Cooper Bussmann 858 User's Manual
Contents
1. SIGN FLOOR FLANGES SIGN POWER LEG 8 LONG 1 2 13 UNC L HOOK ue ANCHOR BOLT AT LEAST 6 MUST BE EMBEDDED IN THE NA POWER CORD INSIDE CONCRETE SECURE TO FLOOR N FRANGIBLE COUPLING FLANGE WITH 1 2 13 U LED SIGN VIEWING SIDE HEBDO ISTON REPISTO oe CIRCUIT CARD BOX TO RIGHT x om 4 MOWER 1 Hl40762 RETAINERS C R RUN SUPPLIED WITH SIGN OJ CLEARANCE CENTERLINE SIGN IS pe PERPENDICULAR TO B CONDUIT ELBOW LATION CENTERLINE 5 E SIGN TETHER S FAA ECONDARY ATTACH T Foe S FLOOR FLANGE LU A DEFINED EDGE T ANCHOR BOLT SIDE F 27 8 DETAIL SCALE eX du ck NCLUDES A SIGN GROUND STUD L LA Les MINIMUM SLOPE FOR r S MOWER DRAINAGE COPPER2. 5 5 o o 56575 0 00 TETHER REF PA 4 65 REF ND STUD REF d FF ALN mi STRATED Figure 5 Distance Marker 24 DOCUMENT 1025 REV B GOOPER Crouse Hinds Instruction Manual AGS LED 858 LED Series Sizes 1 2 3 4 and 5 A DANGER DANGER X DANGER KED MARKED NT AIRFIELD IF OPTION 12 INSTALLED AND THE CIRCUIT BOARD NECT INDICATO POWER SUPPLY CIRCL LOOP BE IN THE ON IONAL TO THE OTHER 3 T LONG AN TO LEAD MARKE 1 FLEXIBLE LIQU 5 FOOT L OPTION 20 ADDITIC ONE MODULE SIGN INCLUD AL TETHER SIZE 5 DMS ONLY Figure 6 Sign Options 23 DOCUMENT 1025 GOOPER Crouse Hinds REV B Instruction Manual AGS LED 858 LED Series Sizes 1 2 3 4 and 5 ARR
3. ERIES ISOLATION TRANSFORMER R CORD INS FRANGIB LIN ROUSESHI CABLE CLAVE cobos pp p N 6 SUPPLIED WITH SIGN 4 75 DIAMETER BOLT CIRCLE TRANSE HOUSING LOCATION TE ae 4 63 DIAMETER HOLES UN iN POWER LEG err dod C LH HM 5 Q Y SPAC NEP NOT USE ALTERNATE TRANSFORMER WE 9 EQUALLY SPACED DN BC CATION WITH SIZE 4 DISTANCE 22 1 ANG JU CATIONS ES 5 x Siet Mate EFAN ES 3 SECONDARY CONNECTOR S R FLANGE SIGN POWER LEG WHICH MAY BE PRESENT 8 LONG 1 2 13 UNC L HOO S AS DN A CABLE EXTENDER ANCHOR BOLT AT LEAST _ DETAIL SCALE 2X MUST BE EMBEDDED IN T INSIDE CONCRETE SECURE TO LANGE WITH 1 2 CHUPLING X WING a CORROSION RESIST 2 z LED SIGN VIEWING SIDE A HAS DWARE CIRCUIT CARD BOX TO RIGHT Ces i SS AN 1040762 RETAINERS f SUPPLIED WITH SIG CENTERLINE SIGN IS j PERPENDICULAR TI CONDUIT SERIES ISOLATION I 4 MOWER CLEARANCE CENTERLINE SEE H TRANSFORMER MEER IE S FAA AC 150 5340 18 STYLE 8 SECONDARY 3 8 THICK COVERPLATE SS FOR PAVEMENT CONNECTOR 7 COVERPLATE GASKET T DEFINED EDGE TO H RANSFORMER HOUSING SIDE DF SIGN LE 2x 3 MINIMU
4. EE O Su 1 BOARD C l CONNECTOR 14 PIN 2 el b 9 3 O SUPPLY CIRC 30ARD BLACK RETURN CABLE SIZE 2 LED ARRAY WIRING C gt CNS PIN 2 tH Ed 4 98 O Q Q Y TO POWER SUPPLY CIRCUIT BOARD 5 CONNECTOR CN14 PIN 2 d 9 9 e cH c a EC 7 TO POWER SUPPLY TTT TEL CIRCUIT BOARD BLACK RETURN CABLE SIZE 3 LED ARRAY WIRING CONNECTOR CN9 PIN 2 Figure 10 LED Array Wiring Three Module Signs Reference Figure 7 for LED array orientations 29 DOCUMENT 1025 Instruction Manual 858 LED Series Sizes 1 2 3 4 and 5 _ TO POWER SUPPLY CIRCUIT BOARD l CONNECTOR CN14 PIN 2 6 o 6 o 8 Bl TO POWER SUPPLY CIRCUL D SIZE 1 LED ARRAY WIRING CONNECTOR CN9 PIN 2 59 8 TO POWER SUPPLY 5 925 5 446 CIR BOARD p ONNECTOR CNi4 PIN 2 8 6 5 J e e EETAS BLACK RETURN CABLE SIZE 2 LED ARRAY WIRING UNNECTOS CNS PIN 2 o 6 6 o O 8 B 2 B o o
5. PROBLEM POSSIBLE CAUSE CORRECTIVE ACTION P 2 Sign will not light Input current is below or exceeds specification Input current is specified between 2 8 and 6 6 amps using a true RMS Ammeter L858 Power Supply indicator RED LEDs D4 is ON and D7 is OFF Table 12 Adjust CCR current See Tables 9 11 and or replace isolation transformer with appropriate wattage for sign see Tables 3 8 P 3 Sign will Optional ON OFF switch in OFF Turn switch to ON position not light position P 4 Sign will Power Supply Circuit Card 15V Verify Green LED 1329 is lit not light supply failed See Table 12 Replace Power Supply Board if D29 is not lit Section 10 12 P 5 Sign will Power Supply Circuit Card 3 3V Verify Green LED D11 is lit not light supply failed See Table 12 Replace Power Supply Board if D11 is not lit section 10 12 P 6 Sign will Loose broken wire s missing Verify Power Supply not light connections connections match Power Supply Wiring Diagram Figures 18 amp 21 P 7 Sign will not light Output Electrical Open Circuit See Table 12 Verify LED cable connectors are properly seated in their respective receptacles reseat if necessary See Sections 10 5 amp 10 6 P 8 Sign will not light LED MODULE s mounted wired incorrectly Verify that LED MODULES are mounted and wired according to LED Array Wiring Diagram See Figures 7 11 and Sec
6. d J CONNECTOR 14 PIN 2 O o Q x O le 8 Ed lS 21 7 POWER SUPPLY CIRCUIT BOA BLACK RETURN CABLE CONNECTOR CNS PIN 2 SIZE 1 LED ARRAY WIRING SS xu VACUA IET TO POWER SUPPLY Es u5 0 0 9 0 ES 5 0 0 0 0 G09Jg CIRCUIT BOARD 10 CONNECTOR CNI4 PIN 2 B oO p o aX BLACK RETURN CABLE SIZE 8 LED ARRAY WIRING e o aD b O o O 65 4 3 ON 4 By FE TO POWER SUPPLY EE ap CIRCUIT BOARD O CONNECTOR CNI4 PIN 2 ba d b 1 d 9 7 TO POWER SUPPLY eee CIRCUIT BOA BLACK RETURN CABLE CONNECTOR CN9 PIN 2 SIZE 3 LED ARRAY WIRING Figure 9 LED Array Wiring Two Module Signs Reference Figure 7 for LED array orientations 28 8 DOCUMENT 1025 i REV B COOPER Crouse Hinds Instruction Manual AGS LED 858 LED Series Sizes 1 2 3 4 and 5 TO POWER SUPPLY CIRCUIT BOARD CONNECTOR CNI4 PIN 2 I S 9 7 TO POWER SUPPLY ENTER ZS CIRCUIT BOARD BLACK RETURN CABLE SIZE 1 LED ARRA WIRING CONNECTOR CN9 PIN 2 TO POWER SUPPLY CIRCUIT LO O 0 0 0 OHS
7. L 823 STYLE 7 ALE 2X SECONDARY CONNECTOR SIGN FLOOR FLANGEA sies vB WHICH MAY BE PRESENT 8 LONG 1 2 13 UNC 1 1 CABLE EXTENDER ANCHOR BOLT AT LEASTEY XX A DETAIL SCALE 2X MUST BE EMBEDDED IN T POWER CORD INSIDE CONCRETE SECURE F FRANGIBLE COUPLING FLANGE WITH 1 2 UR CORROSION RESISTAN HARDWARE 40762 RETAIN SUPPLIED WITH SIGN CONDUIT ELBOW SERIES ISOLATION TRAN NSF ORMER NDARY DETAIL SCALE 2X Figure 12c Expanded top section of Figure 12 35 GOOPER Crouse Hinds Instruction Manual AGS LED 858 LED Series Sizes 1 2 3 4 and 5 CONCRETE 4 MODULE SIZE 1 120 1 CONCRETE 3 MODULE SIZE 1 r 61 7 CONCRETE 20 9 CONCRETE 2 MODULE SIZE 1 1 MODULE SIZE 1 27 8 CL NCRE TE GN 2 MODULE SIGN i MODULE SIGN HOUSING END DOCUMENT 1025 J SIGN FLOOR FLANGE SIDE TE FOUNDATION PAD LENGTHS AND wWIDTHS 36 Figure 13 Concrete Foundation Pad configurations Size 1 REV B AVANA vl A p p GOOPER Crouse Hinds 173 3 CONCRETE Instruction Manual AGS LED 858 LED Series Sizes
8. 11 Pigures and Tables eet m erede ted ee 20 vil GOOPER Crouse Hinds 7 Instruction Manual AGS LED 858 LED Series Sizes 1 2 3 4 and 5 List of Figures and Tables Figure 1 Single module 818 a 20 Figure 2 Double module sign eg ten etae teh ee Hc 21 Figure 3 Three module sign uiti tenen e entere eit 22 Figure 4 Four module sign ne p n erp t be pe ert ode 23 Figure5 Distance Marker 4 2 SEES NAO 24 Figure 6 Sign Opus a ae ense eg tette decet tet es 25 Figure 7 Heat Sink LED Assembly showing wiring input and output connections 26 Figure 8 LED Array Wiring One Module Signs eene 27 Figure 9 LED Array Wiring Two Module Signs nennen 28 Figure 10 LED Array Wiring Three Module Signs eene 29 Figure 10 LED Array Wiring Four Module Signs eene 30 Figure 11 LED Array Wiring Distance Marker eese nennen 31 Figure 12 Recommended Transformer Housing Location amp Concrete Foundation Pad Details 32 Figure 12a Expanded left section of Figure 12 sees eene 33 Figure 12b Expanded right section of Figure 12 34 Figure 12c Expanded top section
9. Isolation Isolation Primary y Isolation y Isolation Secondar Isolation Xfrmr Xfrmr Isolation Xfrmr Xfrmr y Isolation Transforme Style Sign Size Modules CCR type 6 6A 6 6A Xfrmr 6 6A 6 6A Xfrmr r Type 2 1 1 Series 180 87 0 49 87 67 0 77 200W 2 1 2 Series 181 90 0 50 89 70 0 78 200W 2 1 3 Series 182 92 0 50 92 71 0 78 200W 2 1 4 Series 183 93 0 51 94 73 0 78 200W 2 2 1 Series 180 88 0 49 41 37 0 89 200W 2 2 2 Series 181 91 0 50 90 70 0 78 200W 2 2 3 Series 182 93 0 51 93 73 0 79 200W 2 2 4 Series 183 94 0 51 95 75 0 79 200W 2 3 1 Series 181 90 0 50 89 70 0 78 200W 2 3 2 Series 183 93 0 51 94 73 0 78 200W 2 3 3 Series 186 98 0 53 99 77 0 78 200W 2 3 4 Series 277 101 0 36 102 82 0 80 300W 2 4 2 Series 185 97 0 52 97 77 0 79 200W Table 6 AGS 858 LED Sign Style 2 VA Load amp Matching Isolation Transformer Series 49 GOOPER Crouse Hinds DOCUMENT 1025 REV B Instruction Manual AGS LED 858 LED Series Sizes 1 2 3 4 and 5 Sign Sign VA Watts Power Sign VA Sign Watts Power Primary Primary Factor Secondar Secondar Factor Isolation Isolation Primary y Isolation y Isolation Secondar Isolation Xfrmr Xfrmr Isolation Xfrmr Xfrmr y Isolation Transforme Style Sign Size Modules CCRtype 6 6A 6 6A Xfrmr 6 6A 6 6A Xfrmr r Type 3 1 1 Series 180 87 0 49 87 67 0 77 200W 3 1 2 Series 181 90 0 50 89
