spare parts list - flight light€¢ return a failed fitting to alstom power conversion ltd,...

abcd

Issue : 4 Date : Dec. 2003Fitting : ZA280 & ZA281 200mm (8”) High Intensity, Inset Taxiway

Centreline & Stopbar. Includes IEC body style. (ZA280 i &ZA281 i)

Author : ALL

Ref : L:\ Avd\IMM CURRENT\immza280_281_280 i-4 Page : 1 of 24©2003 ALSTOM Ltd ALSTOM Power Conversion Ltd

AIRPORT EQUIPMENT

INSTALLATION AND MAINTENANCE INSTRUCTIONS

And

SPARE PARTS LIST

for the

200 MM (8”) HIGH INTENSITY, INSET TAXIWAY CENTRELINE &STOPBAR FITTINGS

TYPES ZA280, ZA281, (PSA BODY STYLE)

ZA280 (I) & ZA281 (I) (IEC BODY STYLE)

abcd



Author : ALL


CONTENTS

ISSUE RECORD, SAFETY ADVICE NOTICE, TOOLS & CONSUMABLES .............3

ZA280, ZA281, ZA280 IEC & ZA281 IEC 200MM (8”) HIGH INTENSITY, INSETTAXIWAY CENTRELINE & STOPBAR FITTINGS..............................................4

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

2. PREPARE SITE FOR INSTALLATION OF ZM109, ZM181 OR ZM203 (I) SEATINGPOTS .......................................................................................................................5

3. INSTALL INTO ZM109, ZM181 OR ZM203 (I) SEATING POTS, OR ADAPTOR ...5

4. REMOVE A FITTNG FROM A SEATING POT...........................................................6

5. ON SITE MAINTENANCE........................................................................................7

6. WORKSHOP MAINTENANCE .................................................................................76.1 PREPARE AND CLEAN A FITTING ...............................................................76.2 DIS-ASSEMBLE BODY ASSEMBLY FROM BOTTOM COVER ASSEMBLY .....86.3 BODY ASSEMBLY ........................................................................................96.4 BOTTOM COVER ASSEMBLY....................................................................166.5 RE-ASSEMBLE BOTTOM COVER AND BODY ASSEMBLIES ......................17

7. SPARES ..................................................................................................................187.1 SPARE PARTS ORDERING..........................................................................18

SPARE PARTS SCHEDULE ..........................................................................187.2 FITTING OPTION ORDERING CODES.....................................................21

APPENDIX 'A' - SAFETY ADVICE...............................................................23

1. COMPLIANCE WITH INSTRUCTIONS IN THIS MANUAL .....................................23

2. GUIDANCE NOTES FOR USERS ON THE SAFETY OF PERSONNEL ....................23

3. INSTALLATION, OPERATION AND MAINTENANCE............................................23

4. VOLTAGES GREATER THAN 50V A.C./120V D.C................................................24

5. APPARATUS SUPPLIED AS LOOSE ITEMS, CHASSIS ETC......................................24

6. ACCESS TO THE APPARATUS DESCRIBED IN THIS MANUAL ..............................24

abcd



Author : ALL


ISSUE RECORD

Issue Status

ISSUE: 3 4

DATE: OCT. 2002 Dec. 2003

AUTHOR: A L LANDLESS A L Landless

AUTHORISED: P M HUMBER P M Humber

SAFETY ADVICE NOTICE

Please ensure that personnel are made aware of all safety aspects. Appendix ‘A’ containssafety advice. This appendix can be copied and used to record authorised personnel.

TOOLS AND CONSUMABLES

• 11mm A/F socket

• 17mm A/F socket

• Ratchet Spanner

• Torque wrench

• Fitting extractor tool. Alstom SLC 21226

• Mild detergent

• Stiff bristle paint brush

• Contact cleaning fluid in an aerosol

• Lint free cloth

• Loctite grade 222

• Compressed air system capable of 10 PSI minimum

• 1/8 th BSP adaptor for compressed air system

• Tank of clean water.

abcd



Author : ALL


ZA280, ZA281, ZA280 (I) & ZA281 (I), 200MM (8”), HIGHINTENSITY, INSET TAXIWAY CENTRELINE & STOPBAR FITTINGS

1. INTRODUCTION

The ZA280 and ZA281, high intensity, taxiway centreline and stop-bar fitting has beendesigned to meet ICAO requirements for Categories I, II and III, all weather operationlighting systems.

