THORN PAPI Lights Installation Manual

Installation documentation for PAPI units PU3L
INSTALLATION DOCUMENTATION for PU3L DOC 2111.E
www.ThornAirfieldLighting.com
Thorn Airfield Lighting France 156 boulevard Haussmann 75379 Paris Cedex 08 FRANCE Tel : +33 (0) 1 49 53 62 62 Fax : +33 (0) 1 49 53 62 89 info@ThornAirfieldLighting.fr Thorn Airfield Lighting Version 6.0 (27 October 2010) Thorn Airfield Lighting Pty Ltd 7-9 Newcastle Road Bayswater Victoria 3153 AUSTRALIA Tel : +61 (0) 3 97 20 32 33 Fax : +61 (0) 3 97 20 82 33 info@ThornAirfieldLighting.com Page 1 / 43 Thorn Airfield Lighting UK Ltd 11 Town Quay Wharf, Abbey Road, Barking, Essex, IG117BZ UNITED KINGDOM Tel : +44 (0) 208 594 2747 Fax : +44 (0) 208 594 2848 info@ThornAirfieldLighting.co.uk PU3L Doc 2111.E
RECORD of CHANGE Documentation 2111.E

Revision 1 2 3 4 5 6 First issue Second issue Modifications (text and drawings) New Logo and addresses New section on the use of the clinometer Correction on page 6 Designation Editor JMD JMD JMD JMD FR FR SD Checked Date January 2000 July 2000 September 2000 December 2003 September 2008
Thorn Airfield Lighting Version 6.0 (27 October 2010)
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TABLE OF CONTENTS
1 INTRODUCTION ........................................................................................................................................ 4 1.1 USE RESTRICTION NOTICE AND WARRANTY ............................................................................................. 4 1.1.1 Use of the Document....................................................................................................................... 4 1.1.2 Warranty......................................................................................................................................... 4 1.2 SAFETY INSTRUCTIONS ............................................................................................................................ 5 2 3 4 REFERENCE DOCUMENTS..................................................................................................................... 5 GENERAL STATEMENTS ABOUT PAPI SYSTEM INSTALLATION.............................................. 6 TOOLS AND ACCESSORIES REQUIRED ............................................................................................. 7 4.1 4.2 5 STANDARD TOOLS ................................................................................................................................... 7 SPECIAL TOOLS ....................................................................................................................................... 7
INSTALLATION.......................................................................................................................................... 8 5.1 CIVIL WORKS .......................................................................................................................................... 8 5.1.1 PU3L unit possible height .............................................................................................................. 8 5.1.2 Concrete plinth standard dimensions ............................................................................................. 9 5.1.3 Electrical circuits.......................................................................................................................... 11 5.2 INSTALLING THE LEGS ON THE CONCRETE PLINTH.................................................................................. 13 5.3 MOUNTING THE PU3L BOX ONTO THE LEGS .......................................................................................... 14 5.4 ELECTRICAL CONNECTIONS ................................................................................................................... 16 5.4.1 Connection of the secondary cables on the PU3L........................................................................ 16 5.4.2 Fixing and connecting the lamps.................................................................................................. 18 5.5 ADJUSTMENT OF ELEVATION ANGLE..................................................................................................... 19 5.5.1 Use of the clinometer .................................................................................................................... 19 5.5.2 Calibration procedure .................................................................................................................. 20
INSTALLATIONS OF OPTIONAL DEVICES...................................................................................... 21 6.1 INSTALLATION OF THE TILT SWITCH ...................................................................................................... 21 6.1.1 Mounting and adjustment ............................................................................................................. 21 6.1.2 Cabling of the tilt switch system ................................................................................................... 23
6.1.2.1 6.1.2.2 PU3L internal cabling ............................................................................................................................. 23 PU3L external cabling ............................................................................................................................ 24
6.1.3
6.1.3.1 6.1.3.2 6.1.3.3
Commissioning of the tilt switch system ....................................................................................... 29

Test in normal status.............................................................................................................................. 29 Test in normal status.............................................................................................................................. 30 Problem occurred during commission ................................................................................................. 31
6.2 INSTALLATION OF HEATING RESISTOR ................................................................................................... 33 6.2.1 Mounting of heating resistors and terminal plates ....................................................................... 33
6.2.1.1 6.2.1.2 Mounting of heating resistors ................................................................................................................ 33 Mounting the terminal plates ................................................................................................................. 34
6.2.2
6.2.2.1 6.2.2.2
Cabling of the heating resistors.................................................................................................... 35

PU3L internal cabling ............................................................................................................................. 35 PU3L external cabling ............................................................................................................................ 36
DIMENSIONS OF THE PU3L ................................................................................................................. 41
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1 Introduction
The documentation lists the different steps to follow in order to install the PU3L PAPI unit. You will find in this document two main paragraphs: "General Information and Requirements": This chapter gives general description and use of the fitting covered by this document. "Installation of the fitting": This chapter describes how to maintain the fitting covered by this document.
1.1
Use restriction notice and warranty
1.1.1 Use of the Document