10. 22 If the Power Supply Output Voltage is greater than 30 VDC then you must wait until the Power Supply Output Voltage drops below 30 VDC before you proceed with the next step Remove the black return cable connector from the last LED MODULE output cable connector see Figure 20 Replace the output cable connector in the second LED MODULE with the black return cable connector Turn on main power to the sign If both LED MODULES momentarily light and then turn off 13 DOCUMENT 1025 REV B GOOPER Crouse Hinds Instruction Manual AGS LED 858 LED Series Sizes 1 2 3 4 and 5 or stays lit then the second LED MODULE and the cable from the first LED MODULE to the second LED MODULE are operating normally Turn off main power to the sign Wait five minutes for the high voltage to dissipate Verify that the output voltage is less than 30 VDC with a multimeter as described in the opening paragraph of this section Replace the black return cable connector with the first LED MODULE output cable connector Replace the black return cable connector in the output connector housing of the last LED MODULE If the sign does not light at all then replace the second LED MODULE and or the cable connecting from the output connector of LED MODULE 1 to the input of LED MODULE 2 see Section 10 10 Then repeat the test outlined above in this section 109 Continue Checking the Rest of the LED MODULES It is assumed that the first two LED MODULES ha
11. 50 0 87 41 35 0 86 65W 3 2 3 Ferro 62 55 0 88 47 42 0 89 100W 3 2 4 Ferro 68 61 0 89 53 48 0 90 100W 3 3 1 Ferro 57 50 0 88 39 34 0 86 65W 3 3 2 Ferro 67 58 0 87 52 45 0 87 100W 3 3 3 Ferro 77 69 0 90 62 56 0 90 100W 3 3 4 Ferro 102 88 0 86 77 68 0 89 200W 3 4 2 Ferro 74 66 0 90 60 53 0 88 100W Table 4 AGS 858 LED Sign Style 3 VA Load amp Matching Isolation Transformer Ferro 47 COOPER Crouse Hinds Instruction Manual AGS LED 858 LED Series Sizes 1 2 3 4 and 5 DOCUMENT 1025 REV B 5 1 1 Ferro 42 36 0 86 29 25 0 84 65W 5 1 2 Ferro 47 42 0 88 34 30 0 88 65W 5 1 3 Ferro 51 46 0 89 39 35 0 90 65W 5 1 4 Ferro 56 51 0 91 45 41 0 91 65W 5 2 1 Ferro 43 38 0 87 30 26 0 86 65W 5 2 2 Ferro 49 44 0 89 35 32 0 89 65W 5 2 3 Ferro 54 49 0 90 43 39 0 89 100W 5 2 4 Ferro 60 55 0 91 49 44 0 91 100W 5 3 1 Ferro 47 42 0 88 34 30 0 88 65W 5 3 2 Ferro 56 51 0 91 45 41 0 91 65W 5 3 3 Ferro 68 62 0 91 56 52 0 92 100W 5 3 4 Ferro 82 75 0 91 70 64 0 91 100W 5 4 2 Ferro 43 38 0 87 30 26 0 86 65W Table 5 AGS 858 LED Sign Style 5 VA Load amp Matching Isolation Transformer Ferro 48 GOOPER Crouse Hinds DOCUMENT 1025 REV B Instruction Manual AGS LED 858 LED Series Sizes 1 2 3 4 and 5 Sign Sign VA Watts Power Sign VA Sign Watts Power Primary Primary Factor Secondar Secondar Factor
12. OFF OFF ON OFF ON ON OFF Open Open 3 4 x ON OFF OFF OFF OFF ON OFF OFF ON OFF Open Open 4 2 ON OFF OFF ON OFF OFF OFF ON ON ON OFF Close Open Table 2 Power Supply Switch and Jumper Selection SERIES CCR 45 COOPER Crouse Hinds Instruction Manual AGS LED 858 LED Series Sizes 1 2 3 4 and 5 DOCUMENT 1025 REV B 2 1 1 Ferro 53 45 0 85 35 29 0 83 65W 2 1 2 Ferro 57 50 0 88 39 34 0 86 65W 2 1 3 Ferro 64 54 0 84 48 41 0 84 100W 2 1 4 Ferro 67 58 0 87 52 45 0 87 100W 2 2 1 Ferro 51 44 0 86 34 29 0 85 65W 2 2 2 Ferro 58 50 0 87 41 35 0 86 65W 2 2 3 Ferro 62 55 0 88 47 42 0 89 100W 2 2 4 Ferro 68 61 0 89 53 48 0 90 100W 2 3 1 Ferro 57 50 0 88 39 34 0 86 65W 2 3 2 Ferro 67 58 0 87 52 45 0 87 100W 2 3 3 Ferro 77 69 0 90 62 56 0 90 100W 2 3 4 Ferro 102 88 0 86 77 68 0 89 200W 2 4 2 Ferro 74 66 0 90 60 53 0 88 100W Table 3 AGS 858 LED Sign Style 2 VA Load amp Matching Isolation Transformer Ferro 46 COOPER Crouse Hinds Instruction Manual AGS LED 858 LED Series Sizes 1 2 3 4 and 5 DOCUMENT 1025 REV B 3 1 1 Ferro 53 45 0 85 35 29 0 83 65W 3 1 2 Ferro 57 50 0 88 39 34 0 86 65W 3 1 3 Ferro 64 54 0 84 48 41 0 84 100W 3 1 4 Ferro 67 58 0 87 52 45 0 87 100W 3 2 1 Ferro 51 44 0 86 34 29 0 85 65W 3 2 2 Ferro 58
13. ON LED ARRAY INDICATES ARROW AT INPUT AND OUTPUT DIRECTION THIS END F POWER SUPPLYING ARRAY INDICATES N UT SIDE ARRUW AT THIS END INDICATES INDICATOR UTPUT IN DUR APPLICATION kaj D J 7 oS Or J 1 M 8 Za KZ iN P PE Figure 7 Heat Sink LED Assembly showing wiring input and output connections 26 DOCUMENT 1025 8 COOPER Crouse Hinds REV B Instruction Manual AGS LED 858 LED Series Sizes 1 2 3 4 and 5 POWER SUPPLY CIR BOARD CONNECTOR 4 PIN 2 TO POWER SUPPLY CIRCUIT BOARD BLACK RETURN CABLE CONNECTOR CN9 PIN 2 SIZE 1 LED ARRAY WIRING POWER SUPPLY CIRCUIT BOARD CONNECTOR CN14 PIN 2 BLACK RETURN CABLE SIZE 2 LED ARRAY WIRING pul Op OQ Am W I x Ve a iG OL TO POWER SUPPLY CIRCUIT BOARD CONNECTOR CNI4 PIN 2 nj 4 O 9 o Oe ko fe CIRCU BLACK RETURN CABLE CONNECTOR CNS PIN 2 SIZE 3 LED ARRAY WIRING TO POWER SUPPLY Figure 8 LED Array Wiring One Module Signs Reference Figure 7 for LED array orientations p DOCUMENT 1025 REV B GOOPER Crouse Hinds Instruction Manual AGS LED 858 LED Series Sizes 1 2 3 4 and 5 TO POWER SUPPLY 5 2 CIRCUIT BOARD
14. WILL ALLOW THIS SEPARATION DISTANCE TO REMAIN WITHIN THE FAA SPECIFICATION 38 54 07 p GOOPER Crouse Hinds 196 8 CONCRETE 4 Instruction Manual AGS LED 858 LED Series Sizes 1 2 3 4 and 5 MODULE SIZE 3 NCRETE 3 MODULE SIZE 3 112 0 CONCRETE 2 MODULE SIZE 3 RETE 1 MODULE SIZE 3 amp 72 1 CONC CONCRETE X 7 A ke Ke Z SIGN L 2 MODULE SIGN END HOUSING END FACE SIDE 3GESTED SIZE 3 AND 5 CONCRETE FOUNDATION PAD LENGTHS Figure 16 Sizes 3 amp 5 Concrete Foundation Pad Configurations 39 DOCUMENT 1025 REV B MO K DOCUMENT 1025 2 REV B GOOPER Crouse Hinds Instruction Manual AGS LED 858 LED Series Sizes 1 2 3 4 and 5 BIB SIZE 4 DMS 27 8 us Ne AN Es J CONCRETE slo N 22 P X N e z x SIGN FLOOR FLANGE SIDE A FACE SIDE SUGGESTED SIZE 4 CONCRETE FOUNDATION PAD LENGTH AND WIDTH Figure 17 Size 4 Concrete Foundation Pad Configurations 40 COOPER Crouse Hinds Instruction Manual AGS LED 858 LED Series Sizes 1 2 3 4 and 5 Hex Nut Do not Over Tighten A a Filter Em 27 Bridge Rectifier Power Supply LED cae e Figure 18 Power Supply Bo
15. edge to the near side of the sign A WARNING IMPORTANT FAA specifications and Engineering Briefs may be obtained by b searching the FAA web site www faa gov See Figures 12 17 for suggested concrete foundation pad Concrete foundations pads should be of adequate mass reinforcement and psi strength rating for the maximum sustained force on the sign body and floor flange anchors must endure at its maximum plus a safety margin The concrete foundation pad should be installed in soil conditions that will help facilitate drainage and foundation pad support The floor flange anchor bolt material should also meet the maximum sustained force on the sign body plus a safety margin and must be inch in diameter for use with the 25684 1 Floor Flange See Table 14 for estimated maximum sustained force on the sign body Concrete foundations pads should extend at least 12 inches below the local frost line Contact your local or regional building inspector if the depth is unknown for your area The foundation pad should extend at least 1 foot beyond the sign body to minimize damage from mowers GOOPER Crouse Hinds g DOCUMENT 1025 REV B Instruction Manual AGS LED 858 LED Series Sizes 1 2 3 4 and 5 The concrete foundation pad should be not more than 1 inch above grade in order to maintain the 3 inch maximum overall height above grade to the point of frangibility per FAA Engineering Brief no 79 See the Engineering Brief for acce
16. eee hes vii 9 Dast of Piguressand Tables nie RU rdo viii S General Information ua use a p eee eiecit 1 8 1 General Description a A SEMAN LAS au 1 8 2 Classification of SIgns 1o er oi Iasis 1 50 3 Part Numbers 22cm SER aspe pra lo SENS la vlan 2 9 Installationz e 3 10 Maintenance and Troubleshooting eese nne rennen 6 10 l neue e BERE NEU GM aies 6 102 Problem Solving Gilde sirere a iE nennen erem 7 10 3 Measuring Input Current Signs Without Optional Power Switch 10 10 4 Measuring Input Current Signs With Optional Power Switch sss 10 10 5 Checking Power Supply LED Cable eene nennen 11 10 6 Checking LED MODULE Cable Connections ren ene 12 10 7 Checking the First LED MODULE eene nem nennen rennen nennen 12 10 8 Checking the Second LED MODULE seen nemen nennen 13 10 9 Continue Checking the Rest of the LED MODULBES eene 14 10 10 Replacing an LED MODULE essere nennen nnne nnne nnne eterne 15 10 11 Sign PC Board P N 62277 Calibration nennen nnne 17 10 12 Replacing Sign Power Supply Board Heat Sink P N 62277 17
