Installing - Lumacurve Airfield Signs

Installing: Lumacurve LED Upgrade kits
Size 4 Distance Remaining Signs
Section D: “Installation & Modification”
Installing Lumacurve Distance Remaining Size 4 LED Upgrade kits
The purpose of this guide is to help contractors and airfield personnel install Lumacurve LED Upgrade Lighting
Kits into existing Lumacurve Size 4 Distance Remaining signs. Work through the steps below and if you have any
problems, don’t hesitate to call us for technical support at 800-258-1997.
We recommend reading through the entire instructions first and familiarizing yourself with the procedures before
beginning the installation.
NOTE: Using Non-OEM after-market parts will void FAA Certification and void manufacturer warranties.
WARNING: The sign must be de-energized before working on Lumacurve airfield guidance signs, unless
otherwise instructed. Failure to do so may result in personal injury or damage to internal sign components.
Recommended tools: (Additional tools may be needed to remove existing lighting system.)
Small Standard Screwdriver
#2 Phillips Screwdriver
3/8” Socket Wrench or NutDriver
Round file
Power Drill
Drill Bits: 13/64”, ¼”, 5/32”, 1/8”
9/16” Socket or Wrench
Pop Rivet Tool 1/8”
5/16” Nutdrivers
1. Removing of existing lighting system
a) Remove one face panel, exposing “power” leg to your left. Be careful to not strip fiberglass frame
components.
b) Completely remove existing lighting system.
2. Installing the Line Filter (image)
a) Position the filter mounting plate on the lower two U-bolt threaded ends as shown in figure #1
b) Secure using two 3/8” hex nuts
c) Install power cord leads through cable clamp, then connect to terminal strip, shown in figure #2
3. Installing the Distance Marker LED Light Bars
d)
e)
f)
g)
Install the light bars with lead wires into position first on the power side of sign.
Install the non-power side light bar.
Install lamp socket wiring in terminal strip as shown in figure #2
Light bars need to be 3” from flat edge of the end panel.
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Cable Clamp
Power Cord
Entrance
Figure 2
Figure 1
4. Installing the Controller
a)
b)
c)
d)
Remove Power side access door.
Carefully install new access door (with controller and controller plate.)
Secure wire harness end furthest from controller to filter mounting plate at top right with #8 x 5/8” screw
Install controller leads in terminal strip as shown in in figure #2
5. Making Electrical Connections
a) Identify the controllers input leads. Install these black and white leads into the terminal strip opposite of the
power cord leads. These leads are in parallel with surge protector as shown in figure #2.
b) Identify the AC input leads from the filter shown in figure #3. Connect these black and white wires to the
filter plate terminal strip as shown in figure #2.
c) Identify the DC output leads (Figure #3). Connect these red and black wires opposite the lamp socket red
and black wires on the filter plate terminal strip as shown in figure #2.
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6. Using the switches on the revised
L610 – REV.07M Controller
•
Switch SW2 (Run & Test) is used to isolate
controller programming functions when
troubleshooting (1 out all out).
•
Switch SW3 (Ferro & SCR) is used to
set controller functions with constant
current regulators (CCR’s)
“L610 – REV. 07M”
7. Installing the Shielding Screen
On each side of the controller are screws and fender washers (Figure #3). These hold the shielding screen in place.
If the fender washers are tight to the side of the controller, loosen them slightly to slip the edge of the screen
between the fender washer and the controller case. The shielding screen is shaped to precisely fit the controller.
Once the screen is in place, tighten the screw & fender washers to secure screen.
8. Installing the OEM Electrical Upgrade Nameplate
Each Lumacurve LED Upgrade kit comes with an OEM upgrade
nameplate (Photo #4) & (2) 1/8” pop-rivets. It is essential that
thecorrect nameplate be installed after the electrical installation is
completed. This is critical information for the future maintenance
of the sign. The nameplate should be mounted adjacent to the
original factory nameplate.
Photo 4
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9. Checking system & restoring the sign to service
All the electrical components should now be mounted and wired properly.
a) Insert all lamps into the sockets.
Warning: the use of non-OEM replacement lamps may damage electrical components
and cause premature lamp failure. Only OEM Lumacurve lamps will maintain
FAA photometric requirement and factory warranties.
b) Check that the properly sized isolation transformer is being used. See chart.
c) Signs powered by SCR regulators (solid state) must have jumper in place on the controller. (see step #6)
d) Power up sign and check that all lamps are functioning properly.
Note: If sign is not functioning, revisit above steps once again to ensure the sign is wired properly.
If there are still problems, contact us for technical support at 800-258-1997.
e) Reinstall the legend panel.
Use the chart below to identify the proper size isolation transformer:
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5
AIRFIELD SIGNS
25
27
R
21
See wiring
diagram for
items 12 & 13
14
12
15
Copyright 2016 by STANDARD SIGNS, INC.
ALL RIGHTS RESERVED.
16
13
23
17
26
Inside Electrical View
8
"L"
22
6
STANDARD SIGNS, INC.
(Mode 3 only)
21
10
9
11
9115 Freeway Drive, Macedonia, OH 44056
Phone: 800.258.1997 / 330.467.2030 Fax: 330.467.2076
www.lumacurve.com
24
7
LED Lighting System
Size 4 Distance Remaining Sign
LUMACURVE PARTS LIST
19
18
20
1a
Outside View
2
4
3
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5
1
LUMACURVE PARTS LIST
Size 4 Distance Remaining Sign
"L"
LED Lighting System
Certified to current FAA Advisory Circular 150/5345-44
Specification for Runway and Taxiway Signs
View our Certificate of Conformance
LED Lighting System
Item
Description
DCLT-1A
Leg Cap
* 1.
D-1
Leg
2.
D-2
Top/Bottom Channel
3.
DTG-2
End Panel
* 4.
D-4AB
U-Bolts w/ nuts & washers
5.
D-4ABC
Access Door (handle on power side)
6.
210/220/230/232
1/4” Hardware
7.
394
1/4” x 3/4” Hex Head
8.
D-8P
Light Bar
9.
D-15
48" x 48" legend panel
10.
LED Lamp
4W LED Lamp
11.
500
Lampholder
12.
G Ferrite A
Ferrite Core Split
13.
G Ferrite B
Ferrite Core Not Split
14.
480
Cable Clamp
15.
L610
LED PCB Controller,
DC (1-12 lamps)
16.
G Low Pass
Filter
ALD Low Pass Filter
17.
E416
Surge Protector
18.
2" Al Coupling
2" Pipe Coupling
1a.
* 19. 140A
* 20. 15-HD
Enlarged Views
12
17
Frangible Coupling-2600 ft/lbs
5” x 8“ Galv. Floor Flange
21.
CLT-19
Tether
22.
430
Cord & Plug
23.
420
Terminal Strip (6 block)
24.
PS Bracket
Angle Brackets
25.
3/8” Conduit
Flexible Conduit
26.
G EMI Shield
Screen
360
Controller Screen
27.
13
3/8” Hardware
*Mode 3 parts may be different or not listed.
Please call for more information.
STANDARD SIGNS, INC.
9115 Freeway Drive, Macedonia, OH 44056
Phone: 800.258.1997 / 330.467.2030 Fax: 330.467.2076
www.lumacurve.com
Copyright 2013 by STANDARD SIGNS, INC. ALL RIGHT RESERVED.
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