9211 rev Y - Cooper Industries · Document 9211 Rev. Y Instruction Manual Airside Guidance Sign...

Document 9211

Revision Y

April 10, 2012

Instruction Manual

Airside Guidance Sign

Series 858XX-X

Sizes 1, 2, 3, and 5

62 Watt Lamp

Cooper Industries

Crouse-Hinds Division

Crouse-Hinds Airport

Lighting

1200 Kennedy Road

Windsor, CT 06095

Copyright © 2012 Cooper Technologies Company

For Parts or Technical Service Call (860) 683-4300

Document 9211

Rev. Y Instruction Manual


Series 858XX-X


ii

Revisions

Revision

Number

Issue/Reissue

Letter

Number Description Checked Approved

T A203-281A See Record Copy for Previous Revisions.

Revised extensively to delete use of 60880-X

P.C. Board and related data. Added 61153-1

P.C. Board and related data

1/21/04 GFR

U A204-291 Removed all references to LED Lamp out

Indicator P/N 61158 and its operation.

Incorporated Option 13 (tethers) as standard

equipment. Added Options 19 and 20 to 1.3

Part Number and deleted Options 13 & 14.

Added Symptom 5 to Table 1. Added Para

4.5 and Figure 10A.

1/10/05 GFR

V A205-056 Added instructions and info to Para. 4.5

8/30/05 GFR

W A208-004 Added copyright to cover page; Figure 21,

deleted alternate method (used Rawl 7324 or

equal)

1/23/08 PG

X A208-243 Updated Table 6 and Table 7; Updated

Figures 1 thru 7 to reflect changes in Table 6

and Table 7.

11/7/08 AJ

Y A212-165 Page 12, Item 24 was 62241-1 thru 62241-3 5/10/12 MCB

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iii

Limited Product Warranty

THE FOLLOWING WARRANTY IS EXCLUSIVE AN 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.

Crouse-Hinds Airport Lighting Products (the “Company”) warrants each original Buyer of

Products Manufactured by the Company that such Products are, at the time of delivery to the

Buyer free of material and workmanship defects, provided that no warranty is made with

respect to:

(a) any Product which has been repaired or altered in such a way, in Company’s

judgment, as to affect the Product adversely;

(b) any Product which has in Company’s judgment, 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 specifications of

company; and,

(d) any Products, component parts or accessories manufactured by others but supplied

by Company (any claims should be submitted directly to the manufacturer thereof).

Crouse-Hinds Airport Lighting Products’ obligation under this warranty is limited to use

reasonable efforts to repair or, at its option, replace, during normal business hours at any

authorized service facility of Company, any Products which in its judgement proved not to

be as warranted within the applicable warranty period. All cost of transportation of Products

claimed not to be as warranted and of repaired or replacement Products to or from such

service facility shall be borne by Purchaser. Company may require the return of any Product

claimed not to be as warranted to one of its facilities as designed by Company,

transportation prepaid by Purchaser, to establish a claim under this warranty. The cost of

labor for installing a repaired or replacement product shall be borne by Purchaser.

Replacement parts provided 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.

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iv

Safety Notices

This equipment is normally used or connected to circuits that may employ voltages which

are dangerous and may be 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 Operating and maintenance personnel must at all times observe all safety regulations.

WARNING:

WARNING DO NOT PERFORM MAINTENANCE ON INTERNAL COMPONENTS FOR

RELAMP WITH POWER ON.

RESUSCITATION

Maintenance personnel should familiarize themselves with the technique for resuscitation

found in widely published manuals of first aid instruction.

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v

Safety Symbols

DANGER:

DANGER The hazard or unsafe practice will result in severe injury or death.

WARNING:

WARNING The hazard or unsafe practice could result in severe injury or death.

CAUTION:

CAUTION The hazard or unsafe practice could result in minor injury.

NOTICE:

NOTICE Possibly dangerous situation, goods might be damaged.

IMPORTANT:

IMPORTANT Helpful information.