17. in Company s judgment as to affect the Product adversely Any Product which has in Company s judgment been subject to negligence accident or improper storage Any Product which has not been operated and maintained in accordance with normal practice and in conformity with recommendations and published specification of Company and Any Products component parts or accessories manufactured by others but supplied by Company any claims should be submitted directly to the manufacturer thereof Crouse Hinds Airport Lighting Products obligation under this warranty is limited to use of reasonable efforts to repair or at its option replace during normal business hours at any authorized service facility of Company any Products which in its judgment proved not to be as warranted within the applicable warranty period All costs of transportation of Products claimed not to be as warranted and of repaired or replacement Products to or from such service facility shall be borne by Purchaser Company may require the return of any Product claimed not to be as warranted to one of its facilities as designed by Company transportation prepaid by Purchaser to establish a claim under this warranty The cost of labor for installing a repaired or replacement product shall be borne by Purchaser Replacement parts provided under the terms of this warranty are warranted for the remainder of the warranty period of the Products upon which they are installed to
18. of Figure 12 sess een eene 35 Figure 14 Concrete Foundation Pad configurations Sizes 2 esee 37 Figure 15 Concrete Foundation Pad configurations Two 4 Module Signs Side by Side 38 Figure 16 Sizes 3 5 Concrete Foundation Pad Configurations esee 39 Figure 18 Power Supply BOx niece en n 41 Figure 21 Power Supply Wiring Diagram eese ren rennen 42 Figure 22 Checking the Power Supply Output Voltage After Turn OfTf 43 Table 1 Power Supply Switch and Jumper Selection 44 Table 2 Power Supply Switch and Jumper Selection 5 45 Table 3 AGS 858 LED Sign Style 2 VA Load amp Matching Isolation Transformer Ferro 46 Table 4 AGS 858 LED Sign Style 3 VA Load amp Matching Isolation Transformer Ferro 47 Table 5 AGS 858 LED Sign Style 5 VA Load amp Matching Isolation Transformer Ferro 48 Table 6 AGS 858 LED Sign Style 2 VA Load amp Matching Isolation Transformer Series 49 Table 7 AGS 858 LED Sign Style 3 VA Load amp Matching Isolation Transformer Series 50 Table 8 AGS 858 LED Sign Style 5 VA Load amp Matching Isolation Transformer Series 51 Table 9 Style 2 Three step regulator currents nennen een nennen 52 Table 10 Style 3 Five step
19. regulator currents eese nennen 52 Table 11 Style 5 Fixed regulator current eese nennen nennen 52 Table 12 Power Supply Faults 2 0 dete m Let aee eite ib logis iine 53 Table 13 Parts Vist Rete 54 Table 14 Estimated max sustained force on the sign body Does not include safety margin 55 viii DOCUMENT 1025 REV B DOCUMENT 1025 REV B GOOPER Crouse Hinds Instruction Manual AGS LED 858 LED Series Sizes 1 2 3 4 and 5 8 General Information 8 1 General Description Crouse Hinds Airport Lighting Products AIRSIDE internally illuminated LED 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 Signs are available as single or double faced and are provided with retro reflective sign face For further information on Taxiway Signs and their use consult the latest revision FAA Advisory Circulars AC 150 5220 9 AC 150 5340 18 and AC 150 5345 44 8 2 Classification of Signs The signs covered in this manual are designed and manufactured in accordance with the requirements of FAA Advisory Circular AC 150 5345 44J Specifications for Taxiway and Runway Signs and conform to the following classifications as indicated in paragraph 1 2 of the above Advisory Type L 858Y Dire
20. the LED MODULE 5 with the black return cable connector 14 DOCUMENT 1025 REV B GOOPER Crouse Hinds Instruction Manual AGS LED 858 LED Series Sizes 1 2 3 4 and 5 Turn on main power to the sign If LED MODULES 1 to 5 momentarily light and then turn off then the LED MODULE 5 and the cable from the LED MODULE 4 to the LED MODULE 5 are operating normally A WARNING Failure to turn off power to the sign and wait five minutes could result WARNING S in severe injury or death Turn off main power to the sign Wait five minutes for the high voltage to dissipate Verify that Power Supply Output Voltage measures less than 30 VDC as described above Replace the black return cable connector with the LED MODULE 5 output cable connector Replace the black return cable connector into the output connector housing of the 6 LED MODULE If the sign does not light at all then replace the LED MODULE 5 and or the cable connecting from the output connector of LED MODULE 4 to the input of LED MODULE 5 see Section 10 10 Then repeat the test as described in this section 10 10 Replacing an LED MODULE In the case where an LED MODULE has failed and needs to be replaced use the following instructions INSTRUCTIONS FOR REPLACING AN LED MODULE The following instructions assume that the sign front face is removed and that the failed LED MODULE has been previously identified A WARNING Failure to turn off power to the
21. the LED MODULE connector Figure 7 is connected to the input of the next LED MODULE indicated by the inward pointing arrow at the LED MODULE connector Figure 7 The Last LED MODULE in the series string is terminated with a black return connector amp cable assembly See Figure 7 11 Verify that the black terminator cable connector is properly inserted into the connector housing at the Last LED MODULE output connector indicated by the inward pointing arrow 10 7 Checking the First LED MODULE A WARNING Failure to turn off power to the sign and wait five minutes could result WARNING 2a in severe injury or death 12 DOCUMENT 1025 REV B GOOPER Crouse Hinds Instruction Manual AGS LED 858 LED Series Sizes 1 2 3 4 and 5 Turn off power to the sign by turning off the corresponding Constant Current Regulator CCR power WARNING Wait five minutes after sign power is turned off to service the sign This will allow any residual high voltage stored in Power Supply PCB components to bleed off With your multimeter set to DC Volts verify that the Power Supply Output Voltage is less than 30 VDC at TP6 Positive lead and TP3 Negative Lead as indicated in Figure 22 If the Power Supply Output Voltage is greater than 30 VDC then you must wait until the Power Supply Output Voltage drops below 30 VDC before you proceed with the next step Remove the black return cable connector from the last LED MODULE output cable connecto
22. the same extent as if such parts were original components thereof Warranty services provided under the Agreement does not assure uninterrupted operations of Products Company does not assume any liability for damages caused by any delays involving warranty service The warranty period for the Products is 24 months from date of shipment or 12 months from date of first use whichever occurs first ii DOCUMENT 1025 REV B GOOPER Crouse Hinds Instruction Manual AGS LED 858 LED Series Sizes 1 2 3 4 and 5 3 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 Extreme caution should be exercised when working with this equipment While practical safety precautions have been incorporated in this equipment the following rules must be strictly observed 31 Keep Away from Live Circuits Operating and maintenance personnel must at all times observe all safety regulations Do not perform maintenance on internal components or service with power ON A WARNING DO NOT PERFORM MAINTENANCE ON INTERNAL WARNING COMPONENTS OR SERVICE WITH POWER ON 32 RESUSCITATION Maintenance personnel should familiarize themselves with the technique for resuscitation found in widely published manuals of first aid instruction iv DOCUMENT 1025 GOOPER Crouse Hinds REV B Instruction Manua
23. 1 4 MODULE 2 3 4 and 5 SIZE E DOCUMENT 1025 REV B 137 7 CONCRETE MODULE SIZE 8 1021 CONCRETE MODULE SIZE 8 6539 CONCRETE 1 MODULE SIZE 8 4 27 8 X E xx Xe N N SIGN FLOOR FLANGE EN N 4 MODULE SIGN HOUSING END N 6 MODULE SIGN HOUSING END 1 MODULE SIGN HOUSING END 3 MODULE SIGN HOUSING END SIDE A FACE SIDE SUGGESTED SIZE 2 CONCRETE FUOUNDATION PAD LENGTHS AND WIDTHS Figure 14 Concrete Foundation Pad configurations Size 2 37 FAV IXVl UN DOCUMENT 1025 REV B COOPER Crouse Hinds Instruction Manual AGS LED 858 LED Series Sizes 1 2 3 4 and 5 RUNWAY AY MAXIMUM 3 MINIMUM PAVEMENT SIDE FACE SIDE CIRCUIT CARD BOX WILL BE ON LEFT SIDE FOR THIS FIRST SIGN SIDE FACE SIDE CIRCUIT CARD BOX WILL BE ON LEFT SIDE FOR THIS FIRST SIGN TWO SIGNS MOUNTED SIDE BY SIDE 2 4 MODULES SIZE 1 SIGNS USED IN THIS EXAMPLE AXIW Figure 15 Concrete Foundation Pad configurations Two 4 Module Signs Side by Side NOTE IF 3 SIGNS ARE USED IN AN ARRAY MAKE SEPARATION DISTANCE 12 INCHES TO ALLOW CIRCUIT CARD BOX DOOR TO OPEN IN THIS SPACE WHEN ANOTHER CIRCUIT CARD BOX IS MOUNTED IN THIS SAME SPACE UTILIZED ON ADJACENT SIGN THIS