This Installation documentation is the property of THORN Airfield Lighting 156 bd. Haussmann 75379 Paris Cedex 08 France This documentation or any parts of this documentation may not be reproduced, stored in a retrieval system or transmitted in any form or by any means (mechanical, photocopying, recording, electronic,) without THORN's prior consent.
1.1.2 Warranty
THORN Airfield Lighting guarantees that the performance of the inset lights described in this document, when sold by THORN Airfield Lighting or its licensed representatives, meets the requirements of ICAO Annex 14 volume 1 and FAA specification AC 150/5345-28. Any defect in design, material or workmanship, which may occur during proper and normal use over a period covered by the warranty stipulate in the contract, will be replaced by THORN Airfield Lighting free of charge, ex works. Operational failure resulting from lamp burnt out, improper installation, damage due to runway maintenance equipment is not considered a result of proper use and is beyond the scope of the warranty. The above constitutes the limits of THORN Airfield Lighting 's liabilities concerning the equipment covered by this document.
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1.2
Safety instructions
WARNING: Prior to the commencement of work all electrical services MUST be isolated from the
supply and connected to earth. Full details of the work involved must be given to the Authorise Person responsible for the electrical engineering services at the airport with regard to the duration of the work, etc.. It is recommended that prior to starting any cutting work the nature and location of services such as cable ducts, etc... should be identified. It is a prerequisite of this type of installation that the work should be carried out by trained and experienced personnel.
2 Reference documents
This paper refers to following documents: THORN Commercial Documentation General Brochure Doc 1001.E, THORN PU3L Commercial Documentation Doc 1111.E, Last Edition of ICAO Annex 14 Edition of July 1995, Last Edition of FAA Advisory Circular AC 150/5345-28.
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3 General statements about PAPI System Installation

The first step of PAPI System installation is the calculation required to accurately locate the positionning of the units relative to the runway threshold and the runway edge. The distance from the threshold will be determine by the largest aircraft to use the runway, the height of the aircraft wheels over the threshold, possible obstacles in approach zone, accordance with ILS System For more details concerning this calculation please se the Paragraph 8.4 of the Part 4 of ICAO Aerodrome Design Manual Once the above distance has been calculated the PAPI position are given as follows :
Fig 1 : LOCATION OF PAPI RELATIVE TO RUNWAY EDGE
The PU3L is mounted on three legs, each comprising a tripod stand, frangible coupling and an aluminium tube, the length of which has to be determined at the time of installation. The final length of the tubes will depend upon the individual heights of the PAPI units, these heights being dependent upon local ground conditions etc.. On the centre of each PAPI body is a datum point which can be used to ensure that all of the units are the same level. Please note that the PAPI units should be mounted as low as possible. The tube supplied are 60 mm diameter and 400 mm long. Please note that 92 mm of tube is placed inside the frangible coupling and this must be allowed for in calculating the required length.
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4 Tools and accessories required

4.1 Standard Tools
Two open end wrench of 22 mm. One 22 mm box spanner / socket. Two open end wrench of 17 mm. One 8 mm box spanner / socket. One small flat screwdriver One brush or cloth One spirit level
4.2
Special Tools
One set of adjustment tools (supplied in a little case). Note : Standard surveyors equipment shall be also required to determine the location of the foundation blocks etc.. One multimeter (for Tilt Switch Installation).
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5 Installation
5.1 Civil Works
5.1.1 PU3L unit possible height

In order to help you to fix the topographic heights of the top of the concrete plinth dedicated to support the four PU3L Unit of the PAPI. Please take into account the following data (See Fig 2) : 1) The Threaded Rods of the three Legs permit an maximum vertical adjustment of 55 mm. 2) The Maximum possible distance between the top of Concrete Block and the Bottom of the PU3L Box is 570 mm (on the Front Legs). 3) The Minimum possible distance between the top of Concrete Block and the Bottom of the PU3L Box is 300 mm (on the Rear Legs).
Fig 2 : MAXIMUM AND MINIMUM HEIGHT OF PU3L
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5.1.2 Concrete plinth standard dimensions

Once the location of the foundations for the PAPI units have been determined, each of the units will need to have a concrete plinth constructed as per the dimensions given in Fig.3. Note : These dimensions are minimum requirements suitable for compacted and stabilised ground and may need to be increased due to local conditions. Ideally, the concrete plinths should be level with the ground, however, the requirements for chamfered edges should be bourn in mind. Three sets of three sealing rods with M10 threads (one per tripod base) may be fixed into the concrete whilst wet, alternatively, the use of rawl bolts is recommended. We would also recommend that a conduit elbow tube be placed in the concrete plinth for the secondary AGL cables.
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Fig 3 : STANDARD SIZES OF THE CONCRETE PLINTH
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5.1.3 Electrical circuits

