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Instruction Manual AM.02.512e



Edition 3



Precision Approach Path Indicator (P.A.P.I.)



Type PPL 400/2 PPL 600/2



AM.02.512e edition 3



Record of Change AM.02.512e



Revision



Description



Editor Checked Date



1.0



First edition



TXA



WL



2.0



Lay out modified



TXA



WL



6/ 98



3.0



Inclusion of PAPI 600/2 in manual



MR



VI/WL



6/00



1



AM.02.512e edition 3



Safety Instructions Safety precautions



Operating and maintenance personnel should refer to ICAO Annex 14 chapter 9, Airport Services Manual Part 9, “Airport Maintenance Practices” and to FAA Advisory Circular AC 150/5340-26 "Maintenance of Airport Visual Aid Facilities" for instructions on maintenance requirements and on safety precautions. Personnel must always observe the safety regulations. The equipment has been designed and manufactured to allow safe and secure operation, however, the following rules must be strictly observed.



Keep away from Operating and maintenance personnel must always observe all safety regulations. live circuits Do not change lamps or components or make adjustments to equipment when the light circuit is switched on. See FAA Advisory Circular AC 150/5340-26 concerning safety.



Resuscitation



Operating and maintenance personnel should get acquainted with the resuscitation techniques described in the First Aid Instruction Manual as issued by the Red Cross Organisation or similar.



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AM.02.512e edition 3



Use Restriction Notice and Warranty Use restriction notice



This Instruction Manual is the property of n.v. ADB s.a. 585, Leuvensesteenweg B-1930 Zaventem - Belgium Tel. 32 2 722 17 11



Fax 32 2 722 17 64



E-mail : [email protected] Internet: http://www.atd.siemens.de/airports This manual or parts thereof may not be reproduced, stored in a retrieval system or transmitted, in any form or by any means, electronic, mechanical, photocopying, recording or otherwise, without ADB's prior written consent.



Warranty



N.v. ADB s.a. guarantees that the performance of the products described in this manual, when sold by ADB or its licensed representatives, meets the requirements of ICAO Annex 14 volume 1 and FAA specification AC 150/5345-46. Any defect in design, material or workmanship, which may occur during proper and normal use over a period of one (1) year from date of installation or a maximum of 18 months from date of shipment, will be replaced by ADB free of charge, ex works. Operational failure resulting from lamp burnt out, improper maintenance or installation, damage due to runway maintenance equipment, snow ploughs or aircraft arresting gear hooks is not considered a result of proper use and is beyond the scope of the warranty. The above constitutes the limits of ADB’s liabilities in connection with the product covered by this manual.



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AM.02.512e edition 3



Information About this Manual Chapter overview



Each chapter starts with an overview of the topics of that chapter.



Using icons



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.



Caution



A ‘caution’ is used when there is danger that the reader, through incorrect manipulation, may damage equipment, get an unexpected result or has to restart (part of) a procedure.



Warning



A ‘warning’ is used when there is danger of personal injury.



Reference



A ‘reference’ guides the reader to other places in this manual, where he/she will find additional information on a specific topic.



Parts Identification



Parts identification symbols (e.g. A1, B4, …) appearing in the text refer to the page 46 .



Comments and Proposals



This manual has been compiled with all possible care and in view of providing a valuable and practical tool to the Airport Maintenance personnel. We encourage customers to address us their comments and proposals for improving further the contents of this manual. Communications should be addressed to the “ATM department” of ADB:



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AM.02.512e edition 3



Table of content SAFETY INSTRUCTIONS .........................................................................2 USE RESTRICTION NOTICE AND WARRANTY............................................3 INFORMATION ABOUT THIS MANUAL .......................................................4 TABLE OF CONTENT ..............................................................................5 CHAPTER 1: GENERAL INFORMATION AND REQUIREMENTS ......................6 Overview ................................................................................................................6 General information................................................................................................7 Equipment data ......................................................................................................8 Operational conditions for A(PAPI) ..................................................................... 10 What the pilot sees.............................................................................................. 11



CHAPTER 2: PAPI



OR APAPI LOCATION AND INSTALLATION ................13



Overview ............................................................................................................. 13 Location of a (A) PAPI on a runway without ILS................................................. 14 Location of a (A) PAPI on a runway without ILS, continued ............................... 17 Location of a (A) PAPI on a runway without ILS, continued ............................... 17 Harmonisation of the (A)PAPI location with the ILS ........................................... 18 Installation ........................................................................................................... 23 PAPI wiring.......................................................................................................... 27 Levelling of units ................................................................................................. 29 Checking slope angles of the light beams .......................................................... 34 Reference bases for checking stick .................................................................... 35 Electrical connection ........................................................................................... 35



CHAPTER 3: MAINTENANCE.................................................................37 Overview ............................................................................................................. 37 Preventive maintenance ..................................................................................... 38 How to replace a lamp ........................................................................................ 39 How to replace the filters .................................................................................... 39



CHAPTER 4: TROUBLESHOOTING .........................................................41 CHAPTER 5: ASSEMBLIES AND EXPLODED VIEWS .................................42 Overview ............................................................................................................. 42 Assemblies.......................................................................................................... 43 Exploded view PPL 400/2 ................................................................................... 46 Exploded view PPL 600/2 ................................................................................... 46 Description of part names ................................................................................... 47



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AM.02.512e edition 3



Chapter 1: General Information and Requirements Overview Introduction



In this chapter you will find all the information about the supplied and not-supplied (but necessary) equipment for installation and maintenance of the ADB PAPI units PPL 400/2 and PPL 600/2.



