Cooper Bussmann 858 manual

DOCUMENT 1025 REVISION B July 14, 2011 I n s t r u c t i o n M a n u a l 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 Windsor, CT 06095 Copyright © 2011 Cooper Technologie s Company F or Parts or Technical Se rvice Call (860) 683-4300[...]

DOCUMENT 1025 REV. B Instruction Manual AGS-LED 858 LED Series Sizes 1, 2, 3, 4 and 5 ii 1 Revisions Revision Number Issue/Reissue Number Letter Description Checked Approved A A211-188 Initial Release of AGS- LED 858 Sign Manual MEG 6/8/11 B A211-218 Update to reflect new single conductor wiring SD 7/14/11[...]

DOCUMENT 1025 REV. B Instruction Manual AGS-LED 858 LED Series Sizes 1, 2, 3, 4 and 5 iii 2 Limited Product Warran ty THE FOLLOWING WARRANTY IS EXCLUSIVE AND I N LIEU OF ALL OTHER WARRANTIES, WHETHER EXPRESS, I MPLIED OR STATUTORY, I NCLUDING, BU T NOT BY WAY OF LI MITATION, ANY WARRANTY OF MERCH ANTABILITY OR FITNESS FOR A NY PARTICULAR PURPOSE. C[...]

3 Safety Notices This equipment is normally used or connec ted to circuits that m ay employ voltages which are dangerous and may be fatal if accidenta lly contacted by operating or m aintenance personnel. Extreme caution should be exercised when wo rking with precautions have been incorporated in th is equipment, the following rules m ust be strict[...]

4 Safety Symbols 4.1 Danger DANGER The hazard or uns afe practice will result i n severe injury or death. 4.2 Warning WARNING The hazard or uns afe practice 4.3 Caution CAUTION The hazard or uns afe practice could result in minor in jury. 4.4 Warning: Notice NOTICE Possibly dangerous situation, goods might be damaged. 4.5 Warning : Important IMPORT[...]

DOCUMENT 1025 REV. B Instruction Manual AGS-LED 858 LED Series Sizes 1, 2, 3, 4 and 5 vi 5 Test Equip ment and Tools There is a wide variety of tools and equipm ent needed to safely and correctly perform airfield lighting equipment installation and m aintenance. In addition to the obvious tools (screwdr ivers, wrenches, etc.), there is a specialize[...]

DOCUMENT 1025 REV. B Instruction Manual AGS-LED 858 LED Series Sizes 1, 2, 3, 4 and 5 vii 6 Table of Con tents 1 Revisions ............................................................................................................................... ii 2 Limited Product Warranty .....................................................................[...]

DOCUMENT 1025 REV. B Instruction Manual AGS-LED 858 LED Series Sizes 1, 2, 3, 4 and 5 viii 7 List of Figures and Tables Figure 1. Single module sig n ....................................................................................................... 20 Figure 2. Double module sig n ...............................................................[...]

DOCUMENT 1025 REV. B Instruction Manual AGS-LED 858 LED Series Sizes 1, 2, 3, 4 and 5 1 8 General Information 8.1 General Description Crouse-Hinds Airport Lighting Product s, “AIRSI DE” internally illuminated LED Taxiway and Runway Signs provide outstanding message visibility, day or night. Wh ite on Red and Yellow on Black and Black on Yellow [...]

DOCUMENT 1025 REV. B Instruction Manual AGS-LED 858 LED Series Sizes 1, 2, 3, 4 and 5 2 8.3 Part Numbers:[...]

9 Installation NOTICE Sign foundatio ns/pad and their design are the responsibi installer and/ or airport and recommendations/s uggestions herein are for guidance only. covers , series isolation transformers isolation transf ormer secondary cable extend consolidatin g harness ground wire and connectors, floor flange anchor bolts an d hardware are n[...]

d. The concrete foundation/pad should be not m ore than 1 inch above grade in or inch maximum ov erall height above grade to the point of frangibility per FAA En gineering 79. See the Engineering Brief for accept able grading around the foundation/pad. The foundat ion/pad pad must be level. e. It is re commended that the contractor who i s to insta[...]

