thorn papi lights maintenance manual

Maintenance documentation for PAPI units PU3L

Thorn Airfield Lighting Page 1 / 19 PU3LVersion 3.0 (01 April 2004) Doc 3111.E

MAINTENANCE DOCUMENTATIONfor PU3L

DOC 3111.E

www.thornairfield.com

THORN EUROPHANE156 bd Haussmann

75379 ParisCedex 08FRANCE

Tel : +33 (0) 1 49 53 62 62Fax : +33 (0) 1 49 53 62 89

[email protected]

Thorn DNT Airfield Lighting7-9 Newcastle Road

Bayswater Victoria 3153AUSTRALIA

Tel : +61 (0) 3 97 20 32 33Fax : +61 (0) 3 97 20 82 33

[email protected]

THORN LIGHTING3 King George CloseEastern Avenue West

Romford, Essex RM7 7PPUNITED KINGDOM

Tel : +44 (0) 1708 776 289Fax : +44 (0) 1708 742 322

[email protected]

THORN CLK Airfield lighting19/F Jardine Engineering House

260 Kings RoadNorth point HONG KONG

Tel : +852 (0) 2988 4128Fax : +852 (0) 2988 4139

[email protected]



RECORD of CHANGE Documentation 3111.E

Revision Designation Editor Checked Date

1 First issue JMD January 2000

2 Second issue JMD Marsh 2001

2 Modifications (text and drawings) + New logo and new addresses JMD JPB April 2004



TABLE OF CONTENTS

1 INTRODUCTION ........................................................................................................................................ 4

1.1 USE RESTRICTION NOTICE AND WARRANTY ......................................................................................... 41.1.1 Use of the Document ..................................................................................................................... 41.1.2 Warranty ....................................................................................................................................... 4

1.2 SAFETY INSTRUCTIONS .......................................................................................................................... 51.3 REFERENCE DOCUMENTS ...................................................................................................................... 5

2 GENERAL INFORMATION AND REQUIREMENTS........................................................................... 5

2.1 DELIVERY OF THE FITTINGS.................................................................................................................. 52.2 DESCRIPTION OF THE FITTING .............................................................................................................. 52.3 TOOLS REQUIRED................................................................................................................................... 52.4 BASIC MAINTENANCE PROGRAMME ...................................................................................................... 62.5 GENERAL STATEMENT CONCERNING MAINTENANCE OPERATIONS ..................................................... 6

3 MAINTENANCE.......................................................................................................................................... 7

3.1 REMOVING THE COVER ......................................................................................................................... 73.2 MOUNTING THE COVER ......................................................................................................................... 73.3 REPLACING A LAMP ............................................................................................................................... 8

3.3.1 Removing the defective lamp ....................................................................................................... 83.3.2 New lamp mounting and connecting ........................................................................................... 9

3.4 REPLACING A FILTER........................................................................................................................... 103.4.1 Removing the defective filter ..................................................................................................... 103.4.2 Installing the new filter............................................................................................................... 11

3.5 REPLACING THE PROTECTION FRONT GLASS AND ITS GASKET.......................................................... 123.5.1 Removing the defective front glass and gasket......................................................................... 123.5.2 Mounting a new front Glass and a new gasket......................................................................... 13

3.6 REPLACING A REFLECTOR................................................................................................................... 143.6.1 Removing the defective reflector ............................................................................................... 143.6.2 Installing the new reflector ........................................................................................................ 15

3.7 TILT SWITCH ........................................................................................................................................ 163.7.1 The PAPI system is light off ....................................................................................................... 163.7.2 Some PU3L of The PAPI system remain light off .................................................................... 18



1 Introduction

The documentation lists the different steps to follow in order to maintain 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 fittingcovered by this document.

"Maintenance of the fitting": This chapter describes how to maintain the fitting covered by thisdocument.

1.1 Use restriction notice and warranty

1.1.1 Use of the Document

This Installation documentation is the property of

THORN Airfield Lighting156 bd. Haussmann

75379 Paris Cedex 08France

This documentation or any parts of this documentation may not be reproduced, stored in a retrievalsystem or transmitted in any form or by any means (mechanical, photocopying, recording,electronic,) without THORN's prior consent.

1.1.2 Warranty

THORN Airfield Lighting guarantees that the performance of the inset lights described in thisdocument, when sold by THORN Airfield Lighting or its licensed representatives, meets therequirements 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 aperiod covered by the warranty stipulate in the contract, will be replaced by THORN Airfield Lightingfree of charge, ex works.

Operational failure resulting from lamp burnt out, improper installation, damage due to runwaymaintenance equipment is not considered a result of proper use and is beyond the scope of thewarranty.

The above constitutes the limits of THORN Airfield Lighting 's liabilities concerning the equipmentcovered by this document.