Manholes and conduits dedicated to receive respectively Isolating Transformers and Power supply Cables (Primary and Secondary) must also be supplied and installed into the ground to shelter the equipment used to power supplied the PAPI System. Manholes and conduits characteristics are function of local needs (type of soil, type of climate, etc). Nevertheless we can give as an example the great following statements (See Fig 4 and Fig 5) : Use one Manhole (A) for 2 PU3L Units (=> 2 Manholes for one PAPI System), Minimise the length of the conduit (B) dedicated to lead the secondary cables (= minimise the distance between the Manhole (A) and the concrete block (C) which support the PU3L Unit), Use one conduits (D) network for each independent Primary circuits used for Power supplied the PAPI System (the use of only one or two independent circuits is possible).
Fig 4 : MANHOLE AND CONDUITS (I)
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Fig 5 : MANHOLE AND CONDUITS (II)
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5.2
Installing the legs on the concrete plinth

FOR EACH LEG A) Mount the Tripod Stand (B) on the Sealing Rods (A). B) Fix the Tripod Stand (B). Using an open spanner n 10, screw and lock three M10 nuts (C) on the three Sealing Rods (A). C) Use a 55 mm open ended spanner to fix the Frangible Coupler (D) to the Tripod Stand (B). D) Mount The Tube of the Leg (E) in the Frangible Coupling (D). The Tube Must be previously cut to obtain the requested height (See paragraph 3.). Please note that the maximum amount of adjustment with the threaded Rods (H) is 55 mm. - Minimum distance between the plinth and the Base of the PU3L = 260 mm (on the rear Leg) - Maximum distance between the plinth and the base of the PU3L Box = 570 mm (on the Front Legs) E) Use a spirit level (J) and a open ended ,10 mm spanner to set the tube (E) Vertically in the Frangible Coupling (D), adjusting the six fixing screws (F) to suit. F) Then tightening the six Locknuts (G) G) Place the lower locknut (I) on the Threaded Rod (H). H) Screw the threaded Rod (H) into position in the Tube (E). Note : A minimum of 25 mm is required to be inserted. I) When the Rod is correctly positioned tighten the lower Locknut (I).
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5.3
Mounting the PU3L box onto the legs

FOR EACH LEG A) Screw the Upper Locknut (B) on the Threaded Rod of the Leg (A) about 20 mm below its final Position. B) Screw the Fixing Nut (C) on the Threaded Rod (A) about its final fixing position (height h above the Concrete Plinth. C) Place the Lower Fixing Washer (D) on the Threaded Rod (A). D) Place the first part of lower Knee Joint (E) on the Threaded Rod (A). E) Place the Second part of lower Knee Joint (F) on the Threaded Rod (A).
REMOVE THE PU3L COVER A) Opening the Three catches (A). * the catches are of the locking type and a stab (B) needs to be press before the catch will open. Note :The locking Part of the catches is use to secure the closing. If you forget to push on it you will never be able to open the Catches. Dont force on the Catches you can damage it. B) Lock the three catches in the upright position C) Remove the PU3L Cover
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INSTALL THE PU3L BASE PLATE ON THE THREE LEGS A) Having remove the Cover (A) of the PU3L. B) Place the Base Plate (B) on the Three Legs (C).
FOR EACH LEG A) Place the upper Knee Joint (F) on the Threaded Rod (A). B) Mount the top part of the Knee Joint (E) on the Threaded Rod (A). C) Mount the Upper Fixing Washer (D) on the Threaded Rod (A). D) Screw the PU3L Fixing Nut (C) on the Threaded Rod of the Leg (A). Do not tighten it at this stage. E) Screw the PU3L Locknut (B) on the Threaded Rod (A) about 10 mm over the fixing Nut (C).
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5.4
Electrical connections
5.4.1 Connection of the secondary cables on the PU3L

Note : On the four legs of PU3L the connection of Secondary cables must be done using Compression Packers marked (1), (2) and (3) in the drawing (the Compression Packer (4) is not used). For PU3L equipped with two lamps only Compression Packer marked (2) and (3) are used.
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FOR EACH CABLE A) Unscrew and Remove the Lower Nut (C) of the Compression Packer (A). B) Remove the Plug (D) from the Lower Nut (C) of the Compression Packer (A). Note : all the unused cable entries must have the blanking plug left in situ in order to maintain IP rating of the unit. C) Pass the Secondary Cable (F) - Through the Compression Packer Lower Nuts (C), - Then through the Compression Packer Gasket (E), - And through the Compression Packer Body (B). D) Pull the Secondary Cable about 15 cm into the box E) Strip back the outer sheath of the cable by approx. 20 mm. F) bare the cables cores for a distance of about 10 mm. G) Connect the two cable cores to the PU3L dedicated Terminal (Two connections par secondary cable). H) Pull back the Cable to leave the minimum amount inside the unit. I) Reassemble the Compression Packer Body (B) and tighten to suit.
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5.4.2 Fixing and connecting the lamps