Isolation Transformer should be pla contact with metal. The Series Isolation Transformer secondary cable should then be inserted from inside the housing up the condui t elbow. Using the two 40762 retainers supplied with the sign like a cupped washer with a slot), placing one b elow the secondary cable recep tacle (L looks like a ball), and one abov[...]

10 Maintenance and Troubleshooting WARNING Remove Power Before Attempting Any Servicin g. 10.1 General Work on electrical circuits shoul knowledge of airfield lighting circuits. Trouble elimination. It should be checked that the tried, POWER is reapplied. Then etc. Repeat this until the problem is solv ed. It is also assumed that the circuit is in [...]

CAUTION Do not over tighten hex n ut on stud retaining bridge rectif ier. 8in max. (See Figure 18) adhesive surf aces before installing. IMPORTANT When tightenin g cover screws, do not use power drivers as you may exceed the maximu m torque of DANGER When replacing p arts inside the circuit box or si gn housing, lock out series circuit po 10.2 Prob[...]

DOCUMENT 1025 REV. B Instruction Manual AGS-LED 858 LED Series Sizes 1, 2, 3, 4 and 5 8 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 an d 6.6 amps using a true RMS Am meter. L858 Power Suppl y indicator RED LEDs D4 is ON, and D7 is OFF; T[...]

DOCUMENT 1025 REV. B Instruction Manual AGS-LED 858 LED Series Sizes 1, 2, 3, 4 and 5 9 PROBLEM POSSIBLE CAUSE CORRECTIVE ACTION MODULE(s) (See Sec 10.10) (P.10) Upon applying power, sign momentarily lights and then turns off. Incorrect LED Power Suppl y Circuit Board Switch Configuration Verify/Set Power Suppl y Board Switches and jum pers are set[...]

10.3 Measuring Inp ut Curre WARNING Failure to turn off power to the sign and w ait five minutes could result in severe injury or death . Turn off power to the sign by turning off ( WARNING : W ait five minutes a fter sign power is turned off any residual high voltage stored in Power Supply multimeter set to DC Volts, v erify that the Power Supply [...]

Voltage is greater than 30- VDC, then you m ust w 30- VDC before you proceed with the next step. Open the Power Supply Box cov er. Place current clamp around one of the wires connected to the switch labeled with switch marker PWR. C onnect the current c the input current. Current should m easur current level or current step. Upon completing the mea[...]

10.6 Checking LED MODULE WARNING Failure to turn off power to the sign and w ait five minutes could result in severe injury or dea Turn off power to the sign by turning off the corresponding Constant Current Re gulator (CCR) power. ( WARNING : W ait five minutes a fter sign power is turned off any residual high voltage stored in Power Supply multim[...]

Turn off power to the sign by turning off the corresponding Constant Current Re gulator (CCR) power. ( WARNING : W ait five minutes a fter sign power is turned off any residual high voltage stored in Power Supply multimeter set to DC Volts, v erify that the Power Supply Output Voltage is (Positive lead) and TP3 (Negative Lead) as ind icated in Figu[...]

or stays lit, then the second LED MODULE LED MODULE are operating normally. Turn off main power to the sign. Wa it five minutes for the high voltage to dissipate. 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 Replace the black return cable connec[...]

Turn on main power to the sign. If LED the LED MODULE #5 and the cable from the normally. WARNING Failure to turn off power to the sign and w ait five minutes could result in severe injury or death . Turn off main power to the sign. Wa it five minutes for the high voltage to dissipa Power Supply Output Voltage mea sures less than 30 return cable co[...]

2. With your multimeter set to DC Volts, ver ify tha VDC at TP6 (Positive lead) and TP3 (Negative Lead) as indicated in Figure 22. I f the Power Supply Output Voltage is greater than 30 drops below 30- VDC before you proceed with the next step. 3. Carefully remov e the input and output cables from the failed connected to the LED MODULE MODULE is de[...]

10.11 Sign PC Board P/N 62277 The 62277 PC Board doesn ’t normally need to be cal replaced. IMPORTANT In this section, i t is assumed that the Sign PC Boa rd P/N 62277 is correctly confi gured for this particular sign (see Table 1or 2) and that the sign ligh ts continuously when m the normal mode of op eration (SW3 INSTRUCTIONS FOR C ALIBRATION O[...]