Contents



This chapter contains the following topics. Topic



See Page



General information



7



Equipment data



8



Operational conditions for A(PAPI)



10



What the pilot sees



11



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AM.02.512e edition 3



General information Application



Annex 14 Part 5.3.5.1 lists the conditions where a visual approach slope indicator system should be provided : a) Runways used by turbojet or other aeroplanes with similar approach guidance requirements ; b) The pilot of any aeroplane may have difficulty in judging the approach due to : 1) Inadequate visual guidance - water, featureless terrain by day or the absence of sufficient extraneous lights by night, or 2) Misleading information produced by deceptive surrounding terrain or runway slopes; c) The presence of objects in approach area involving serious hazard if the plane descends below normal approach path; d) Physical conditions at either end of the runway present a serious hazard in event of aeroplane undershooting or overshooting runway; and e) Terrain or prevalent meteorological conditions are such that aeroplane may be subjected to unusual turbulence during approach. PAPI’s may either be installed on the left side of the approached runway (=Unilateral PAPI) on each side of it (=Bilateral PAPI). Bilateral PAPI’s are recommended to gain visual roll guidance in VFR or non-precision approach systems



What makes the PAPI so successful?



The features that make a PAPI system so successful are : • Digital feature of the sharp transition which enables the pilot to know his precise position on the approach slope and to detect immediately and distinctively any deviation from the correct path. • The concentrated origin of the information which defines a narrow channel, the height of which reducing as the range reduces, and allows for compatibility with ILS, down to less than 1000 feet from touchdown.



Purpose of this manual



This manual provides general, operation, troubleshooting, maintenance and installation information. Refer to the table of contents to locate the information you need.



Scope of this manual



This manual covers the ADB type PPL 400/2 PAPI and PPL 600/2 units in full compliance with ICAO requirements Annex 14, Volume I paragraph 5.3.5.23 through 5.3.5.45. They also comply with FAA L-880 specification AC 150/5345-28D and with NATO specification, STANAG 3316.



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AM.02.512e edition 3



Equipment data Equipment supplied



A PAPI system consists of 4 units (or 2 in case of an APAPI). Each unit consists of a main housing bearing two (PPL 400/2) or three (PPL 600/2) optical channels. The units are supplied with a fully gasketed cover, mounting legs and connection cables. Most of the components are made of aluminium protected against corrosion, optical glassware and stainless steel. The units are supplied precisely calibrated, with the lamps already mounted in the units.



Equipment required, but not supplied



In the table below you will find a list of the optional equipment, required for installation, but not supplied with the PAPI unit itself. Description



Quantity



Spanner open ended (for 2” cap) 67mm



1



Spanner open ended (breakable coupling) 54mm



1



Set of standard open ended for spanners hexagon screws



1



Aiming device



1



Drilling jig (for FAA breakable legs)



1



Positioning frame (if mounted with non-frangible anchoring legs)



1



Connection kit (optional) containing: - Mechanical cable protection between unit and conduit in the ground. Depending on the system design : - 2 or 3 conduit elbows with stoppers - L-867-B bases with cover 200W 6,6/6,6A RST type series transformers



1



Note:



1/PAPI unit 2 or 3/ PAPI unit



Where approaching angles higher than normal (> 5°) are required (stolports and heliport applications), a set of bias washers will be required for each unit.



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AM.02.512e edition 3



Equipment data, continued PAPI data



Below you find the technical characteristics of both the PPL 400/2 and PPL 600/2.



Overview



The table below lists technical data of the PPL 400/2: Data



Specifications



Type



PPL 400/2



PPL 600/2



Lamps



2 × 200W quartz per unit



3 × 200W quartz per unit



Input current



6,6 A



6,6 A



Rated lamp life



1000 hours



1000 hours



Luminous intensity in red light



+/- 20000 Cd Max. 15000Cd min over –7° to +7° Horizontal and 4° Vert.



+/-22000 Cd Max 15000Cd min over –7° to +7° Horizontal and 4° Vert.



Transmission factor of red sensor



> 15%



> 15%



Transmission sector



3’ arc over the full beam spread



3’ arc over the full beam spread



Temperature range for operation



- 35°C to + 55°C



- 35°C to + 55°C



Humidity



0% to 100%



0% to 100%



Wind



Velocities up to 161 km per hour



velocities up to 161 km per hour



Degree of Protection



IP34



IP34



Ordering codes and reference data pertinent to the equipment are listed in the tables on page 43.



Note :



In order to better match the light output of other AGL-Products the PAPI units may be equipped with 100W lamps (luminous intensity reduced by ~ 50%). This may be the case in medium or low intensity airport lighting systems, as well as for the use as APAPI.



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AM.02.512e edition 3



Operational conditions for A(PAPI) Introduction



The operation conditions for the PAPI system are explained below.



Normal operation



The PAPI system must operate continuously when the runway is in service. When



Intensity setting



During the day: • When aircraft are approaching



Use the high intensity setting (100%).



• When no aircraft are approaching



Reduce to the normal standby setting.



At night



The system may operate continuously at 30% brightness or less.



Failure to adopt this practice will result in an increased consumption of lamps.



Regions with heavy snowfall and frost



Units should operate continuously at normal standby brightness, even when the runway is not in use. Any snow will thus melt and drain off. It is advisable to have separate constant current regulators for each PAPI system (instead of circuit selectors) so that all the systems can be operated simultaneously under snowstorm conditions. When snowfall is expected to bury the units, the location of the units should be marked with sticks or flags (approx. 2 m high), to prevent damage to the units by snow removal equipment. As an option, ADB provides PAPI units with a heating system.



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AM.02.512e edition 3



What the pilot sees. Introduction



The PAPI system consists of a bar of four units, each one producing a light beam divided into an upper white and a lower red sector.



Colour transition



When viewed by an observer at a distance of 300m (1000 feet), the transition from red light to white light occurs within an angle of three minutes of arc at the beam centre and within an angle of 3 minutes of arc.



Installation



The units are installed on a line perpendicular to the runway centre line and are set in elevation at varying angles, the difference between adjacent units is normally 20’ of arc.