(Note: For information on switchable stopbar fittings ZA280 S, see manualimmza280s).

Two body styles are available, the original standard is the PSA style that is generallyadopted by UK airports.. Also available is the IEC body style which complies with IEC61827.

Fittings are normally supplied complete with one long life, low energy reflector lampand single 'B' type (L823) plug lead.

an internal lamp by-pass device is available as an option, in each fitting.

The fitting is lightweight and robust due to its predominantly aluminium alloyconstruction which also gives good protection against corrosion. The glass prisms orcast aluminium blanks are accurately located in the main body casting, secured by aretaining clamp without the need for sealing compounds.

The optical system employed is completely free of adjustment on installation and inservice, thereby considerably simplifying installation and maintenance procedures.

PSA body style fittings are suitable for installation into 200mm (8”) ZM109 or ZM181seating pots. IEC body style fittings are installed into ZM203 i (IEC) seating pots.Dry or wet versions of each of the above seating pots are available and suppliedseparately to order.

Alternatively a range of PSA and FAA adaptors are available for mounting the fittinginto 12" and 15.5" diameter seating pots.

It is important when ordering or installing the fitting that the correct seating pot oradaptor is available. Alstom can advise on the selection.

abcd



Author : ALL


2. PREPARE SITE FOR INSTALLATION OF ZM109, ZM181 OR ZM203IEC SEATING POT

Prior to the installation of the seating pot, the runway pavement surface will have beencorrectly prepared. Installation and Maintenance Manuals, imm-zm-seating-pots-3 and imm-zm109-2-stud seating-pot-1, contain detailed procedures forinstallation. These manuals can be obtained from Alstom Airports.

• Align the seating pot level so that the two fixing studs locate the fitting in thecorrect orientation to provide the required beam angle(s) relative to the runwaycentreline.

Important Note:

When an Alstom ZA280, ZA281, ZA280 i or ZA281i Taxiway Centreline or Edge fittingis to be mounted into an Alstom ZM181 Seating Pot.

• Install the seating pot into the taxiway in the orientation shown in Fig.1 below.(i.e. an axis taken through the holding down studs is at 60° to the TaxiwayCentreline).

Fig. 1.

3. INSTALL INTO ZM109, ZM181 OR ZM203 (I) SEATING POT ORADAPTOR

When the seating pot and transformer secondary socket lead are installed inaccordance with section 2.

• Check that the light unit is of the correct type/option for the relevant position onthe runway, in accordance with a site plan.

• Release & remove the two M10 holding down nuts and washers in the seating pot.

60°

CENTRELINE

STUDSHOLDING DOWN

RUNWAY/TAXIWAY

30°

abcd



Author : ALL


• Check that the studs themselves are secure in the seating pot and do not projectmore than 2mm above the rim of the pot.

• Clean any debris from the seating pot flange. Check that there are no internalprotrusions or casting faults on the seating surface.

• Check and clean the underside seating surface of the light fitting for debris, thatcould prevent correct beam alignment.

• Wipe clean the moulded plug and socket connector mating surfaces. Ensure thatthe female connector contacts are free from debris. When necessary, Flush outwith a suitable contact cleaner aerosol.

• Connect the secondary lead plug to the transformer secondary lead socket inaccordance with the site layout information. Take care to observe correct pinpolarisation.

• When the installation is ‘Dry’. Assemble the seating gasket to the seatingpot/adaptor ring using the studs for alignment and ensure it lays flat.

• Install the light unit into the seating pot, oriented correctly to the site plan. Use theextractor tool recommended for this purpose ALSTOM type SLC21226. Take carenot to trap any leads between mating surfaces.

DO NOT USE THE EXTRACTOR TOOL TO CARRY THE FITTING TO OR FROM THESEATING POT.

• Re-assemble both M10 crinkle washers and nuts to secure the light unit in theseating pot. Tighten each nut progressively, until a torque of 40Nm (29lbf.ft) isachieved.

