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Thorn Airfield Lighting France 156 boulevard Haussmann 75379 Paris Cedex 08 FRANCE Tel : +33 (0) 1 49 53 62 62 Fax : +33 (0) 1 49 53 62 89 info@ThornAirfieldLighting.fr Thorn Airfield Lighting Version 6.0 (27 October 2010) Thorn Airfield Lighting Pty Ltd 7-9 Newcastle Road Bayswater Victoria 3153 AUSTRALIA Tel : +61 (0) 3 97 20 32 33 Fax : +61 (0) 3 97 20 82 33 info@ThornAirfieldLighting.com Page 1 / 43 Thorn Airfield Lighting UK Ltd 11 Town Quay Wharf, Abbey Road, Barking, Essex, IG117BZ UNITED KINGDOM Tel : +44 (0) 208 594 2747 Fax : +44 (0) 208 594 2848 info@ThornAirfieldLighting.co.uk PU3L Doc 2111.E
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TABLE OF CONTENTS
1 INTRODUCTION ........................................................................................................................................ 4 1.1 USE RESTRICTION NOTICE AND WARRANTY ............................................................................................. 4 1.1.1 Use of the Document....................................................................................................................... 4 1.1.2 Warranty......................................................................................................................................... 4 1.2 SAFETY INSTRUCTIONS ............................................................................................................................ 5 2 3 4 REFERENCE DOCUMENTS..................................................................................................................... 5 GENERAL STATEMENTS ABOUT PAPI SYSTEM INSTALLATION.............................................. 6 TOOLS AND ACCESSORIES REQUIRED ............................................................................................. 7 4.1 4.2 5 STANDARD TOOLS ................................................................................................................................... 7 SPECIAL TOOLS ....................................................................................................................................... 7
INSTALLATION.......................................................................................................................................... 8 5.1 CIVIL WORKS .......................................................................................................................................... 8 5.1.1 PU3L unit possible height .............................................................................................................. 8 5.1.2 Concrete plinth standard dimensions ............................................................................................. 9 5.1.3 Electrical circuits.......................................................................................................................... 11 5.2 INSTALLING THE LEGS ON THE CONCRETE PLINTH.................................................................................. 13 5.3 MOUNTING THE PU3L BOX ONTO THE LEGS .......................................................................................... 14 5.4 ELECTRICAL CONNECTIONS ................................................................................................................... 16 5.4.1 Connection of the secondary cables on the PU3L........................................................................ 16 5.4.2 Fixing and connecting the lamps.................................................................................................. 18 5.5 ADJUSTMENT OF ELEVATION ANGLE..................................................................................................... 19 5.5.1 Use of the clinometer .................................................................................................................... 19 5.5.2 Calibration procedure .................................................................................................................. 20
INSTALLATIONS OF OPTIONAL DEVICES...................................................................................... 21 6.1 INSTALLATION OF THE TILT SWITCH ...................................................................................................... 21 6.1.1 Mounting and adjustment ............................................................................................................. 21 6.1.2 Cabling of the tilt switch system ................................................................................................... 23
6.1.2.1 6.1.2.2 PU3L internal cabling ............................................................................................................................. 23 PU3L external cabling ............................................................................................................................ 24
6.1.3
6.1.3.1 6.1.3.2 6.1.3.3
6.2 INSTALLATION OF HEATING RESISTOR ................................................................................................... 33 6.2.1 Mounting of heating resistors and terminal plates ....................................................................... 33
6.2.1.1 6.2.1.2 Mounting of heating resistors ................................................................................................................ 33 Mounting the terminal plates ................................................................................................................. 34
6.2.2
6.2.2.1 6.2.2.2
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1 Introduction
The documentation lists the different steps to follow in order to install the PU3L PAPI unit. You will find in this document two main paragraphs: "General Information and Requirements": This chapter gives general description and use of the fitting covered by this document. "Installation of the fitting": This chapter describes how to maintain the fitting covered by this document.
1.1
1.1.2 Warranty
THORN Airfield Lighting guarantees that the performance of the inset lights described in this document, when sold by THORN Airfield Lighting or its licensed representatives, meets the requirements of ICAO Annex 14 volume 1 and FAA specification AC 150/5345-28. Any defect in design, material or workmanship, which may occur during proper and normal use over a period covered by the warranty stipulate in the contract, will be replaced by THORN Airfield Lighting free of charge, ex works. Operational failure resulting from lamp burnt out, improper installation, damage due to runway maintenance equipment is not considered a result of proper use and is beyond the scope of the warranty. The above constitutes the limits of THORN Airfield Lighting 's liabilities concerning the equipment covered by this document.