Illustration



This illustration shows you what the pilot will see during the landing procedure: PAPI



Too high Slightly high On slope Slightly low



On slope



Too low



APAPI



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AM.02.512e edition 3



What the pilot sees, Continued Introduction



The approach slope is



The pilot will see



> 30’ (35’) of arc away from the correct slope



The four units in the same colour.



> 10’ (15’) and < 30’ (35’) of arc from the correct slope



Three units of the same colour and only one of the other colour.



Correct



Two red lights on the runway side and two white lights outwards.



I.e. red below the correct slope and white above.



Values between brackets are the deviations generally adopted in order to improve the harmonisation with the ILS.



Bilateral PAPI’s (=a PAPI system on each side of the runway) are recommended to gain visual roll guidance in VFR or non-precision approach systems



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AM.02.512e edition 3



Chapter 2: PAPI or APAPI location and installation Overview Introduction



This chapter instructs you on how to position the (A) PAPI systems and how to install the PPL 400/2 and PPL 600/2.



Receiving, storage and unpacking



1. Upon receipt of goods at the site store, check all packing 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. 2. Store the light assembly preferably in its original packing in a protected area. When stored unpacked, please take care not to damage the cable insulation. 3. Unpack the light assembly at the installation site to avoid damage during transportation and handling.



Contents



This chapter contains the following topics. Topic



See Page



Location of a (A) PAPI on a runway without ILS



14



Harmonisation of the (A)PAPI location with the ILS



18



Installation



23



PAPI wiringPAPI wiringPAPI wiring



27



Levelling of units



29



Checking slope angles of the light beams



34



Reference bases for checking stick



35



Electrical connection



35



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AM.02.512e edition 3



Location of a (A) PAPI on a runway without ILS Introduction



When a runway is not provided with an ILS, it is vital to ensure that an adequate wheel clearance over threshold is provided by the (A)PAPI. To comply with specifications of threshold wheel clearance, aircraft’s have been classified in four groups, according to their eye to wheel height (EWH).



Eye to wheel group selection



The table below lists the wheel clearance over threshold for PAPI and APAPI in ICAO Annex 14, Table (5-2). Eye to wheel height of aeroplane in the approach configuration (1)



Desired wheel clearance (2)



Minimum wheel clearance (3)



Up to but not including 3 m



6



3



3 m up to but not including 5 m



9



4



5 m up to but not including 8 m



9



5



8 m up to but not including 14 m



9



6



For selecting the "eye to wheel height (EWH)" group, only aeroplanes meant to use the system on a regular basis shall be considered. The most demanding amongst such aeroplanes shall determine the eye-to-wheel height group (EWH). Desired wheel clearances shown in column 2 shall normally be provided. The wheel clearances in column 2 may be reduced to those in column (3) where an aeronautical study indicates that such reduced wheel clearances are acceptable.



Eye to wheel and eye to aerial heights



Refer to Appendix 6 of Aerodrome Design Manual Part 4 to find the eye to wheel and eye to aerial heights of aeroplanes.



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AM.02.512e edition 3



Location of a (A) PAPI on a runway without ILS, continued



Theoretical Location of (A)PAPI system



The theoretical location of the (A)PAPI system can be calculated by following next procedure: Step



Action



1



Select the class of the aircraft (Appendix 6 of Aerodrome Design Manual Part) to determine the EWH (eye to wheel height)



2



Determine WTH (wheel-to-threshold height) , according to their eye-towheel height (see previous page).



3



Theoretical distance is calculated from the formula: D1 = (EWH + WTH) . cotg (θ x –2’) in which: • EWH is the eye-to-wheel height • WTH is the wheel-to-threshold height • θx is the setting angle of unit 2 in a PAPI configuration or is the setting angle of unit 1 in an (A) PAPI configuration.



Illustration 4



3



2



1



2



EWH PAPI



WTH D1



Threshold



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AM.02.512e edition 3



Location of a (A) PAPI on a runway without ILS, continued



Checking interference’s



For checking interferences with obstacle clearance surface ICAO has defined an obstacle clearance surface. Refer to the pictures below and table 5.3 in Annexe14, Volume I.



Threshold



rface



ction Su



le Prote Obstac



8.5˚ or 15%



300 m



Obstacle Protection Surface



60 m



Approach Surface Inner Edge 15 km



This surface has an inner edge length of 300 m at a distance from threshold of 60m. The length of the surface is 15 km and the divergence is 8.5° or 15%. Typical case : definition of the OPS slope in case of an APAPI installation on a code I or II runway Obstacle Protection Surface Typical case



1˚ 56' 60 m



ce



n Surfa



rotectio



le P Obstac



3.37 m



Threshold



100 m



Approach Surface Inner Edge 15 km



The slope of the surface can be calculated by the following formula: θ2 – 0.9°. θ2 corresponds to the setting angle of unit B. If the glide path is 3°, the slope of the OCS shall be 2°45’ – 54’ = 1°51’. It shall be checked whether an object protrudes above that surface.



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AM.02.512e edition 3



Location of a (A) PAPI on a runway without ILS, continued Adaptation of the (A)PAPI-location to obstructions Obstacles above surface



If obstacles project above the surface, one of the following measures must be taken: •



Remove the obstacle if practicable.



•



The approach slope of the system may be suitably raised.



•



The axis of the system and its associated obstacle protection surface may be displaced by no more than 15° (an aeronautical study shall be conducted).



•



The threshold may be suitably displaced.



•



The (A)PAPI system may be suitably displaced upwind of the threshold to provide an increase in threshold crossing height equal to the height of the obstacle penetration.



