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Elevated light
EL 224/225
ALALH_MA-EL224_225_V.1.3.doc
List of changes ALALH_MA-EL224/225
ALALH_MA-EL224_225_V.1.3.doc 2
Manual EL 224&225 ERNI Licht-Technik AG
Index
General
Operation
Maintenance
Drawings
by ERNI Licht-Technik AG
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General
General
Safety precautions
The measures described in ICAO Airport Services Manual Part 9, "Airport Maintenance Practices" and
FAA Advisory Circular AC 150/5340-26 "Maintenance of Airport Visual Aid have to be observed.
Also the material safety data sheets of used products have to be observed, e.g. silicone, cleaning liquid
a.s.o.
- Operation, service and maintenance of the lights must be effected according this manual
- This manual is addressed to experts for technical operation and maintenance of electrical and
mechanical equipment
- Instruction, training, qualification of staff as well as operational safety runs in the responsibility of the
operator
- Make sure all lights are rated and approved for the environment in which you are using it
- Disconnect and lock out electrical power circuits before touching the lights
- Never operate lights or equipment with a known malfunction
- Use only approved ERNI components and tools
- Remove all slackly objects on the runway after finishing work
- Carry out periodic inspections of lights
(Maintenance frequency depends on operational requirements set by the user. Recommended practices
are described in FAA Advisory Circular AC 150/5340-26)
- The lights are intended for the use with constant current regulators and secondary transformers for
airfield lighting according ICAO and FAA
- Availability of ERNI spare parts is guaranteed for a minimum of 10 years. However, ERNI recommends
to maintain a stock of selected fast turning spare parts to assure on-site availability for regular
maintenance work. Quantity and type of parts depend on users requirements
- Upon request ERNI provides spare parts and information's of tests and inspections
- Upon request ERNI provides training and instruction
- It is possible to arrange a service and maintenance agreement with ERNI
Lifetime
Our light have a lifetime of 25 years and more. Precondition to this is a carefully and professional service.
Especially the following articles have to keep in mind:
- Use only original ERNI spare parts
- All surfaces must be clean, dry and free of any impurities
- All bolts must be properly tightened
Detailed life cycle cost analysis can be obtained from ERNI. These analysis is based on many years of
experiences from several airports under various operating conditions.
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General
First aid
First-aid measures as described in the material safety data sheets of the used products have to be ob-
served. The material safety data sheets could be ordered at the appropriated supplier or producer.
Equipment is packed and marked for shipment and delivery according to a contract.
Unless otherwise agreed, the lights will be delivered in cardboard boxes on non-returnable pallets (dimen-
sions: 120x80x120 cm/16kg or 60x80x90 cm/11kg) with a total weight of max. 300kg/pallet. The pallets
are not stackable.
The lights should be stored unrestrained in accordance with standards of FAA, ICAO and IEC - at a stor-
age temperature of -55°C ...+55°C.
Each unit is packed in a one-way, corrugated cardboard carton. Each cardboard box and light is individu-
ally labelled. The label indicates the ERNI type and ERNI production number.
To avoid unnecessary damage to the light assembly, unpack the carton at the installation site. To unpack
the carton, open the flaps and lift the light assembly from the shipping carton. Keep unpacked light assem-
blies in a protected area prior to installation.
Warning: Don't hold the light fixture by the cables. This may damage the insulation, break
the water proof seal of the cable glands and cause insulation faults and water leakage.
Make sure not to drop the light fixture nor to pinch the cables while installation.
If damage to any equipment is detected, file a claim form with the forwarding agent immediately. The agent
may request to inspect the equipment.
This manual has been compiled with all possible care to the qualified personnel. Nevertheless mistakes in
the manual are possible and the specification have to be followed.
We encourage customers to address us their comments and proposals for improving further the contents
of this manual.
ERNI Licht-Technik AG
Zürichstrasse 72
CH-8306 Brüttisellen
Phone: +41 (0)44 835 33 43
Fax: +41 (0)44 833 07 92
Email: info@erniairlight.com
Internet: www.erniairlight.com
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General
General information
This manual is intended for use by operating personnel. They must be specially trained or instructed on
the product. Upon request, ERNI Licht-Technik AG offers such a training.
We shall not be held liable for damages and/or operating problems that result from failure to comply
with the instructions as described herein.