FOR EACH LAMP A) Open the lamp retaining spring (A). B) Install the Lamp (C) in Lamp Holder (B). Note : Ensure that the indentations in the Lamp Holder line up with those in the Pk30d Lamp (See (D)). C) Close the lamp retaining Spring (A). D) Connect the Two Lamp Leads to the appropriate terminals (F) inside the PU3L.
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5.5
Adjustment of Elevation Angle
At this stage the PU3L PAPI Units has been : - Installed on their Concrete plinths. - Equipped of secondary Cables (two or three). - Equipped with Lamps (two or three). The final stage of the installation process is to set the elevation angles of the Units.
Note : The angle of approach on the typical airfield is normally 3 degrees, however , this has to be verified with the client and the local Aviation Authority. The standard angular displacement between each unit is 20 minutes of arc. For a 3 degree approach this would give the unit closest to the runway a setting of 330, the next 310, the next 250 and the last one 230. 5.5.1 Use of the clinometer
Degrees on this line Minutes on this line
The 0 of the line of the spirit level is in regard of the first division after the 3. As one division on the body line is 15 minutes, the clinometer is adjusted to 3 and 15minutes. If you want to adjust to 3 and 20 minutes, you have to add 5 minute. The line for the minute is fixed on the spirit level, so you need to adjust the division n5 in regards with the next division on the body line Then you get 3+15 +5=3 20. Secure the position by the brake under the spirit level.
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5.5.2 Calibration procedure

SETTING UP THE TWO SPECIAL ALIGNMENT TOOLS A) Position the Spirit Level over the Front Legs of the PU3L on the dedicated reference point (A). B) Set and Lock the required Elevation Angle on the Clinometer by moving the spirit level on the body of the tool. Adjust the 0 on the spirit level line with the division you need on the line of the body. C) Position the Clinometer near the rear Leg on the dedicated reference point (B). ADJUSTEMENT OF PU3L A) If Necessary, Using The lower Fixing Nuts (A), adjust the height h of the PU3L Base Plate. Do not tighten it at this stage. B) Adjust the front legs fixing nuts (A), whilst observing the spirit level, to set the front of the unit horizontal and level. Do not tighten it at this stage. C) Adjust the rear leg fixing nuts (B), whilst observing clinometer, to set the required angle of the unit. Do not tighten it at this stage. D) Tighten the Upper Fixing Nuts (C) of the three Legs. After ensuring that the angle setting have not changed. * Correct the adjustment if necessary. E) Tighten the locknuts (D) (Upper and Lower) of the three legs to fix in place. F) Remove the Spirit Level and the Clinometer and store them in the Alignment Tools Case. G) Replace the PU3L Cover and Close the Three Catches.
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Now the PAPI Unit PU3L is operational. When the 4 Units of a PAPI System are all operational the System itself is operational and then could be put in service and use.
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6 Installations of optional devices

As all the PU3L Units are delivered without lamps and any optional devices (Tilt Switch and Heating Resistors), you must install yourself the corresponding devices in the PU3L unit if you want to implement the corresponding optional function.
6.1
Installation of the tilt switch
The Tilt Switch system is composed of four Tilt Switch devices (One Master Tilt Switch Unit and three Slave Tilt Switch Units mounted in the corresponding PU3L (one became the Master and the three other became Slaves) linked together by Cables. The installation of aTilt Switch System can be made in three main operations :
1) Mechanical Mounting and Adjustment of the Devices in the PU3L Units 2) Wiring of the System 3) Commissioning of the Whole System. 6.1.1 Mounting and adjustment
The first operation to do is to mount and adjust the four Tilt switch Devices in the corresponding four PU3L.
MOUNTING
FOUR EACH PU3L UNITS
A) Remove the Cover of the PU3L (see Paragraph 5.3.). B) Using the Two Fixing Holes (D) located on the PU3L Base Plate (A) and the two Fixing Screw (C) located on the Tilt Switch Devices (B), fix and lock the Tilt Switch Device on the PU3L Base Plate.
Note : a) One of the three PU3L Units must be equipped with The Master Tilt Switch Device and the three other with Slave Tilt Switch devices. You can recognise the Master Tilt Switch Devices because it is the only one equipped with Power Supply and Control Module (= Big Module located under the Tilt Switch Device. Thorn Airfield Lighting Version 6.0 (27 October 2010) Page 22 / 43 PU3L Doc 2111.E
b) Following the design of the AFL circuits and what is more convenient for you (see Paragraph 6.1.2.2.2.). You can install Master Tilt Switch device in the first or in the last (starting from the runway edge) PU3L Unit of the PAPI System.
ADJUSTMENT
A) Put the Spirit Level use in Paragraph 5.5 on the Plate of the Tilt Switch Device which support the two Mercury Contact in (A). B) Using the Adjustment screw (B) and looking at the Spirit Level set Horizontally the Plate of the Tilt Switch Device which support the two Mercury Contact. C) Verify that the Mercury Contact are Closed. * For Master PU3L Unit, using an Ohmmeter Verify that Connection 13 of the Tilt Switch Device Main Terminal and Connection 1 of the Mercury Contact Terminal are short circuited. * For Slave PU3L Units, using an Ohmmeter Verify that Connection 3 and 13 of the Tilt Switch Device Main Terminal are short circuited. D) If necessary put back in place the PU3L Cover.
MASTER
SLAVE
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6.1.2 Cabling of the tilt switch system

After Mounting and adjustment of the four Tilt Switch Devices in the four PU3L Unit, the next operation is to make the electrical cabling over the system. This cabling operations are divided in two separate steps : Cabling internal to PU3L Units and Cabling External to PU3L Units.
6.1.2.1 PU3L internal cabling

