Instruction Manual Edition 1.4 AM.11.
AM.11.100e edition 1.4 Record of Change AM.11.100e Revision Description Editor Checked Date - Draft 1 - FTO version for TLOF - WL - MR 15/05 1.1 Safety instructions, warranty, procedures to unlock and fasten screws, screw references, Loctite types, tightening torques, adapter ring BUG TP, KC, VDV, VI 4/09 1.2 Spare parts, limitation of the scope to TLOF application BUG RAS 05/09 1.3 Rebranding EV 1.
AM.11.100e edition 1.4 Safety Instructions Safety precautions This section contains general safety instructions for using your ADB equipment. Some safety instructions may not apply to the equipment in this manual. Task- and equipment-specific warnings are included in other sections of this manual where appropriate. Note all warnings and follow all instructions carefully. Failure to do so may result in personal injury, death, or property damage.
AM.11.100e edition 1.4 Safety Instructions, continued Safety Symbols Become familiar with the safety symbols presented in this section. These symbols will alert you to safety hazards and conditions that may result in personal injury, death, or property and equipment damage. WARNING 1 : Failure to observe this warning may result in personal injury, death, or equipment damage. WARNING 2 : Risk of electrical shock. Failure to observe this warning may result in personal injury, death, or equipment damage.
AM.11.100e edition 1.4 Safety Instructions, continued Intended Use Use of this equipment in ways other than described in the catalog leaflet and this manual may result in personal injury, death, or property and equipment damage. Use this equipment only as described in this manual. ADB cannot be responsible for injuries or damages resulting from non-standard, unintended applications of its equipment. This equipment is designed and intended only for the purpose described in this manual.
AM.11.100e edition 1.4 Safety Instructions, continued Installation Read the installation section of all system component manuals before installing your equipment. A thorough understanding of system components and their requirements will help you install the system safely and efficiently. Failure to follow these safety procedures can result in personal injury or death. • Allow only qualified personnel to install ADB and auxiliary equipment. Use only approved equipment.
AM.11.100e edition 1.4 Safety Instructions, continued Operation Only qualified personnel, physically capable of operating the equipment and with no impairments in their judgment or reaction times, should operate this equipment. Read all system component manuals before operating this equipment. A thorough understanding of system components and their operation will help you operate the system safely and efficiently.
AM.11.100e edition 1.4 Safety Instructions, continued Action in the Event of a System or Component Malfunction • • Maintenance and Repair Do not operate a system that contains malfunctioning components. If a component malfunctions, turn the system OFF immediately. Disconnect and lock out electrical power. Allow only qualified personnel to make repairs. Repair or replace the malfunctioning component according to instructions provided in its manual.
AM.11.100e edition 1.4 Use Restriction Notice, Warranty and Disclaimers Use restriction notice This Instruction Manual is the property of ADB 585, Leuvensesteenweg B-1930 Zaventem - Belgium Tel. 32 2 722 17 11 Fax 32 2 722 17 64 E-mail: info.adb@adb-air.com Internet: http://www.adb-air.
AM.11.100e edition 1.4 Information about this Manual Chapter overview Each chapter starts with an overview of the topics of that chapter. Using icons Additionally to safety symbols, icons are used to attract the attention of the reader to specific information. The meaning of each icon is described in the table below: Icon Type of information Description Note A ‘note’ provides information that is not indispensable, but may nevertheless be valuable to the reader, such as hints and tips.
AM.11.100e edition 1.4 Table of Contents Safety Instructions ..............................................................................................................................2 Use Restriction Notice, Warranty and Disclaimers .............................................................................8 Information about this Manual.............................................................................................................9 Chapter 1: Product Information ......................
AM.11.100e edition 1.4 Chapter 1: Product Information Overview Introduction In this chapter you will find all the information about the shipment and the identification of the ADB FTO inset lights for heliports. Contents This chapter contains the following topics.
AM.11.100e edition 1.4 General information FTO Inset Lights The ADB FTO inset lights are light fixtures providing optimum visual guidance with minimal maintenance, low life-cycle costs and maximum reliability. It is designed to withstand the high impact and roll-over loads imposed by today's widebody aircraft during taxiing operations while remaining waterproof and serviceable.
AM.11.100e edition 1.4 Equipment data Equipment supplied Each unit is supplied completely assembled, tested and sealed, ready for installation. The electrical connection is made via a cable assembly with FAA L-823 style 2-pole plug. A labyrinth gasket is included. The FTO light for 230V AC parallel supply is always supplied mounted on a shallow base. (with dedicated extension housing the transformer).
