OPERATING & MAINTENANCE MANUAL MODEL : TGS –LED series

Technical Specification
&
Operation Manual

TGS–LED : TAXIWAY GUIDANCE SIGN

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OPERATING & MAINTENANCE MANUAL MODEL : TGS –LED series

REVISION RECORD

This Revision Record of Manual is written in below Table and we supply new
updated Manual with product.

This Manual can be Revised anytime for better improvement of products and its
Revision contents are made by company production process regulation and will
give to customers as newly updated Hard copy and Soft copy by CD.

This Manual not including a content for finished parts and Products.

REVISION RECORD

REV. No. Contents DATE SIGN

Rev 0 Initial registration 2009-12-22

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OPERATING & MAINTENANCE MANUAL MODEL : TGS –LED series

CONTENTS

1. General

1.1 Knowledge before Operation(use)

1.2 Cautions for Safety

1.3 Quality guaranty

2. Product specification

3. Installation

4. Maintenance & Repair procedure

5. Transportation & Storage

6. Drawings & Data List

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OPERATING & MAINTENANCE MANUAL MODEL : TGS –LED series

1. General

1.1 Knowledge before use

Please read carefully this Manual with below Caution before use and use correctly.

If you do not understand and have any questions, please contact with below
department and make best Installation, Operation and Maintenance after sufficient
knowledge from us.

Please transfer this Manual to person in charge of end user and maintenance person

and Duty maintenance manager.

Please store this Manual where can see easy by person in charge always and use
anytime when required.

Company: YOUYANG AIRPORT LIGHTING EQUIPMENT INC. KOREA

Department: Quality Assurance Team
Tel: +82-31-422-0021
Fax: +82-31-424-6044
E - Mail [email protected]

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OPERATING & MAINTENANCE MANUAL MODEL : TGS –LED series

1.2 Cautions for Safety

Keep this Caution to use products at safely and correctly to prevent before any
troubles and dangerous cases are occurred.

Use this product function as sufficiently and safely after carefully reading of this
Manual.

The Caution means as below 2 kinds:

When user do violate this Introduction of Manual, it

WARNING cause serious injury and death to user.

When user do violate this Manual introduction, it

NOTICE cause light injury to user and made products

troubles.

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OPERATING & MAINTENANCE MANUAL MODEL : TGS –LED series

WARNING

1. Do not Repair work when Power is ON and electrical circuit operated. This will make
Electric Shock to user.

2. Do not cabling work and disassembly work of products even Power is not connected.
Do period check only by eye. Otherwise this will make Electrical shock.

3. Do not work and touch when any small Water is covered on the product. This will
make Electrical shock to user.

4. Do not use when a Cable is peeled off and damaged. This will make Electrical shock to
user.

5. Do Make sure Fastening and fix after installation of product.

NOTICE

1. Please use input power as allowed range. Otherwise, this will make product damage
and fire reason.

2. Please do not make water input and dust entering to product. This will make product
damages and fire reason.

3. Please use all parts must be correct parts to products. Otherwise, this will make
product damages and fire reason.

4. Please do not make product inside cabling by arbitrary changing. This will make
product damages and fire reason.

5. Please do maintenance by trained technician only. Otherwise, non-qualified persons

make product damages and trouble.

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OPERATING & MAINTENANCE MANUAL MODEL : TGS –LED series

1.3 QUALITY GUARANTY

The product guaranty under this manual applied is 1 year after supply to site. The
consumable parts are excluded from guaranty period.

The troubles caused by products defects will be free of charge during guaranty period,
but, user mistakes and mis-use will be charged.

PRODUCT GUARANTY RANGE

Div. A/S charge Guaranty & support period

Product free A/S 2 years after supply to site

defect charge A/S 10 years after supply to site

Free A/S Non

User defect
Charge A/S 10 years after supply to site

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OPERATING & MAINTENANCE MANUAL MODEL : TGS –LED series