APAPI : H = L- (D-60).tan (θ2 – 0,57°) Formula



PAPI : H= L- (D-60) .tan (θ1– 0.9°) Suppose an object at a distance D with its top at a level L above the threshold: H



height of projection above the OCS



D



horizontal distance between the object and the threshold



θx



setting angle of the unit on which the calculations are based(2 in case of a PAPI, 1 in case of an APAPI)



L



height of the object above the threshold level



The new theoretical PAPI location will be in this case: D1 = ( EWH + WTH + H ) . cotg θx



Picture x



Theoretical Location of (A)PAPI



OCS



Corrected Location of (A)PAPI Considering Projection Above OCS



H



D1



Th 60 m



L



H



ETH



2-0.9˚



D



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AM.02.512e edition 3



Harmonisation of the (A)PAPI location with the ILS



Harmonisation of (A)PAPI and ILS



A harmonisation between ILS and PAPI is necessary. In installing (A)PAPI’s on runways equipped with an ILS, it is desirable that there be harmonisation between indications of the visual and non-visual approach aids. The difference between the position of the pilot's eye and the position of the aircraft's glide path antenna created a difficulty in achieving this goal. It is agreed that it is difficult to achieve harmonisation down to the touchdown point but compatibility shall be obtained as close as possible to the threshold. A good method recommended by the ICAO is to classify the aeroplanes in three groups according to their eye to aerial range, and to calculate the horizontal distance between ILS glide path and the theoretical (A)PAPI location. This distance is to be taken farther from threshold than the assumed ILS glide path origin. Eye-to-aerial height range



Figure



Class of aircraft



3.7 to 6.7 m



Large aircraft



1.3 to 1.7 m



Medium aircraft’s



Up to 1.3 m



Small aircraft’s



1. ILS Reference Datum and MEHT The following figure shows the type of height survey required to effectively locate the (A)PAPI units.



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AM.02.512e edition 3



Harmonisation of the (A)PAPI location with the ILS, Continued



Example (taken from ICAO Aerodrome design manual part 4 ed. ’93)



Sitting and installation data for the ILS will provide the height of the ILS glide path over the runway threshold (ILS datum height). For this example, assume ILS datum height to be 15 m with a 3-degree glide path. A) Effective ILS glide path origin assuming a level runway : 15 x cot 3° = 286m from threshold B) Average eye-to-aerial height for aircraft using aerodrome, in this case B737 to A300: 1.7m C) Nominal (A)PAPI position for 1.7m eye-to-aerial height: (15 + 1.7) cot 3° = 318.6m D) Minimum-Eye-Height-over Threshold (MEHT): 318.6 x tan 2°43’ = 15.1m On course sector expanded to 30’ so unit 2 becomes 2°45’ The angle for MEHT is taken as 2’ below the setting for unit 2 Note – To achieve better harmonisation with the ILS, a 30’ on-course sector is used giving a setting for unit 2 of 2°45’.



Example



2. Check for Wheel Clearance A) Eye path to lowest wheel path B737



5.18m



A300



9m



B) From Annex 14, Volume 1, Chapter 5, Table 5-2 Desired wheel



Minimum wheel



Clearance



clearance



B737



6m



3m



A300



9m



6m



C) Using MEHT of 15m, wheel clearance for B737, I.e. better than the desired clearance: 15 – 5.18 = 9.82m. Wheel clearance for A300, I.e. minimum wheel clearance which in this case is acceptable by local authority: 15 – 9 =6m; Therefore use MEHT 15m. Note – Should a higher MEHT of 18m be used to give the desired wheel clearance for A300, the harmonisation of (A)PAPI with ILS will be lost further out on the approach for aircraft with smaller eye-to-aerial heights. At this point, the officer sitting the (A)PAPI must resolve the priorities between retaining harmonisation of the aids and providing the desired wheel clearance.



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AM.02.512e edition 3



Harmonisation of the (A)PAPI location with the ILS, continued



3.



Correct nominal PAPI position for ground height variation (from survey data (see figure below) Ground height at 318.6m: 63.79m Ground height at threshold: 60.65m Difference: -3.14m Move PAPI towards threshold : 3.14 x cot 2°43’ = 66.33 m Amended position of PAPI : 318.6 – 66.33 = 252.27m Recheck the ground heights Ground height at 318.6m: 63.79 Ground height at 252.27m: 63.08 Difference : 0.71m Move PAPI away from threshold by 0.71 x cot 2°43’ = 14.96m New position for PAPI : 252.27 + 14.96 =267.23 m Recheck the ground heights Ground height at 267.23m: 63.31 Ground height at 252.27m : 63.08 Difference : 0.23m Difference is less than 0.3m; therefore position needs no further refinement 4. Correct PAPI position for lens height Assume height of lens centre above ground level is 0.3m Move PAPI towards threshold: 0.3 x cot 2°43’ =6.32m Final position of PAPI : 267.27 – 6.32 = 260.91m or 261m.



Figure



MEHT back check



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AM.02.512e edition 3



Harmonisation of the (A)PAPI location with the ILS, continued 5. Back check MEHT for gross error – See above fig or Visual aids manual part 4 Fig. 8-20 MEHT: 261 x tan 2°43’ + (63.21 – 60.65) + 0.3 = 12.37 + 2.56 + 0.3 = 15.23 m This value is greater than 15 m so ok. 6. Compensation for transverse slopes in the runway Transverse slopes exist on all runways and these must be taken into account in the calculations. All levels must refer back to a datum, which is the runway centreline. A survey must be carried out either side of the runway at the various PAPI locations.



•



This shift shall be towards the threshold when the theoretical location is higher than the threshold and away from the threshold if the location is lower.



•



This shift shall also take into account the actual dimensions of the PAPI units and the real elevations of the ground determined by the survey.



The figure below shows that when it is mounted on a breakable coupling with adjustable tube length, the beam axis of an ADB PPL 400/2 or PPL 600/2 can be set at any elevation above the ground between 45 cm and 90 cm. Thus the elevation difference can be compensated on 45 cm.



Max 90 cm



Beam height adjustment



Compensation for runway shoulders, strips and slopes. All previous location of the PAPI bar considers the PAPI units beam axis at the same level as threshold reference level. In fact slopes exist on all runway strips and they are to be compensated by an adequate shift of the PAPI units.