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1.2
Safety instructions
WARNING: Prior to the commencement of work all electrical services MUST be isolated from the
supply and connected to earth. Full details of the work involved must be given to the Authorise Person responsible for the electrical engineering services at the airport with regard to the duration of the work, etc.. It is recommended that prior to starting any cutting work the nature and location of services such as cable ducts, etc... should be identified. It is a prerequisite of this type of installation that the work should be carried out by trained and experienced personnel.
2 Reference documents
This paper refers to following documents: THORN Commercial Documentation General Brochure Doc 1001.E, THORN PU3L Commercial Documentation Doc 1111.E, Last Edition of ICAO Annex 14 Edition of July 1995, Last Edition of FAA Advisory Circular AC 150/5345-28.
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The PU3L is mounted on three legs, each comprising a tripod stand, frangible coupling and an aluminium tube, the length of which has to be determined at the time of installation. The final length of the tubes will depend upon the individual heights of the PAPI units, these heights being dependent upon local ground conditions etc.. On the centre of each PAPI body is a datum point which can be used to ensure that all of the units are the same level. Please note that the PAPI units should be mounted as low as possible. The tube supplied are 60 mm diameter and 400 mm long. Please note that 92 mm of tube is placed inside the frangible coupling and this must be allowed for in calculating the required length.
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4.2
Special Tools
One set of adjustment tools (supplied in a little case). Note : Standard surveyors equipment shall be also required to determine the location of the foundation blocks etc.. One multimeter (for Tilt Switch Installation).
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5 Installation
5.1 Civil Works
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5.2
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5.3
REMOVE THE PU3L COVER A) Opening the Three catches (A). * the catches are of the locking type and a stab (B) needs to be press before the catch will open. Note :The locking Part of the catches is use to secure the closing. If you forget to push on it you will never be able to open the Catches. Dont force on the Catches you can damage it. B) Lock the three catches in the upright position C) Remove the PU3L Cover
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INSTALL THE PU3L BASE PLATE ON THE THREE LEGS A) Having remove the Cover (A) of the PU3L. B) Place the Base Plate (B) on the Three Legs (C).
FOR EACH LEG A) Place the upper Knee Joint (F) on the Threaded Rod (A). B) Mount the top part of the Knee Joint (E) on the Threaded Rod (A). C) Mount the Upper Fixing Washer (D) on the Threaded Rod (A). D) Screw the PU3L Fixing Nut (C) on the Threaded Rod of the Leg (A). Do not tighten it at this stage. E) Screw the PU3L Locknut (B) on the Threaded Rod (A) about 10 mm over the fixing Nut (C).
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5.4
Electrical connections
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FOR EACH CABLE A) Unscrew and Remove the Lower Nut (C) of the Compression Packer (A). B) Remove the Plug (D) from the Lower Nut (C) of the Compression Packer (A). Note : all the unused cable entries must have the blanking plug left in situ in order to maintain IP rating of the unit. C) Pass the Secondary Cable (F) - Through the Compression Packer Lower Nuts (C), - Then through the Compression Packer Gasket (E), - And through the Compression Packer Body (B). D) Pull the Secondary Cable about 15 cm into the box E) Strip back the outer sheath of the cable by approx. 20 mm. F) bare the cables cores for a distance of about 10 mm. G) Connect the two cable cores to the PU3L dedicated Terminal (Two connections par secondary cable). H) Pull back the Cable to leave the minimum amount inside the unit. I) Reassemble the Compression Packer Body (B) and tighten to suit.
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5.5
At this stage the PU3L PAPI Units has been : - Installed on their Concrete plinths. - Equipped of secondary Cables (two or three). - Equipped with Lamps (two or three). The final stage of the installation process is to set the elevation angles of the Units.
Note : The angle of approach on the typical airfield is normally 3 degrees, however , this has to be verified with the client and the local Aviation Authority. The standard angular displacement between each unit is 20 minutes of arc. For a 3 degree approach this would give the unit closest to the runway a setting of 330, the next 310, the next 250 and the last one 230. 5.5.1 Use of the clinometer
Degrees on this line Minutes on this line
The 0 of the line of the spirit level is in regard of the first division after the 3. As one division on the body line is 15 minutes, the clinometer is adjusted to 3 and 15minutes. If you want to adjust to 3 and 20 minutes, you have to add 5 minute. The line for the minute is fixed on the spirit level, so you need to adjust the division n5 in regards with the next division on the body line Then you get 3+15 +5=3 20. Secure the position by the brake under the spirit level.
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Now the PAPI Unit PU3L is operational. When the 4 Units of a PAPI System are all operational the System itself is operational and then could be put in service and use.
