The Flight Light HL-860F is an L860 Elevated LED Perimeter Light with an integrated LED Flood Light, designed for heliport lighting systems. This user manual, Revision D dated August 20th, 2021, provides comprehensive instructions for installation, wiring, and safety measures, along with a limited warranty.
Function Description:
The HL-860F light fixture serves as both a perimeter light and a flood light for heliports. The perimeter light and flood light are typically wired together in parallel within the fixture, ensuring both illuminate simultaneously when power is applied. However, options for separate wiring of the two light sources may be available, in which case there would be two sets of AC wiring. The lights are designed for installation in a parallel circuit to maintain constant voltage and brightness across all fixtures. The device is available in AC models (100-240VAC) and DC models (10-30VDC), catering to different power supply configurations. The 10-30 VDC + Dimming model allows for dimming of the HL-860 LED perimeter light, while the LED flood light does not dim.
Important Technical Specifications:
- Power Requirements:
- AC Models: 90-135VAC or 208-277VAC (for LED), or 120VAC or 240VAC (for Halogen, though the manual focuses on LED).
- DC Models: 10-30VDC.
- Wiring:
- Standard AC wiring includes Black (AC Line), White (AC Neutral), and Green (Ground).
- For 90-135VAC, connections are L (Black), N (White), GRD (Green).
- For 208-277VAC, connections are L (Brown), N (Blue), G (Green/Yellow).
- For 10-30VDC, connections are (+) (Red) and (-) (Black).
- For 10-30VDC + Dimming, connections are (+) (Red), (-) (Black), and Control (Blue).
- AWG14 wire gauge is generally adequate for most locations, according to NEC 2014, but local electrical codes should be consulted.
- Dimensions (Packaging): Each light is packed in an 18" x 12" x 12" box.
- Mounting Stake (L895): Galvanized to ASTM-A123/A123M-02, with a length of 30 inches (762 mm). Shipped with 1 x 2-hole cable clamp and 2 x #10-24 x 1 ¾” SS machine screws.
Usage Features:
- Installation Flexibility: Can be installed in both existing pavements (requiring core drilling and saw cuts) and new helipad constructions.
- Base Can Installation:
- Requires a 12"-14" diameter core-drilled hole, with depth determined by terrain and civil engineer's recommendations.
- Saw cuts (typically 3" deep x 1/2" wide) are needed for fixture power cables, aligned with conduit holes.
- Drainage system is crucial; base cans come with drain fittings (1-1/2" size, schedule 40 PVC pipe) to extend 3"-4" into drain rock.
- Plywood cover (8” diameter, ¾” thick) is used during concrete pouring to imitate the base plate thickness.
- Mounting jig is recommended for proper alignment of base cans.
- Gasket installation between the base plate and the can is essential for flush or slightly above-grade mounting, promoting water flow away from the fixture.
- Soil-Stake Installation (L895):
- Stake is installed in a 6-inch (15 cm) diameter hole at a depth of 30 inches (76 cm); driving the stake is not permitted.
- Backfill around the stake with thoroughly compacted earth (passing a 1-inch sieve).
- Concrete backfill is recommended for unstable soil conditions.
- Top of the stake should be even with or not more than 1½-inch (1.3 cm) above finished grade, maintained within 1 degree of vertical.
- In frost-prone areas, anchor with concrete and use permeable backfill (sand) around buried electrical components, covered with an impervious material to reduce moisture penetration.
- Safety Measures:
- Crucial to ensure power is OFF before installation or servicing.
- Adherence to local NEC code is mandatory.
- Equipment must be rated for the intended environment (e.g., humid, flammable, explosive).
- Use appropriately gauged and insulated electrical wire.
- Electrical wiring must be routed along a protected path.
- Protection from harsh environmental conditions is required.
- Safety devices (interlocks, fire detection systems, panels, covers) must be fully functional.
- Never operate equipment with a known malfunction or if standing water is present.
- Avoid touching exposed electrical connections when power is ON.
- WARNING: Do not look at Infrared Light Fixtures while they are ON, as infrared light output is hazardous to the eye.
Maintenance Features:
- Drainage System: Regular testing of the drainage system by pouring water into the base can is recommended to ensure proper absorption by the underlying ground. Modifications may be necessary if drainage is inadequate.
- Warranty:
- Lamps: 90 days from shipment (limited to replacement, excludes incidental labor).
- FAA Products: 1 year from installation or 2 years from shipment.
- LED Light Fixtures: 2 years from shipment.
- Complete Systems (with Flight Light Inc. Controller and LED Light Fixture): 5 years from shipment.
- Warranty Exclusions: Unauthorized repairs, damage from natural phenomena, misuse, abuse, accident, alteration, incorrect electrical current/voltage, improper installation, or shipping damage.
- Warranty Limitations: Does not cover workmanship of the installer, damage from acts of nature, vandalism, improper installation/maintenance. The 5-year system warranty for LED fixtures is reduced to 2 years if subjected to abrasive materials or chemicals. Flight Light Inc. reserves the right to repair or replace defective components. Flight Light Inc. disclaims implied warranties of merchantability or fitness for a particular purpose and is not liable for special, indirect, incidental, consequential, or liquidated damages.
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