Min 45 cm



Compensation



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AM.02.512e edition 3



Harmonisation of the (A)PAPI location with the ILS, continued



Beam height adjustment, cont.



The figure below shows the PAPI unit located at a suitable distance in such a way that the lenses are strictly corresponding with the beam axis while its feet length falls between 45 cm and 90 cm. As the four units are to be located on the same line, the final location will be chosen in compliance with those very requirements for the four units.



Runway Center Line 9m



9m



9m



15 m



Min 0.45 m



1.25 %



Profile at d from Threshold Max 0.9 m



Sometimes, when the slope of the runway strips are important, it is necessary to locate the PAPI on a sloped line as shown in the figure to fit with the feet length limits keeping the four PAPI aligned on a same perpendicular axis to the runway.



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AM.02.512e edition 3



Installation Introduction



The preferred method of installation for PPL 400/2 and PPL 600/2 is on concrete slabs at ground level with frangible couplings. The concrete is cast directly into the foundation pit so that the slab rests on firm soil below the frost line. The figure below shows dimensions, which are generally acceptable but can be modified to satisfy local conditions.



Before starting • Do not deform the PAPI-unit if placed on to the legs. Besides problems in the levelling of the units, twisting the units may lead to cracks in the lenses. • Especially, in case of installation close to the ground, make sure that all steps in the mounting procedure are carried out with sufficient accuracy.



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AM.02.512e edition 3



Assemblies, continued Illustration of a typical PPL400/2 installation



Towards Threshold



PPL 400 400/2 PPL



Flexible Conduits Flexible conduits



0,45m to 0,9m



Breakable Coupling Breakable Coupling



Breakable Coupling Breakable Coupling



Base Base FAA L-867 (FAA L-867)



Primary Primary Cables Cable



Note : the FAA L-867 base can also be replaced by conduit elbows leading via conduits to a transformer housing further away from the PAPI's.



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AM.02.512e edition 3



Installation , continued The following table instructs you on how to cast the concrete slabs and to anchor the support feet. Step



Action



1



Stake out the longitudinal axis of the light units parallel to the runway centreline.



2



Dig the foundation hole with respect to the min. dimensions given on figure page 23.



3



Install the base at the rear of the PPL in accordance to manual AM.05.120.



4



Pour in the concrete and allow it to harden for at least one day.



5



After concrete sets up, draw (using chalk) a longitudinal axis (in accordance with the axis staked out on the ground) on the upper surface of the slab. Draw a transverse axis perpendicular to the other axis.



6



Lay the drilling jig on the slab; centre it by positioning the central hole at the intersection of both axes. Align the plate along the longitudinal axis using the V-notches in the plate.



7



Mark the 16 locations of the screws on the slab. Drill the 16 holes to the diameter and depth required for the expansion sleeves and insert the sleeves. See the picture below:



81.5 80



340 500 Dimensions in mm



Anchor Sleeve Or



Approx. 80



637



24 Holes dia 10 at 90˚ for Anchor Bolt



Approx. 80



81.5



Dia 121



800



Casting of the concrete slab



Anchor Bolt



80



(drawing typical for PPL400/2) 8



Place and fasten the flanges (17) with four bolts.



Instead of anchor sleeves, M10 or M12 anchor j-bolts can be cast into the concrete at the proper locations on a 121-mm diameter bolt circle, 4 places.



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AM.02.512e edition 3



Installation , continued Installation of the PPL units



The following table instructs you on how to install the PPL 400/2 and 600/2 Step



Action



1



Install and tighten the frangible couplings (14) on the flanges (17).



2



Out of factory, the legs are provided with a length allowing you to install the PPL with the cut-off plane (plane passing through the centre of the objective lenses and the lower end of the red filters) located 900 mm above the ground. Adjusting with the positioning of the PPL onto the top part of the leg (ref 11) and the positioning of this top part onto the bottom part (ref 14), this distance can be reduced to about 700 mm. If this distance has still to be reduced, the bottom part of the leg assembly has to be cut to the adequate value (900 mm - the desired value). Place the bottom part of the leg assembly (ref 14) loose in the breakable coupling.



Illustration



3



Screw the adjustable differential setting sleeves (ref. 11 & 12) in the bottom part of the leg assembly (ref 14) and remove the top nut and washers.



4



Remove the cover from the unit and gently mount the unit on the legs .



5



Install the washers and hex nuts on the threaded top part (ref 11); do not tighten.



6



Make sure that the PPL rests on the nut of the right front leg F (see figure page 31).



7



Make sure that the centre point of the lens near the right front leg F is at a distance d as defined in figure page 22.



8



Tighten all locking nuts of the frangible coupling.



The following drawing shows the details of the leg assembly:



11 Length = 190 mm



12



Length = 80 mm



14



17



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AM.02.512e edition 3



PAPI wiring Introduction



Following figure will give an overview of different PAPI wiring methods. The four units at each side of the runway are wired into a series circuit. Two independent circuits are used to feed bilateral PAPI systems. Each lamp is fed trough an isolating transformer.



Illustration of typical wiring (for PPL400/2)



To the PAPI system at the other end of the Runway



Circuit Selectors



Constant Current Regulators To the PAPI system at the other end of the Runway



Circuit Selector



Constant Current Regulator



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AM.02.512e edition 3



PAPI wiring, Continued Single unit wiring



Illustration



The illustration below shows the wiring diagram of a single unit with the optional heating system.



PPL 400/2



PPL 600/2



Heating with thermostat (optional)



Heating with thermostat (optional)



Two pole plugs and receptacles



Two pole plugs and receptacles 200W 200W



Individual transformers



PRIMARY SERIES CIRCUIT



Individual transformers



PRIMARY SERIES CIRCUIT



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AM.02.512e edition 3



Levelling of units Definitions



The setting angle of the PAPI units is the angle between a horizontal plane and the cut-off plane. The cut-off plane is the plane passing through the centre of the objective lenses and the lower edge of the red filters and lies parallel to the reference plane formed by the reference adjusting screws A, B, and slots C and D (see figure next page).