IMPORTANT Power Supply B oard must be re 1. Turn off power to the sign by turning off the corresponding Constant Current Re gulator (CCR) power. ( WARNING : W ait five minutes a fter sign power is turned off will allow any residual high vol tage WARNING Failure to turn off power to the sign and w ait five minutes could result in severe injury or de[...]

DOCUMENT 1025 REV. B Instruction Manual AGS-LED 858 LED Series Sizes 1, 2, 3, 4 and 5 19 14. Set DIP switches SW1, SW2, & SW3for the sign style, size, and num ber of modules as shown in Table 1 or 2. (For locations Fig ure 18) 15. The Power Supply Board and Heat Sink rep lacement is complete[...]

DOCU MENT 1025 REV. B Instruction M anual AGS-L ED 858 LED Ser ies Sizes 1, 2, 3, 4 and 5 20 11 Figure s and Tables F igure 1. Single module sign[...]

DOCU MENT 1025 REV. B Instruction M anual AGS-L ED 858 LED Ser ies Sizes 1, 2, 3, 4 and 5 21 Figure 2. Do uble module sign[...]

DOCU MENT 1025 REV. B Instruction M anual AGS-L ED 858 LED Ser ies Sizes 1, 2, 3, 4 and 5 22 Figure 3. Three m odule sign[...]

DOCU MENT 1025 REV. B Instruction M anual AGS-L ED 858 LED Ser ies Sizes 1, 2, 3, 4 and 5 23 Figure 4. Fo ur m odule sign[...]

DOCU MENT 1025 REV. B Instruction M anual AGS-L ED 858 LED Ser ies Sizes 1, 2, 3, 4 and 5 24 Figure 5. Dista nce Marker[...]

DOCU MENT 1025 REV. B Instruction M anual AGS-L ED 858 LED Ser ies Sizes 1, 2, 3, 4 and 5 25 Figure 6. Sign O ptions[...]

DOCU MENT 1025 REV. B Instruction M anual AGS-L ED 858 LED Ser ies Sizes 1, 2, 3, 4 and 5 26 Figure 7. H eat Sink/LED Assembly showing w iring input and output connections[...]

DOCUMENT 1025 REV. B Instruction Manual AGS-LED 858 LED Series Sizes 1, 2, 3, 4 and 5 27 Figure 8 . LED Array Wiring , One M odule Signs (Referenc e Figure 7 for LED a rray orient ations)[...]

DOCUMENT 1025 REV. B Instruction Manual AGS-LED 858 LED Series Sizes 1, 2, 3, 4 and 5 28 Figure 9 . LED Array Wiring , Two Mo dule Signs (Referenc e Figure 7 for LED a rray orient ations)[...]

DOCUMENT 1025 REV. B Instruction Manual AGS-LED 858 LED Series Sizes 1, 2, 3, 4 and 5 29 Figure 1 0. LED Arra y Wiring, Three M odule Signs (Referenc e Figure 7 for LED a rray orient ations)[...]

DOCU MENT 1025 REV. B Instruction M anual AGS-L ED 858 LED Ser ies Sizes 1, 2, 3, 4 and 5 30 Figure 10. LED Array Wiring, Four Mo dule Signs (Reference Figure 7 for LED array orientat ions)[...]

DOCU MENT 1025 REV. B Instruction M anual AGS-L ED 858 LED Ser ies Sizes 1, 2, 3, 4 and 5 31 Figure 11. LED Array Wiring, Distance Mar ker (Reference Figure 7 for LED array orientat ions)[...]

DOCU MENT 1025 REV. B Instruction M anual AGS-L ED 858 LED Ser ies Sizes 1, 2, 3, 4 and 5 32 Figure 12. Recomm ended T ransformer Housing Locatio n &Concrete Foundation/Pad Det ails[...]

DOCU MENT 1025 REV. B Instruction M anual AGS-L ED 858 LED Ser ies Sizes 1, 2, 3, 4 and 5 33 Figure 12a. Exp anded left sect ion of Figure 12[...]

DOCU MENT 1025 REV. B Instruction M anual AGS-L ED 858 LED Ser ies Sizes 1, 2, 3, 4 and 5 34 Figure 12b. Expanded right section of Figure 1 2[...]

DOCU MENT 1025 REV. B Instruction M anual AGS-L ED 858 LED Ser ies Sizes 1, 2, 3, 4 and 5 35 Figure 12c. Expanded top section of Fig ure 12[...]