This operation Permit to connect the Contacts of the relay dedicated to short circuit the lamps (when at least one of the PU3L Unit is miss-adjusted) to the two poles of each lamps. All the Tilt Switch Devices are delivered equipped with one set of three two pole cable each one dedicated to be connected to one lamp.
PU3L INTERNAL CABLING

FOUR EACH PU3L UNITS A) If necessary Remove the Cover of the PU3L (see Paragraph 5.3.). B) Depending of the number of lamps of your PU3L Connect 2 or 3 cables (B) of the Tilt Switch Device to the dedicated Connections of the PU3L Main Terminal (A). Note : the Connection corresponding to the lamps are marked on the PU3L base Plate casting. * L1 for Lamp 1 * L2 for Lamp 2 * L3 for Lamp 3 C) If necessary put Back in place the PU3L Cover.
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6.1.2.2 PU3L external cabling

6.1.2.2.1 Passing a cable through a compression packer
Concerning connection of cables coming from out of the PU3L Units the first step is always to pass the corresponding cables through the Compression Packers.
FOR EACH CABLE TO CONNECT A) Unscrew and Remove the Lower Nut (C) of the Compression Packer (A). B) Remove the Plug (D) from the Lower Nut (C) of the Compression Packer (A). Note : all the unused cable entries must have the blanking plug left in situ in order to maintain IP rating of the unit. C) Pass the corresponding Cable (F) - Through the Compression Packer Lower Nuts (C), - Then through the Compression Packer Gasket (E), - And through the Compression Packer Body (B). D) Pull the corresponding Cable about 20 cm into the box E) Strip back the outer sheath of the cable by approx. 20 mm. F) Bare the cables cores for a distance of about 10 mm. G) Connect the cable cores to the tilt Switch Device dedicated terminal (see Paragraph 6.2.2.2.2.2.). H) Pull back the Cable to leave the minimum amount inside the unit. I) Reassemble the Compression Packer Body (B) and tighten to suit.
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6.1.2.2.2 Connections on tilt switch device main terminal
The wiring overview drawing below shows the different electrical connections necessary on a PAPI system with Tilt Switch option equipped of PU3L Units.
WIRING OVERVIEW
1. Isolating Transformer for the lamps 2. Isolating Transformer for the Supply of the Master Tilt Switch devices 3. Primary Cable 4. Secondary Cable
5. Heating Resistors Supply 230 Vac (Option) 6. Alarm Feed Back Cable (Option) 7. Cable for - Mercury contacts Loop - Relays Supply (+12 Vdc) - Heating Resistors Supply (Option)
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6.1.2.2.2.1 Compression packers correspondence

Find here after the correspondence between Functions (Master Tilt Switch Device Supply 6.6 A, Alarm Feed Back Signal, Heating Resistor Supply, Mercury contacts Loop, Relays Supply) and Compression Packers.
MASTER PU3L UNIT

1. Master Tilt Switch Device Supply (2.8 to 6.6 A) 2. Alarm Feed Back Signal (Dry Contact) 3. Heating Resistor Supply (Option) = 230 Vac 4. Control Out = Mercury Contacts Loop + Relays Supply (+12 Vdc) + Heating Resistors Supply 230 Vac (Option)
SLAVE PU3L UNIT

1. Not Used 2. Not Used 3. Control In
= Mercury Contacts Loop + Relays Supply (+12 Vdc) + Heating Resistors Supply 230 Vac (Option) 4. Control Out = Mercury Contacts Loop + Relay Supply (+12 Vdc) + Heating Resistors Supply 230 Vac (Option)
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6.1.2.2.2.2 Main terminal connections correspondence

Find here after the correspondence between Functions (Master Tilt Switch Device Supply 6.6 A, Alarm Feed Back Signal, Heating Resistor Supply, Mercury contacts Loop) and Connection on the Tilt Switch Device Main Terminal.
MASTER PU3L UNIT

1 and 2 3 and 4 5 and 6 11 and 12 13 and 14 15 and 16 Master Tilt Switch Device Supply (2.8 to 6.6 A), Input Alarm Feed Back Signal, Internal Dry Contact (Option) Heating Resistors Supply In (Option) 230 V, Input Relays Supply (+12 Vdc), Output Mercury Contacts Loop, Output Heating Resistors Supply Out (Option) 230 V, Output
SLAVE PU3L UNIT

1 and 2 3 and 4 5 and 6 11 and 12 13 and 14 15 and 16 Relays Supply (+12 Vdc), Input Mercury Contacts Loop, Input Heating Resistors Supply In (Option) 230 V, Input Relays Supply (+12 Vdc), Output Mercury Contacts Loop, Output Heating Resistors Supply Out (Option) 230 V, Output
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6.1.2.2.2.3 Connections between PU3L units

Find here after the wiring you have to make on and between the Main Terminals of the Tilt Switch Device of PU3L for the commissioning of the Tilt Switch function on the PAPI System.
Connection Between Master PU3L Unit and the First Slave PU3L Unit
MASTER TERMINAL FIRST SLAVE TERMINAL
1. Master Tilt Switch Device Supply 2. Alarm Feed Back Signal (Option)
3. Heating Resistors Supply (Option)