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vi

Table of Contents

Title Page .....................................................................................................................................i

Revisions ................................................................................................................................... ii

Limited Product Warranty ......................................................................................................... iii

Safety Notices ............................................................................................................................ iv

Table of Contents ....................................................................................................................... vi

Test Equipment and Tools .......................................................................................................... ix

Section 1. General Information ................................................................................................... 1

1.1 General Description ................................................................................................... 1

1.2 Classification of Signs ............................................................................................... 1

1.3 Part Numbers ............................................................................................................. 2

Section 2. Installation ................................................................................................................. 3

Section 3. Adding Additional Sign Modules ............................................................................... 4

Section 4. Maintenance and Troubleshooting – Electrical ............................................................ 4

4.1 Lamp Current Check for Style 2 (3-step) and Style 3 (5-step) AGS Signs .................. 4

4.2 Troubleshooting 3/5 Step AGS Signs ......................................................................... 5

4.3 Lamp Current Check for Style 5 (5.5A fixed current) AGS signs ............................... 8

4.4 Lamp Replacement .................................................................................................... 8

4.4 Sign PC Board P/N 61153-1 Calibration .................................................................... 9

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vii

List of Tables

Table 1 – Troubleshooting 3/5 step signs ..................................................................................... 6

Table 2 – Three step current levels .............................................................................................. 7

Table 3 – Five step current levels ................................................................................................ 7

Table 4 – Measured Load and Power Factor (Style 2 and Style 3) ............................................. 10

Table 5 – Measured Load and Power Factor (Style 5)................................................................ 10

Table 6 – Parts list ..................................................................................................................... 11

Table 7 – Recommended two year Spare Parts Stock................................................................. 14

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viii

List of Figures

Figure 1 – Typical AGS sign, side view.................................................................................. 5

Figure 2 – Single Module Sign, Series Circuit ...................................................................... 15

Figure 3 – Double Module Sign, Series Circuit ..................................................................... 16

Figure 4 – Single Module with Join Section, Series Circuit .................................................. 17

Figure 5 – Double Module with Joint Section, Series Circuit ................................................ 18

Figure 6 – Typical Jointing of Signs ..................................................................................... 19

Figure 7 – Joint Section ........................................................................................................ 20

Figure 8 – Wiring Schematic, Single Module, 3 or 5 Step...................................................... 21

Figure 9 – Wiring Schematic, Double Module. 3 or 5 Step .................................................... 22

Figure 10 – Tapped Transformer Wiring Detail, 3/5-Step ....................................................... 23

Figure 10A – Calibration of the 61153-1 Printed Circuit Board ................................................. 24

Figure 11 – Other configurations ............................................................................................ 25

Figure 12 – Wiring Schematic, Single Module, Style 5 (5.5A Fixed Current) .......................... 26

Figure 13 – Wiring Schematic, Double Module, Style 5 (5.5A Fixed Current) ......................... 27

Figure 14 – Tapped Transformer Wiring Detail, Style 5 (5.5A Fixed Current) ........................ 28

Figure 15 – Not Used ............................................................................................................. 29

Figure 16 – Concrete Pad Dimensions .................................................................................... 30

Figure 17 – Concrete Pad Dimensions, Elbow to Base ............................................................ 31

Figure 18 – Sign Dimensions ................................................................................................. 32

Figure 19 – Mounting Detail, Steel Base ................................................................................ 33

Figure 20 – Mounting Detail, Elbow Assembly ...................................................................... 34

Figure 21 – Flange Installation ............................................................................................... 35

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ix

Test Equipment and Tools

There is a wide variety of tools and equipment needed to safely and correctly perform airfield

lighting equipment installation and maintenance. In addition to the obvious tools (screwdrivers,

wrenches, etc.), there is a specialized equipment needed to do the job.

Refer to the equipment manufacturer’s manuals for the proper use, maintenance and calibration (if

necessary) of all meters.

Multimeter

One of the most important pieces of test equipment is the Multimeter. It is used to measure

voltages, currents, and resistances. Almost every single maintenance task requires the use of a

multimeter at one point or another. A quality meter in good repair and calibration is a must because

airfield lighting power distribution equipment produces non-sinusoidal waveforms, traditional

average reading meters are inaccurate and have very limited use. Checking or adjusting equipment

based upon incorrect current reading may dramatically reduce lamp life and adversely affect power

equipment performance. A meter with TRUE RMS measuring capability and a current clamp-on

probe is needed to accurately measure distorted or chopped waveforms. All meter manufacturers

offer TRUE RMS measuring meters. The following is a short list of TRUE RMS Multimeters from

Fluke:

Manufacturer Model Number

Fluke 85III, 87III, 187, 189, 335, 336, 337

Our recommended meter is the Fluke 87III with the Fluke 80I-600A current clamp.