DOCU MENT 1025 REV. B Instruction M anual AGS-L ED 858 LED Ser ies Sizes 1, 2, 3, 4 and 5 36 Figure 13. Con crete Foundation /Pad con figurations, S ize 1[...]

DOCU MENT 1025 REV. B Instruction M anual AGS-L ED 858 LED Ser ies Sizes 1, 2, 3, 4 and 5 37 Figure 14. Concrete Foundation/Pad configura tions, Size 2[...]

DOCU MENT 1025 REV. B Instruction M anual AGS-L ED 858 LED Ser ies Sizes 1, 2, 3, 4 and 5 38 Figure 15. Concrete Foundation/Pad configura tions: Two 4-Module Signs, Side by Si de NOTE, IF 3 SIGNS ARE US ED IN AN ARRAY, M AKE SEPARATION DIS TANCE 12 INCHES TO ALLOW CIRCUIT CARD B OX DOOR TO OPEN IN THIS SPACE W HEN ANOTHER CIRCUIT CARD BOX IS M OUNT[...]

DOCU MENT 1025 REV. B Instruction M anual AGS-L ED 858 LED Ser ies Sizes 1, 2, 3, 4 and 5 39 Figure 16. Sizes 3, & 5 Concrete Foundation/Pa d Configurations[...]

DOCU MENT 1025 REV. B Instruction M anual AGS-L ED 858 LED Ser ies Sizes 1, 2, 3, 4 and 5 40 Figure 17. Siz e 4 Concre te Found ation/Pad Config urations[...]

DOCU MENT 1025 REV. B Instruction M anual AGS-L ED 858 LED Ser ies Sizes 1, 2, 3, 4 and 5 41 Figure 18. Power Supply Box[...]

DOCU MENT 1025 REV. B Instruction M anual AGS-L ED 858 LED Ser ies Sizes 1, 2, 3, 4 and 5 42 Figure 21. Power Supply Wiring Diagra m[...]

Figure 22. Checking the Power Supply Output Vo DOCU MENT 1025 Instruction M anual AGS-L ED 858 LED Ser ies Sizes 1, 2, 3, 4 and 5 43 Checking the Power Supply Output Vo ltage After Turn-Off. DOCU MENT 1025 REV. B[...]

DOCUMENT 1025 REV. B Instruction Manual AGS-LED 858 LED Series Sizes 1, 2, 3, 4 and 5 44 L858 AGS Output Current Setting Input voltage configuration Output LED Configuration Calibration Mode/ Normal Operation Ferro CCR Size #Mods SW1- 4 SW1- 5 SW1- 6 SW2- 1 SW2- 2 SW2- 3 SW2- 4 SW2- 5 SW2- 6 SW3-1 JP1 JP2 1 1 x ON OFF ON ON O N ON ON ON ON/OFF Clos[...]

DOCUMENT 1025 REV. B Instruction Manual AGS-LED 858 LED Series Sizes 1, 2, 3, 4 and 5 45 L858 AGS Output Current Setting Input voltage configuration Output LED Configuration Calibration Mode/ Normal Operation Series CCR Size #Mods SW1- 4 SW1- 5 SW1- 6 SW2- 1 SW2- 2 SW2- 3 SW2- 4 SW2- 5 SW2- 6 SW3-1 JP1 JP2 1 1 x ON OFF ON ON O N ON ON ON ON/OFF Clo[...]

DOCU MENT 1025 REV. B Instruction M anual AGS-L ED 858 LED Ser ies Sizes 1, 2, 3, 4 and 5 46 Style Sign Size # Modu les CCR type CCHALP Sign VA (Primary Isolation Xfrmr@ 6.6A) CCHALP Sign Watts (Primary Isolation Xfrmr @ 6.6A) CCHALP Power Factor (Primary Isolation Xfrmr) CCHALP Sign VA (Seconda ry Isolation Xfrmr@ 6.6A) CCHALP Sign Watts (Seconda [...]

