Airport Light Bases And Transformer Housings Compliance With Standards

Transcript

Fig. 1: L-867 / L-868 Airport Light Bases and Transformer Housings Compliance with Standards FAA: In compliance with FAA L-867 or L-868 specification AC 150/5345-42B, and with FAA E-1315 specification. Moreover bases can be developed or adapted to accomodate non-FAA semi-flush lights and also to meet particular installation requirements. Fig. 2 Uses - Installation of elevated lights (Fig. 7). The base houses the isolating transformer and its connectors. - Installation of semi-flush lights (Fig. 10). The base may also house the isolating transformer and its connectors. - As an underground housing for one or more isolating transformers (Fig. 8-9). - As a cable pulling box or test link box. Table A - Types and Sizes Available Place where lnstalled NOT subject to aircraft or surface vehicle loads FAA Spec. L-867 Type Size B(12") D 16 Subject to L-868 aircraft or surface vehicle loads A (10") B (12") C (15") E-1315 LB-1 LB-4 LB-4 16" Uses Mounting of elevated lights on base plates (Fig. 7)* Installation of some types of semi-flush lights (e.g. edge lights)* Installation of L-852 type III semi-flush lights* Installation of semi-flush lights L-852 and VSF/1 VCF/1 type IV, L-850A and B (Fig. 10)* VCF/1 type IV, L-850A and B (Fig. 10)* lnstallation of semi-flush lights L-850C, D and E* lnstallation of semi-flush lights E-2491 (Fig. 14) A lnstallation of semi-flush lights -850C, D and E * Transformer housing (Fig. 8-9) Cable pulling box Test link pits A.05.120e Features • Steel bases constitute a safe and proven method for anchoring semi flush lighting fixtures into paved surfaces. Although other systems do exist, they rely on the pouring in situ of quick setting concrete which supports the lights and place heavy reliance upon the skill of the contractor and the quality of the concrete mixing. • Metal bases are self supporting and have the characteristics to bear by themselves, and transfer the loads of the heaviest aircraft without Notes 1. Grommets (Figure 19) are located on XX’axis, except if otherwise required. 2. Upon request grounding lug entailing stress concentrations into concrete and ground. Steel equally resists compression, traction, bending moments and shear. All these are (External,Internal or both). stresses actually generated by the dynamic loads of landing and rolling aircraft. • The bases are factory made to a very demanding specification, fully tested and certified prior to shipment. Thousands of these steel bases have now been in satisfactory use around the world for many years. • Universal mounting system for installation of elevated and semi-flush lighting fixtures. Fig. 3: BASE FAA L-867 Table B - Bases FAA L-867 Size B D A 314 413 Dimensions (mm) B C 260 203 362 314 D 343 441 • Hot dip galvanization effectively protects base against corrosion. • PCP grommets (ADB patented design) ensure watertight conduit entrances. - easy installation (no need to thread the conduit) - will accept any kind of conduit: steel, PVC, PET, asbestos-cement, GRP, ... - fits tightly around conduit while allowing for free expansion and contraction of conduit Notes 1. Grommets are located on XX’axis, except if otherwise required. 2. Anchor ring not included when base is installed in non-load bearing surfaces or in a concrete block independent from pavement slab 3. Upon request grounding lug (external, internal or both) - compensates for slight angular offset of conduit in all directions (Fig. 19). • Rings and extensions allow for raising the lighting fixture after pavement overlays. • When used as a transformer housing: - the base will keep transformer and connectors in clean conditions - the lightweight steel cover facilitates speedy inspection and trouble shooting operations - the base is technically superior and cheaper compared to concrete or brick pits with heavy covers. - the base being metallic forms an integral part of the electrical counterpoise (earthing) system. Fig. 4: BASE FAA L-868, IN ONE PIECE Table C - Bases FAA L-868 Size A B C Dimensions (mm) A A’ B 254 263 235 305 318 286 381 394 362 C 203 254 330 Note 6 D E 292 152 343 235 419 314 F 264 314 391 G 210 260 337 G’ 235 286 362 • The ADB technical department will assist Designers and Contractors to solve any specific problem. Construction The