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Series 858XX-X


1

1.0 General Information

1.1 General Description

Crouse-Hinds Airport Lighting Products, “AIRSIDE” internally illuminated Taxiway and Runway

Signs provide outstanding message visibility, day or night. White on Red and Yellow on Black and

Black on Yellow color combinations may be ordered with any desired message. Signs are available

as single or double faced and are provided with retroreflective sign face. For further information on

Taxiway Signs and their use, consult the latest revision FAA Advisory Circulars AC 150/5340-18

and AC 150/5345-44.

1.2 Classification of Signs

The signs covered in this manual are designed and manufactured in accordance with the

requirements of FAA Advisory Circular AC 150/5345-44H. Specifications for Taxiway and

Runway Signs and conform to the following classifications as indicated in paragraph 1.2 of the

above Advisory.

Types:

Type L-858Y – Direction destination and boundary sign – black legend on a yellow background.

Type L-858R – Mandatory instruction sign white legend on a red background.

Type L-858L – Taxiway and runway location sign yellow legend and border on a black

background.

A sign may consist of multiple arrays of the above messages.

NOTE: Size 5 information in this manual is the same as the Size 3 single module unless noted

otherwise. For size 4 distance marker signs, see Manual 9213.

P/N Sizes

8581X-X Size 1 – 12 inch legend (small body)

8582X-X Size 2 – 15 inch legend (mid-size body)

8583X-X Size 3 – 18 inch legend (large body)

8585X-X Size 5 – 25 inch legend (large body DMS)

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2

CAT. # FAA Styles

-3 Style 2 – For operation from a 3 step series lighting circuit (4.8 to 6.6 amperes)

-5 Style 3 – For operation from a 5 step series lighting circuit (2.8 to 6.6 amperes)

-1 Style 5 – A (fixed) 5.5 ampere series lighting circuit

Environmental Requirements

Class 2 – For operation from -55ºC to +55ºC (+131ºF)

Mode 2 – Sign for use in areas subjected to wind speed of up to 200 mph (322 km/h)

1.3 Part Numbers:

8 5 8 - - -

FAA Type:

FAA Size:

1 = Taxiway Sign, 30” High



4 = Distance Marker, 60” High

5 = Distance Marker, 42” High

Number of Faces: 1 = Single Face

2 = Double Face

Brightness Levels: 1 = FAA Style 5 (fixed, 5.5A)*

3 = FAA Style 2 (3 Steps, 4.8 o 6.6A)**

5 = FAA Style 3 (5 Steps, 2.8 to 6.6A)**

Number of Lamp Modules: 1 to 4 (Note: 4 Module Size 2 exceeds spec. by 0.6 in)

Options: 10 = Unenclosed Power Cable: 3 Ft. with Plug

11 = Flexible Liquidtight Conduit Enclosed 3 Ft. Power Cable

12 = External Power Switch

19 = Lamp Out Indicator

20 = Additional Tether (Single Module Sign Only)

* Use 33101 and 33102 isolation transformers only. Use step 2 of a 3 step regulator.

** Circuit board P/N 61153-1 allows for either 3 or 5 step operation, with no adjustments.

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Series 858XX-X


3

2.0 Installation

PLEASE READ ALL OF THIS SECTION CAREFULLY BEFORE DOING ANYTHING!

a. Refer to Figures 16 to 20 for the sign mounting pad layout and power feed location.

b. Remove sign from the shipping container.

c. Signs are usually installed so that the power connections are located towards the Taxiway or

Runway. See Figures 2, 3 and 18. Notice the POWER LEG location in relation to the sign

SIDE “B”.

d. The concrete foundation for the sign must be flat and level (see Concrete Pad Dimensions –

Figures 16 and 17). The foundation must extend below the frost line. The overall length of the

pad will depend on the number of sign modules and the location of the transformer base. If the

transformer base is to be located directly under a sign leg, the transformer base must be steel. If

the transformer base is to be located at the end of the sign (using a 90º elbow to get the power

cord into the sign, a plastic base may be used).

e. It is recommended that the contractor who is to install the concrete pad use cast in place anchor

bolts. See Figure 21. This requires that the anchor bolts be installed accurately as shown in the

concrete pad dimensions Figures 16 and 17. Be sure to locate floor flanges so that the ribs are

parallel to the sign centerline as indicated on the floor flange.

f. Leveling the floor flanges is important for ease of installation of the sign. A long carpenter’s

level can be placed across the top of the floor flanges to be sure they are all in line and level.