24. 5 3 2 Series 112 63 0 56 60 52 0 87 200W 5 3 3 Series 116 70 0 61 67 59 0 88 200W 5 3 4 Series 121 78 0 65 76 66 0 88 200W 5 4 2 Series 115 69 0 60 66 57 0 87 200W Table 8 AGS 858 LED Sign Style 5 VA Load amp Matching Isolation Transformer Series 51 DOCUMENT 1025 8 COOPER Crouse Hinds REV B Instruction Manual AGS LED 858 LED Series Sizes 1 2 3 4 and 5 Regulator Setting Current Range A RMS BIO 4 7 4 9 4 80 nominal B30 5 3 5 7 5 50 nominal B100 6 4 6 7 6 60 nominal Table 9 Style 2 Three step regulator currents Regulator Setting Current Range A RMS Bl 2 7 2 9 2 80 nominal B2 3 3 3 5 3 4 nominal B3 4 0 4 2 4 10 nominal B4 5 0 5 4 5 20 nominal B5 6 4 6 7 6 60 nominal Table 10 Style 3 Five step regulator currents Regulator Setting Current Range A RMS Fixed 5 4 5 6 5 50 nominal Table 11 Style 5 Fixed regulator current Note See page vi for a list of meters that would be suitable for these measurements 52 GOOPER Crouse Hinds DOCUMENT 1025 REV B Instruction Manual AGS LED 858 LED Series Sizes 1 2 3 4 and 5 D4 D7 D11 D29 Fault Red Red Green Green ON ON ON ON Output open circuit ON OFF ON ON Output Voltage is less than or equal to 75 of Calibrated Output Voltage or Output Voltage is greater than or equal to 125 of Calibrated Output Voltage OFF ON ON ON Inpu
25. 62317 13 118 Size 1 1 module Size 2 module Size 3 amp 5 1 module Size 1 2 module Size 2 2 module Size 3 2 module Size 1 3 module Size 2 3 module Size 3 3 module Size 1 4 module Size 2 4 module Size 3 4 module Size 4 DMS Table 13 Parts List 54 REV B GOOPER Crouse Hinds Instruction Manual AGS LED 858 LED Series Sizes 1 2 3 4 and 5 DOCUMENT 1025 REV B Sign Size Mod Force in Newtons Force in Lbs Size 1 Imodule 3 080 692 Size 1 2modules 6 186 1 391 Size 1 3modules 8 984 2 020 Size 1 4modules 12 531 2 817 Size 2 Imodule 4 773 1 073 Size 2 2modules 9 587 2 155 Size 2 3modules 14 442 3 247 Size 2 4modules 19 420 4 367 Size 3 amp 5 I1 module 7 107 1 598 Size 3 2modules 13 657 3 070 Size 3 3modules 20 573 4 625 Size 3 4modules 27 664 6 220 Size 4 DMS 11 582 2 604 Table 14 Estimated max sustained force on the sign body Does not include safety margin Fp Based on Cp 1 2pV A V 89 408 M S p 1 2047 M 20 C dry Cp 1 16 for 1 module amp size 4 and 5 DMS 1 165 for 2 module 1 17 for 3 module and 1 18 for 4 module 55
26. 70 0 78 200W 3 1 3 Series 182 92 0 50 92 71 0 78 200W 3 1 4 Series 183 93 0 51 94 73 0 78 200W 3 2 1 Series 180 88 0 49 87 68 0 78 200W 3 2 2 Series 181 91 0 50 90 70 0 78 200W 3 2 3 Series 182 93 0 51 93 73 0 79 200W 3 2 4 Series 183 94 0 51 95 75 0 79 200W 3 3 1 Series 181 90 0 50 89 70 0 78 200W 3 3 2 Series 183 93 0 51 94 73 0 78 200W 3 3 3 Series 186 98 0 53 99 77 0 78 200W 3 3 4 Series 277 101 0 36 102 82 0 80 300W 3 4 2 Series 185 97 0 52 97 77 0 79 200W Table 7 AGS 858 LED Sign Style 3 VA Load amp Matching Isolation Transformer Series 50 GOOPER Crouse Hinds DOCUMENT 1025 REV B Instruction Manual AGS LED 858 LED Series Sizes 1 2 3 4 and 5 Sign Sign VA Watts Power Sign VA Sign Watts Power Primary Primary Factor Secondar Secondar Factor Isolation Isolation Primary y Isolation y Isolation Secondar Isolation Xfrmr Xfrmr Isolation Xfrmr Xfrmr y Isolation Transforme Style Sign Size Modules CCRtype 5 5A 5 5A Xfrmr 5 5A 5 5A Xfrmr r Type 5 1 1 Series 108 56 0 52 54 46 0 85 200W 5 1 2 Series 109 58 0 53 55 47 0 86 200W 5 1 3 Series 111 60 0 54 57 49 0 85 200W 5 1 4 Series 112 63 0 56 60 52 0 87 200W 5 2 1 Series 110 56 0 51 53 45 0 85 200W 5 2 2 Series 110 59 0 53 55 48 0 87 200W 5 2 3 Series 111 61 0 56 59 51 0 86 200W 5 2 4 Series 112 65 0 58 62 54 0 86 200W 5 3 1 Series 109 58 0 53 55 47 0 86 200W
27. COVERPLATE GASKET un eR SECURE TU TRANSFORMER HOUSING DETAIL SCALE ex 3 MINIMUM USING 3 8 16 UNC CORROSION ae RESISTANT HARDWARE GRADE LEVEL SLOPE FORS E DRAINAC N i CONCRETE FOUNDATION i PAD HEIGHT ABOVE GRADE A 7 GRADE GONG E i H LEVEL GRADE LEVEL 17 ATN TO FANGIBLE POINT 7 MIN DO NOT EXCEED CONCRETE 3 SEE FAA ENG BRIEF 79 pe MINIMUM WIRE CREINFORCEMENT lt MESH 6 x6 NUMBER HEAT SHRINK CLIN KIT APPLIED e OVER PRIMARY C DNNECTDRS T APPROPRIATE SIZE SERIES ISOLATION TRANSF RMER Figure 12b Expanded right section of Figure 12 34 DOCUMENT 1025 2 GOOPER Crouse Hinds Instruction Manual AGS LED 858 LED Series Sizes 1 2 3 4 and 5 SIGN FRANGIBLE COUPL e BASEPLATE P N API9 NOTE DO NOT USE GASK POWER CORD FROM SIGN CONCRETE FOUNDATION PAD NG 32 gt ET UNDER BASEPLATE 6 DIAMETER FROM SERIES ISOLATION TRANSFORMER 22 Bas i POWER CORD INSIDE IN L 867 18 DIA LIGHT BASE FRANGIBLE COUPLING BEAT DS CABLE CLAMP 25003 RETAINER N 25684 p re UU 3 1 SUPPLIED WITH BASEPLATE D SUPPLIES VITO SIGN A 435 DIAMETER BOLT CIRCLE ALTERNATE TRANSFORMER HOUSING LOCATION i Pe DO NOT USE ALTERNATE TRANSFORMER N D 1 E
28. DOCUMENT REVISION July 14 2011 COOPER Crouse Hinds Instruction Manual Airside Guidance Sign AGS LED 858 LED Series Sizes 1 2 3 4 and 5 Cooper Industries Crouse Hinds Division Airport Lighting Products 1200 Kennedy Road Copyright O 2011 Cooper Technologies Company Windsor CT 06095 For Parts or Technical Service Call 860 683 4300 DOCUMENT 1025 E l REV B COOPER Crouse Hinds Instruction Manual AGS LED 858 LED Series Sizes 1 2 3 4 and 5 1 Revisions Revision Issue Reissue Number Number Letter Description Checked Approved A A211 188 Initial Release of AGS LED 858 Sign Manual MEG 6 8 11 B A211 218 SD 7 14 11 Update to reflect new single conductor wiring 8 DOCUMENT 1025 P REV B COOPER Crouse Hinds Instruction Manual AGS LED 858 LED Series Sizes 1 2 3 4 and 5 2 Limited Product Warranty THE FOLLOWING WARRANTY IS EXCLUSIVE AND 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 Crouse Hinds Airport Lighting Products the Company warrants to each original Buyer of Products manufactured by the Company that such Products are at the time of delivery to the Buyer free of material and workmanship defects provided that no warranty is made with respect to Any Product which has been repaired or altered in such a way
29. GROUND WIRE NIEA 7 p USE 14 AWG COPPER MIN A 2 CLEARANCE NTE BAKI COPPER G CLAMP aL 1101 z 54 REF 18 MINI umd BELOW LOCAL FROST LINE i 3 MINIMUM 3 MINIMUM koza Lar MINIMUM 2 CONDUIT ELBOW AND COUPLING 17 5 CROUSE HINDS P N 40799 P 2P PLASTIO AC1242HX00301 FAA L 86 B STEEL TRANSFORMER HOUSIN Figure 12a Expanded left section of Figure 12 33 Co lt I DOCUMENT 1025 REV B GOOPER Crouse Hinds Instruction Manual AGS LED 858 LED Series Sizes 1 2 3 4 and 5 SIGN FLOOR FLANGE LONG 1 2 13 UNC L HDDK NCHUR BOLT AT LEAST 6 _ 7 SIGN POWER LEG Ce UST BE EMBEDDED IN THE EV POWER CORD INSIDE CONCRETE SECURE TO FLOOR e FLANGE WITH 172 13 UNC CORROSION RESISTANT e 2 HARDWARE CIRCUIT CARD BOX DANGER 40762 RETAIN p SUPPLIED 34 CONDUIT ELBOW c d NV SERIES ISOLATION T 48 MOWER CLEARANCE TRON ca AK100006 3 8 THICK CHVERPLATE STY 8 SECONDARY IUUD UR LUN 105308087
30. IS ON THE ON THE LEGEND LA Figure 2 Double module sign 21 WN DOCUMENT 1025 COOPER Crouse Hinds REV B Instruction Manual AGS LED 858 LED Series Sizes 1 2 3 4 and 5 FACE JOINT EXTRI THE SII ON THE 5 CLE INT CIRCUIT BOX REF E TERR d i b CJ ES 4 63 REF POWER CORD REF Wi W 2 TETHER REF K SIDE A DOUBLE NGLE D S CON UIT X LOCATION IS ON RIGHT AS S CAN ALSO BE LEGEND LAYO THE SAME S END LAYOUT SEE LEGEND LAYOUT 5 THE LEG Figure 3 Three module sign 222 DOCUMENT 1025 GOOPER Crouse Hinds Instruction Manual AGS LED 858 LED Series Sizes 1 2 3 4 and 5 o WENGER 1 POWER CORD REF LTETHER REF NORMAL T JE THE LEGEND LAYOUT Figure 4 Four module sign 23 DOCUMENT 1025 REV B GOOPER Crouse Hinds Instruction Manual AGS LED 858 LED Series Sizes 1 2 3 4 and 5
31. M SIGN GROUND STUDS COPPER GROUND WIRE NIk USE 14 AWG COPPER MIN 1 SLOPE FORS 2 1 DRAINAGE h E FOUNDATION 4 TA GRAD COPPER GROUND amp CLAMP ME 7 F j i GRADE E EE RODE CONCRETE SO ANGIBLE POINT NOT EXCEED E SEE FAA BRIEF 479 FORCEMENT NUMBER 6 HRINK APPLIED OVER PRIMARY 12 MINIMUM BELOW LOCAL FROST LINE MIN M CONNECTORS 3 MINIMUM 3 MINIMUM 7 4 MINIMUM CONNECTOR s X AE APPROPRIATE SIZE SERIES ISOLATION TR 2 CONDUIT ELBOW AND COUPLING CARE LS CROUSE HINDS P N 40799 P 2P PLASTIC AC1242HX00301 FAA L 867B STEEL TRANSFORMER HOUSING RECOMMENDED TRANSFORMER HOUSING LOCATION AND SUGGESTED CONCRETE FOUNDATION PAD DET AILS Figure 12 Recommended Transformer Housing Location amp Concrete Foundation Pad Details 32 DOCUMENT 1025 COOPER Crouse Hinds REV B Instruction Manual AGS LED 858 LED Series Sizes 1 2 3 4 and 5