• RE-TIGHTEN THE M10 HOLDING DOWN NUTS TO THE 35Nm (25 lbf.ft)TORQUE, 1-2 WEEKS AFTER INITIAL INSTALLATION, THEN PERIODICALLY ATPLANNED MAINTENANCE INTERVALS.

4. MAINTENANCE

4.1 REMOVE A FITTING FROM A SEATING POT

• Release & remove the M10 nuts and washers and put safely aside for use when re-assembling a ‘new’ taxiway light. Discard any damaged items and replace withnew items to the same specification.

• Lift the light fitting out of the seating pot using the extractor tool ALSTOM typeSLC21226.

WARNING DO NOT USE THE EXTRACTOR TOOL TO CARRY THE FITTING TO ORFROM THE SEATING POT.

abcd



Author : ALL


• For installation of the replacement fitting see section 3.

5. ON SITE MAINTENANCE

On-site maintenance will normally be restricted to cleaning of prisms, and inspectionfor damage to the prisms and their seals.

• Clean dirt and oil from the exposed surfaces using a suitable detergent appliedwith a stiff bristle paint brush. DO NOT use abrasives, or detergents with highalkalinity, on the prism surfaces.

• Replace a failed fitting with a new or refurbished fitting of an identical type.

• Re-lamp the fitting in a workshop environment.

When a fitting fails to re-energise.

• Return a failed fitting to ALSTOM Power Conversion Ltd, Airports Division forevaluation & possible overhaul.

6. WORKSHOP MAINTENANCE

The main tool required for dis-assembling the fitting is a 5mm A/F Allen key.

When the light fitting is dis-assembled, either for lamp changing or at plannedmaintenance periods.

• Carry out a comprehensive inspection. (This can prevent future failures in serviceand allows efficient spares holding to be defined).

• Generate local site documentation and record the status of fittings and majorcomponents kept.

• Only use approved replacement components. DO NOT attempt to repair anycomponents

• Re-assemble the fitting in the reverse order to dis-assembly, with the addition ofLoctite 222 Screwlock to be applied to all M6 screw thread, to ensure correcttorque is maintained after tightening.

6.1 PREPARE AND CLEAN A FITTING

In order to avoid internal contamination when the fitting is dis-mantled.

• Locate a fitting in a ‘dirty’ area.

• Clean any dirt or oil from its external surfaces prior to opening the light fitting forinspection and maintenance reasons. Use a suitable household detergent appliedwith a stiff bristle paint brush.

abcd



Author : ALL


• Clean the prisms external optical surfaces. DO NOT use abrasive substances ordetergents with high alkalinity.

• Wash in clean water and remove all traces of moisture from the light units exteriorsurfaces and dry with a lint free cloth or tissue!. DO NOT use compressed airdirectly onto the prism surfaces.

• Locate a fitting in a ‘clean’ area.

6.2 DIS-ASSEMBLE BODY ASSEMBLY FROM BOTTOM COVER ASSEMBLY

Carry out the following work in a workshop environment that is free from dust,vapours and other atmospheric pollutants likely to cause contamination of prism, lampand reflector surfaces.

Fig. 2. Fitting with body inversed and bottom cover removed.

• Place the light fitting on a clean, flat, work surface with its bottom coveruppermost.

• Release and remove the two M6 cap head screws attaching the bottom cover tothe body assembly. Place the screws and crinkle washers aside for re-assembly.Discard and replace any damaged items.

• Carefully remove the bottom cover (9) and disconnect lamp(s) from the plug leadterminations.

• Place bottom cover onto the work surface with the top, (bell mouth) uppermost.

abcd



Author : ALL


6.3 BODY ASSEMBLY

6.3.1 Removal of Prism

Fig. 3. Prism clamp removed to show gaskets.

• Release and remove the four M6 socket head screws to release the prism clampand gasket.

• Check the prisms internal and external surfaces, for contamination, physicaldamage, chips and cracks.

• Check prisms gaskets for obvious signs of physical damage or for evidence ofwater ingress.

When removing a prism that is intact, place the body assembly on some cushioningmaterial such as bubble wrap and wear protective gloves.