Setting angles



If θ is the established glidepath angle for the airport and the units are set at angles progressively staggered by 20 minutes of arc, the setting angles of the units will be as follows : Unit n°



Angle



1



θ - 30 minutes of arc ( unit farthest from runway )



2



θ - 10 minutes of arc



3



θ + 10 minutes of arc



4



θ + 30 minutes of arc ( unit closest to runway )



If the centre channel is widened to 30 minutes of arc, the setting angles of the units will be as follows : Unit n°



Remark



Angle



1



θ - 35 minutes of arc ( unit farthest from runway )



2



θ - 15 minutes of arc



3



θ + 15 minutes of arc



4



θ + 35 minutes of arc ( unit closest to runway )



When handling the unit and in particular during installation and setting, movement of the reference adjusting screws A and B is prohibited. Any accidental movement of these screws will require resetting in the factory by specialised personnel. The levelling procedures are identical for PPL400/2 and PPL600/2. The drawings in this chapter are typical for the PPL400/2.



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AM.02.512e edition 3



Levelling of units, Continued Aiming device



This illustration shows you an aiming device.



Aiming notch (rear) Bubble level Aiming notch (Front) Graduated scale ( Degrees )



Bar Locator screws Base B D Movable arms



C



B



A



C D



A



(2 X)



Positioning of the Aiming Device



To install the aiming device, proceed as follows: Step



Action



1



Set the aiming device at the required setting angle for the unit



2



Open the light unit



3



Open up the two movable arms on the instrument, and place it on the light unit with the graduated scale near point C. Refer to the picture above to place it : A and B references correspond to the two reference screws and C and D correspond to the two slots.



4



Carefully position the precision bubble level between the locator screws on the bar or against the locator screws on the moveable arms.



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AM.02.512e edition 3



Levelling of units, Continued Aiming in Azimuth



To aim in azimuth, proceed as follows: Step



Action



1



Install the aiming device as explained above.



2



Place a rod 50 m from the unit and at the same distance from the runway as the reference points B-C.



3



Check the alignment through the V-sites of the bar of the aiming device. Use the sight picture:



If necessary, adjust the unit alignment. 3



Tighten nuts on the right front leg F: Leg F A



B



D



C



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AM.02.512e edition 3



Levelling of units, Continued Rough elevation setting



For the rough elevation setting, proceed as follows: Step 1



Action Place the level between A - B. Level by adjusting nuts of the front leg E. Leg E



A



B



D



C



Leg H



Leg G



Tighten these nuts simultaneously. 2



Place the level between B and C. Level by adjusting nuts of the right rear leg G. During this operation, the rigid bottom of the unit must be free from its nut on the left hand side H. These nuts may require loosening. Position upper nut of the right rear leg G against unit. Tighten simultaneously the two nuts.



Checking Azimuth setting



3



Place the level between C and D. Level by adjusting nuts on the left rear leg H. Position upper nut of the left rear leg H against unit. Simultaneously tighten both nuts.



4



Cross check the coarse setting.



Make sure that the rod located at 50 m from the unit is still properly aligned with the V-sites on the aiming device. If not, loosen all the lock-nuts and nuts. Align the unit in azimuth and repeat the previous operations It is not necessary for the alignment to be absolutely perfect. An error of 50 cm at 50 m yields an error of only 0.5°, which would still be acceptable.



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AM.02.512e edition 3



Levelling of units, Continued



Fine elevation setting



For fine adjustment of the elevation and normally for any subsequent adjustment, the following steps on the differential ring (Item 12) will need to be taken: Step



Action



1



Place the aiming device.



2



Make sure that the locking screw of the differential ring on the right front leg F is tightened. The locking screws of the other legs (E, G and H) have to remain loose.



3



Place the level between A and B. Proceed with the leveling process by turning the differential ring on the left front leg E in the proper direction. Tighten the locking screw of leg E differential ring.



4



Place the level between B and C. Proceed with the levelling procedure by adjusting the differential ring on the rear legs G, and H, turning both rings in the same direction with equal amplitude. Tighten the locking screw of the right rear leg G.



5



Place level between C and D. Proceed with the levelling process by turning the ring of the left rear leg H in the appropriate direction. Tighten the locking screw on leg H.



After these operations are completed, the unit will be accurately set both in azimuth and elevation.



Illustration 11 Length = 190 mm



12



Differential ring Locking screw Length = 80 mm



14



17



Bilateral systems



In case of bilateral systems, the corresponding units at each side of the runway shall be set consecutively without disturbing the setting of the aiming device. This will ensure a perfect synchronisation of the units on both sides of the runway.



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AM.02.512e edition 3



Checking slope angles of the light beams



Introduction



Procedure



It may be requested that when the equipment is put initially into operation and at regular intervals thereafter, that the cut-off angle of the units be checked. To make this measurement it will be necessary to use a surveying instrument or a bubble level with telescope and a surveyor's stake.



The procedure is as follows: Step



Action



1



Position the surveying instrument 2 to 3 metre behind the unit pointing down beam.



2



A surveyor's stake is held by an assistant approximately 5 metre in front of the unit.



3



Take reading A for the intersection of the horizontal of the telescope with the stake.



4



Take reading B for the intersection of the cut-off plane of the light beam with the surveyor's stake.



5



The assistant should now move a precisely measured distance D of about 20 metre (+0.25%) down beam and take the same measurements A' and B'



6



The angle x of the beam cut-off to the horizontal is found from : tan x = (A'B' - AB)/D where D is the horizontal distance between the two stake positions. If similar checks are to be scheduled in the future, a small concrete slab holding a galvanised pipe may be installed in front of each unit at the distances used above.