bases are fabricated from A36 grade steel. After cutting, bending and machining, the parts are arc-weld assembled. A steel lug for ground connector is welded outside for E-1315 (LB-1, LB-4 and LB-4A) bases and on request inside, outside or both for L-867, L-868 and special models. A temporary plywood cover provides protection during transportation and erection. Quantity, location and diameter of conduit entrances must be specified with order. Top gasket and screws are not part of the base and must be ordered separately. They are generally supplied with the lighting fixture, with the cover or with the flange rings. For outline dimensions and details refer to: Fig. 3 - Base L-867 Fig. 4 - Base L-868 in one piece Fig. 5 - Base L-868 in multiple sections Fig. 6 - Base E- 1315 types LB-1, LB-4 and LB-4A Fig. 16 - Covers Fig. 19 - Grommets. a.Top section b.Middle section c.Bottom section 6x3/8” - 16 UNC @ 60° (standard). 12x3/8” - 16 UNC @ 30° (on request). no holes on XX’ axis for size A base (see figure 4). Fig. 5: BASE FAA L-868, MULTIPLE SECTION Notes 1. 20 x5mm steel anchor welded to section side at 120° intervals 2. To order: 115 mm minimum 3. To order: 51 mm minimum 4. Upon request grounding lug in top section (external, internal or both). 5. Grommets are in line with two opposite bolt holes. 6. A and G must be used for top section. A’ and G’ must be used for extensions installed on top section after overlay. 7. Slotted holes 12 mm wide by 35 mm long. Finish - Base and extensions: hot dip galvanized - Rings: zinc or cadmium plated and chromated. Installation General ADB proposes a twenty minute video movie (VHS, Betamax/PAL, Secam, NTSC) covering bases installation. This tape details the successive steps to be carried out by the contractor, on site, to install bases; - In rigid cement concrete pavement. - In flexible asphalt pavement. - In shoulders. - Using the glue-in method (for L-850 shallow bases). A copy may be obtained from the ADB technical department. Specify: Video Standard: VHS or Betamax Color System: PAL, SECAM or NTSC. L-867 Bases After levelling, aiming and bonding to an external counterpoise wire, if specified, the base is encased in concrete poured in situ. Minimum recommended thickness of concrete is 10cm all around base. See Fig. 7. Fig. 6: BASES FAA E-1315 types LB-1 /LB-4/LB-4A Alternatively the base may be supported on a concrete slab cast in advance Table D - Bases Types LB-1, LB-4 AND LB-4A at the bottom of the excavation. The soil material is then tightly compacted Type LB-1 LB-4 LB-4A Dimensions (mm) A B 413 362 413 362 413 362 all around the base. A concrete slab is cast on the top to provide adequate C 314 314 314 D 441 441 441 H 508 711 711 Notes 1. Base LB-1 and LB-4A: 6 tapped holes 3/8” - 16 UNC 2 Base LB-4: 6 holes 11 mm dia. 2. Grommets (Fig. 19) are located on XX’axis, except if otherwise required. 3. Fitted with external grounding lug. Optional internal lug on request finish and good stability. See Fig. 8 and 9. L-868 Bases General Since they shall have to bear and transmit considerable loads these bases shall always be installed in concrete structures of appropriate sizes. lf it is found necessary to reinforce the concrete, the steel reinforcement cage may be welded to the base. See Fig.11 and 12 (not supplied by ADB). A. Installation in rigid, cement concrete pavement This method applies to runway centre line, (Fig. 10) touchdown zone, high speed turn off lights etc. One piece bases shall be used (Fig. 4). The bases must be «integrated» into the paved surface , therefore they will be positioned together with the conduit system prior to paving operations. This technique is known as «Monolithic base and conduit system» and is summarized on Fig. 11. Monolithic base and conduit system (Fig. 11) The main steps of «monolithic» base and conduit installation in rigid cement concrete pavement. Step 1: Dig into gravel undercourse for base and conduits. Locate base into final position and level it. Hold in place, using appropriate jigs. «A»: 38mm below level of finished typical pavement. Step 2: Pour concrete around base and conduits. Install temporary spacer ring or plywood cover and eventually mud plate. Step 3: Proceed with runway paving. Step 4: Remove mud plate and temporary spacer ring or plywood cover. Install final spacer ring and flange ring. Top