Fig. 4. Body correct way up and prism being pushed out by hand.

abcd



Author : ALL


• Place both thumbs on the outer surface of the prism and press the prism/gasketassembly back through into the lamp cavity in the same direction as the lightchannel, until it is free of the casting.

• Remove prism gasket and check for damage and or signs of deterioration.Replace when necessary.

6.3.2 Replacement of Prism

DO NOT OVER TIGHTEN THE PRISM RETAINING CLAMP SCREWS AS THIS CANDAMAGE THE PRISM.

WHEN HANDLING A COLOURED PRISM, DO NOT SCRATCH OR OTHERWISEDAMAGE THE DICHROIC COATING.

• Lay the body casting, upside down, on a flat surface. (Step 1)

Step1.

• Prepare prism gasket for insertion into the lens cavity,by lightly lubricating thecorners of the gasket with P80 rubber lubrication emulsion or equivalent. (Step2)

Step 2.

abcd



Author : ALL


Step 3.

• Insert the prism gasket and hold in place at the two corners with thumb and firstfinger. (Step 3).

Step 4.

• Gently insert the prism with the other hand. (Step 4)

abcd



Author : ALL


Step 5.

• Ensure that prism does not snag on the wall of the gasket. Carefully push theprism down into the cavity. Ensure that gasket is not pushed out of the windowarea and ensure that the gasket is equally spaced around the prism. (Step 5)

Step 6.

• Repeat steps 2 to 5 for the second prism resulting in Step 6.

abcd



Author : ALL


Step 7.

• Re-assemble the prism retaining clamp and the prism clamp gasket. Tighten thefour prism retaining clamp screws progressively to a torque of 9.04 Nm (80 lbsfins). (Step 7).

6.3.3 Bottom Cover Gasket

Fig. 5. Body with gasket in place.

The bottom cover gasket is located in a recess in the prism body casting and is subjectto ageing.

• Check for evidence of water contamination of internal components and castingsurfaces.

• Remove the bottom cover gasket from its recess in the body casting.

abcd



Author : ALL


• Clean the gasket and examine carefully.

When it is in good condition.

• Place the gasket on one side for re-use.

When it shows evidence of deterioration or damage.

• Replace the gasket prior to re-assembly.

• Clean the bottom cover gasket sealing face, to ensure the gasket forms aneffective pressure seal on re-assembly.

6.3.4 Remove & Replace Lamp, Lamp Gasket and Colour Filter (When Fitted)

Fig. 6. Remove a lamp from the clamp.

DO NOT touch or otherwise contaminate the bulb of the lamp or reflector surface.

• Push the lamp retaining spring fingers away from the lamp reflector using twofingers of one hand. With the other hand pull the lamp back until the reflector rimis clear of the prism clamp enabling the lamp to be lifted clear.

Alternatively

• Slacken off the two M6 cap head screws retaining the lampholder and remove thelamp.

When a colour filter is fitted and the prism clamp is in place,

abcd



Author : ALL


• Remove the lamp gasket by carefully pinching the rim of the gasket usingtweezers/long nose pliers.

When the prism clamp has been removed from the body casting.

• Remove the lamp gasket and filter by pushing out from the prism side of the prismclamp.

• Re-assemble in reverse of the dis-assembly procedure. Ensure that the lampgasket is seated correctly in the prism clamp before locating the lamp.

6.3.5 Lamp Retaining Spring

Fig. 7. Lamp retaining spring in good condition. (i.e. 3mm gap betweenclamp and lamp reataining at the arrow).

• Check the lamp retaining spring for damage or loss of tension. (It is importantthat the lamp is held securely in position).

When necessary, replace the lamp retaining spring

• Release and remove the two M6 cap head screws.

• Remove and replace the lamp retaining spring with a ‘new’ approved component.

abcd



Author : ALL


6.4 BOTTOM COVER ASSEMBLY

6.4.1 Plug Lead and Cable Gland

Fig. 8. Cable and gland in bottom cover.

• Check the cable outer sheath for abrasion, nicks, cuts and cracks. Ensure that thecable is in good condition where the cable moulds into the connector housing andenters the bottom cover cable gland.