AM.11.100e edition 1.4 Chapter 2: Mounting and connection Overview Introduction This chapter instructs you how to connect and mount the TLOF inset light on its base or adapter ring. It includes important safety notifications regarding the choice and use of fixing hardware. It is supposed that the base supporting the TLOF inset light, the adapter ring (if needed) and the secondary connector are already installed.
AM.11.100e edition 1.4 Important safety notifications Fixing hardware Various types of fixing hardware can be used for the fixation of the light on its base or adapter ring (e.g. screws or studs and nuts). Moreover, bases and adapter rings may be supplied with threaded holes according either to ISO metric or UNC standards.
AM.11.100e edition 1.4 General recommendations Receiving, storage and unpacking Upon receipt of goods at the site store, check all packings for visible damage. Every damaged box should be opened and its content inspected for damage. If equipment is damaged, a claim form shall be filed with the carrier immediately. It may then be necessary for the carrier to inspect the equipment. Store the light assembly preferably in its original packing in a protected area.
AM.11.100e edition 1.4 How to mount the light assembly? Before you start Make sure that the contact surfaces of the light assembly with base or adapter ring and the gaskets are absolutely clean and smooth.
AM.11.100e edition 1.4 How to mount the light assembly?, continued How to mount the light assembly? Step 3 Action Slightly moisten the gasket with soapy water, to lubricate. CAUTION: Never lubricate the gasket with silicone or any other kind of grease. Avoid the use of soap containing silicone or glycerine.
AM.11.100e edition 1.4 Installation of adapter ring Adapter ring Installation To install the adapter ring, proceed as follow: Step Action 1 Clean the contact surfaces of the deep base and adapter ring. In case an adapter ring has already been mounted on the base, remnants of Loctite are present in the fixation holes. Clean them using a cleaning tap for blind holes (preferably use a tap with a right spiral groove) and blow with dry, oil-free compressed air.
AM.11.100e edition 1.4 Chapter 3: Maintenance Overview Introduction This chapter describes the general ideas on workshop maintenance and preventive maintenance and you will learn how to lift the unit out of the base or adapter ring. The servicing of the light assembly in the maintenance workshop will be described in detail in Chapter 4: Servicing in the Maintenance Base, page 24. Warranty limitation The lights are delivered fully tested and sealed.
AM.11.100e edition 1.4 Workshop maintenance and preventive maintenance In the field maintenance The light assemblies can be serviced in the field, but it is recommended to limit field maintenance to cleaning the lens. It is recommended to replace the inset lights at regular intervals and to have them overhauled in the maintenance shop. The same applies to lights found unserviceable in the field. No specific tools are required to remove or re-install the fittings, except for the lifting tool (see page 23).
AM.11.100e edition 1.4 Workshop maintenance and preventive maintenance, continued Preventive maintenance tasks In the table below you will find a checklist of preventive maintenance tasks: In case lights are found to be defective during the warranty period, do not open them as explained below, but replace them by new units, and send the defective ones, unopened, to ADB. Interval Daily Check Action for lamp failure Replace lamp and film disc cut-out (if any). for low light output 1.
AM.11.100e edition 1.4 How to lift the light assembly out of the base or adapter ring Lifting tools Beside the simple jig delivered with the standard tool case, ADB has developed a more sturdy and efficient lifting tool (see illustration below). See paragraph Accessories, page 48 for references. Procedure To lift the optical unit out of the base receptacle or adapter ring, proceed as follows: Step Action 1 Remove the fixing screws and washers (A1-A2) or self locking nuts and discard them.
AM.11.100e edition 1.4 Chapter 4: Servicing in the Maintenance Base Overview Introduction Preliminary Contents In this chapter you will learn how to perform the servicing tasks in the maintenance base. All the screws used in this product are listed at the end of this manual. Refer to the table "Screws Overview ", page 44 for the tool to use and the torque to apply. This chapter contains the following topics.
AM.11.100e edition 1.4 How to open the light assembly Procedure To open the light assembly, proceed as follows (for the tools to use, refer to, page 44"Screws Overview "): Step Action 1 Turn the light unit upside-down. In order for the light to rest on a stable surface it is advised to lay it upside down on the top of a shallow base. 2 Remove the pressure release screw (F9). F9 / F12 3 Remove the four screws (F4). The use of an attack driver may be required to unlock the screws (see page 48).
AM.11.100e edition 1.4 How to open the light assembly, continued Procedure Step 4 Action Introduce the special opening tool (see page 48) in the dedicated slot between cover and inner cover and rotate it to separate the inner cover from the cover.
