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Cooper Crouse-Hinds 858 Series Instruction Manual

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Document
9211
Revision
Y
April 10, 2012
Cooper Industries
Crouse-Hinds Division
Crouse-Hinds Airport
Lighting
1200 Kennedy Road
Windsor, CT 06095
Instruction Manual
Airside Guidance Sign
Series 858XX-X
Sizes 1, 2, 3, and 5
62 Watt Lamp
Copyright © 2012 Cooper Technologies Company
For Parts or Technical Service Call (860) 683-4300

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  • Page 1 Document 9211 Revision 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...

  • Page 2: Revisions

    Document 9211 Rev. Y Instruction Manual Airside Guidance Sign Series 858XX-X Sizes 1, 2, 3, and 5 Revisions Issue/Reissue Revision Letter Number Number Description Checked Approved A203-281A See Record Copy for Previous Revisions. 1/21/04 Revised extensively to delete use of 60880-X P.C.

  • Page 3: Limited Product Warranty

    Document 9211 Rev. Y Instruction Manual Airside Guidance Sign Series 858XX-X Sizes 1, 2, 3, and 5 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.

  • Page 4: Safety Notices

    Document 9211 Rev. Y Instruction Manual Airside Guidance Sign Series 858XX-X Sizes 1, 2, 3, and 5 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.
  • Page 5 Document 9211 Rev. Y Instruction Manual Airside Guidance Sign Series 858XX-X Sizes 1, 2, 3, and 5 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.

  • Page 6: Table Of Contents

    Document 9211 Rev. Y Instruction Manual Airside Guidance Sign Series 858XX-X Sizes 1, 2, 3, and 5 Table of Contents Title Page .............................i Revisions ........................... ii Limited Product Warranty ......................iii Safety Notices ..........................iv Table of Contents ........................vi Test Equipment and Tools ......................
  • Page 7 Document 9211 Rev. Y Instruction Manual Airside Guidance Sign Series 858XX-X Sizes 1, 2, 3, and 5 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 –...
  • Page 8 Document 9211 Rev. Y Instruction Manual Airside Guidance Sign Series 858XX-X Sizes 1, 2, 3, and 5 List of Figures Figure 1 – Typical AGS sign, side view.................. 5 Figure 2 – Single Module Sign, Series Circuit ..............15 Figure 3 –...

  • Page 9: Test Equipment And Tools

    Document 9211 Rev. Y Instruction Manual Airside Guidance Sign Series 858XX-X Sizes 1, 2, 3, and 5 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.

  • Page 10: Section 1. General Information

    Document 9211 Rev. Y Instruction Manual Airside Guidance Sign Series 858XX-X Sizes 1, 2, 3, and 5 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.

  • Page 11: Part Numbers

    Document 9211 Rev. Y Instruction Manual Airside Guidance Sign Series 858XX-X Sizes 1, 2, 3, and 5 CAT. # FAA Styles Style 2 – For operation from a 3 step series lighting circuit (4.8 to 6.6 amperes) Style 3 – For operation from a 5 step series lighting circuit (2.8 to 6.6 amperes) Style 5 –...

  • Page 12: Section 2. Installation

    Document 9211 Rev. Y Instruction Manual Airside Guidance Sign Series 858XX-X Sizes 1, 2, 3, and 5 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.

  • Page 13: Section 3. Adding Additional Sign Modules

    Document 9211 Rev. Y Instruction Manual Airside Guidance Sign Series 858XX-X Sizes 1, 2, 3, and 5 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.

  • Page 14: Troubleshooting 3/5 Step Ags Signs

    Document 9211 Rev. Y Instruction Manual Airside Guidance Sign Series 858XX-X Sizes 1, 2, 3, and 5 Figure 1. Typical AGS sign, Side View. 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).
  • Page 15 Document 9211 Rev. Y Instruction Manual Airside Guidance Sign Series 858XX-X Sizes 1, 2, 3, and 5 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.
  • Page 16 Document 9211 Rev. Y Instruction Manual Airside Guidance Sign Series 858XX-X Sizes 1, 2, 3, and 5 Table 2 For three step regulator circuits, the airfield current levels should be: Regulator Setting Current Range (A, RMS) 4.7-4.9 5.3-5.7 B100 6.4-6.7 Table 3 For five step regulator circuits, the airfield current levels should be: Regulator Setting...