• Check for arcing or physical damage to the cable plug pins.

• Check the cable tail receptacles for looseness, evidence of arcing and overheatingof the cable cores.

When there is evidence of water contamination within the fitting, this can indicate apermeable cable or faulty gland seal, therefore replace a plug lead.

• Unscrew the cable gland and withdraw plug lead with the gland assembly fromthe bottom cover.

• Check and clean the cable gland entry hole.

ALWAYS assemble a complete ‘new’ gland assembly and lead to ensure a leak freeassembly. DO NOT repair an ‘old’ plug lead, or seal.

• Thread the cable gland assembly onto the end of the plug lead cable. Positionthe gland at 80mm from the free end. Assemble the components in the orderof gland nut, skid washer and compression bush.

• Insert the lead tails through the cable gland entry hole in the bottom cover until theouter sheath projects approximately 5mm into the inner chamber of the bottomcover.

• Tighten the gland nut into cable entry hole to create a water-tight seal. (The sealwill be checked at a later stage by conducting a compressed air pressure test).

abcd



Author : ALL


6.5 RE-ASSEMBLE BOTTOM COVER AND BODY ASSEMBLIES

Fig. 9. Bottom cover being offered up to body assembly.

• Place the body assembly, flat onto a work surface with the underside uppermost.

• Locate the bottom cover gasket correctly into the body casting recess.

• Locate the insulating sleeves onto the lamp cables.

• Re-connect the lamp terminals to plug lead receptacles. Ensure that electricalconnections are tight.

• Re-position the PTFE insulation sleeving, to ensure that no electrical shortingoccurs.

• Re-assemble the bottom cover to the body assembly.

• Re-assemble the M6 cap head screws and crinkle washers, to secure the bottomcover to the body assembly. Torque tighten progressively to 6.8Nm, (60 lbf ins).

• Pressure test the assembled unit for leaks by attaching a compressed air line to thetest plug hole, using a 1/8" BSP adapter.

• Apply an air pressure of 350 mbar (approx. 5 p.s.i.) to the fitting and immerse in atank of clean water. Check for the emission of air bubbles from the bottomcover joint, prism seals, and the cable gland.

When a satisfactory test has been completed.

• Re-assemble the pressure test plug. DO NOT OVER TIGHTEN TEST PLUG.

A torque value of 3.5Nm (30 lbs f ins) must not be exceeded, otherwise the nylonthread of the pressure test plug will strip.

abcd



Author : ALL


7. SPARES

7.1 SPARE PARTS ORDERING

To order spare PARTS refer to the parts schedule and state.

Fitting typeItem descriptionPart no.Stock List Code

SPARE PARTS SCHEDULE

Key to Abbreviations:

ST STL = Stainless Steel LG = LongHex = Hexagonal A/R = As requiredI/D = Inside Diameter ALT = AlternativeItemNo. Part No Stock

ListCode

Description Qty perFitting

1 29037 040102 Blank for Prism Aperture 1

ALT 29016 Z 016072 Clear Prism (Wide Beam) 1 or 2

ALT 29016 X 016078 Clear Prism (Narrow Beam) 1 or 2

2 29030 A/R 019155 Full Red Filter 1

ALT 29030 A/G 019156 Full Green Filter 1

ALT 29030 A/Y 019157 Full Yellow Filter 1

ALT 29030 B/R 019158 Half Red Filter 1

ALT 29030 B/G 019159 Half Green Filter 1

ALT 29030 B/Y 019160 Half Yellow Filter 1

2A 29031 032051 Half Filter Divider 1

3A 033094 IEC Body ‘O’ Ring Seal 1

4 29018 A 021268 Prism Clamp, Straight (ZA280) 1

ALT 29018 B 021269 Prism Clamp, Curved (ZA281) 1

5 29020 033071 Prism Gasket 2

6 29021 A 033072 Prism Clamp Gasket – Straight (ZA280) 1

ALT 29021 B 033074 Prism Clamp Gasket – Curved (ZA281) 1

abcd



Author : ALL


ItemNo. Part No Stock

ListCode

Description Qty perFitting

7 28877 033064 Lamp Gasket 1

8 28825 032039 Lamp Retaining Spring 1

9 008065 Reflector Lamp 49 Watt 6.6 Amp 1

ALT 008072 Reflector Lamp 105 Watt 6.6 Amp (RedOnly)