2. PRODUCT SPECIFICATION
2.1 PRODUCT SPEIFICTION

No Item Specification Remark

1 Product name Taxiway Guidance Sign ICAO, Annex 14, Part1, 5.4
2 Model name TGS 3
3 Environment Operating
-40 ~ + 55℃ FAA AC150/5345-44
characterist temperature
ic
Wind Exposure to wind velocities of 200
FAA AC150/5345-44
mph (322 km/h)
Rain Exposure to driving rains FAA AC150/5345-44
Sunlight Exposure to direct sunlight FAA AC150/5345-44
4 Electrical In put power 4.8A~6.6A Series circuit
characterist
Isolating Power : 6.6A 100W, Current
ic
transformer sensing : 6.6A 15W
Lamp LED Lamp
Power consumption Refer to DWG
Life time 50,000 hour
5 Photometric Sign face Mandatory sign: Red(Back ground),
characterist White(Letter)
ic Direction sign: Yellow(Back ground), ICAO Annex14
Black(Letter) ICAO Annex14
Information sign: Yellow(Back ICAO Annex14
ground), Black(Letter) ICAO Annex14
Location sign: Black(Back ground),
Yellow(Letter)
Luminance
White : 300 cd/㎟ ICAO Annex14, appendix 4, para 4
(In put
Yellow : 150 cd/㎟ ICAO Annex14, appendix 4, para 4
current=6.6A)
Red : 30 cd/㎟ ICAO Annex14, appendix 4, para 4

Luminance Ratio Red : White = 1:5 ~ 1:10

Adjacent grid (15cm spacing) = 1.5 : ICAO Annex14, appendix 4, para 5
1 ICAO Annex14, appendix 4, para 8
Adjacent grid (7.5cm spacing) = ICAO Annex14, appendix 4, para 8
1.25 : 1 ICAO Annex14, appendix 4, para 8
Maximum : Minimum = 5 : 1
Chromaticity Yellow = x: 0.482 y: 0.514 ICAO, Appendix 1 Fig A1-4
Red = x: 0.662 y: 0.321 ICAO, Appendix 1 Fig A1-4
White = x: 0.301 y: 0.312 ICAO, Appendix 1 Fig A1-4
Brightness step 3 step(10%, 30%, 100%)

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OPERATING & MAINTENANCE MANUAL MODEL : TGS –LED series

6 Mechanical Face height Minimum 800mm

characterist
Installation height Maximum 1,100mm
ic
Legend height Minimum 400mm
7 Surface Painting powder electrostatic painting
treatment
Color White (Standard)
8 Composition Body Aluminum profile 3mm
Rear panel Aluminum sheet 2mm
Sign face Polycarbonate sheet 6mm
Color sheet Avery / 5505(Yellow), 5506(Red),
White(5500)
Coupling Aluminum die-casting
Base plate Aluminum die-casting ￠150mm
LED Lamp 60mA 12V (1 bar = 12 ea)
Converter 4.8~6.6A / 12V
2 Pole plug FAA, L-823 (3.5mmSQ x 2c)
2.1.1 TGS-LED: TAXIWAY GUIDANCE SIGN

2.2 OUT FIGURE DRAWING

A B C D E F
1000~3200 850 250 1100max 500 CHANGIBLE AS PER TGS

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OPERATING & MAINTENANCE MANUAL MODEL : TGS –LED series

3. INSTALLATION

3.1 General

The Light product is supplied after assembled and tested to meet with usages.

The Light product is supplied under KS, IEC, ICAO, FAA, MAK regulation requirement and
Light capacity, color and intensity can be decided with user to meet with airfield site
condition.

The Light installation method is meet with ICAO and FAA installation requirement and
see below procedure.

3.2 JIG & TOOLS for INSTALLATION

The Jig & Tools for installation work must be prepared and refer below list.

1) Torque Wrench (12mm/13mm)

2) Electrical insulation tpe

3) Spanner set(7mm)

4) Driver set

5) Wrench (5mm)

6) Other necessary tools.

3.3 Check points before installation

The Deep base(box) or Shallow base(box) must be installed before Light to be

installed as requirement as below.

 The Light position is met with KS, ICAO, FAA and MAK Requirement?
 The base box arrangement is met with requirement?
 The Isolation transformer is connected with series circuit and secondary
receptacle is connected with flange?

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OPERATING & MAINTENANCE MANUAL MODEL : TGS –LED series

3.4 Notice when installation of TGS

1) During installation of TGS, be careful That water not to enter into pipe and inside of

TGS.

2) The connection between TGS lead wire and secondary cable of Transformer should

be firmly connected.