A . Optional Wires
Connection Between First Slave PU3L Unit and the Second Slave PU3L Unit
FIRST SLAVE TERMINAL SECOND SLAVE TERMINAL
A . Optional Wires only for Heating Resistors supply
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Connection Between Second Slave PU3L Unit and the Last Slave PU3L Unit
SECOND SLAVE TERMINAL LAST SLAVE TERMINAL
1. Jumper (Absolutely necessary to Close the Mercury Contacts Loop)

A . Optional Wires only for Heating Resistors supply
6.1.3 Commissioning of the tilt switch system

After Mounting and Adjustment of the all Tilt Switch Devices in the PU3L Unit and after wiring of the whole System, you have to Commission the Tilt Switch System. During this commissioning you have to test either the Normal Status or the Default Status.
6.1.3.1 Test in normal status

1) Power On the PAPI System (Supply the Corresponding AFL loop(s) with in Current with TRMS Value From 2.8 to 6.6 Amps. 2) Control that all the PU3L Units of the PAPI System is light on and operational. 3) Remove the Cover of the PU3L Master Unit, and Control the Following things. A) Control the status of the three LEDs of the Tilt Switch Device (See Drawing here after). * The Red LED (1) showing that the Power Supply Module supply 12 Vdc is light on. * The Green LED (2) Showing that the Mercury Contacts Loop is Closed is Light on. * The Red LED (3) Showing that the Mercury Contacts Loop is open is Light off. 4) With an Ohmmeter, verify that the Dry Contact of the Alarm Feed Back information is open (meaning PAPI System in Serviceable). Make the measurement between the connections 3 and 4 of the Master Tilt Switch Device Main Terminal.
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6.1.3.2 Test in normal status

1) Now Push Down the Plate Supporting the Mercury Contacts In (A) (see Drawing here after). 2) Wait 5 seconds. 3) Verify that all the PU3L Unit Light off. 4) Control the Following things. A) Control the status of the three LEDs of the Tilt Switch Device. * The Red LED (1) showing that the Power Supply Module supply 12 Vdc is light on. * The Green LED (2) Showing that the Mercury Contacts Loop is Closed is Light off. * The Red LED (3) Showing that the Mercury Contacts Loop is open is Light on. 5) With an Ohmmeter, verify that the Dry Contact of the Alarm Feed Back information is Close (meaning PAPI System is Out Off Service on miss-alignment). Make the measurement between the connections 3 and 4 of the Master Tilt Switch Device Main Terminal. 6) Stop to push Down the Plate Supporting the Mercury Level. 7) Wait 5 seconds. 8) Control that now all the PU3L Units of the PAPI System is light on and operational.
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9) Repeat Three time the test (from 1) to 7)) creating the default separately on the three Salve PU3L Unit A) Remove the cover and create the Default describe in 1) on the corresponding Slave PU3L Unit. B) Control the status of the three LEDs of the Master PU3L like in 4) A). C) Put Back in place the Cover of the corresponding PU3L Unit. D) Test the next Slave PU3L Unit.
When Default Status have been tested on the four PU3L Units with success your Tilt Switch System is consider as operational. 6.1.3.3 Problem occurred during commission
6.1.3.3.1 The PAPI system is light off when it is power on
1) Verify the PAPI AFL Loop(s) are Powered On with a TRMS value of at least 2.8 Amps. 2) Remove the covers of all the PU3L 3) Control the status of the three LEDs of the Master Tilt Switch Device. A) The Red LED (1) showing that the Power Supply Module supply 12 Vdc must be light On. * LED light Off means that the Control and Supply Module doesnt supply the 12 Vdc to all the relays and by default all the lamps are short Circuited. - Verify that the Master Tilt Switch Module is Supplied (2.8 to 6.6 amps). If it is the case change the Master Tilt Switch Module and restart the commissioning. B) The Green LED (2) Showing that the Mercury Contacts Loop is Closed must be Light On. * LED light Off means that the Mercury Contacts Loop is Open somewhere. Find where the loop is open, correct the problem and restart the commissioning. - To find where the Loop is open do as follow : a) Power Off the PAPI System. b) Open the loop on the PU3L Master Unit. Disconnect the wire Connected to the connections 13 and 14 of the Master Tilt Switch Device Main Terminal. Thorn Airfield Lighting Version 6.0 (27 October 2010) Page 32 / 43 PU3L Doc 2111.E
c) With an Ohmmeter tested the Mercury Contacts Loop. Verify that the loop is closed (Make Measurement on the wires disconnected in c). . If the loop is Closed the Problem came from the Master Tilt Switch Device. Test again that the Master Mercury Contacts are Closed. If it is not the case Adjust it again and restart the commissioning . Otherwise Change the Master Tilt Switch Device. d) If the loop is Open, find where the loop is Open. To do this operate as follow : 1) Go to the First Slave PU3L and measure the Mercury Contacts Loop on the Tilt Switch Device Main Terminal. Make measurement between the connections 2 and 3 of the Main Terminal. If the loop is closed. The problem is located on the Wiring between Actual PU3L and the Previous one (here between the Master and the First Slave). Find and Correct it, then restart the * commissioning. If the loop is Open. Test the Mercury Contacts of the Actual PU3L (here the First Slave PU3L). Make measurement between the connections 3 and 13 of the Main Terminal. If the Mercury Contacts are Open the problem is located on Mercury Contacts Plate. Find and Correct it ( make again the adjustment), then restart the * commissioning. 2) If the Problem is not located on the First Slave do the same operations than in 1) on the Second Slave PU3L. 3) If the Problem is not located on the second Slave do the same operations than in 1) on the Last Slave PU3L. * Before restarting the commissioning dont forget to reconnect the corresponding wires on the connections 2 and 3 of the Main Terminal of the Master Tilt Switch Device and put back in place the covers of the four PU3L.
6.1.3.3.2 Some PU3L of the PAPI system remain light off