1.2 Safety instructions

WARNING: Prior to the commencement of work all electrical services MUST be isolated from thesupply and connected to earth. Full details of the work involved must be given to the Authorise Personresponsible 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 suchas cable ducts, etc... should be identified. It is a prerequisite of this type of installation that the workshould be carried out by trained and experienced personnel.

1.3 Reference documents

This paper refers to following documents:

THORN Commercial Documentation General Brochure Doc 1001.E,

THORN PU3L Commercial Documentation Doc 1111.E,

THORN PU3L Installation Documentation Doc 2111.E,

Last Edition of ICAO Annex 14 Edition of July 1995,

Last Edition of FAA Advisory Circular AC 150/5345-28.

2 General information and requirements

2.1 Delivery of the fittings

Each unit is individually packed in a durable cardboard box, labelled with its reference mane and code.On request one set of fitting documents (= commercial brochure, installation manual, maintenancemanual and spare parts list) is delivered the fittings. 2.2 Description of the fitting

The PU3L is an equipment dedicated to be use as a unit in PAPI (= four units) and APAPI (= twounits) systems. 2.3 Tools required

Two open end wrench of 22 mm. Two open end wrench of 17 mm. One 22 mm box spanner / socket. One 8 mm box spanner / socket. One small flat screwdriver One brush or cloth



2.4 Basic maintenance programme

Based on the historical experience in airfield lighting, the following list is a recommendation for thevarious maintenance tasks to be achieved to keep the equipment in correct operating conditions.

Daily : General visual check of the PAPI Unit

Weekly : Visual inspection of the PAPI unitRemove dust from external of the PAPI unit

Monthly : Checking the optical part of the unit (=> mechanical damages)Checking the proper fixing of the unit on its base

Yearly : Detailed inspection of the PAPI unitsVerification of angles adjustmentCleaning of the optical part

Note : This basic maintenance program is proposed (as an example) for the PU3L PAPI unitinstalled on a standard airport in normal operating conditions.

2.5 General statement concerning maintenance operations The last operation of the production of a PU3L box in our factory is its complete optical adjustment(Positioning in the PU3L of Filter supports, Reflector Holders and Lens Supports). As all theseadjustment operations can only be made in a Laboratory, the corresponding fixing/ adjusting screwsand nuts are Marked and Locked during this operation using a special Red Marking Glue.

That means that :All fixing and holding components locked and marked by Red Marking Gluemust not be move to preserve the quality of the optical adjustments made inLaboratory.

That means also that the following operations could not be made without a new Laboratory Optical Adjustment :

- Changing a Lens.- Changing a Lens Holder.- Changing a Reflector Support.- Changing a Filter Holder.

If you need to make one or more of these operations on a PU3L Unit, please send back thecorresponding PU3L Unit to THORN AFL to be repaired.

Note : All the maintenance operations describe in this document are available forstandard Three Legs version and for optional Four Legs version of the PU3L.



3 Maintenance

3.1 Removing the cover

A) Opening the Three catches (A).* the catches are of the locking type anda stab (B) needs to be press before thecatch will open.

Note :The locking Part of thecatches is use to secure the closing.If you forget to push on it you willnever be able to open the Catches.Dont force on the Catches you candamage it.

B) Lock the three catches in the uprightposition

C) Remove the PU3L Cover

3.2 Mounting the cover

A) Put back in place the PU3L Cover

B) Opening the Three catches (A).

C) Close and Lock the three catches in theupright position



3.3 Replacing a lamp

3.3.1 Removing the defective lamp

A) Remove the PU3L Cover (SeeParagraph 3.1).

B) Disconnect the Two Lamp Leads fromthe appropriate terminals (F).

C) Open the lamp retaining spring (A).

D) Remove the Lamp (C) from its LampHolder (B)



3.3.2 New lamp mounting and connecting

A) Install the Lamp (C) on its Lamp Holder(B).

Note : Ensure that the indentations inthe Lamp Holder line up with those inthe Pk30d Lamp (See (D)).

B) Close the lamp retaining Spring (A) onthe Lamp (C).

C) Connect the Two Lamp Leads(E) to theappropriate terminals (F).

D) Put Back in place the PU3L Cover (SeeParagraph 3.2).



3.4 Replacing a filter

3.4.1 Removing the defective filter


B) Turn on the side the Filter FixingSpring (A).

C) Slide up and remove from its Holder thedefective Filter (B).



3.4.2 Installing the new filter

A) Slide down and place the new Filter (B)on its Holder.

B) Verify the position of the Filter on itsHolder. Contact of both supporting partwith the bottom of the Filter.

C) Turn down Back in Place the FilterFixing Spring (A).

Note : As the Filter have been installcorrectly, this one is automaticallyadjusted. In this case you dont need tomake any optical adjustment. Dontchange the Filter Holder Adjustment.

D) Put Back in place the PU3L Cover (SeeParagraph 3.2).