Trouble-free operation of the runway lights entirely depends on properly maintaining each light. All
maintenance work, described in the following pages, must be performed in perfect agreement to the
manual.
We recommend to order specific tools designed by ERNI Licht-Technik AG. Using these tools, simple
maintenance work can be guaranteed.
Additional copies of this manual are available from ERNI Licht-Technik AG. (Address see index page)
Technical data
Wattage: 45W - 150W
Rated current: 6,6 A
Light intensity and
chromaticity: Better or equivalent to ICAO Annex 14, Vol 1, latest edition
Halogen lamps: Prefocused, socket PK30d or PKX30d or two stud lamp G 6,35
life-span nom. 1000h, operation average > 5000h
150W min. 3600 lm
100W min. 2700 lm
45W min. 800 lm
Isolation resistance: ≥ 3000MΩ at 1000V dry
Projection above
surface: Standard 220mm (incl. pedestal and base plate)
2
Windload surface: ∼ 190cm (incl. pedestal)
Weight of light fixture: EL 224 = 1,6 kg / EL 225 = 2,2 kg + 0,2 kg pedestal
Vibration resistance: Without lamp min. 3g (between 20 ÷ 2000Hz) in all axes
Corrosion resistant: Against fuel, airport-chemicals and de-icing materials
Density: IP 67
Composition: Cable and plug - silicone
Housing - high quality aluminium alloy
Hardware - stainless steel
Lenses - borosilicate glass
Cable: Standard length 30cm, tension force max. 100N
Cable connection: FAA plug L-823 type II class A style 1
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General
Field of applications
These elevated lights were designed for runway, taxiway and apron applications. The application in
highly explosive areas is not permitted. (e.g. oil drilling rigs)
ATTENTION: If several lights are working on one current transformer, the operation tension, laid
out for low voltage applications, can exceed this range.
The light fixtures will be mounted on a separate, fix installed, already adjusted, frangible pedestal.
By changing the light housing, the light beam's direction eventually has to be readjusted.
Having a coloured ray of light, a corresponding colour glass dome is used. All glass parts are protected
from metallic contact. They are embedded to achieve attenuation of vibration.
The direction of the light beam is guaranteed without adjustment by the prefocused halogenlamp and by
the lampholder. It runs through the glass dome with beam spreading function.
Electrical connection results from a male cable plug according to FAA-L 823. The cable
entry into the housing is leakproof.
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General
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General
Safety instructions
Generally, customary and industry standard safety instructions - as well as the instructions and recom-
mendations contained in the ICAO Appendix 14 - prevail. (e.g. max. rating of light intensity / dirt)
Before removing any light fixture from pavement or pedestal, make sure the electrical current has been
switched off.
Always use well ventilated rooms when working with cleaning material or solvent.
If grease, oils, solvents or cleaning materials come into contact with skin or eyes, flush the affected
area very carefully and extensively with lukewarm water. In severe cases of exposure, seek medical
attention immediately.
Protective glasses
- when working with silicone oil
- when warming-up lamp
Gloves
- when replacing lamp
- when cleaning anything
- when removing / installing the light
- when removing glass parts
Use the supplied or equivalent tools to perform any repair or maintenance work.
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General
ATTENTION: The ray of light's direction has to be adjusted through the pedestal. (see pedestal adjust-
ment)
ATTENTION: Do not leave behind any tools on the working or installation place.
ATTENTION: The mounting pedestal should always be covered by the light or, when servicing, by a
dummy cover. (Risk of corrosion on the connector plug)
- Screw base plate and foundation together Earthing: Fix earth connection with lock washer
(max. 6 screws M10) or anchor the conduit into on a fixing screw M10.
the foundation.
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General
Remark:
Check the settings of the light beam direction peri-
odically, especially in case of extended pedestals or
applications on masts.
S 6.3
S 6.4
S 6.5
S 6.2
S 6.1
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General
Trouble shooting
ERNI’s airport lights are expertly assembled and tested at the factory. They are usually in operation for
years until they have to be serviced for the first time.
Under normal use and condition, problems with installing or maintaining ERNI fixtures should be minimal.
Below is a list of potential problems along with their appropriate solutions. If any other problems not covered
in this manual are encountered, contact ERNI Licht-Technik AG.
When you start troubleshooting, always follow the instructions of this manual. You find important tips for
each step to take.