1) Remove the covers of all the PU3L. 2) With a Voltmeter Verify the distribution on the System of the 12 Vdc dedicated to open the Short Circuit Relay. A) On the first Light Off Slaves PU3L (starting from the Master) * Verify the Input 12 Vdc. Make measurement between the connections 1 and 2 of the Tilt Switch Device Main Terminal. - If the 12 Vdc is not present. The problem is located on the Wiring between Actual PU3L and the Previous one. Find and Correct it, then restart the commissioning. * Otherwise verify the output 12 Vdc. Make measurement between the connections 11 and 12 of the Tilt Switch Device Main Terminal. - If the 12 Vdc is not present. The problem is located inside the PU3L. Find and Correct it, then restart the commissioning. 3) Put Back in place the Covers on all the PU3L.
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6.2
Installation of heating resistor
For use in cold or wet areas the PU3L unit could be equipped as an option with one special Heating Resistor. This Heating Resistor must be supplied in 230 Vac (this option need a dedicated supply wiring). The installation of Heating Resistors on a PAPI System is made in two main operations :
1) Mechanical Mounting in the PU3L Units 2) Wiring
6.2.1 Mounting of heating resistors and terminal plates

The first operation to do is to mount one Heating Resistor and one Terminal Plate in the four PU3L of the PAPI System.
6.2.1.1 Mounting of heating resistors
MOUNTING OF HEATING RESISTOR

A) Remove the Cover of the PU3L (see Paragraph 5.3.). B) Using the Two set of fixing screw (D) and nut (E), fix the Heating Resistor (B) and its two Radiators (C) on the Separating Screen (A) of the PU3L. C) If necessary put back in place the PU3L cover.
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6.2.1.2 Mounting the terminal plates

The connections of the Heating Resistors with external wiring are done using Terminals Mounted on Plates that you have also to mount in the PU3L Units. Note : If your PU3L is also equipped with the Optional Tilt switch System. The connection of the Heating Resistors are done on the Main Terminal of the Tilt Switch Devices. In this case see previous chapter for the mechanical installation of the Tilt Switch Devices. If your PU3L is not equipped with the Optional Tilt switch System. You have to install special Terminal Plates in all the PU3L.
MOUNTING OF TERMINAL PLATES

FOUR EACH PU3L UNITS A) Remove, if necessary, the Cover of the PU3L (see Paragraph 5.3.). B) Using the Two Fixing Holes (D) located on the PU3L Base Plate (A) and the two Fixing Screw (C) located on the Terminal Plate (B), fix and lock the Terminal Plate on the PU3L Base Plate.
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6.2.2 Cabling of the heating resistors

The second operation to do is to make the electrical cabling over the PAPI system This cabling operations are divided in two separate steps : Cabling internal to PU3L Units and Cabling External to PU3L Units.
6.2.2.1 PU3L internal cabling

This operation permit to connect the two poles of the heating Resistor to the Main Terminal of the Terminal Plate or of the Tilt Switch Device.
PU3L INTERNAL CABLING

FOUR EACH PU3L UNITS A) If necessary Remove the Cover of the PU3L (see Paragraph 5.3.). B) Pass the Resistor two Wires under the Reflector Holder (A), under the Terminal Plate (or Tilt Switch Device) (B). Then connect them to the Connections 15 and 16 of the main Terminal. C) If necessary put Back in place the PU3L Cover.
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6.2.2.2 PU3L external cabling

6.2.2.2.1 Passing a Cable Through a Compression Packer
Concerning connection of cables coming from out of the PU3L Units the first step is always to pass the corresponding cables through the Compression Packers.
FOR EACH CABLE TO CONNECT A) Unscrew and Remove the Lower Nut (C) of the Compression Packer (A). B) Remove the Plug (D) from the Lower Nut (C) of the Compression Packer (A). Note : all the unused cable entries must have the blanking plug left in situ in order to maintain IP rating of the unit. C) Pass the Cable (F) - Through the Compression Packer Lower Nuts (C), - Then through the Compression Packer Gasket (E), - And through the Compression Packer Body (B). D) Pull the Cable about 20 cm into the box E) Strip back the outer sheath of the cable by approx. 20 mm. F) Bare the cables two cores for a distance of about 10 mm. G) Connect the cable two cores to the Terminal Plate dedicated terminal (see next Paragraph). H) Pull back the Cable to leave the minimum amount inside the unit. I) Reassemble the Compression Packer Body (B) and tighten to suit.
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6.2.2.2.2 Connections on main terminal