of flange ring to be 19mm (3/4”) below pavement level. Use appropriate spacer ring to compensate possible variations in level. Step 5: Install lighting fixture on flange ring fitted with «O» ring gasket. lnsert A = Minimum 10 cm (4”) Fig 7 ELEVATED RUNWAY EDGE LIGHT - TYPICAL INSTALLATION Fig. 7 screws and tighten at specified torque. CONSTRUCTION 1. Base L-867 2. Plain cover with gasket 3. Asphalted shoulder 4. Runway pavement 5. Conduit elbow 6. Compacted elbow 7. Concrete Alternative installation method. Transformer base outside paved shoulder Fig. 8 CONSTRUCTION 1. Base L-867 2. Plain cover with gasket 3. Asphalted shoulder 4. Resin filter 5. Runway pavement 6. Compacted material 7. Concrete 8. Resin sealant Touchdown zone lighting barette. Typical installation of inset lights on shallow (L-800) bases. Transformer base in paved shoulder Fig. 9 INSTALLATION OF SQ2100 SEMI-FLUSH LIGHT ON FAA L-868 BASE (runway centre line) (Isolating transformer type RCE with earthing terminal) CONSTRUCTION 1. Base L-868, one section 2. shielded AFL cable 3. Grounding wire 4. Isolating transformer type RCE 5. Earthing lug 6. Runway slab (concrete) 7. Subgrade Fig. 10 One-pice based «monolithic» installation (cement concrete pavement) Fig. 11 B. Installation in flexible, asphalt pavements This technique is similar to the one described hereabove, yet it requires a multiple section base since the paving is executed in several layers. See Fig. 5. The height of the different sections is defined by the thickness of the successive layers. Fig. 13 gives a short description of this method of installation. Spacer rings and flange rings should also be used. They are identical to those used with the one-piece bases. Existing Runways A technique similar to that described in Fig. 13 is applicable to the installation of semi-flush lights in existing runways that have to be resurfaced. Please contact ADB for more details. C. Installation in paved areas not subject to aircraft and vehicle traffic This applies mainly to threshold lights, runway end lights and to semi-flush Fig. 12: «monolithic» installation under way (step 2 partly completed) approach lights installed in overrun areas. Thickness of these pavements is The bases are in one piece as per Fig. 4.They must be completed with spacer rings, a flange ring and sometimes with a remedial spacer ring if the base has been wrongly oriented. See Fig. 17. generally small, hence the base shall be encased in a concrete block cast in-situ. A simplified L-868 base, without anchor ring shall be used in this case (See Fig. 4, note 2). The concrete block may be common to several lights forming a barrette. lf particular circumstances preclude the digging of deep holes in these areas, the lights may be installed on shallow depth bases (90 to 150mm) sealed by means of resin into cored-out recesses. Fig. 14 shows an H.l. approach light type ATF-1 -350 installed on a base 150mm deep. Bases LB-1, LB-4 AND LB-4A Theses bases are installed in the same way as L-867bases. See figure 15. Main steps of base and conduit installation in asphalt concrete (flexible) pavement. Standard procedure (Fig. 13) Step 1 Dig into gravel undercourse for base and conduits. Locate bottom section of base into final position and level it. Hold in place, using appropriate jigs. Step 2 Install mud plate fitted with target rings. Pour concrete around base and conduits up to original undercourse level. Step 3 Lay base course. Step 4 Core out 3” or 4” pilot hole and observe target. Measure depth «D» and order middle section of proper height Step 5 Core out at diameter slightly larger than O.D. of middle section, including anchor blades. Step 6 Remove core and mud plate. Install middle section. Seal around with resin. Reinstall mud plate on top of middle section Step 7 Lay filler course and top (wearing) course. Step 8 Repeat steps 4 and 5. Step 9 Remove core and mud plate. Bolt top section to middle section. Seal around with resin, up to top flange. Step 10 Install spacer and flange rings, plywood cover. Install lighting fixture on flange ring equipped with «O» ring gasket. Tighten screws at specified torque. Multiple section base installation (flexible pavement) Fig. 13 Accelerated procedure (Fig. 13) An alternative procedure can be carried out according to the drilling equipment available on site. Steps 