1

ALT 008074 Reflector Lamp 45 Watt 6.6A 1

10 M6 x 20 long St Stl Socket Head Screw 4

11 M6 x 25 long St.Stl Socket Head Screw 2

12 M6 x 8 long St.Stl Socket Head Screw 4

13 M6 Crinkle Washer 8

21 29023 B 033080 Bottom Cover Gasket 1

22 10453 A 013001 Lead ‘B’ Type 1

ALT 29035 3 Pin Lead with Earth 1

23 ELKAY Gland Set M20 1

24 28934 021256 Pressure Test Plug 1

27752 019151 PTFE Sleeving 450 long x 6.81 I/D 2

Optional Bypass Assembly

28848 ??? Bypass Block Assy P.L. 1

abcd



Author : ALL


Fig. 9. Exploded view of ZA280 series fitting.

abcd



Author : ALL


7.2 FITTING OPTION ORDERING CODES

To order spare FITTINGS identify those required by using the following orderingcode:

abcd



Author : ALL


Fig. 10. Two body styles used. The PSA style is designated ZA280 & ZA281.The IEC style is designated ZA280 i & ZA281 i.

abcd



Author : ALL


APPENDIX ‘A’ - SAFETY ADVICE

1. COMPLIANCE WITH INSTRUCTIONS IN THIS MANUAL

The purchaser/user is advised to comply with the instructions and information in thismanual and ensure that all personnel to be associated with the apparatus under thiscontract are made familiar with the information contained herein.

2. GUIDANCE NOTES FOR USERS ON THE SAFETY OF PERSONNEL

Every employer shall ensure that his employees are informed, trained and supervisedand use a safe system of work to ensure their safety. He is advised to comply with theinformation provided, to maintain the plant in a safe condition.

Electrically skilled personnel may have to gain access to apparatus that is notcompletely isolated. The burden of responsibility, for the safety of such personnelcarrying out the work, rests on those under whose authority they act.

3. INSTALLATION, OPERATION AND MAINTENANCE

The purchaser/user is advised to ensure that each piece of apparatus supplied to thepurchaser's order is correctly installed, in a suitable location, by technically qualifiedand competent persons experienced in the class of work involved. The rules forensuring the safety of personnel can be summarised as follows:-

During normal use, ensure that plant operators:-

l are fully conversant with all controls, particularly those for emergency shutdown,

l comply with safety warning notices and keep all enclosures shut,

l are trained to recognise signs of mal-operation and know what action to takein the event of trouble or difficulty.

During Maintenance, Testing etc., ensure that only suitably skilled persons arepermitted to carry out work and that they:-

l comply with user's safe system of work and safe working procedures,

l isolate the apparatus completely, where possible, before opening enclosuresand starting work,

l are conversant with the information provided particularly on measures relatingto their safety,

l recognise the hazards which can arise when working on live apparatus andtake all the necessary precautions,

l comply with all local safety regulations.

abcd



Author : ALL


4. VOLTAGES GREATER THAN 50V A.C./120V D.C.

The purchaser/user is advised to ensure that apparatus operating on a voltage greaterthan 50V a.c./120V d.c. is isolated and made safe before any work is carried outupon it.

5. APPARATUS SUPPLIED AS LOOSE ITEMS, CHASSIS ETC.

The purchaser/user responsible for installing such apparatus is advised that, whenlive, it could constitute a safety hazard and relevant safety procedures are necessary.

6. ACCESS TO THE APPARATUS DESCRIBED IN THIS MANUAL

It is the purchaser's/user's responsibility to ensure that all personnel obtaining access tothe apparatus are competent and work in accordance with the user's safe system ofwork.

Record of Personnel made aware of Safety Advice.

Position/Job Title: ………………………………………………….

Signature: ………………………………………………….

Date: ………………………………………………….

spare parts list - flight light€¢ return a failed fitting to alstom power conversion ltd,...

Documents