Do not tighten the anchor nuts tight (only finger-tight) until the frangible couplings are installed.

The frangible couplings can be removed from the sign and the sign lowered onto the couplings

after they have been screwed into the floor flanges. An alternative is to lower the sign with the

legs and flanges into place. Check the sign itself with a long carpenter’s level to be sure it is

level.

Note: Some vertical adjustments can be obtained by rotating the floor flanges a turn or two on

the frangible coupling.

g. Make sure all flanges are in full contact and sit flush on the pad before tightening the anchor

bolts. Once the sign has been leveled, attach the sign tether to the closest anchor bolt and

tighten all the anchor nuts securely. (NOTE: Anchor hardware is not supplied with the sign.)

Anchor hardware should be corrosion resistant. The sign body must not be bent or distorted due

to an uneven installation procedure.

h. Install the power cord input lead to the output of isolation transformer.

i. Electrical connections are shown in Figures 8-15 as applicable.

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4

3.0 Installation of Additional Modules

If additional sign modules must be added at a later date or during initial installation, proceed as

follows:

a. See Figures 4-7.

b. Examine the construction of an existing joint section if available.

c. The joint section is designed like the end of a sign. There is an angle bracket that slides into two

vertical grooves in the extrusion. The end of the sign (See Figures 4-7) will connect to the joint

section in a manner almost identical to the opposite end of the sign.

d. After assembling the joint section, insert the four long screws in the bottom and two long screws

at the top. Tighten the screws securely. Do not over-tighten or crush the plastic extrusion. Be

sure the color of the joint section matches the sign face.

e. Color matching is as follows:

1. For yellow sign face with black and yellow face on either side of the joint, use yellow joint.

2. For red and yellow face on either side of the joint, use yellow or red. In most cases, yellow

will be provided.

3. If two red faces are used, the joint must be red.

f. Attach the sign tether to the closest anchor bolt and tighten all the anchor nuts securely

(NOTE: Anchor hardware is not supplied with the sign.) Anchor hardware should be

corrosion resistant

4.0 Maintenance and Troubleshooting – Electrical

Problems in this area should be referred to a qualified electrician due to the potential shock

hazard.

WARNING:

WARNING REMOVE POWER BEFORE ATTEMPTING ANY SERVICING.

4.1 Lamp Current Check for Style 2 (3-step) and Style 3 (5-step) AGS Signs

a. These signs are not adjustable and are calibrated at the factory. In addition, these signs

may be connected to a 3-step or 5-step CCR without any modifications. However, to

verify that the sign is operating properly, current delivered to the lamps should be

checked. After signs have been installed and with power removed, remove the lamp

access cap (see Figure 1) and use a true RMS ammeter to measure current to the lamps.

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5

Figure 1. Typical AGS sign, Side View.

b. Turn the lighting circuit on to any step and observe current through lamps. After about 3

seconds, the current should be between 5.9 and 6.4 amps (nominal is 6.2 amps). See Table 1

at the end of this section if there are any problems here or in any of the subsequent steps.

c. Repeat (b) through all steps. There may be a 2-4 second a delay between steps before lamps

are fired.

d. Re-connect lamp, install the lamp access cap and sign is ready for operation.

4.2 Troubleshooting 3/5 Step AGS Signs

When the circuit board is operating correctly, upon power up a sequence of 7 green LED’s will turn

on and off, and will settle on one of them. Once this is done, the lamp(s) will turn on at the

appropriate current (6.2 amps nominal). This circuit selects the proper tap on a transformer which

either steps up the current from the airfield current loop to 6.2 amps (nominal) or steps the current

down to 6.2 amps (nominal). The flashing sequence of LED’s at power-up is a pre-scan which

determines that all taps from the transformer are connected to the circuit board, and whether there is

a burned-out lamp or not. If there is a burned-out lamp, the circuit will immediately shunt the

lamp(s). See Table 1 below if problems are encountered.