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6.1
The Tilt Switch system is composed of four Tilt Switch devices (One Master Tilt Switch Unit and three Slave Tilt Switch Units mounted in the corresponding PU3L (one became the Master and the three other became Slaves) linked together by Cables. The installation of aTilt Switch System can be made in three main operations :
1) Mechanical Mounting and Adjustment of the Devices in the PU3L Units 2) Wiring of the System 3) Commissioning of the Whole System. 6.1.1 Mounting and adjustment
The first operation to do is to mount and adjust the four Tilt switch Devices in the corresponding four PU3L.
MOUNTING
FOUR EACH PU3L UNITS
A) Remove the Cover of the PU3L (see Paragraph 5.3.). B) Using the Two Fixing Holes (D) located on the PU3L Base Plate (A) and the two Fixing Screw (C) located on the Tilt Switch Devices (B), fix and lock the Tilt Switch Device on the PU3L Base Plate.
Note : a) One of the three PU3L Units must be equipped with The Master Tilt Switch Device and the three other with Slave Tilt Switch devices. You can recognise the Master Tilt Switch Devices because it is the only one equipped with Power Supply and Control Module (= Big Module located under the Tilt Switch Device. Thorn Airfield Lighting Version 6.0 (27 October 2010) Page 22 / 43 PU3L Doc 2111.E
b) Following the design of the AFL circuits and what is more convenient for you (see Paragraph 6.1.2.2.2.). You can install Master Tilt Switch device in the first or in the last (starting from the runway edge) PU3L Unit of the PAPI System.
ADJUSTMENT
FOUR EACH PU3L UNITS
A) Put the Spirit Level use in Paragraph 5.5 on the Plate of the Tilt Switch Device which support the two Mercury Contact in (A). B) Using the Adjustment screw (B) and looking at the Spirit Level set Horizontally the Plate of the Tilt Switch Device which support the two Mercury Contact. C) Verify that the Mercury Contact are Closed. * For Master PU3L Unit, using an Ohmmeter Verify that Connection 13 of the Tilt Switch Device Main Terminal and Connection 1 of the Mercury Contact Terminal are short circuited. * For Slave PU3L Units, using an Ohmmeter Verify that Connection 3 and 13 of the Tilt Switch Device Main Terminal are short circuited. D) If necessary put back in place the PU3L Cover.
MASTER
SLAVE
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FOR EACH CABLE TO CONNECT A) Unscrew and Remove the Lower Nut (C) of the Compression Packer (A). B) Remove the Plug (D) from the Lower Nut (C) of the Compression Packer (A). Note : all the unused cable entries must have the blanking plug left in situ in order to maintain IP rating of the unit. C) Pass the corresponding Cable (F) - Through the Compression Packer Lower Nuts (C), - Then through the Compression Packer Gasket (E), - And through the Compression Packer Body (B). D) Pull the corresponding Cable about 20 cm into the box E) Strip back the outer sheath of the cable by approx. 20 mm. F) Bare the cables cores for a distance of about 10 mm. G) Connect the cable cores to the tilt Switch Device dedicated terminal (see Paragraph 6.2.2.2.2.2.). H) Pull back the Cable to leave the minimum amount inside the unit. I) Reassemble the Compression Packer Body (B) and tighten to suit.
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The wiring overview drawing below shows the different electrical connections necessary on a PAPI system with Tilt Switch option equipped of PU3L Units.
WIRING OVERVIEW
1. Isolating Transformer for the lamps 2. Isolating Transformer for the Supply of the Master Tilt Switch devices 3. Primary Cable 4. Secondary Cable
5. Heating Resistors Supply 230 Vac (Option) 6. Alarm Feed Back Cable (Option) 7. Cable for - Mercury contacts Loop - Relays Supply (+12 Vdc) - Heating Resistors Supply (Option)
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= Mercury Contacts Loop + Relays Supply (+12 Vdc) + Heating Resistors Supply 230 Vac (Option) 4. Control Out = Mercury Contacts Loop + Relay Supply (+12 Vdc) + Heating Resistors Supply 230 Vac (Option)
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Connection Between Master PU3L Unit and the First Slave PU3L Unit
MASTER TERMINAL FIRST SLAVE TERMINAL
1. Master Tilt Switch Device Supply 2. Alarm Feed Back Signal (Option)
Connection Between First Slave PU3L Unit and the Second Slave PU3L Unit
FIRST SLAVE TERMINAL SECOND SLAVE TERMINAL
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Connection Between Second Slave PU3L Unit and the Last Slave PU3L Unit
SECOND SLAVE TERMINAL LAST SLAVE TERMINAL
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9) Repeat Three time the test (from 1) to 7)) creating the default separately on the three Salve PU3L Unit A) Remove the cover and create the Default describe in 1) on the corresponding Slave PU3L Unit. B) Control the status of the three LEDs of the Master PU3L like in 4) A). C) Put Back in place the Cover of the corresponding PU3L Unit. D) Test the next Slave PU3L Unit.