AM.11.100e edition 1.4 How to replace the lamp Film disc cut-out When used, always replace the film disc cut-out each time a lamp has to be replaced. Procedure To replace a lamp, proceed as follows: Step Action 1 Open the light assembly ( see page 25). 2 Unplug the lamps fast-on connectors from the terminal block (F1). 3 Pull out the lamp (E3) from underneath, take care for the lamp spring (E6).
AM.11.100e edition 1.4 How to replace the lamp, continued Procedure Step 6 Action Introduce a new lamp and secure with the lamp spring (E6). CAUTION: Never touch the bulb of the lamp with your bare fingers. It would reduce the lifetime of the lamp considerably. Should it happen, clean the bulb with methylated spirit. Make sure there is good contact between fast-on connectors and terminals.
AM.11.100e edition 1.4 How to replace the outer lens To replace a lens, proceed as follows: Procedure Step Action 1 Open the light assembly (see page 25). 2 Unplug the lamps fast-on connectors from the terminal block (F1). 3 Pull out the lamp (E3) from underneath; take care for the lamp spring (E6). 4 Unscrew the 4 screws (E5). Remove the lockwashers. B1 Lubricant B2 B3 B4 B5 B6 E2 E5 E3 E6 5 Remove the lamp support plate (E2) . 6 Unscrew the 4 screws (B6). Remove the lockwashers.
AM.11.100e edition 1.4 How to replace the outer lens, continued Procedure Step Action 8 Push the lens (B2) with the lens gasket (B3) towards the inside of the cover (B1) 9 Clean and degrease the lens chamber with any effective solvent. CAUTION: Never use any abrasive substance. Remnants of Loctite are present in the fixation holes of the screws B6. Clean them using a cleaning tap for blind holes (preferably use a tap with a right spiral groove) and blow with dry, oil-free compressed air.
AM.11.100e edition 1.4 How to replace the optical assembly Procedure To replace the optical assembly, proceed as follows: Step Action 1 Open the light assembly (see page 25). 2 Unplug the lamps fast-on connectors from the terminal block (F1). E3 E2 E6 Keying pins E5 3 Pull out the lamp (E3) from underneath; take care for the lamp spring (E6). 4 Unscrew the 4 screws (E5). Remove the lockwashers. 5 Remove the lamp support plate assy’ (E2) with sealed inner lens.
AM.11.100e edition 1.4 How to replace the optical assembly, continued Procedure Step Action 7 Reinstall a new support plate assy’ (E2) by means of 4 new screws E5. Respect the keying pins and don’t forget the lock washers. Refer to the table “Screws Overview” page 44 for the tool to use and the torque to apply. 8 Introduce the lamp (E3) and secure with the lamp spring (E6).. CAUTION: Never touch the bulb of the lamp with your bare fingers. It would reduce the lifetime of the lamp considerably.
AM.11.100e edition 1.4 How to replace the cable set assembly ADB cable sets Only use ADB cable sets. Usage of substitutes voids the warranty. Procedure To replace the cable set assembly, proceed as follows: Step Action 1 Open the light assembly ( see page 25). 2 Remove both screws (F7) and the wire clamp (F6). F6 F3 F8 / F2 F5 F7 3 Cut the fast-on connectors (F2) from the cable assembly (F8). 4 Pull the cable assembly out of the inner cover and discard the grommets (F5).
AM.11.100e edition 1.4 How to close and test the light fixture Procedure To close an optical unit, proceed as follows: Step Action 1 Turn the cover (B1) upside down. In order for the cover to rest on a stable surface it is advised to lay it upside down on the top of a shallow base. 2 Make sure that the contact surfaces with the O-ring are clean. Remnants of Loctite may be present in the fixation holes of the screws F4.
AM.11.100e edition 1.4 How to close and test the light fixture, continued Procedure Step Action 5 Gently put the inner cover (F3) on top of the cover, taking into account the keying pin between both parts. Make sure the optical assembly (F14) and the lamp (E3) are correctly positioned and that the wires do not get damaged between both parts: cover (B1) and inner cover (F3). 6 Press the inner cover (F3) on the cover (B1) and secure with new screws (F4).
AM.11.100e edition 1.4 Chapter 5: Troubleshooting Troubleshooting In the table below a number of problems are listed in the first column. In the table second column, you will find the possible causes of the problem and in the third column the solution. Problem Light does not energise. Light does not energise at normal level. Possible cause Solution Lamp defective 1. Replace lamp. 2. Replace film disc cut-out (when used). Loose or broken contacts Tighten or replace the contacts.