32. N OFF Close Open 2 1 x X ON ON ON ON OFF ON ON ON OFF Close Close 2 2 x X ON ON ON ON OFF ON OFF ON OFF Close Close 2 3 x X ON ON OFF ON OFF OFF ON ON OFF Close Open 2 4 x X ON ON OFF ON OFF OFF OFF ON OFF Close Open 3 1 x ON OFF ON ON OFF ON ON ON ON OFF Close Close 3 2 x ON OFF ON OFF OFF ON ON OFF ON OFF Close Open 3 3 x ON OFF ON OFF OFF ON OFF ON ON OFF Close Open 3 4 x ON OFF OFF OFF OFF ON OFF OFF ON OFF Open Open 4 2 ON OFF OFF ON OFF OFF OFF ON ON ON OFF Close Open Table 1 Power Supply Switch and Jumper Selection FERRO CCR 44 GOOPER Crouse Hinds Instruction Manual AGS LED 858 LED Series Sizes 1 2 3 4 and 5 DOCUMENT 1025 REV B Calibration L858 AGS Output Current Input voltage Output LED Configuration Mode Series CCR Setting configuration Normal Operation Size Mods m xg um E poe E d SW3 1 JP1 JP2 1 1 x ON OFF ON ON ON ON ON ON ON OFF Close Close 1 2 x ON OFF ON ON ON ON ON OFF ON OFF Close Close 1 3 x ON OFF ON ON ON ON OFF ON ON OFF Close Close 1 4 x ON OFF ON OFF ON ON OFF OFF ON OFF Close Open 2 1 x X ON ON ON ON OFF ON ON ON OFF Close Close 2 2 x X ON ON ON ON OFF ON OFF ON OFF Close Close 2 3 x X ON ON OFF ON OFF OFF ON ON OFF Close Open 2 4 x X ON OFF OFF ON OFF OFF OFF ON OFF Open Open 3 1 x ON OFF ON ON OFF ON ON ON ON OFF Close Close 3 2 x ON OFF ON OFF OFF ON ON OFF ON OFF Close Open 3 3 x ON OFF OFF
33. This will allow any residual high voltage stored in Power Supply PCB components to bleed off A WARNING Failure to turn off power to the sign and wait five minutes could result in severe injury or death With your multimeter set to DC Volts verify that the Power Supply Output Voltage is less than 30 VDC at TP6 Positive lead and TP3 Negative Lead as indicated in Figure 22 Ifthe Power Supply Output Voltage is greater than 30 VDC then you must wait until the Power Supply Output Voltage drops below 30 VDC before you proceed with the next step Remove input power cabling at CN1 CN2 CN3 CN11 CNI7 amp CNIS See Figure 15 Remove LED Power Supply Cable at CN9 See Figure 15 Remove the three nuts that secure the main heat sink to the Power Supply Box Remove the six screws that fasten the Power Supply Board onto the Power Supply Box Remove the Power Supply Board Assembly by sliding the attached main heat sink off the mounting studs extending from the side of the Power Supply Box Slide the new Power Supply Board onto the mounting studs extending from the side of the Power Supply Box Fasten board to the Power Supply Box with six mounting screws Attach the three nuts that secure the heat sink to the studs extending from the side of the Power Supply Box Connect the LED Power Supply cable at CN9 Connect the input power cabling at CN1 CN2 CN3 CN11 CN17 amp CN18 Set the jumpers JP1 amp JP2 for the sign style siz
34. ading may dramatically reduce lamp life and adversely affect power equipment performance A meter with TRUE RMS measuring capability and a current clamp on probe is needed to accurately measure distorted or chopped waveforms All meter manufacturers offer TRUE RMS measuring meters The following is a short list of TRUE RMS Multimeters from Fluke Manufacturer Model Number Fluke 87V 287 Our recommended meter is the Fluke 87V with the Fluke 800 current clamp Refer to the equipment manufacturer s manuals for the proper use maintenance and calibration if necessary of all meters vi DOCUMENT 1025 GOOPER Crouse Hinds REV B Instruction Manual AGS LED 858 LED Series Sizes 1 2 3 4 and 5 6 Table of Contents l ReVISIODS A e Aso e tette il 2 Product Warranty iode ee etes t bebe meer iii 3 cede Re EH iv 3 1 Keep Away from Live Circuits nennen nenne iv 3 2 RESUSCITATION ne konka a ene en en e de e deus iv 4 Ssafety Symbols nep eph edo eM all cj ied v 41 Dangerns LE v 42 WAN sana an a AJ v 4 5 o p tr ore Oron tuin 44 Warning NOtCe 5 aed edente eii 45 1111 1 11110 518 111 9595595555 RH e e rte e ee 5 TestEquipment and Tools soo ses eceso vi 6 Table of Contents eoe er oda
35. ard See Figure 18 On the Power Supply Board set switch SW3 1 to the ON position e am Apply main power to the sign Green LED D3 will flash ON OFF slowly for approximately three seconds to indicate the beginning of the calibration process During calibration D3 will remain OFF At the conclusion of the calibration process D3 remain constant ON see Figure 18 5 If D3 does not light and remain constant then calibration has failed Based on the assumption listed under WARNING above replace the power supply board See section 10 12 Turn off the main power to the sign Set SW3 1 to the OFF position Close the Power Supply cover 9o 53 tA The Power Supply Board is now calibrated to the sign 10 12 Replacing Sign Power Supply Board amp Heat Sink P N 62277 In this section it is assumed that the sign has failed and the trouble shooting guide recommends replacement of the Power Supply Board INSTRUCTIONS FOR REPLACING 62277 PC BOARD amp HEAT SINK 17 DOCUMENT 1025 COOPER Crouse Hinds REV B IMPORTANT l WARNING ERON epu 10 11 12 13 Instruction Manual AGS LED 858 LED Series Sizes 1 2 3 4 and 5 A WARNING Power Supply Board must be re calibrated after replacement see Section 10 11 Turn off power to the sign by turning off the corresponding Constant Current Regulator CCR power WARNING Wait five minutes after sign power is turned off to service the sign
36. ction destination and boundary sign black legend on a yellow background Type L 858R Mandatory instruction sign white legend on a red background Type L 858L Taxiway and runway location sign yellow legend and border on a black background Type L 858B Runway Distance Remaining sign with a white legend on a black background Type L858C Taxiway Ending Marker sign yellow strips on black background 2 module sign only A sign may consist of multiple arrays of the above messages NOTE Size 5 information in this manual is the same as the Size 3 single module unless noted otherwise P N Sizes 858S5 1X X X X XX Size 1 12 inch legend small body 858S5 2X X X X XX Size 2 15 inch legend mid size body 858S5 3X X X X XX Size 3 18 inch legend large body 85885 AX X X X XX Size 4 40 inch legend large body DMS numerals and AGM symbol 858S5 5X X X X XX Size 5 25 inch legend large body DMS numerals only CAT FAA Styles 3 Style 2 For operation from a 3 step series lighting circuit 4 8 to 6 6 amperes 5 Style 3 For operation from a 5 step series lighting circuit 2 8 to 6 6 amperes 1 Style 5 A fixed 5 5 ampere series lighting circuit Class 2 For operation from 40 C to 55 C 131 F Mode 2 Sign for use in areas subjected to wind speed of up to 200 mph 322 km h 8 DOCUMENT 1025 l REV B COOPER Crouse Hinds Instruction Manual AGS LED 858 LED Series Sizes 1 2 3 4 and 5 8 3 Part Nu
37. depending on the CCR current level or current step Upon completing the measurement of the input current turn off power to the CCR Remove the current clamp Disconnect the female crimp receptacle at CN17 and reconnect to CN18 Reconnect the female crimp receptacle attached to wire BRPH to CN18 Close the Power Supply Box cover 104 Measuring Input Current Signs With Optional Power Switch A WARNING Failure to turn off power to the sign and wait five minutes could result in severe injury or death WARNING Turn off power to sign by toggling sign power switch to the off position See Figure 6 Turn off power to the sign WARNING Wait five minutes after sign power is turned off to service the sign This will allow any residual high voltage stored in Power Supply PCB components to bleed off With your multimeter set to DC Volts verify that the Power Supply Output Voltage is less than 30 VDC at TP6 Positive lead and TP3 Negative Lead as indicated in Figure 22 If the Power Supply Output 10 DOCUMENT 1025 COOPER Crouse Hinds REV B Instruction Manual AGS LED 858 LED Series Sizes 1 2 3 4 and 5 Voltage is greater than 30 VDC then you must wait until the Power Supply Output Voltage drops below 30 VDC before you proceed with the next step Open the Power Supply Box cover Place current clamp around one of the wires connected to the switch labeled with switch marker PWR Connect the current clamp to the true RMS curr
38. e and number of modules as shown in Table 1 or 2 For locaction see Figure 18 18 DOCUMENT 1025 REV B GOOPER Crouse Hinds Instruction Manual AGS LED 858 LED Series Sizes 1 2 3 4 and 5 14 Set DIP switches SW1 SW2 amp SW3for the sign style size and number of modules as shown in Table 1 or 2 For locations Figure 18 15 The Power Supply Board and Heat Sink replacement is complete 19 DOCUMENT 1025 REV B GOOPER Crouse Hinds Instruction Manual AGS LED 858 LED Series Sizes 1 2 3 4 and 5 1 Figures and Tables malag TT mmm IN TETHER REF i GROUND STUD REF Ses THE THE LEGEND LAYOUT Figure 1 Single module sign 20 DOCUMENT 1025 REV B GOOPER Crouse Hinds Instruction Manual AGS LED 858 LED Series Sizes 1 2 3 4 and 5 TETHER REFA X p POUND S d 4 63 REF GROUND STUD REF 3 A 3 MAX MODULE SID TION AYOUT FOR SIDE A AE SIDE AS THE POV OUT OWN ION CIRCUIT NOT ILLUSTRATED BOX