Bulb can be moved in socket Bulb is loose, lamp is defective Replace lamp
Lamp glows weaker than other Lamp is defective Replace lamp
of same type
Dirty glass dome Clean glass dome
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General
Maintenance
General check
The following tools may ease the removal of the
light fixture from the light base. The well-functioning of the lights has to be
checked in regular intervals.
(Those marked with an * are specific tools and
can be ordered from ERNI Licht-Technik AG) Each time the lamp is replaced, verify the colour
glass dome is free of dirt and functioning well.
- screwdriver small + middle Also check the general condition of the light fix-
- * socket wrench ture. (Dirt, tightness, damages and corrosion). In
- if necessary, crimp-tongs case something is not alright, appropriate repair
- cleaning material has to be done before putting the light into opera-
- silicone oil/grease tion again.
- screw grease
Replacement of lamp
Open / Close housing
Preparatory work according to:
- Open locking device and carefully slew away the Operation "Open / Close housing"
glass dome. Lamp located inside back part.
The O-ring should be replaced every time the PAY ATTENTION to the correct positioning.
light has been opened.
- Connect plug with the connecting cable. (plug-in
connection)
- Remove PROTECTIVE COVER. (only when
Replacement of O-ring lamp is definitely placed)
- The inside of the lamp housing must be dry. - Assembly information
Close light fixture when warm.
- Close the housing carefully to prevent damages
on lamp and glass dome. PAY ATTENTION
Before assembling of glass dome regard that the
lamp connection wires are arranged so that they
ATTENTION: Do not forget O-ring gasket.
couldn't be clamped between holding ring and
housing lower part and not disturb the light beam.
The 2 coding pins of the lower part have to be
Function check snapped in the coding holes of the glass dome.
There could otherwise arise sealing problems.
- Check if lamp is burning.
- Check the colour of the light.
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General
- Loosen lamp clamp and replace it. The bonding force of the silicone can be reduced
when heating locking ring to ∼ 350°C.
Replacement of connecting cable
ATTENTION: Wear gloves to prevent injuries
- Loosen clamp and remove it. Loosen the screws caused by splinters of glass.
and remove plugs from clamp
- Remove squeeze ring and pull out of cable bush- - Clean locking ring properly and grease-free from
ing. silicone and dirt.
- If necessary, remove cable bushing completely - Apply silicone putty on the glass sealing flange.
from the housing. (not too much to prevent additional cleaning
- Replace O-ring. works)
- Lubricate joints of O-ring with silicone oil. - Recommended silicone putty: according recom-
- Fix the cable bushing to the O-ring. (counter nut). mendation of ERNI Licht-Technik AG
- Put in the connecting cable. - Glue on new glass dome, press gently
- Fix squeeze ring, washer and cap nut.
- Put plug in clamp. Glass-metal contacts have to be avoided under
- Assemble clamp and fix it inside the clamping any circumstances.
fixture.
ATTENTION:
The glass domes (inside glass and outside glass)
Replacement of locking device can be placed onto the locking ring in one specific
position only.
- Loosen screws, remove locker. (safety for beam-setting)
- Tighten the new locker. Pay attention to a correct Let the silicone harden. (about 4 days)
locking tension. (position of locker) Remove surplus silicone putty.
Assemble light fixture and glass dome.
ALALH_MA-EL224_225_V.1.3.doc 13
General
EL 224 EL 224
drwg general general
item pcs. (G6.35) pcs. (Pk30d)
Light complete, drawing-no. E19-1-A118 E19-1-A122
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General
EL 225
drwg general
item pcs. (Pk30d)
Light complete, drawing-no. E19-1-A120
8 O-Ring 1 201.700
9 Locking device 2 201.540
10 Screw M3 x 10 4 099.173
11 Nut M3 4 099.046
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General
EL 225
drwg general
item pcs. (G6.35)
Light complete, drawing-no. E19-1-A119
9 O-Ring 1 201.700
10 Locking device 2 201.540
11 Screw M3 x 10 4 099.173
12 Nut M3 4 099.046
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General
EL 225
Drwg general
item pcs. (Pk30d with ceramic terminal)
Light complete, drawing-no. E19-1-A121
11 O-Ring 1 201.700
12 Locking device 2 201.540
13 Screw M3 x 10 4 099.173
14 Nut M3 4 099.046
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