B'



B



A'



A Unit



Theodolite



7



Approx 5m



Approx. 20m ±5cm



1st position of stake



2nd position of stake



According to the ICAO, prior to use a PAPI or APAPI system, a flight check should be organized by the local civil aviation, operations or Airport Authorities



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AM.02.512e edition 3



Reference bases for checking stick As soon as the system is found to be operationally acceptable in all respects, permanent sighting bases should be installed in front of each light unit to allow for routine checks of the elevation setting using the checking stick. 23 mm



Introduction



500 mm



Approx. 300 mm



Approx. 400 mm



Locating reference bases



Observations with checking stick



Step



Piece of 1" steel gas pipe, closed at top and Galvanised



Action



1



A concrete sighting base should be located on the extended center line of each unit.



2



When the PAPI is switched on, walk along the center line of the unit observing it from time to time through the screen until the lower limit of the white sector is about to disappear under the first scored line.



3



At this point, dig a hole approximately 400 mm square and 300 mm deep. Drive in a steel pipe vertically in the center of the hole until its top is at ground level. Place the bottom end of the checking stick on top of the pipe and observe the light unit through the screen. Gradually drive the pipe into the hole, while frequently observing the light unit through the screen, until the light beam no longer appears completely white just below the upper line of the screen.



4



Repeat this procedure for the other units, using the same observer.



5



Pour concrete in the holes.



Place checking stick on the concrete sighting base in front of the light unit and switch the PAPI system on. Observe the light unit through the screen. Just below the upper line of the screen, the light beam should no longer appear completely white. If this is not the case, the unit is out of alignment and requires resetting. Distance from unit will vary according to light beam level, ground elevation and unit angle setting.



Electrical connection 35



AM.02.512e edition 3



Connection Kit



Using the connection kit described below the picture, operate as follows: Towards treshold PPL



1



2



Flexible conduits Breakable coupling 1 3 Base ( FAA L-867 ) 3



Primary cables



2 or 3 threaded holes for compression glands PG 13.5



Item



Procedure



Designation



Qty/Unit PPL400/2



PPL600/2



Remarks



1



Gland ( PG 13,5 ) for flexible conduit



4



6



Supplied



2



Flexible conduit (1m long)



2



3



Supplied



3



Steel cover 10mm with 2 or 3 holes for gland 13.5



1



1



Optional



(2 holes)



(3 holes)



Step



Action



1



Remove the compression glands PG16 (A) and the two feeder cables with FAA 2-pole plug (B).



2



Cut the 1m long flexible conduits at the desired length (according to the PPL height).



3



Put the special glands for flexible (2) on each side of the conduits (1).



4



Fasten one end of the conduit fitted with the gland (1) on the steel cover (3).



5



Put the reducer PG16/PG13,5 (1) on the other end of the flexible conduit.



6



Fasten the reducer to the PPL unit by means of the nut (A') removed from the compression gland (A). Beginning at the steel cover, run the cables from its fast-on connectors side through the conduits.



7



Connect the cable on the fast-on connectors of the lamp. Connect the plug FAA-L823 (on the other side of the feeder cable) to the transformer secondary female plug into the steel base (5).



8



Close the base, tighten the screw with respect to the torque (20Nm).



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AM.02.512e edition 3



Chapter 3: Maintenance Overview Introduction



In order to reduce maintenance to a minimum, ADB has adopted the simplest possible design and has used the best materials and protective treatments. The light unit will give the best results only if handled with great care and well maintained throughout its lifetime.



Contents



This chapter contains the following topics. Topic



See Page



Preventive maintenance



38



How to replace a lamp



39



How to replace the filters



39



The front protection glass should always be present and replaced if damaged to avoid later lens damage. Lenses cannot be field replaced as they need to be callibrated parallel and in level to guarantee a perfect transition of a precision system.



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AM.02.512e edition 3



Preventive maintenance Preventive maintenance tasks



In the table below you will find a checklist of preventive maintenance tasks:



Interval Daily *



Check



Action



Check elevation angle of units (first few weeks).



Reset units if out of alignment (see Checking slope angles of the light beams page 34).



Check equipment for proper operation.



Repair, adjust or replace.



Weekly ** Using soft cotton cloth moistened with alcohol, clean outer surface of front protection glass. Monthly



Inspect housing and closure system, lamps, electrical connections, filters and protective glass for damage, breakage or warpage.



Repair or replace.



Clean interior surface of housing, remove any foreign matter. Use soft cotton cloth moistened with alcohol to clean both sides of the protective glass, colour filters, lenses and reflectors. Make sure unit mounting is rigid.



Tighten loosen hardware nuts, screws, etc. Realign unit if hardware has loosened.



Make sure no vegetation obscures the light beam.



Remove growth in the vicinity of equipment. Use weed killer.



Make flight check of system if possible.



Observe proper approach angle.



* When the light unit has stabilised, checks may be made weekly. ** More frequently during the rainy season and when there is bare soil in front of the light units



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AM.02.512e edition 3



How to replace a lamp Procedure



The following table instructs you on how to replace a lamp: Step



Action



1



Deenergize the circuit.



2



Open the light fixture.



3



Remove the electrical fast-on fitting on burned-out lamp (8). Check cable fast-on and replace if necessary.



4



Swing back the springloaded fork (9).



5



Remove the lamp from the reflector (7).



6



A new lamp can be installed by reversing this procedure.



Caution: Wear cotton gloves when handling the lamps. Touching the quartz bulb with your bare fingers may seriously shorten the lamp life. If the quartz bulb has been touched, wipe it carefully with lens cleaning tissue or similar material moistened with isopropyl alcohol or methylated spirit. It is recommended that a systematic replacement of all the lamps be made after a service period of approx. 800 hours at the 100% brightness level. An elapsed time recorder connected to the constant current regulator may be used to determine the time for replacement.