39. e clearly marked with inward pointing and outward pointing black arrows respectively on the LED MODULE PCB see Figure 7 11 DOCUMENT 1025 REV B GOOPER Crouse Hinds Instruction Manual AGS LED 858 LED Series Sizes 1 2 3 4 and 5 10 6 Checking LED MODULE Cable Connections A WARNING Failure to turn off power to the sign and wait five minutes could result WARNING mar in severe injury or death Turn off power to the sign by turning off the corresponding Constant Current Regulator CCR power WARNING Wait five minutes after sign power is turned off to service the sign This will allow any residual high voltage stored in Power Supply PCB components to bleed off With your multimeter set to DC Volts verify that the Power Supply Output Voltage is less than 30 VDC at TP6 Positive lead and TP3 Negative Lead as indicated in Figure 22 Ifthe Power Supply Output Voltage is greater than 30 VDC then you must wait until the Power Supply Output Voltage drops below 30 VDC before you proceed with the next step The LED MODULES are electrically wired in series This means that if any of the cable connectors are improperly seated in their respective LED MODULE housing then no current can flow through any of the LED MODULES and subsequently the sign will not light Therefore verify that all cable connectors are properly seated in their housing and that the output of one LED MODULE indicated by the outward pointing arrow at
40. ent meter Measure the input current Current should measure between 2 7 ARMS and 6 7 ARMS depending on the CCR current level or current step Upon completing the measurement of the input current remove current clamp and close Power Supply Box cover 10 5 Checking Power Supply LED Cable A WARNING Failure to turn off power to the sign and wait five minutes could result WARNING i e in severe injury or death Turn off power to the sign WARNING Wait five minutes after sign power is turned off to service the sign This will allow any residual high voltage stored in Power Supply PCB components to bleed off With your multimeter set to DC Volts verify that the Power Supply Output Voltage is less than 30 VDC at TP6 Positive lead and TP3 Negative Lead as indicated in Figure 21 If the Power Supply Output Voltage is greater than 30 VDC then you must wait until the Power Supply Output Voltage drops below 30 VDC before you proceed with the next step Remove the sign top cover bolts and then lift the top cover from the sign Remove the front face from the sign Check the Power Supply LED Cable for visible damage Make sure the Power Supply LED cable connector is properly seated in CN9 at the Power Supply Board see Figure 18 Verify that the Power Supply LED cable connector connects to the input connector of the first LED MODULE and is properly seated in the input connector housing The LED MODULE input connector and the output connector ar
41. l AGS LED 858 LED Series Sizes 1 2 3 4 and 5 4 Safety Symbols 41 Danger A DANGER DANGER The hazard or unsafe practice will result in severe injury or death 4 2 Warning A WARNING WARNING The hazard or unsafe practice could result in severe injury or death 4 3 Caution A CAUTION CAUTION The hazard or unsafe practice could result in minor injury 4 4 Warning Notice A WARNING NOTICE Possibly dangerous situation goods might be damaged 4 5 Warning Important A WARNING IMPORTANT Helpful information DOCUMENT 1025 REV B GOOPER Crouse Hinds Instruction Manual AGS LED 858 LED Series Sizes 1 2 3 4 and 5 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 Multimeter One of the most important pieces of test equipment is the Multimeter It is used to measure voltages currents and resistances Almost every single maintenance task requires the use of a multimeter at one point or another A quality meter in good repair and calibration is a must because airfield lighting power distribution equipment produces non sinusoidal waveforms traditional average reading meters are inaccurate and have very limited use Checking or adjusting equipment based upon incorrect current re
42. lation flickering transformer that matches sign type size modules See Tables 3 8 DOCUMENT 1025 REV B GOOPER Crouse Hinds Instruction Manual AGS LED 858 LED Series Sizes 1 2 3 4and 5 10 3 Measuring Input Current Signs Without Optional Power Switch A WARNING Failure to turn off power to the sign and wait five minutes could result WARNING mar in severe injury or death Turn off power to the sign by turning off the corresponding Constant Current Regulator CCR power WARNING Wait five minutes after sign power is turned off to service the sign This will allow any residual high voltage stored in Power Supply PCB components to bleed off With your multimeter set to DC Volts verify that the Power Supply Output Voltage is less than 30 VDC at TP6 Positive lead and TP3 Negative Lead as indicated in Figure 22 If the Power Supply Output Voltage is greater than 30 VDC then you must wait until the Power Supply Output Voltage drops below 30 VDC before you proceed with the next step Open Power Supply cover See Figure 18 Disconnect female crimp receptacle at CN17 from Power Supply Board Note When removing female crimp receptacle grasp by the terminal not the wire Disconnect female crimp receptacle from CN18 and connect to CN17 Place current clamp around primary power wire and connect to a true rms current meter Turn on power to the CCR Current should measure between 2 7 ARMS and 6 7 ARMS
43. ligned with the mounting bracket holes Note The replacement LED MODULE input connector should be closest to the marked input cable connector 7 Push the mounting bracket bolts through the mounting bracket and the LED MODULE heat sink holes 8 Attach nuts to the mounting bracket bolts and tighten 9 Gently slide the input cable connector into the replacement LED MODULE connector input housing 10 Likewise slide the output cable connector into the replacement LED MODULE output connector housing 11 The LED MODULE replacement is complete 12 Power Supply Board must be re calibrated after replacing an LED MODULE see Section 10 11 A WARNING IMPORTANT Power Supply Board must be re calibrated after replacing an LED MODULE see Section 10 11 16 DOCUMENT 1025 REV B GOOPER Crouse Hinds Instruction Manual AGS LED 858 LED Series Sizes 1 2 3 4 and 5 10 11 Sign PC Board P N 62277 Calibration The 62277 PC Board doesn t normally need to be calibrated in the field unless an LED MODULE is replaced A WARNING In this section it is assumed that the Sign PC Board P N 62277 is correctly configured for this particular sign see Table lor 2 and that the sign lights continuously when main power is applied in the normal mode of operation SW3 1 OFF IMPORTANT INSTRUCTIONS FOR CALIBRATION OF 62277 PC BOARD Turn off main power to the sign Open the Power Supply Cover and locate SW3 1 on the Power Supply Bo
44. mbers Zea ANAT A Noah IG IG IG BRIGHTNE NCLOSED 3 FOOT LONG PC XIBLE LIQUIDTIGHT METALLIC O ITCH ONG POWER CORD NOT FAA COMPLIANT ONE MODULE amp SIZE 5 DMS SIGN ONLY TIONAL TETHER GOOPER Crouse Hinds 9 a DOCUMENT 1025 REV B Instruction Manual AGS LED 858 LED Series Sizes 1 2 3 4 and 5 Installation A WARNING NOTICE Sign foundations pad and their design are the responsibility of the installer and or airport and recommendations suggestions herein are for guidance only Transformer housing and baseplates and or covers series isolation transformers primary connector kits series isolation transformer secondary cable extender series isolation consolidating harness if required heat shrink kits grounding rods ground wire and connectors floor flange anchor bolts and hardware are not included as part of the sign Underlined items may be ordered from Crouse Hinds Airport Lighting Refer to FAA AC 150 5345 18F section 14 for Taxiway Guidance Sign location and for the perpendicular distance from the defined pavement edge to the near side of the sign Similarly see section 25 of FAA AC 150 5345 18F for Runway Distance Remaining Sign location and perpendicular distance from the defined pavement