3) No move TGS under the status connected between TGS wire and secondary cable of

Transformer.

4) No leave any tools and devices on site after working.

3.5 Installation of TGS

WARNING
1. The LIGHT installation and repair works must be done after power OFF.

1) Clean the Base(box) inside and dry by cloth to make no water inside.

2) Install base plate firmly on the ground after putting base plate on anchor bolts.

Tighten nuts in 30N.m with torque wrench

3) At this time, The wire which protect TGS not to move away should be fixed with

anchor bolts together. And assemble coupling on base plate.

4) Put supporting pipe of TGS on coupling and stand TGS checking vertical axis. And

tighten 8 bolts and nuts in 20N.m.

5) Remove legend face after releasing fixing plate of Left & right side

At this time, color film should not be damaged.

6) Connect flexible connector and flexible pipe for piping.

7) Install transformer as per quantities and capacity of each TGS. (Installation method

should follow to airport regulation.)

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OPERATING & MAINTENANCE MANUAL MODEL : TGS –LED series

8) Install secondary cable through installed pipe to TGS. And indicate capacity of

transformer on end of cable.

9) Clean connection parts, receptacle of transformer and secondary cable. And

connect according to drawing and then do taping work with EPR tape and PVC

insulation tape.

(Installation method should follow to airport regulation.)

10) Connect secondary cable to terminal according to drawing.

At this time, connect earth wire (White) of cable to [E] parts on terminal.

11) Fix and arrange lead wire inside TGS using cable tie.

12) Check cleanliness of legend face..

13) Put legend face into body and fix fixing plate with bolt.

14) Connect earth wire to earth terminal of TGS.

(Installation method should follow to airport regulation.)

15) After finishing TGS installation, do final checking and clean around of TGS.

TGS is installed on deep base or elbow conduit. And installation method is as below.

Installation of deep base should follow to FAA AC 150/5340-26. But It should follow
requested method after discussing with airport if there are requests from purchase
party.

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OPERATING & MAINTENANCE MANUAL MODEL : TGS –LED series

3.5.1 INSTALLATION OF TGS ON DEEP BASE

TGS is installed on concrete base and should be fixed with base plate and anchor bolts.

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OPERATING & MAINTENANCE MANUAL MODEL : TGS –LED series

4. Maintenance & Repair procedure

WARNING
1. The LIGHT installation and repair works must be done after power OFF.

4.1 Check period & check points

This Precaution, Maintenance and Repair works are very important for Aircraft safety
operation. The below check points are recommended by FAA for Inset type Light.

PRECAUTION & MAINTENANCE CHECK POINTS

HALF EMERGEN
CHECK POINT( ITEMS) DAYLY WEEKLY MONTHLY YEARLY
YEARLY CY

LIGHT LAMP ON ●

WEED&GRASS REMOVAL AROUND

●
LIGHT

LENS BROKEN CHECK AND CLEAN ●

LIGHT ARRANGEMENT & BEAM

●
DIRECTION

LIGHT & SOCKET CLAENING ●

LIGHT INSTALLATION HIGHT ●

INSIDE WATER ●

RUST & PAINT REMOVAL ●

LIGHT BROKEN ●

CABLE INSUATION ●

ALL PACKING & SEALING ●

SNOW & ICE REMOVAL ●

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OPERATING & MAINTENANCE MANUAL MODEL : TGS –LED series

4.2 TROUBLE STATUS & ACTION for Maintenance

Please follow up as below action for trouble shooting.
*Do change assembly of light at site and then, troubled light must be repaired at
maintenance shop to prevent runway shut-down time.

TROUBLE STATUS & ACTION

TROUBLE REASON ACTION

- Power parts fail Power parts change

- LED fail LED bar change

NO LIGHTING
ND
-2 PLUG OF TR DIS-CONNECTION TR CABLE CONNECTION

- TR Detect TR change

LOW
- LED fail LED bar change
INTENSITY(BRIGHTNESS

- LED fail LED bar change

Brightness of TGS is - Dust on panel CLEANING

darker than other TGS.

- TR Detect TR change

- Power parts fail Power parts change

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OPERATING & MAINTENANCE MANUAL MODEL : TGS –LED series

4.3 Repair procedure

4.3.1 Legend face change

-. When it can’t use more due to damage and color spoil, legend face should be

replaced.

