Maintenance Practices or by Faa AC 150 5340-30.

4.10.1 Daily operational check

A daily operation check should be made of the light unit. The lights should be energized
and visually inspected. If any lamps are out, the location of the fixture should be recorded
and the lamps replaced at the time when the circuit is de-energized, as described at
paragraph 4.4.

4.10.2 Cleaning

Regular cleaning is necessary in order to ensure that in-pavement lighting fixtures operate
at maximum efficiency. The outside of the polycarbonate ring and channels for beam
output should be cleaned periodically as per paragraph 4.2.1. The regularity and type of
cleaning will be dictated by the weather and the location of the fixtures.

4.10.3 Snowplow operations


Edition 11/11/04

Snowplow operators should exercise extra care not to strike the light fixtures with
snowplow blades. After snow removal operations, inspect all light fixtures to locate and
replace, if necessary, any damaged light assemblies.
Passes over the light rows should be made with a power broom only if practical. Whenever
snowplows must traverse in-pavement light fixtures, they should be either travelling at less
than 10 km/h or have the blades lifted clear of the fixtures. Recommended snow removal
techniques are described in Airport Services Manual - Part 9 - Airport Maintenance
Practices or described in Faa AC 150/5200-30.

4.10.4 Monthly inspections

This light unit is designed to exclude both ground and surface water from entering. If the
lights are not properly maintained (e.g. screws not properly tightened and O-rings or
gaskets in bad condition) water may enter inside the fixture and create serious problems.
To prevent this from occurring, it is recommended that each fixture be inspected from the
presence of water at least once a month. More frequent inspection is desirable during and
following rainy season.

4.10.5 Screw tightness

Light unit locking screws should be checked for proper torque at least once every three
months or more frequently during the two-four weeks following the reinstallation of a
serviced light unit.

4.10.6 Leak testing

If any fixture contains water, remove the water and clean and dry the entire fixture.
Pressure test the fixture to find the leak. Inspect the O-ring and gasket grooves and clean.
The O-rings and gaskets should be replaced, the fixture repaired and reinstalled as
specified herein.

Edition 11/11/04

5.0 LIST OF RECOMMENDED SPARE PARS

Codice
[P/N]

Descrizione FIGURE Numero
303.2440 Bidirectional dome 1 2
152.5300 Lower cover with a cable lead with plug and bush
and internal connections cables
1/3/4 1

152.5305 Lower cover with two cable leads with plug and bush
and internal connections cables
1/5/6 1

152.1500 Complete lamp supporting plate RCLF 35 1 7
152.5320 Vibration-damping block with hardware
760.2191 48 W tungsten-halogen, 6.6 A, with dichroic reflector 1 8
341.0831 Aluminium screen for unidirectional light
318.8165 Dichroic RED filter 1 16
318.3075 Dichroic YELLOW filter 1 16
318.8214 Dichroic GREEN filter 1 16
318.1241 Prism L-850A/B 1 19
318.1290 Prism L-852A/C 1 19
325.0430 Prism gasket 1 20
758.2120 O-Ring 4600 silicone 1 4
758.2014 O-Ring 4775 silicone 1 5
758.2008 O-Ring 4625 silicone 1 6
758.2035 O-Ring 2056 Viton 1 26
000.1466 Fuse cutout 1 25
329.3025 Insulating strip for fuse cutout with hardware 3 3
202.0012 Electronic relay with hardware 5 3
786.7045 Pressare valve 3 5
329.0050 Cable lead with plug L-823 and terminal bush, length
0,500m
3 1
323.2610 Cable lead with receptacle L-823 for shallow base 9/10 3
712.0025 Lower anaerobic adhesive, 50 cc
752.0003 Screw paste, 100 gr
712.0004 Medium anaerobic adhesive, 50 cc
152.6045 Shallow base fixing hardware, dia 8":
700.2228 - screw HH M10x30 stainless steel (2)
706.1106 - elastic washer M10 stainless steel (2 )
706.5206 - washer M10 nylon (2)
152.8060 Shallow base fixing hardware (with adaptor ring), dia 12":
700.2228 - screw HH M10x30 stainless steel (6 )
706.1106 - elastic washer M10 stainless steel (6 )
706.5206 - washer M10 nylon (6 )

Ut MT 0428 - RCLF

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