DOCU MENT 1025 REV. B Instruction M anual AGS-L ED 858 LED Ser ies Sizes 1, 2, 3, 4 and 5 47 Style Sign Size # Modules CCR type CCHALP Sign VA (Primary Isolation Xfrmr@ 6.6A) CCHALP Sign Watts (Primary Isolation Xfrmr @ 6.6A) CCHALP Power Factor (Primary Isolation Xfrmr) CCHALP Sign VA (Seconda ry Isolation Xfrmr@ 6.6A) CCHALP Sign Watts (Seconda r[...]

DOCU MENT 1025 REV. B Instruction M anual AGS-L ED 858 LED Ser ies Sizes 1, 2, 3, 4 and 5 48 Style Sign Size # Modules CCR type CCHALP Sign VA (Primary Isolation Xfrmr@ 5.5A) CCHALP Sign Watts (Primary Isolation Xfrmr @5.5A) CCHALP Power Factor (Primary Isolation Xfrmr) CCHALP Sign VA (Seconda ry Isolation Xfrmr@ 5.5A) CCHALP Sign Watts (Seconda ry[...]

DOCU MENT 1025 REV. B Instruction M anual AGS-L ED 858 LED Ser ies Sizes 1, 2, 3, 4 and 5 49 Style Sign Size # Modules CCR type Sign VA (Primary Isolation Xfrmr@ 6.6A) Sign Watts (Primary Isolation Xfrmr @ 6.6A) Power Factor (Primary Isolation Xfrmr) Sign VA (Seconda r y Isolation Xfrmr@ 6.6A) Sign Watts (Seconda r y Isolation Xfrmr @ 6.6A) Power F[...]

DOCU MENT 1025 REV. B Instruction M anual AGS-L ED 858 LED Ser ies Sizes 1, 2, 3, 4 and 5 50 Style Sign Size # Modules CCR type Sign VA (Primary Isolation Xfrmr@ 6.6A) Sign Watts (Primary Isolation Xfrmr @ 6.6A) Power Factor (Primary Isolation Xfrmr) Sign VA (Seconda r y Isolation Xfrmr@ 6.6A) Sign Watts (Seconda r y Isolation Xfrmr @ 6.6A) Power F[...]

DOCU MENT 1025 REV. B Instruction M anual AGS-L ED 858 LED Ser ies Sizes 1, 2, 3, 4 and 5 51 Style Sign Size # Modules CCR type Sign VA (Primary Isolation Xfrmr@ 5.5A) Sign Watts (Primary Isolation Xfrmr @ 5.5A) Power Factor (Primary Isolation Xfrmr) Sign VA (Seconda r y Isolation Xfrmr@ 5.5A) Sign Watts (Seconda r y Isolation Xfrmr @ 5.5A) Power F[...]

DOCUMENT 1025 REV. B Instruction Manual AGS-LED 858 LED Series Sizes 1, 2, 3, 4 and 5 52 Regulator Setting Current Range (A, RMS) B10 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 re gulator currents Regulator Setting Current Range (A, RMS) B1 2.7-2.9(2.80 nominal) B2 3.3-3.5(3.4 nominal)[...]

DOCUMENT 1025 REV. B Instruction Manual AGS-LED 858 LED Series Sizes 1, 2, 3, 4 and 5 53 D4 (Red) D7 (Red) D11 (Green) D29 (Green) Fault ON ON ON ON Output open c ircuit ON OFF O N ON Output Volta ge is less than or equal to 75% of Ca librated Output Volta ge or Outpu t Voltage is greater than or equal to 125% of Ca librated O utput Voltage. OFF ON[...]

DOCUMENT 1025 REV. B Instruction Manual AGS-LED 858 LED Series Sizes 1, 2, 3, 4 and 5 54 DESCRIPTION PART NUMBER USED ON Frangible Coupling 62245-1 62245-2 62245-3 62245-4 Size 1 Size 2 Size 3 & 5 Size 4 Power Supply PCB (locate d inside circuit box) 62277 All Sizes Heatsink/LED Assembly (located inside sign housing ) 62288 All Sizes Filter PCB[...]

DOCUMENT 1025 REV. B Instruction Manual AGS-LED 858 LED Series Sizes 1, 2, 3, 4 and 5 55 Sign Size/#Mod Force in Newtons Force in Lbs Size 1, 1module 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, 1module 4,773 1,073 Size 2, 2modules 9,587 2,155 Size 2, 3modules 14,442 3,247 Size 2, 4module[...]