1) Tools and materials

TOOLS MATERIALS

+ driver 1. Legend face

2) Work procedure

NO PHOTO CONTENTS

This TGS is sample for replacement. For indication of power parts, film of legend
is intentionally removed.

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OPERATING & MAINTENANCE MANUAL MODEL : TGS –LED series

This photo is the one before

replacement.
And each parts are as below.
2 1. Legend face,
2. Body,
3. Fixing plate,
4. Bolt

Release 3 bolts on fixing plate

3
using + driver.

5 Separate fixing plate from body.

Separate legend face from body

6
sliding face by hand.

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OPERATING & MAINTENANCE MANUAL MODEL : TGS –LED series

Old legend face has been removed

7
from TGS body.

Replace legend face with new one.

Assembly is vice and versa.

4.3.2 Power parts change

1) Tools and materials

Tools Material

No need. 1. Power parts

2) Power parts change

NO PHOTO CONTENTS

This TGS is sample for replacement. For indication of power parts, film of
legend is intentionally removed.

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OPERATING & MAINTENANCE MANUAL MODEL : TGS –LED series

This photo is the one before

replacement.
And each parts are as below.
2 1. Legend face,
2. Body,
3. Fixing plate,
4. Bolt

Release 3 bolts on fixing plate

3
using + driver.

5 Separate fixing plate from body.

Separate legend face from body

6 sliding face by hand.

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OPERATING & MAINTENANCE MANUAL MODEL : TGS –LED series

Old legend face has been removed

from TGS body. And each parts are
as below.
7
1, Legend face, 2. Body,
3. Fixing plate, 4. LED Assy’,
5. Power parts

8 The photo of Control board.

Separate lead wire by releasing

9
fixing bolts.

Remove fixing bolts which

10 connected to illuminant parts by
releasing fixing bolts.

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OPERATING & MAINTENANCE MANUAL MODEL : TGS –LED series

-. Remove failed control board

which equipped on body by
releasing 4 fixing bolts.
-. Replace with prepared control
board.
-. Assembly is vice versa.

4.3.3 LED ASSY’ CHANGE

1) TOOLS AND MATERIALS

TOOLS MATERIAL

+ DRIVER 1. LED ASSY’

2.) 전원부교환 방법.

NO PHOTO CONTENTS

This TGS is sample for replacement. For indication of power parts, film of
legend is intentionally removed.

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OPERATING & MAINTENANCE MANUAL MODEL : TGS –LED series

This photo is the one before

replacement.
And each parts are as below.
2 1. Legend face,
2. Body,
3. Fixing plate,
4. Bolt

Release 3 bolts on fixing plate

3
using + driver.

5 Separate fixing plate from body.

Separate legend face from body

6
sliding face by hand.

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OPERATING & MAINTENANCE MANUAL MODEL : TGS –LED series

Old legend face has been removed

from TGS body. And each parts are
7 as below.
1, Bodt, 2. Led bar,
3. Fixing plate, 4. Terminal

-. Separate terminal [1] from LED

bar by releasing fixing bolts.
8 -. Disconnect connector [3].
-. Release bolts of fixing spring
[4] which fix LED bar.

-. Separate connector [4] of LED

bar.
-. Release bolts of fixing spring
9 [4] which fix LED bar.
-. Remove failed LED bar and
replace to new one.
-. Assembly is vice and versa.

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OPERATING & MAINTENANCE MANUAL MODEL : TGS –LED series

5. TRANSPORTATION & STORAGE

5.1 STORAGE

1) All Lights are supplied by each packing box and each box have name plate and
indicated box content at outside of box.

2) All light must be stored at dry condition without dust in the room.

5.2 Storage Atmosphere condition

1) Place : Dry and No dust place
2) Temperature : - 55~ +70 °C
3) Humidity : below than 90%

5.3 TRANSPORTATION

1) Arrange as low load box to be upper side and heavy load box to be lower side.

2) Marking at outside of big box when several small boxes input in big box what is
content in big box.

3) When transportation, the container, selves and boxes can be used.

4) Make a protection action for box contents from dust when container is opened.

5) The general regulation must be kept when transportation is made by air and sea
shipment and shall be followed with International transportation regulation.

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6. DRAWINGS and PARTS LIST

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