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Series 858XX-X


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Table 1

Troubleshooting 3/5 step signs

Symptom Possible Cause/Solution

1. Lamps do not turn on

a) Lamp circuit is open. Check for open lamps, or discontinuity between L1

and L2 of Fig. 8 (single module) or between L1 and B1 of Figs 9-11.

b) Check wiring, ensure all connections between tap transformer and circuit

board are sound.

c) Check input current to circuit board at wires 1 or 10 of Figures 8-10.

Should correspond to current loop currents of Tables 2 and 3. Replace

isolation transformer if out of spec. If not, there is most likely a problem

with the circuit board.

2.Lamps do not turn on

a) Circuit cannot determine which tap to select. Check for proper current

levels as in 1 (c) above. Check thoroughly for poor connections between

the tap transformer and the circuit board. An open/loose contact can

simulate a lamp out condition, or prevent the circuit from selecting the

correct tap. In the latter case, the board will wait until a different current is

selected on the airfield. If all connections and currents check out ok, then

there is likely a bad component on the circuit board.

3. Lamps are too bright or too

dim

a) Check that current to lamps is between 5.9 and 6.4 amps. If ok, then

replace lamp(s). Old lamps can get very dim without burning out. If not

within these limits, check input current to sign. It should be within the

specifications given in Tables 2 and 3.

b) There is a problem with the circuit board. Swap out with another to check,

or replace.

4. Lamps flicker a) If using a series-type regulator, check that it is over 30% loaded. There is a lamp bypass built into the circuit that may be prematurely triggering,

thereby stealing current from the lamps. Unloaded series regulators can

produce large voltage spikes on the power line that can trigger the lamp

bypass.

b) Other sources of noise on the power line can cause the circuit to behave as

if the current step is being changed. The circuit will attempt to re-find the

ideal tap to be selected, and in the meantime the lamps may be bypassed

(no current to lamps) which causes the ‘flicker’. Contact the factory for

assistance.

5. A) Sign will not work in all

brightness levels but works in

others. B) Sign will not work in

any level but lamps and current

input are okay.

a) Do calibration procedure. See Paragraph 4.5 for calibration instructions..

b) Check that the jumpers on PC Board 61153-1 are in the correct positions.

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Table 2

For three step regulator circuits, the airfield current levels should be:

Regulator Setting Current Range (A, RMS)

B10 4.7-4.9

B30 5.3-5.7

B100 6.4-6.7

Table 3

For five step regulator circuits, the airfield current levels should be:

Regulator Setting Current Range (A, RMS)

B1 2.7-2.9

B2 3.3-3.5

B3 4.0-4.2

B4 5.0-5.4

B5 6.4-6.7

Note: See page ix for a list of meters that would be suitable for these measurements.

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Series 858XX-X


8

4.3 Lamp Current Check for Style 5 (5.5A fixed current) AGS signs

Note: There is no circuit board in the Style 5 sign. The Style 5 sign operates with a step-

up isolation transformer which bumps the current up to 6.2 amps from an input of 5.5

amps and drives the lamps directly.

See Figures 12-15 for schematics and wiring configurations for Style 5 signs.

a. Remove the lamp access cover nearest the power cord and use a true RMS current meter

to measure current to the lamps.

b. Turn the lighting circuit on to 5.5 amps

c. If there is no current flowing through the lamps, turn the circuit off and check the

continuity of each lamp in the sign. Replace the lamps that are open (blown). Turn the

lighting circuit on.

d. If the current level to the lamps is less than 5.9 A or greater than 6.4 amps, check the

input current to the isolation transformer to make sure it is 5.5 amps. If so, replace the

isolation transformer. Otherwise, adjust the output current of the regulator to 5.5 Amps

and repeat current check. Fortunately there is not much that can go wrong with this type

of sign so it is very easy to trouble shoot.

4.4 Lamp Replacement

The signs are wired with a maximum of four lamps per power transformer in series, which

means that when one lamp goes out, all lamps on that power transformer also go out.

WARNING:

WARNING BE SURE POWER TO THE SIGN HAS BEEN TURNED OFF.

a. Remove the lamp access cap (Figure 1) by loosening the three screws and lifting off the

cap. It may be necessary to supply power with the cover removed to determine which

lamps are out. It is recommended that all the lamps in this sign loop be replaced at this

time, however, you may choose to replace just those lamps that are burned out. Slide the

lamps into brackets, install sockets and replace the covers and turn the power back on.