When Default Status have been tested on the four PU3L Units with success your Tilt Switch System is consider as operational. 6.1.3.3 Problem occurred during commission
6.1.3.3.1 The PAPI system is light off when it is power on
1) Verify the PAPI AFL Loop(s) are Powered On with a TRMS value of at least 2.8 Amps. 2) Remove the covers of all the PU3L 3) Control the status of the three LEDs of the Master Tilt Switch Device. A) The Red LED (1) showing that the Power Supply Module supply 12 Vdc must be light On. * LED light Off means that the Control and Supply Module doesnt supply the 12 Vdc to all the relays and by default all the lamps are short Circuited. - Verify that the Master Tilt Switch Module is Supplied (2.8 to 6.6 amps). If it is the case change the Master Tilt Switch Module and restart the commissioning. B) The Green LED (2) Showing that the Mercury Contacts Loop is Closed must be Light On. * LED light Off means that the Mercury Contacts Loop is Open somewhere. Find where the loop is open, correct the problem and restart the commissioning. - To find where the Loop is open do as follow : a) Power Off the PAPI System. b) Open the loop on the PU3L Master Unit. Disconnect the wire Connected to the connections 13 and 14 of the Master Tilt Switch Device Main Terminal. Thorn Airfield Lighting Version 6.0 (27 October 2010) Page 32 / 43 PU3L Doc 2111.E
c) With an Ohmmeter tested the Mercury Contacts Loop. Verify that the loop is closed (Make Measurement on the wires disconnected in c). . If the loop is Closed the Problem came from the Master Tilt Switch Device. Test again that the Master Mercury Contacts are Closed. If it is not the case Adjust it again and restart the commissioning . Otherwise Change the Master Tilt Switch Device. d) If the loop is Open, find where the loop is Open. To do this operate as follow : 1) Go to the First Slave PU3L and measure the Mercury Contacts Loop on the Tilt Switch Device Main Terminal. Make measurement between the connections 2 and 3 of the Main Terminal. If the loop is closed. The problem is located on the Wiring between Actual PU3L and the Previous one (here between the Master and the First Slave). Find and Correct it, then restart the * commissioning. If the loop is Open. Test the Mercury Contacts of the Actual PU3L (here the First Slave PU3L). Make measurement between the connections 3 and 13 of the Main Terminal. If the Mercury Contacts are Open the problem is located on Mercury Contacts Plate. Find and Correct it ( make again the adjustment), then restart the * commissioning. 2) If the Problem is not located on the First Slave do the same operations than in 1) on the Second Slave PU3L. 3) If the Problem is not located on the second Slave do the same operations than in 1) on the Last Slave PU3L. * Before restarting the commissioning dont forget to reconnect the corresponding wires on the connections 2 and 3 of the Main Terminal of the Master Tilt Switch Device and put back in place the covers of the four PU3L.
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6.2
For use in cold or wet areas the PU3L unit could be equipped as an option with one special Heating Resistor. This Heating Resistor must be supplied in 230 Vac (this option need a dedicated supply wiring). The installation of Heating Resistors on a PAPI System is made in two main operations :
A) Remove the Cover of the PU3L (see Paragraph 5.3.). B) Using the Two set of fixing screw (D) and nut (E), fix the Heating Resistor (B) and its two Radiators (C) on the Separating Screen (A) of the PU3L. C) If necessary put back in place the PU3L cover.
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FOR EACH CABLE TO CONNECT A) Unscrew and Remove the Lower Nut (C) of the Compression Packer (A). B) Remove the Plug (D) from the Lower Nut (C) of the Compression Packer (A). Note : all the unused cable entries must have the blanking plug left in situ in order to maintain IP rating of the unit. C) Pass the Cable (F) - Through the Compression Packer Lower Nuts (C), - Then through the Compression Packer Gasket (E), - And through the Compression Packer Body (B). D) Pull the Cable about 20 cm into the box E) Strip back the outer sheath of the cable by approx. 20 mm. F) Bare the cables two cores for a distance of about 10 mm. G) Connect the cable two cores to the Terminal Plate dedicated terminal (see next Paragraph). H) Pull back the Cable to leave the minimum amount inside the unit. I) Reassemble the Compression Packer Body (B) and tighten to suit.
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WIRING OVERVIEW
4. Heating Resistors Supply 230 Vac 5. Cables for Heating Resistors Supply
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1. Not Use 2. Not Use 3. Heating Resistors Supply In = 230 Vac 4. Heating Resistors Supply Out = 230 Vac
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Not Use Not Use Heating Resistors Supply In 230 V, Input Not Use Not Use Heating Resistors Supply Out 230 V, Output
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COMMENTS
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