  • Page 17: Lamp Current Check For Style 5 (5.5A Fixed Current) Ags Signs

    Document 9211 Rev. Y Instruction Manual Airside Guidance Sign Series 858XX-X Sizes 1, 2, 3, and 5 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.

  • Page 18: Sign Pc Board P/N 61153-1 Calibration

    Document 9211 Rev. Y Instruction Manual Airside Guidance Sign Series 858XX-X Sizes 1, 2, 3, and 5 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.
  • Page 19 Document 9211 Rev. Y Instruction Manual Airside Guidance Sign Series 858XX-X Sizes 1, 2, 3, and 5 TABLE 4 AIRSIDE GUIDANCE SIGNS MEASURED LOAD (VA) AND POWER FACTOR (PF) STYLE 2 AND 3 LAMP ISOLATION XFMR, MODULES PART NO. 6.6/6.6 VA @ STEP B5/B100 33004 (100W) .95 Min...
  • Page 20 Document 9211 Rev. Y Instruction Manual Airside Guidance Sign Series 858XX-X Sizes 1, 2, 3, and 5 Parts List TABLE 6 See Figures 2 – 7 for item location ITEM NO. DESCRIPTION PART USED ON NUMBER Frangible Coupling 62245-1 Size 1 62245-2 Size 2 62245-3...
  • Page 21 Document 9211 Rev. Y Instruction Manual Airside Guidance Sign Series 858XX-X Sizes 1, 2, 3, and 5 ITEM NO. DESCRIPTION PART USED ON NUMBER NOT USED Screw, Hex HD w/Nylok 10000-397 All Sizes #6-32 x 3/8 LG, SS NOT USED NOT USED Name Plate 62092-2...
  • Page 22 Document 9211 Rev. Y Instruction Manual Airside Guidance Sign Series 858XX-X Sizes 1, 2, 3, and 5 ITEM NO. DESCRIPTION PART USED ON NUMBER Bracket, Joint 60854 Size 2, Single/Double Module w/Joint Bracket, Bottom, Joint 60851 Size 1 & 2, Single/Double Module w/Joint Channel Support 60783...
  • Page 23 Document 9211 Rev. Y Instruction Manual Airside Guidance Sign Series 858XX-X Sizes 1, 2, 3, and 5 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...

  • Page 24: Figure 2 - Single Module Sign, Series Circuit

    Document 9211 Rev. Y Instruction Manual Airside Guidance Sign Series 858XX-X Sizes 1, 2, 3, and 5 Figure 2. Single module sign...

  • Page 25: Figure 3 - Double Module Sign, Series Circuit

    Document 9211 Rev. Y Instruction Manual Airside Guidance Sign Series 858XX-X Sizes 1, 2, 3, and 5 Figure 3. Double module sign.

  • Page 26: Figure 4 - Single Module With Join Section, Series Circuit

    Document 9211 Rev. Y Instruction Manual Airside Guidance Sign Series 858XX-X Sizes 1, 2, 3, and 5 Figure 4. Single module with joint section...

  • Page 27: Figure 5 - Double Module With Joint Section, Series Circuit

    Document 9211 Rev. Y Instruction Manual Airside Guidance Sign Series 858XX-X Sizes 1, 2, 3, and 5 Figure 5. Double module with joint section.

  • Page 28: Figure 6 - Typical Jointing Of Signs

    Document 9211 Rev. Y Instruction Manual Airside Guidance Sign Series 858XX-X Sizes 1, 2, 3, and 5 Figure 6. Joining of signs.

  • Page 29: Figure 7 - Joint Section

    Document 9211 Rev. Y Instruction Manual Airside Guidance Sign Series 858XX-X Sizes 1, 2, 3, and 5 Figure 7. Close up of joint section.

  • Page 30: Figure 8 - Wiring Schematic, Single Module, 3 Or 5 Step

    Document 9211 Rev. Y Instruction Manual Airside Guidance Sign Series 858XX-X Sizes 1, 2, 3, and 5 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.

  • Page 31: Figure 9 - Wiring Schematic, Double Module. 3 Or 5 Step

    Document 9211 Rev. Y Instruction Manual Airside Guidance Sign Series 858XX-X Sizes 1, 2, 3, and 5 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.