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4.5 Sign PC Board P/N 61153-1 Calibration

The 61153-1 PC Board doesn’t normally need to be calibrated in the field if the current

levels feeding the sign are reasonably close to the nominal three or five step current levels.

If the current levels feeding the sign are substantially different from the nominal, the 61153-

1 PC Board can be calibrated in an attempt to calibrate the sign to the current levels

provided.

INSTRUCTIONS FOR CALIBRATION OF 61153-1 PC BOARD.

1. Turn the airfield circuit feeding the sign to the highest (6.6 Amp) brightness level.

CAUTION:

CAUTION The hazard or unsafe practice could result in minor injury.

2. Locate and remove the jumper “P7” from the “P7” pins on the 61153-1 PC Board.

See Figure 10A. This operation shuts the PC Board off.

3. Locate and move jumper “P5” from open position on one pin, to the closed position

on both pins in the “P5” location. This operation tells the PC Board to calibrate to the

incoming current.

4. Replace the “P7” jumper on both of the “P7” pins. This operation turns the PC Board

on in the calibrate mode.

5. Wait one minute for the PC Board to calibrate. All the lamps of the sign should be lit

and LED 8 on the PC Board will be green if the calibration is complete. LED 8 will

be flashing “red” if the circuit board did not calibrate.

6. Remove the “P7” jumper and then move the “P5” jumper back to the open position.

Replace the “P7” jumper back on both pins. This operation takes the PC Board out of

the calibration mode and puts it back in the operate mode.

7. If the Sign is calibrated, operate the sign through each step of the regulator. The

following LED’s on the PC Board will indicate green for proper operation:

5 – Step Regulator 3 – Step Regulator

Step #1 LED 7 Step #1 LED 4



Step #4 LED 3

Step #5 LED 1

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TABLE 4

AIRSIDE GUIDANCE SIGNS

MEASURED LOAD (VA) AND POWER FACTOR (PF)

STYLE 2 AND 3

LAMP

MODULES

ISOLATION XFMR,

PART NO. 6.6/6.6 VA @ STEP B5/B100 PF

1 33004 (100W)

100

.95 Min

2* 33006 (200W)

160

.95 Min

3 33010 (300W)

230

.95 Min

4 33010 (300W)

290

.95 Min

Applies to all FAA sizes, single and double face. Tested on a Crouse-Hinds constant current

regulator at 1/2 load. Measured wattage exceeds the total of the lamp wattage due to the power

consumption of the sign internal electrical system.

*Includes FAA Size 4 distance marker sign

TABLE 5 AIRSIDE GUIDANCE SIGN

MEASURED LOAD (VA) AND POWER FACTOR (PF)

STYLE 5 (FIXED 5.5A CURRENT)

LAMP MODULES

ISOLATION

TRANSFORMER, PART

NO. 5.5/6.2A VA PF

1

33101 (100W) 100 .95 min

2

33102 (200W) 160 .95 min

3

33101 & 33102 (300W) * 230 .95 min

4

33101 & 33102 (300W) * 290 .95 min

* Use Consolidating Harness P/N 26811-27

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Parts List

TABLE 6

See Figures 2 – 7 for item location

ITEM NO. DESCRIPTION PART

NUMBER

USED ON

1 Frangible Coupling 62245-1

62245-2

62245-3

62245-5

Size 1

Size 2

Size 3

Size 5

2 Floor Flange 25684-1 All Sizes

3 Leg 60684 All Sizes

4 Power Cord CAS1M-P-B-.86 All Sizes

5 PC Board Assembly (for item 8

lamps)

61153-1

3-Step or 5-Step circuits

6 Tapped Transformer 61143 All Sizes

7 Lamp Cap 60638 All Sizes

8 Lamp, 62W 20590 All Sizes

9 Light Tube Assembly 60685-1

60685-2

60685-3

Size 1

Size 2

Size 3 & 5

10 Cover 62243-1

62243-2

62243-3

62243-5

62243-6

62243-7

Size 1, Single Module


Size 3 & 5, Single Module

Size 1, Double Module



11 Bottom 60758-1

60759-1

60760-1

60758-2

60759-2

60760-2







12 Screw, Hex HD w/Nylok

1/4-20 X 1” LG, SS (7/16”

socket)