1, 2 and 3 are achieved as described in the standard procedure. Step 4 Lay successively the different courses (filler and wearing courses). Step 5 Core out 3” or 4” pilot hole and observe target (Fig. 13 - 11). Measure depth «D» and order top section of proper height. Step 6 Core out at 13” DIA. Step 7 Remove core and mud plate, install top section, Bolt top section to bottom section. Seal around with resin, up to top of flange ring. (Fig. 13 - 12) Step 8 Refer to step 10 of the standard procedure. Installation of ATF-1 -350 Light on shallow depth base 16” DIA. A minimum 900mm diameter and 600mm depth concrete foundation is required. Fig. 14 Existing pavement Follow the same method when lights are to be installed in an overlay to an existing pavement In this case step 1 applies to existing pavement and steps 6, 7 and 8 may be omitted if top section is installed directly on bottom section as will be the case generally. Construction 1. L-868 base 2. Conduit 3. Mud plate (optional) 4. Temporary spacer ring (or plywood cover) 5. Flange ring 6. Spacer ring 7. Lighting fixture 8. «O» ring gasket 9. Screw (variable length) 10. Optional steel reinforcement cage. Notes 1. Diagrammatic only. Not intended to show actual installation details of dimensions. 2. The galvanization of the cone is effective only if the PH of the concrete is comprised between 6 and 12.5. Accessories Plain Covers (Fig. 16 a) For closing all bases listed in table A, except LB-4. Finish: hot dip galvanized. A pressed steel cover is available for L-867 size B base. See Fig. 16 b. Finish: aviation yellow. Covers are supplied with mounting screws and gasket. Gasket is as per Fig. 16 (d) for L-867 and LB-1 bases. An «O» ring gasket is supplied with covers intended for installation on L-868 bases. Base Plates (Fig. 16 c and catalogue leaflet A.05.110.) For mounting an elevated light on L-867 base. Typical application: Fig. 7. Made from pressed steel. Finish: aviation yellow. Supplied with gasket, as per Fig. 16(d), mounting screws and clamp for secondary receptacle of isolating transformer. Installation of an in-pavement DCF-1-120 Light on a LB-4 base Fig. 15 CONSTRUCTION 1. LB-4 base 2. Screw lighting fixture 3. Lighting fixture 4. Outer ring 5. Resin filter 6. Screw mounting ring 7. External grounding lug (standard) may be internal on request Rings (Figure 17) Used with L-868 bases, they mount between the base top flange and the lighting fixture. Flange rings (Fig. 17 b) have a machined groove for the «O» ring gasket. Spacer rings (Fig. 17 c) allow for mounting lighting fixture at correct level. Finish: zinc or cadmium plated and chromated. Dimensions: see figure 17 and table F below. Table E - Refer to Figure 16a For base type Dimensions (mm) L-867 Size A B C T B 343 260 203 10 16” 441 362 314 30** A 254 235* 203 20** B 305 286 254 20** C 381 362 330 32** D LB-1 LB-4A L-868 Fig. 6: BASES FAA E-1315 types LB-1 /LB-4/LB-4A *Only 4 holes: no holes on XX’axis. **Minimum thickness to resist wheel loads. Table F - Rings (Figure 17) a. HEAVY PLAIN COVER: see table E b. LIGHT PLAIN COVER, 12” dia c. BASE PLATE 12” dia d. GASKET Fig. 16 Size A B C A 254 305 381 B 235 286 362 Dimensions (mm) C H 203 207 254 258 330 334 T Specify with Order* *Flange ring: min 7 mm, max 19 mm. (standard) Spacer ring: standard sizes l,5 - 3 - 6 - 10 - 15 - 20mm Conduit Caps (Figure 18) To be installed on threaded steel conduit ends. Typical application: figure 8. Equipped with one or more compression glands («Squeeze connector»). See table G below. Material: malleable iron. Finish: bituminous black paint. Table G - Conduit Caps Cap size 2” gas CONSTRUCTION 1. Lighting fixture 2. <> ring gasker 3. Flange ring 4. Space ring (if any) 5. L-868 base Fig. 17 3” gas 4” gas Qty and size of compression glands 2 x PG 13,5 or 2 x PG 16 or 1 x PG 21 4 x PG 13,5 Outer dia. of cable (mm) min. max. 10 12 12 14 14 17 10 12 or 4 x PG 16 or 3 x PG 21 12 14 14 17 6 x PG 13,5 or 6 x PG 16 or 4 x PG 21 10 12 14 12 14 17 Grommets (Figure 19) The grommet compensates for angular offsets of conduits (Fig. 19b and c) and ensures freedom of conduit under the effects of expansion or soil movement, while ensuring a watertight conduit connection. Material: polychloroprene (PCP) Conduit O.D. should be within tolerances indicated in Table H to ensure proper fit. Special executions - optional extras Note: Special executions and extras always entail a price variation and should be covered by a specific price quotation from ADB. Concreting Collar See figure 20, item A. Not for L-868 bases. - Improves finish and workmanship of installation - Avoids breakage of concrete around lighting fixture. Fig. 2 shows type L-867 bases fitted with concreting collar. Location: threshold. Internal Grounding Lug Useful for earthing of screen of shielded cables and/or ground terminal of isolating transformer type RCE (Fig. 10) Conduit Entrances (See figure 20.) Fig. 18: Cap Iinstalled On 3”Steel conduit (note earrthing screw) - Unthreaded steel hubs - item B. - Tapped steel hubs 2” or 3” gas (11 TPI) - item C - Number, diameter and location different from that of standard model. Drain Hole (See figure 20, item D.) 3/4” drain hole and 3/4” gas, 11 TPI half coupling in bottom centre of base. Height Upon request bases of smaller or larger height can be manufactured. Table H - Grommets Conduit size 2” galv. steel 2” PVC 3” galv steel 1 1/2” PVC Dimensions (mm) Fig. 19 (a) conduit O.D. 60,3 ± 0,6 mm 63 ± 0,6 mm 89 ± 0,9 mm 50 ± 0,6 mm FOR DIMENSIONS SEE TABLE H Fig. 19: GROMMETS A 70 70 99 60 B 60 62,5 89 49,7 CONSTRUCTION A. Concreting collar B. Unthreaded hub C. Tapped hub 2” or 3” gas - 11 TPI D. 3/4” gas - 11 TPI half coupling (drain) Fig. 20: SPECIAL ECECUTIONS OPTIONAL EXTRAS Table I - Net Weights and Volumes Base type Height mm Net weight kg Volume m3 LB-1 B D A B C 16” 610 610 610 610 610 508 23,5 30,3 16,7 28,5 34,4 28,1 LB-4/LB-4A 16” 711 33,1 L-867 L-868 Size 0,074 0,122 0,035 0,071 0,094 0,102 Standard pallet* Qty per pallet 27 12 27 27 12 12 Weight per per kg 685 405 495 820 450 375 Volume per pallet m3 2,35 1,82 1,76 2,35 1,65 1,70 0,142 12 435 2,07 For information purpose only. Note: Packing method: - On pallets except if mentioned otherwise in quotation. - Accessories in boxes or on pallets. Suggested Specification Warranty A temporary plywood cover shall be provided to protect the top flange ADB undertake to remedy any defect resulting from faulty materials or during transportation and erection. The bases equipped with the workmanship appearing during a period of one year after date of shipment appropriate type, quantity and positon of duct entrance(s) and with one exclusive of any defect developing as a result of improper use or handling. external, internal or both earthing terminal. The spacer and flange rings Repairs and / or replacements will take place in our factory. Such correction accurately machined shall be zinc or cadmium plated and chromated. They shall constitute the limit of our liabilities with respect to equipment. Drawings shall include stainless mounting screws and O-ring gaskets to ensure the and sketches are typical and diagrammatic only and are not intended to watertightness of the assembly. The base cover shall be made from hot dip show actual manufacturing and installation details, or dimensions galvanized machined steel or fom zinc coated and vellow painted pressed The Airport Light Bases and Transformer Housing shall be constructed to meet the requirements of FAA specifications, L-867, L-868 (AC150/534542B) or E1315. They shall be fabricated from A36 grade steel, protected by hot dip galvanization. steel. These base covers shall be supplied with stainless steel mounting Ordering Information One-piece bases - Base type L-867, L-868, LB-1 , LB-4 or LB-4A - Nominal sizes: A (10”), B (12”), C (15”) or D (16”) - Nominal depth: 400,500 or 610mm - Number, diameter, type and location of conduit entrances. For bases designed to accommodate semi-flush lights the location(s) should be given with respect to the light beam axis (disregard beam toe-in or toe-out angle if any). - Special execution or optional extras (see Fig. 20). Multiple Section bases - Rings This installation method will generally necessitate a technical study made jointly by the Contractor and ADB. This study shall define all details of the bases and their accessories. screws and with a flat rubber gasket or an O-ring seal. Notes Registered Office: Phone: +32 (2) 7221711 Fax: +32 (2) 7221764 [email protected] www.adb-air.com © ADB all rights reserved order number DOCA05120V2 subject to modifications www.comith.be ADB Airfield Solutions Leuvensesteenweg 585 B-1930 Zaventem Belgium