45. nch below the conduit elbow threaded coupling top surface A WARNING IMPORTANT Check the sign for shipping damage upon arrival and in all cases check for damage prior to installation h Lower the sign with the legs and flanges into place Plug the sign power cable plug into the secondary receptacle inside the conduit elbow while lowering Check the sign itself with a long carpenter s level to be sure it is level As an alternate remove the floor flanges and frangible couplings from the sign unscrewing the frangible couplings from the floor flanges Install the floor flanges onto the sign anchor bolts Level the floor flanges for ease of installation of the sign A long carpenter s level can be placed across the top of the floor flanges to be sure they are all in line and level Do not tighten the anchor nuts tight only finger tight until the frangible couplings are installed back into to floor flanges Note Some vertical adjustments can be obtained by rotating the floor flanges a turn or two on the frangible coupling 1 Make sure all flanges are in full contact and sit flush on the pad before tightening the anchor bolts Shim and grout as required Once the sign has been leveled attach the sign tether to the closest anchor bolt and tighten all the anchor nuts securely Note Anchor hardware is not supplied with the sign Anchor hardware should be corrosion resistant The sign body must not be bent or distorted due to an uneven installa
46. o o o la 6 el e el 9 o 5 o le 5 o o o 5 o la 65 e e 5 5 el 9 9 Y A Y TO POWER SUPPLY e 8 a a CIRCUIT BOARD 5 8 CONNECTOR CNi4 PIN 2 o 9 6 5 o 5 o o 5 o o 5 lo 5 e 9 lo o e o 8 al E 9 lel gt ID POWER SUPPLY BLACK RETURN CABLE SIZE 3 LED ARRAY WIRING SEAN CTO I Figure 10 LED Array Wiring Four Module Signs Reference Figure 7 for LED array orientations 30 CONNECTOR CN9 PIN 2 DOCUMENT 1025 REV B p GOOPER Crouse Hinds Instruction Manual AGS LED 858 LED Series Sizes 1 2 3 4 and 5 KY TO POWER SUPPLY CIRCUIT BOARD CONNECTOR CNI4 PIN 5 E 7 TO POWER SUPPLY E AA vA CIRCUIT BOARD BLACK RETURN CABLE CONNECTOR CNS PIN 2 SIZE 4 DMS LED ARRAY WIRING Figure 11 LED Array Wiring Distance Marker Reference Figure 7 for LED array orientations 31 DOCUMENT 1025 2 GOOPER Crouse Hinds Instruction Manual AGS LED 858 LED Series Sizes 1 2 3 4 and 5 SIGN FRANGIBLE COUPLING amp BASEPLATE P N API POWER CORD FROM 510 g 932 T USE GASKET UNDER BASEPLATE CONCRETE FOUNDATION PA IN e 6 DIAMETER POWER CORD D L 867 18 DIA LIGHT BASE E GR CHRD INS LUS
47. ptable grading around the foundation pad The foundation pad pad must be level It is recommended that the contractor who is to install the concrete foundation pad use cast in place anchor bolts The threaded portion of the anchor bolts should be 1 5 8 inches minimum to 1 7 8 maximum above the top of the concrete foundation pad See Figures 12 12a 12c This requires that the anchor bolts be installed accurately as shown in the concrete foundation pad dimensions Figure 13 The clearance holes on the floor flange are 5 8 inch diameter on a 4 75 inch diameter bolt circle for use with inch anchor bolts The concrete foundation pad should include the series isolation transformer housing It is recommended that this housing not be placed under the sign power leg to allow access to the series isolation transformer and connections for ease of troubleshooting and servicing See Figures 12 12a 12c This housing would be on the side closest to the Taxiway or Runway A 2 inch conduit elbow with threaded coupling attached at sign end would exit from the transformer housing side to the foundation pad and be flush with the with the top of the concrete foundation pad grade level centered between the floor flange bolts nearest the Taxiway or Runway side of the sign The sign as viewed will have the circuit card box to the right on the A side of the sign which is closest to the Taxiway or Runway side of the sign If the location requires an additional housing
48. r see Figures 7 11 amp 20 Replace the output cable connector in the first LED MODULE with the black return cable connector Turn on main power If the first LED MODULE momentarily lights and then turns off then the first LED MODULE and the Power Supply LED cable and Power Supply board are operating normally Turn off main power to the sign Wait five minutes for the power supply voltages to dissipate Verify that the output voltage is less than 30 VDC with a multimeter as described in the opening paragraph of this section Replace the black return cable connector with the first LED MODULE output cable connector If the sign does not light at all then replace the LED MODULE 1 and or the cable connecting from the output of the Power Supply to the input of LED MODULE 1 see Section 10 10 Then repeat the test described above in this section 10 8 Checking the Second LED MODULE A WARNING Failure to turn off power to the sign and wait five minutes could result WARNING 8 in severe injury or death Turn off power to the sign by turning off the corresponding Constant Current Regulator CCR power WARNING Wait five minutes after sign power is turned off to service the sign This will allow any residual high voltage stored in Power Supply PCB components to bleed off With your multimeter set to DC Volts verify that the Power Supply Output Voltage is less than 30 VDC at TP6 Positive lead and TP3 Negative Lead as indicated in Figure
49. ry connectors two pin receptacle to series them together Use electrical tape around the connections to prevent accidental disconnection The Series DOCUMENT 1025 COOPER Crouse Hinds REV B Instruction Manual AGS LED 858 LED Series Sizes 1 2 3 4 and 5 Isolation Transformer should be placed on a brick in order to isolate the transformer from direct contact with metal The Series Isolation Transformer secondary cable should then be inserted from inside the housing up the conduit elbow Using the two 40762 retainers supplied with the sign looks like a cupped washer with a slot placing one below the secondary cable receptacle L 823 Style 8 looks like a ball and one above The bottom cupped washer sits on the conduit elbow top inside the threaded conduit coupling and prevents the secondary cable from dropping back down the conduit The top cupped washer prevents the secondary cable from being pulled out of the ground allowing the sign power cord to disconnect 1f the sign is impacted and shears off at its frangible couplings Ifa consolidating harness is used or a secondary cable extension use electrical tape around connection is required use the 25003 split clamp with screws and hex nuts retainer supplied with the sign Secure this retainer flat side down away from sign around the secondary end L 823 Style 7 looks like a straight tube that will exit the conduit elbow The top of the secondary receptacle should be at least 14 i
50. sign and wait five minutes could result WARNING in severe injury or death 1 Turn off power to the sign by turning off the corresponding Constant Current Regulator CCR power WARNING Wait five minutes after sign power is turned off to service the sign This will allow any residual high voltage stored in Power Supply PCB components to bleed off 15 GOOPER Crouse Hinds DOCUMENT 1025 REV B Instruction Manual AGS LED 858 LED Series Sizes 1 2 3 4 and 5 With your multimeter set to DC Volts verify that the Power Supply Output Voltage is less than 30 VDC at TP6 Positive lead and TP3 Negative Lead as indicated in Figure 22 Ifthe Power Supply Output Voltage is greater than 30 VDC then you must wait until the Power Supply Output Voltage drops below 30 VDC before you proceed with the next step 3 Carefully remove the input and output cables from the failed LED MODULE Mark the cable connected to the LED MODULE input connector Note The input connector on the LED MODULE is denoted by a black arrow pointing toward the input connector see Figure 7 4 Loosen and remove the nuts on the LED MODULE mounting bracket bolts Remove the LED MODULE bracket bolts with one hand while support the LED MODULE with your other hand Carefully remove the failed LED MODULE from the LED MODULE mounting bracket 6 Mount the replacement LED MODULE into the mounting bracket such that the holes in the LED MODULE heat sink are a
51. t current lt 2 5A or Input current gt 6 7A OFF OFF ON OFF 3 3 Volt Supply Failure OFF OFF OFF OFF 15 Volt Supply and or 3 3 Volt Supply Failure assumes the main AC power is applied to the power supply board Table 12 Power Supply Faults 53 GOOPER Crouse Hinds Instruction Manual AGS LED 858 LED Series DOCUMENT 1025 Sizes 1 2 3 4 and 5 PART DESCRIPTION NUMBER USED ON Frangible Coupling 62245 1 Size 1 62245 2 Size 2 62245 3 Size 3 amp 5 62245 4 Size 4 Power Supply PCB located 62277 All Sizes inside circuit box Heatsink LED Assembly 62288 All Sizes located inside sign housing Filter PCB located inside 62279 All Sizes circuit box Bridge Rectifier and Thermal 62314 All Sizes Pad Replacement Kit located inside circuit box Sign Face Panel w Legend 62290 X Contact Factory with legend information Sign Panel Black 60668 X Contact Factory with sign size and number of modules LED Array to LED array input wire white 62278 1 48 62278 2 12 62278 3 6 All sizes All sizes except size 3 1 2 3 4 module and size 5 All sizes except size 1 amp 2 1 2 3 4 module and size 4 Last LED array to power supply PCB CNO return wire black 62317 1 67 62317 2 85 62317 3 105 62317 4 92 62317 5 120 62317 6 144 62317 7 131 62317 8 162 62317 9 192 62317 10 158 62317 11 196 62317 12 232