10000-405 All Sizes

13 Side 60615-1A

60615-2A

60615-3A

Size 1

Size 2

Size 3 & 5

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NUMBER

USED ON

14 NOT USED

15 Screw, Hex HD w/Nylok

#6-32 x 3/8 LG, SS

10000-397 All Sizes

16 NOT USED

16A NOT USED

17 Name Plate 62092-2 All Sizes

18 Label, Isolation Transformer 60870 All Sizes

19 NOT USED

20 Sign Face Panel (w/Legend)

60667-1

60667-2

60667-3

60667-5

60667-6

60667-7



Size 3 & 5 Single Module




21 Sign Panel, Black 60668-1

60668-2

60668-3

60668-5

60668-6

60668-7







22 Bracket, Center Support, Top 62246 All Sizes, Double Module

23 Bracket, Center Support, Bottom 62227 All Sizes, Double Module

24 Center Support 62247-1

62247-2

62247-3




25 NOT USED

26 Bracket, Top, Joint 60852 All Sizes, Single/Double

Module w/Joint, Size 1 & 2,

27 Joint Channel/ Joint Panel 61098

61099

62448

Size 1 Sngl/Dbl Mod w/Joint



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NUMBER

USED ON

28 Bracket, Joint 60854 Size 2, Single/Double Module

w/Joint

29 Bracket, Bottom, Joint 60851 Size 1 & 2, Single/Double

Module w/Joint

30 Channel Support 60783 All Sizes, Single/Double

Module w/Joint

32 Rain Cap, End 60633 All Sizes

33 Rain Cap, Joint/Bottom 60634 All Sizes, Single/Double

Module w/Joint

34 Plastic Extrusion, Machined 61096

61097

60848




35 Cover Bracket 60849 All Sizes w/Joint

36 Channel Bar 60850 All Sizes w/Joint

37 Tether 60728-1 All sizes

38 Hole Plug 10037-621 All Sizes - Single Module

All Sizes - Joint Sections

Single and Double

39 Center Support, Horizontal 62242-3 Size 3 w/ and w/o Joint

Sections, Single and Double

40 Bracket, Center Support, Middle 62244 Size 3 w/ and w/o Joint

Sections, Single and Double

41 Bracket Joint Panel 62249 Size 3 w/ Joint

Note: 3 and 4 module signs are combinations of single and double module signs as shown in

Figures 11 and 15.

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14

RECOMMENDED TWO YEAR SPARE PARTS STOCK

TABLE 7

DESCRIPTION

PART NUMBER RECOMMEDED QUANITY

Lamp, 62W. 20590 1 Per Module

Lamp Socket 61107 1 Per Every 20 Modules

Circuit Card 61153-1 1 Per Every 20 Signs

*Frangible Coupling 62245-X 1 Set Per Every 20 Signs

Internal Tapped X’fmr 61143 1 Per Every 20 Signs

**Cover Assembly

(includes cap, gasket and lamp

screws)

60844-X 1 Per Every 25 Signs

Lamp Cap 60638 1 Per Every 25 Signs

* = -1 For Size 1

-2 For Size 2

-3 For Size 3

-5 For Size 5

** = 60844-1 For Size 1 Single

60844-2 For Size 2 Single

60844-3 For Size 3 Single

60844-5 For Size 1 Double



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15

Figure 2. Single module sign

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Figure 3. Double module sign.

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Figure 4. Single module with joint section

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Figure 5. Double module with joint section.

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19

Figure 6. Joining of signs.

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Figure 7. Close up of joint section.

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21

Figure 8: Wiring schematic, single module, 3/5 Step. See Figure 10 if P/N 61143 is Rev B.

See Figures 9 and 11 for other configurations.

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Figure 9: Wiring schematic, double module, 3/5 step. See Figure 10 if P/N 61143 is Rev B.

See Figures 8 and 11 for other configurations.

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Figure 10: Wiring connections for P/N 61153 PCB to P/N 61143 tap transformer, Rev B or

Rev C. See Figures 8, 9 and 11 for more details.