  • Page 32: Figure 10 - Tapped Transformer Wiring Detail, 3/5-Step

    Document 9211 Rev. Y Instruction Manual Airside Guidance Sign Series 858XX-X Sizes 1, 2, 3, and 5 REV B of P/N 61143, Tap transformer REV C of 61143 P/N 61143 P/N 61143 REV B REV C ACE-12534 ACE-12534 A3 & T2 T11 &...

  • Page 33: Figure 10A Calibration Of The 61153-1 Printed Circuit Board

    Document 9211 Rev. Y Instruction Manual Airside Guidance Sign Series 858XX-X Sizes 1, 2, 3, and 5 Figure 10A Calibration of the 61153-1 Printed Circuit Board.

  • Page 34: Figure 11: Other Configurations

    Document 9211 Rev. Y Instruction Manual Airside Guidance Sign Series 858XX-X Sizes 1, 2, 3, and 5 PC Board PC Board PC Board Figure 11: Other Configurations.

  • Page 35: Figure 12 - Wiring Schematic, Single Module, Style 5 (5.5A Fixed Current)

    Document 9211 Rev. Y Instruction Manual Airside Guidance Sign Series 858XX-X Sizes 1, 2, 3, and 5 Figure 12: Wiring schematic, 5.5A fixed current, single module. See Figures 13, 14 for other configurations.

  • Page 36: Figure 13 - Wiring Schematic, Double Module, Style 5 (5.5A Fixed Current)

    Document 9211 Rev. Y Instruction Manual Airside Guidance Sign Series 858XX-X Sizes 1, 2, 3, and 5 Figure 13: Wiring schematic, 5.5A fixed current, double module. See Figures 12 and 14 for other configurations.

  • Page 37: Figure 14 - Tapped Transformer Wiring Detail, Style 5 (5.5A Fixed Current)

    Document 9211 Rev. Y Instruction Manual Airside Guidance Sign Series 858XX-X Sizes 1, 2, 3, and 5 Figure 14: Tapped Transformer Wiring Detail, Style 5 (5.5 A Fixed Current)

  • Page 38: Figure 15: Not Used

    Document 9211 Rev. Y Instruction Manual Airside Guidance Sign Series 858XX-X Sizes 1, 2, 3, and 5 THIS SHEET INTENTIONALLY LEFT BLANK Figure 15: NOT USED...

  • Page 39: Figure 16 Concrete Pad Dimensions

    Document 9211 Rev. Y Instruction Manual Airside Guidance Sign Series 858XX-X Sizes 1, 2, 3, and 5 Figure 16 Concrete pad dimensions...

  • Page 40: Figure 17: Concrete Pad Dimensions, Elbow To Base

    Document 9211 Rev. Y Instruction Manual Airside Guidance Sign Series 858XX-X Sizes 1, 2, 3, and 5 Figure 17: Concrete pad dimensions, elbow to base...

  • Page 41: Figure 18: Sign Dimensions

    Document 9211 Rev. Y Instruction Manual Airside Guidance Sign Series 858XX-X Sizes 1, 2, 3, and 5 Figure 18: Sign dimensions...

  • Page 42: Figure 19: Mounting Detail, Steel Base

    Document 9211 Rev. Y Instruction Manual Airside Guidance Sign Series 858XX-X Sizes 1, 2, 3, and 5 Figure 19: Mounting detail, steel base...

  • Page 43: Figure 20 - Mounting Detail, Elbow Assembly

    Document 9211 Rev. Y Instruction Manual Airside Guidance Sign Series 858XX-X Sizes 1, 2, 3, and 5 Figure 20: Mounting detail, Elbow Assy...

  • Page 44: Figure 21: Flange Installation

    Document 9211 Rev. Y Instruction Manual Airside Guidance Sign Series 858XX-X Sizes 1, 2, 3, and 5 1.25" (31.75mm) REF 6.75" (171.45mm) MINIMUM FLANGE INSTALLATION WITH 'L' ANCHOR BOLTS USE FOUR (4) 'L' TYPE ANCHOR BOLTS PER FLANGE, #1/2-13 x 8" MINIMUM BOLT MATERIAL TO BE ZINC GALVANIZED STEEL OR STAINLESS STEEL ANCHOR BOLTS MUST BE CAPABLE OF WITHSTANDING A MINIMUM PULL-OUT (TENSION) LOAD OF 8750 POUNDS.

This manual is also suitable for:

L-858yL-858rL-858l

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