AM.11.100e edition 1.4 Chapter 6: Ordering codes and Exploded View Overview Introduction References of the types of products described in this manual, of their spare parts and accessories are listed in this chapter, together with exploded views. Contents This chapter contains the following topics.
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AM.11.100e edition 1.4 Complete products and Spare parts, continued In the table below you will find all fixtures and main assemblies of the FTO TLOF inset lights: Table 1 Fixtures Cate gory TLOF Description Green Ordering code FTO-3-048-0-G-0 Main assemblies ADB code 1TOA33001103 Cover 1411.20.650 Optical assy 1411.22.110 Inner cover 1411.24.520 Note: Complete lights are delivered without fixing hardware.
AM.11.100e edition 1.4 Complete products and Spare parts, continued Table 2 In the table below you will find the FTO TLOFcover and optical assembly parts and their availability as spare part or not; in the latter case, order the complete light (see table 1): No. ADB part number Description Components per fitting Order quantity B1 4071.76.002 FTO cover machined 1 1 B2 1428.00.445 Clear outer lens for TLOF 1 1 B3 4071.76.041 FTO lens gasket 1 10 B4 4071.76.
AM.11.100e edition 1.4 Complete products and Spare parts, continued In the table below you will find the FTO inner cover assembly components and their availability as spare part or not; in the latter case, order the complete inner cover assembly (see table 1): Table 3 No. ADB part number F 1411.24.520 F1 Quantity in filting Order quantity Inner covery assy 1 1 1411.21.010 terminal block assembly with fixing hardware and w/o cut-out 1 10 F1 1411.21.
AM.11.100e edition 1.4 Complete products and Spare parts, continued Table 4 In the table below you will find the fixing hardware kits: METRIC FIXING HARDWARE KITS Metric nut kit 8" For mounting 8" inset lights on to Self-locking metric nut ADB 8" shallow kit 8" bases or adapter rings (1) Metric screw kit 8" (Germany) For mounting 12" inset lights or adapter rings on to ADB 12" shallow or deep bases 2 1411.20.420 2 Metric screw kit 8" (w/o anti-rotation pins) 1411.20.
AM.11.100e edition 1.4 Complete products and Spare parts, continued Table 4, continued UNC FIXING HARDWARE KITS For mounting 8" inset lights on to ADB 8" shallow UNC screw kit 8" bases or adapter rings 1411.20.410 2 2 For mounting 12" inset lights or adapter rings UNC screw kit 12" on to ADB 12" shallow or deep bases 1411.20.450 6 6 4071.50.120 UNC anti-rotation pin St. Steel lock washer M10 7284.10.470 ADB Part Number St. St. Screw 3/8"-16 UNC Description Components 71200.13.
AM.11.100e edition 1.4 Screws Overview Important information The table below gives for each screw used in this product , the reference on the exploded view, the type of screw, the tool to use and the torque. Screw Tool Torque A1 (not supplied with the light) Screw FT.HEX M10 x 25, SST, Hex Head or Screw FT.HEX 3/8”-16UNC X7/8” Socket hex 17mm or Socket hex 9/16” B6 - 7100.08.563 HEX SCREW M6x16 DIN 933-A2-LOCK 2045 Socket head 10mm 3.5 Nm / 31 Lb.in E5 - 7100.08.
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AM.11.100e edition 1.4 Addendum FTO 230V, continued TLOF Inset Light Assy’ A1 A2 H7 F11 H8 H9 H1 H2 H11 H3 H4 H8 – H9 – H11 H5 N° Description ADB Part Number Order quantity H1 Screw M5 x 12 - Stainless steel 7110.08.428 100 H2 Lock washer M5 - Stainless steel 7284.10.428 100 H3 Connector kit PAK3RB500001 1 H4 Sealing 7870.05.120 1 H5 Transformer support 4071.86.360 1 H7 Transformer 230V to 7,27 V 4072.14.460 1 H8 Taptite screw M4 x 10 - Stainless steel 7110.08.
AM.11.100e edition 1.4 Accessories Accessories In the lists below you will find useful accessories for the installation, maintenance and repair of the FTO lights. Tool case ADB has designed a tool case (ADB part number 1411.19.421) including the basic tools necessary for the maintenance of inset lights. It can also be used for the installation of the light fixture (please note this is a general tool case, some tools are of no use for FTO Lights).
ADB Leuvensesteenweg, 585 – B 1930 Zaventem – Belgium Tel: 32/2/722.17.11 – Fax: 32/2/722.17.