3.5 Replacing the protection front glass and its gasket

3.5.1 Removing the defective front glass and gasket

A) Remove the PU3L Cover (See Paragraph 3.1.). B) Remove the Front Glass (C) and its Gasket (B) from the PU3L Cover (A).



3.5.2 Mounting a new front Glass and a new gasket

PU3L COVER INSIDE VIEW

A) Mount the New Gasket (B) on the NewFront Glass (A). Insert the Front Glass inthe Internal groove of the Gasket B) Put Paraffin on the Small Cord (D) usedto install the Front Glass and its Gasket inthe window of the PU3L Cover. C) Insert the Small Cord (D) on the externalgroove of the Gasket. D) Mount the New Front Glass and its newGasket in the window of the Cover.

- Mount only the lip of the upper part ofthe Gasket inside the PU3L Cover onthe upper part of its widow (C). - The ends of the Small Cord must beinside the PU3L Cover.

E) Push the Front Glass and its Gasket onthe front of the PU3L Cover. F) Pull on the Small Cord ends inside thePU3L to pass the lip of the Gasket insidethe PU3L Cover all round the window. D) Put Back in place the PU3L Cover (SeeParagraph 3.2).



3.6 Replacing a reflector

3.6.1 Removing the defective reflector


B) Remove the Lamp from the Reflector(See Paragraph 3.3).

B) Unscrew the three Fixing Screws (B) ofthe Reflector (A).

C) Remove the Reflector from its Holder(C).



3.6.2 Installing the new reflector

TOP

BOTTOM

A) Put in Place the New Reflector (A) on itsHolder (C) . Take Care of the position ofthe Lamp Holder (D) on the Reflector.

B) Mount, screw and lock the threeReflector fixing Screws (B).

C) Put back in place the Lamp on theReflector (See Paragraph 3.3).

D) Put back in place the PU3L Cover (SeeParagraph 3.2).



3.7 Tilt switch

For a PAPI System equipped with the optional Tilt Switch Function already commissioned withsuccess one of the following problems can occur : The PAPI System remain Light Off when it is PowerOn, Some PU3L Units remain Light Off when the PAPI System is Power On. The following Paragraphs give the operation to do to solve the problems. Note tha after someoperation you have to restart the commissioning operations, to do this please refer to our InstallationManual for PU3L (DOC 2111.E).

3.7.1 The PAPI system is light off

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 (See Paragraph 3.1). 3) Control the status of the three LEDs of the Master Tilt Switch Device.

LOCATION OF THE MASTER TILT SWITCH DEVICE LEDs

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 allthe 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 casechange 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.

TILT SWITCH DEVICE MAIN TERMINAL CONNECTIONS

* LED light Off means that the Mercury Contacts Loop is Open somewhere. Find where theloop 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 theconnections 13 and 14 of the Master Tilt Switch Device Main Terminal. 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. Testthat 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 TiltSwitch Device Main Terminal. Make measurement between the connections 2 and3 of the Main Terminal.

. If the loop is closed. The problem is located on the Wiring between ActualPU3L and the Previous one (here between the Master and the First Slave). Findand Correct it, then restart the * commissioning. . If the loop is Open. Test the Mercury Contacts of the Actual PU3L (here theFirst Slave PU3L). Make measurement between the connections 3 and 13 ofthe Main Terminal. If the Mercury Contacts are Open the problem is located onMercury Contacts Plate. Find and Correct it ( make again the adjustment), thenrestart 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 thanin 1) on the Last Slave PU3L.

* Before restarting the commissioning dont forget to reconnect the correspondingwires on the connections 2 and 3 of the Main Terminal of the Master Tilt SwitchDevice and put back in place the covers of the four PU3L (See Paragraph 3.2).

3.7.2 Some PU3L of The PAPI system remain light off 1) Remove the covers of all the PU3L (See Paragraph 3.1). 2) With a Voltmeter Verify the distribution on the System of the 12 Vdc dedicated to open the ShortCircuit Relay.

A) On the first Light Off Slaves PU3L (starting from the Master) * Verify the Input 12 Vdc. Make measurement between the connections 1 and 2 of the TiltSwitch Device Main Terminal.

- If the 12 Vdc is not present. The problem is located on the Wiring between Actual PU3Land the Previous one. Find and Correct it, then restart the commissioning.

* Otherwise verify the output 12 Vdc. Make measurement between the connections 11 and12 of the Tilt Switch Device Main Terminal.

- If the 12 Vdc is not present. The problem is located inside the PU3L. Find and Correct it,then restart the commissioning.

3) Put Back in place the Covers on all the PU3L (See Paragraph 3.2).



COMMENTS

Last page left blank for user comments.

thorn papi lights maintenance manual

Documents

maintenance operations

hkmaintenance documentation

frthorn dnt airfield

basic maintenance programme

issue jmd marsh

new addresses jmd jpb

general statement

general information