52. tion procedure Install a bare 14 AWG minimum copper ground wire to the sign ground stud stud located on sign bottom extrusion exterior and accepts 4 through 14 AWG and the other end to the grounding rod clamp j The sign is shipped set for a Ferro resonant Type L 828 Regulator as illustrated in Table 1 For other Regulator types set sign power supply circuit card jumper according to Table 2 k Return power to series circuit and verify sign illuminates through all Regulator brightness steps GOOPER Crouse Hinds 10 DOCUMENT 1025 REV B Instruction Manual AGS LED 858 LED Series Sizes 1 2 3 4 and 5 Maintenance and Troubleshooting A WARNING WARNING Remove Power Before Attempting Any Servicing 10 1 General Work on electrical circuits should be done only by a qualified electrician with a working knowledge of airfield lighting circuits Trouble shooting is accomplished by means of process of elimination It should be checked that the POWER is OFF and secured and once one solution is tried POWER is reapplied Then PO WER turned OFF and secured and another solution tried etc Repeat this until the problem is solved It is also assumed that the circuit is in proper working order from the isolation transformer secondary connector L 823 style 7or 8 receptacle all the way to and including the power source Use of a calibrated true RMS reading multi meter with a current sensing clamp on attachment will aid in the
53. tions 10 7 10 9 P 9 Sign will not light LED MODULE s open circuit failure Assumes P 7 Action taken Replace suspected open circuit LED MODULE with spare known good LED DOCUMENT 1025 GOOPER Crouse Hinds REV B Instruction Manual AGS LED 858 LED Series Sizes 1 2 3 4 and 5 PROBLEM POSSIBLE CAUSE CORRECTIVE ACTION MODULE s See Sec 10 10 P 10 Upon Incorrect LED Power Supply Verify Set Power Supply applying power Circuit Board Switch Board Switches and jumpers sign Configuration are set according to Table 1 momentarily Ferro CCR or Table 2 Series lights and then CCR turns off P 11 Upon LED MODULE Voltage has Replace any LED applying power dropped 25 below the calibrated MODULE s with non lit sign output voltage See Table 12 LEDs and re calibrate the LED momentarily Power Supply See Sections lights and then 10 10 amp 10 11 turns off P 12 Upon LED MODULE Voltage is greater Verify Set Power Supply applying power than 125 of the expected Board Switches and jumpers sign calibrated output voltage See are set according to Table 1 momentarily Table 12 Ferro CCR or Table 2 Series lights and then CCR turns off P 13 Sign Incorrect LED Power Supply Verify Set Jumpers JP1 and flickering Circuit Board Jumper Setting JP2 according to the Table 1 FERRO CCR or Table 2 Series CCR P 14 Sign Incorrect Isolation Transformer Replace with Iso
54. to accommodate multiple messages then the separation distance between these signs housings can be 3 inches minimum to 12 inches maximum FAA AC 150 5345 44J 3 2 5 2 a This first sign body housing farthest from the adjacent Taxiway will have the circuit card box to the left on the A side of the sign The sign side identification is important with regards to its sign panel legend A grounding rod and clamp should be installed at the end opposite the circuit card box in order to ground the sign housing This grounding rod must not be connected to the field counterpoise A DANGER DANGER Lock out electrical power to the series loop that will power the sign at its source before attempting any electrical connections splices Make electrical connections to the series loop power using L 823 Primary Connector Kits Attach the primary connectors to the appropriate size L 830 Series Isolation Transformer See Tables 3 8 These primary connections single pin plug or receptacle should have Heat Shrink Kits applied over their connections to prevent disconnection and water from entering the cables If two Series Isolation Transformers are required to be attached in series to obtain the correct wattage required for the sign all primary lead connections should have Heat Shrink Kits applied Two Series Isolation Transformers connected in series together will require a Consolidating Harness Crouse Hinds Part Number 26581 1 27 at the transformer seconda
55. trouble shooting of electrical circuits Warning Only use OEM replacement sign legend panels A WARNING NOTICE Only use OEM replacement sign legend panels The entire message element must be replaced per FAA AC 150 5345 44J 3 2 5 10 2 Our proprietary process replacement panels meet the photometric and wind loading requirements of the sign as certified to FAA AC 150 5345 44J DOCUMENT 1025 COOPER Crouse Hinds REV B Instruction Manual AGS LED 858 LED Series Sizes 1 2 3 4 and 5 A CAUTION CAUTION Do not over tighten hex nut on stud retaining bridge rectifier 8in lbs max See Figure 18 Also remover carriers from thermal pad adhesive surfaces before installing A WARNING IMPORTANT When tightening cover screws do not use power drivers as you may exceed the maximum torque of 75 in lbs on the cover screws A DANGER DANGER When replacing parts inside the circuit box or sign housing lock out series circuit power at its source 102 Problem Solving Guide PROBLEM POSSIBLE CAUSE CORRECTIVE ACTION P 1 Sign will No input current LEDs on Power Measure input current not light Supply board not lit according to Sections 10 3 and 10 4 If the measured input current is not within spec see Tables 9 11 check CCR isolation transformer and primary power connections GOOPER Crouse Hinds Instruction Manual AGS LED 858 LED Series Sizes 1 2 3 4 and 5 DOCUMENT 1025 REV B
56. ve been checked successfully as described in previous two sections For signs with more than two LED MODULES continue checking the remaining LED MODULES one at a time and in numerical sequence e g LED MODULE 3 LED MODULE 4 LED MODULE Last Use the same method as we have outlined in previous section For example suppose we have a sign with 6 LED MODULES See Size 2 2 Modules Figure 9 and we have checked all the LED MODULES in sequence from 1 to from 4 and found that the sign momentarily lit Then we would use the following procedure to test the 5th LED MODULE A WARNING Failure to turn off power to the sign and wait five minutes could result WARNING i i in severe injury or death Turn off power to the sign by turning off the corresponding Constant Current Regulator CCR power WARNING Wait five minutes after sign power is turned off to service the sign This will allow any residual high voltage stored in Power Supply PCB components to bleed off With your multimeter set to DC Volts verify that the Power Supply Output Voltage is less than 30 VDC at TP6 Positive lead and TP3 Negative Lead as indicated in Figure 22 If the Power Supply Output Voltage is greater than 30 VDC then you must wait until the Power Supply Output Voltage drops below 30 VDC before you proceed with the next step Remove the black return cable connector from the 6th LED MODULE output cable connector see Figure 20 Replace the output cable connector in
57. x 41 DOCUMENT 1025 REV B LAM _ Supply 45 66 Board DOCUMENT 1025 REV B COOPER Crouse Hinds Instruction Manual AGS LED 858 LED Series Sizes 1 2 3 4 and 5 chassis mount chassis mount Isolation Transformer Bridge Rect chassis mount LED Power Supply Board Power Supply Box Figure 21 Power Supply Wiring Diagram 42 DOCUMENT 1025 REV B GOOPER Crouse Hinds Instruction Manual AGS LED 858 LED Series Sizes 1 2 3 4 and 5 m aN NBC GND m m iu HOI P2 gt 3 RTT IBI IZ nu 1 PROG 685 CNI4 I TPG TO LED MODULE MEASURE DC VOLTAGE AT THIS LOCATION MAXIMUM VOLTAGE COULD BE 290 DCV SAFE TO HANDLE AT LESS THAN 30 DC VOLTS Figure 22 Checking the Power Supply Output Voltage After Turn Off 43 GOOPER Crouse Hinds Instruction Manual AGS LED 858 LED Series Sizes 1 2 3 4 and 5 DOCUMENT 1025 REV B Calibration L858 AGS Output current Input voltage Output LED Configuration Mode Ferro CCR Setting configuration Normal Operation Size Mods Bud Kr ind P ps Ps peroj in SW3 1 JP1 JP2 1 1 x ON OFF ON ON ON ON ON ON ON OFF Close Close 1 2 x ON OFF ON ON ON ON ON OFF ON OFF Close Close 1 3 ON OFF ON ON ON ON OFF ON ON OFF Close Close 1 4 x ON OFF ON OFF ON ON OFF OFF O
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