The wiring overview drawing below shows the different electrical connections necessary on PAPI system without Tilt Switch using PU3L Units equipped with Heating Resistors (= Distribution of 230 Vac Power Supply). For System Equipped of Tilt Switch see previous Chapter.
WIRING OVERVIEW
1. Isolating Transformer for the lamps 2. Primary Cable 3. Secondary Cable
4. Heating Resistors Supply 230 Vac 5. Cables for Heating Resistors Supply
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6.2.2.2.2.1 Compression packers correspondence

Find here after the correspondence between Functions (Heating Resistors Supply Input and Heating Resistors Supply Output ) and Compression Packers.
1. Not Use 2. Not Use 3. Heating Resistors Supply In = 230 Vac 4. Heating Resistors Supply Out = 230 Vac
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6.2.2.2.2.2 Main terminal connections correspondence

Find here after the correspondence between Functions (Heating Resistors Supply Input and Heating Resistors Supply Output ) and Connection on Terminal of the Terminal Plate.
1 and 2 3 and 4 5 and 6 11 and 12 13 and 14 15 and 16
Not Use Not Use Heating Resistors Supply In 230 V, Input Not Use Not Use Heating Resistors Supply Out 230 V, Output
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6.2.2.2.2.3 Connections between PU3L units

Find here after the wiring you have to make on and between the Main Terminals of the Main Terminal Plate for Installation of Heating Resistors on the PAPI System.
Connection Between PU3L Unit n 1 and the PU3L Unit n2

PU3L n1 TERMINAL PU3L n2 TERMINAL
1. Heating Resistors Supply


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7 Dimensions of the PU3L
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COMMENTS
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PU3L Doc 2111.E

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Installation documentation for PAPI units PU3L

INSTALLATION DOCUMENTATION for PU3L DOC 2111.E

Installation documentation for PAPI units PU3L

RECORD of CHANGE Documentation 2111.E

Thorn Airfield Lighting Version 6.0 (27 October 2010)

PU3L Doc 2111.E

Installation documentation for PAPI units PU3L

Commissioning of the tilt switch system ....................................................................................... 29

Cabling of the heating resistors.................................................................................................... 35

DIMENSIONS OF THE PU3L ................................................................................................................. 41

Thorn Airfield Lighting Version 6.0 (27 October 2010)

PU3L Doc 2111.E

Installation documentation for PAPI units PU3L

Use restriction notice and warranty

1.1.1 Use of the Document

Thorn Airfield Lighting Version 6.0 (27 October 2010)

PU3L Doc 2111.E

Installation documentation for PAPI units PU3L

Thorn Airfield Lighting Version 6.0 (27 October 2010)

PU3L Doc 2111.E

Installation documentation for PAPI units PU3L

3 General statements about PAPI System Installation

Fig 1 : LOCATION OF PAPI RELATIVE TO RUNWAY EDGE

Thorn Airfield Lighting Version 6.0 (27 October 2010)

PU3L Doc 2111.E

Installation documentation for PAPI units PU3L

4 Tools and accessories required

Thorn Airfield Lighting Version 6.0 (27 October 2010)

PU3L Doc 2111.E

Installation documentation for PAPI units PU3L

5.1.1 PU3L unit possible height

Fig 2 : MAXIMUM AND MINIMUM HEIGHT OF PU3L

Thorn Airfield Lighting Version 6.0 (27 October 2010)

PU3L Doc 2111.E

Installation documentation for PAPI units PU3L

5.1.2 Concrete plinth standard dimensions

Thorn Airfield Lighting Version 6.0 (27 October 2010)

PU3L Doc 2111.E

Installation documentation for PAPI units PU3L

Fig 3 : STANDARD SIZES OF THE CONCRETE PLINTH

Thorn Airfield Lighting Version 6.0 (27 October 2010)

PU3L Doc 2111.E

Installation documentation for PAPI units PU3L

5.1.3 Electrical circuits

Fig 4 : MANHOLE AND CONDUITS (I)

Thorn Airfield Lighting Version 6.0 (27 October 2010)

PU3L Doc 2111.E

Installation documentation for PAPI units PU3L

Fig 5 : MANHOLE AND CONDUITS (II)

Thorn Airfield Lighting Version 6.0 (27 October 2010)

PU3L Doc 2111.E

Installation documentation for PAPI units PU3L

Installing the legs on the concrete plinth

Thorn Airfield Lighting Version 6.0 (27 October 2010)

PU3L Doc 2111.E

Installation documentation for PAPI units PU3L

Mounting the PU3L box onto the legs

Thorn Airfield Lighting Version 6.0 (27 October 2010)

PU3L Doc 2111.E

Installation documentation for PAPI units PU3L

Thorn Airfield Lighting Version 6.0 (27 October 2010)

PU3L Doc 2111.E

Installation documentation for PAPI units PU3L

5.4.1 Connection of the secondary cables on the PU3L