T7

3 STEP T6

5 STEP T5

T9 FOR 65W,

6.6A LAMP

3 & 5 STEP

T4

A3 & T2

T8

5 STEP T6,

ALSO T9 FOR50W, 12V LAMP

3 & 5 STEP

3 STEP T5

P/N 61143

REV BACE-12534

REV B of P/N 61143, Tap transformer

T7

T6 (3)

T5 (5)

T9

T4

T11 &

T2

T8

T6 (5)

T5 (3)

REV C of 61143

P/N 61143

REV C

ACE-12534

Rev C of

61143 is a

change in

label only

E10

E11

E1

E9

E8

E7

E6 (

5)

E6 (

3)

E5 (

3)

E5 (

5)

E4

E2

E3

A4

FE

MA

LE

CO

UP

LE

R

MA

LE

CO

UP

LE

R

InputPower

B1

A1

To

: T

8

To

: T

7

To

: T

6 (

3)

To

: T

11 &

T2

As per label on 61143 REV C.For 61143 REV B, simply match corresponding tab location

To

: T

9

To

: T

6 (

5)

To

: T

5 (

5)

To

: T

5 (

3)

To

: T

4

To

: T

11 &

T2

plu

g i

nto

back o

f E

11

E1- E9 = FEMALE COUPLERSE11 = FEMALE W/MALE COUPLER

1 TO 4 62 W LAMPS

P/N 61153-1

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Figure 10A Calibration of the 61153-1 Printed Circuit Board.

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Figure 11: Other Configurations.

Fig

ure

11

. W

irin

g s

ch

em

es f

or

3 a

nd

4 m

od

ule

sig

ns (

no

t sho

wn in

Fig

s 8

an

d 9

).

V

iew

ed

fro

m A

-sid

e (

PC

boa

rd/I

np

ut

po

wer

on

rig

ht)

.

L2

PC BoardA

4

E3

L1

L2

L4

L1

B2

B1

B2

B1

L3

Join

t S

ectio

n

Doub

le M

odule

Sin

gle

Module

L2

L4

L3

B2

B1

PC BoardA

4

E3

L2

L4

L1

L3

B2

B1

L1

Join

t S

ection

Do

uble

Modu

leD

ou

ble

Modu

le

PC Board

A4

E3

L1

L2

L4

L1

L3

B2

B1

L2

B1

B2

Join

t S

ection

Dou

ble

Modu

leS

ing

le M

odule

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Figure 12: Wiring schematic, 5.5A fixed current, single module. See Figures 13, 14 for

other configurations.

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Figure 13: Wiring schematic, 5.5A fixed current, double module. See Figures 12 and 14 for

other configurations.

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Figure 14: Tapped Transformer Wiring Detail, Style 5 (5.5 A Fixed Current)

Fig

ure

14. W

irin

g s

chem

es for

3 a

nd 4

module

Sty

le 5

sig

ns (

not show

n in F

igs

1

2 a

nd 1

3).

Vie

wed fro

m A

-sid

e w

ith p

ow

er

input on r

ight.

L2

L4

L3

B2

B1

L2

L4

L1

L3

B2

B1

L1

Double

Mo

dule

Do

uble

Mod

ule

Join

t S

ection

L2

B1

A1

L1

L2

L4

L1

B2

B1

B2

B1

L3

Jo

int

Section

Doub

le M

odule

Sin

gle

Mo

dule

B1

A1

L1

L2

L4

L1

L3

B2

B1

L2

B1

B2

Join

t S

ection

Do

uble

Mod

ule

Sin

gle

Mod

ule

B1

A1

11

0

1 1101

0

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THIS SHEET INTENTIONALLY LEFT BLANK

Figure 15: NOT USED

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Figure 16 Concrete pad dimensions

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Figure 17: Concrete pad dimensions, elbow to base

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Figure 18: Sign dimensions

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Figure 19: Mounting detail, steel base

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Figure 20: Mounting detail, Elbow Assy

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FLANGE INSTALLATION WITH 'L' ANCHOR BOLTS

ANCHOR BOLTS MUST BE CAPABLE OF WITHSTANDING A MINIMUM

BOLT MATERIAL TO BE ZINC GALVANIZED STEEL OR STAINLESS STEEL

USE FOUR (4) 'L' TYPE ANCHOR BOLTS PER FLANGE, #1/2-13 x 8" MINIMUM

PULL-OUT (TENSION) LOAD OF 8750 POUNDS.

FIGURE 21: Flange Installation

6.75" (171.45mm) MINIMUM

1.25" (31.75mm) REF

1

1

9211 rev Y - Cooper Industries · Document 9211 Rev. Y Instruction Manual Airside Guidance Sign...

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Transcript of 9211 rev Y - Cooper Industries · Document 9211 Rev. Y Instruction Manual Airside Guidance Sign...