Illustration



The illustration below clarifies the procedure: (PPL 400/2) 7



9



8



10



How to replace the filters 39



AM.02.512e edition 3



Procedure



The following table instructs you on how to replace a filter: Step



Action



1



Deenergize the circuit.



2



Open the light unit.



3



Loosen the spring (rep 5).



4



Remove the filter.



5



Place a new filter in its holder with the side without chamfer down.



6



Reverse this procedure.



The filters must be perfectly clean. Use a soft cotton cloth moistened with alcohol or methylated spirit to clean filters and wear cotton gloves when handling filters



Illustration



The illustration below clarifies the procedure: (Here for a PPL 400/2) 6



5



10



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AM.02.512e edition 3



Chapter 4: Troubleshooting Troubleshooting In the table below a number of problems are listed in the first column. In the second column, you will find the possible causes of the problem, and in the third table column the solution: Before attempting to service, de-energise and lockout the circuit or the regulator so that the fixture can not be energised by remote means. Problem All lamps out



Lamp(s) dim



Possible cause



Solution



Power supply



Repair or replace loose or broken wire or transformer, check CCR operation.



All lamps burned out



Replace bulbs. Check input current level.



Dirty lens shield



Clean with soft cotton cloth moistened with alcohol or methylated spirit.



Lamp not properly seated in reflector



Re-seat lamp in reflector.



Current level too low



Check with Ampèremeter.



Unit improperly aligned Use checking stick (see Checking slope Broken lens, broken front angles of the light beams page 34). glass, filter or filter positioning Short lamp life



Current level too high



Check input current level at lamp and output current at CCR. Check rating of isolating transformer.



In case they are Thermostat defective installed: Defective heater Heater will not Loose or broken wire operate.



Replace thermostat. Replace heater. Repair or replace.



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AM.02.512e edition 3



Chapter 5: Assemblies and Exploded Views Overview Introduction



In this chapter you will find an overview of the main sub-assemblies and the exploded view of the PPL 400/2 light.



Contents



This chapter contains the following topics. Topic



See Page



Assemblies



43



Exploded view



46



Description of part names



47



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AM.02.512e edition 3



Assemblies Spare parts



In order to limit the MTTR (Mean Time To Replace) of this vital equipment, it is recommended to keep a sufficiently large stock of spare. It will mainly consist of consumables like lamps. Other components that may need replacement, such as filters and hardware, should be stocked in smaller quantities.



List of tables



Below you will find a list of the tables in this chapter: Table



See page



Table 1: Main parts



44



Table 2: Mandatory/ additional parts



45



Table 3: Optional parts



45



Table 4: Tools



45



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AM.02.512e edition 3



Assemblies, continued Table 1: Main parts



In the table below you will find all parts of the PPL units. The basic PPL 400/2-unit described hereunder is suitable either for frangible FAA legs or for anchoring legs mounting . See next page for “additional mandatory parts for mounting system” References



Ref.



Qty/ pcs



Description



Recommended spares



PPL



Code number



400/2-600/2



1434.20.041



1



1434.30.021 1



4071.12.301



1 1



4070.95.570 20



7092.32.222



4m



2



6830.11.321



1



6830.11.360 19



4071.12.350



6m



1



PPL 600/2 unit comprising:



1



Cover assembly PPL 400/2



-



Cover assembly PPL 600/2



-



Gasket between cover and housing



10m



Clear front protection glass PPL400/2



2



Clear front protection glass PPL600/2



2



Gasket for front glass



2



1



Gasket for front glass



2



Red filter Retaining spring for filter



4 8



1 1



4071.41.550



PPL 400/2 unit comprising:



6 5



1438.12.220 4070.64.230



2



3



4



6



8



2990.48.310



2



3



Pre-focus halogen lamp 200W-6,6A Pk30d



16



1458.06.080



2



3



Cable assembly



1



11



4070.97.520



1 4 8 8 8 4 4 4 4 4



1 4 8 8 8 4 4 4 4 4



Compensation assembly consisting of: Upper mounting rod M10 Hex. Nut M10 Lock washer for M10 Flat washer for M10 Setting nut assembly Lower mounting rod M14 Hex. Nut M14 Lock washer for M14 Flat washer for M14



1



12



100%



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AM.02.512e edition 3



Assemblies, continued Table 2: Mandatory/ additional parts



References



Qty/ pcs



Description



Ref.



Code number



13



1434.00.911



4



Anchoring legs



14



1439.11.130



1



Set of frangible legs assembly consisting of:



4 4 4



Table 3: Optional parts



References Ref.



8



Qty/ pcs



Height adjusting leg Breakable coupling Flange ring



Description



Code number 1434.20.910



1



Heater ( anti condensation with thermostat ) 220V



1434.20.920



1



Heater ( anti condensation with thermostat ) 110V



2990.48.320



2



Pre-focus halogen lamp ( 100W – 6.6A ) Pk30d Anti-condensation front glass.



Table 4: Tools



References Ref.



Qty/ pcs



Description



Code number 1439.05.221



Carrying box with install. tools for PPL 400/2 and PPL 600/2



1439.10.020



Drilling jig for PPL 400/2 with FAA adj. Legs Drilling jig for PPL 600/2 with FAA adj. Legs.



1439.10.910



Positioning template for PPL 400/2



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AM.02.512e edition 3



Exploded view PPL 400/2 The illustration below represents the exploded views of the PPL 400/2 PAPI unit.



PPL 400/2



1 19



4



6



7



5



9



8



11 12



20



13



2



14 3 15



17



10 18



16



Exploded view PPL 600/2 46



AM.02.512e edition 3 PPL 600/2



The illustration below represents the exploded views of the PPL 600/2 PAPI unit.



Description of part names 47



AM.02.512e edition 3 PPL



This table will show you the description of the parts as shown in the exploded view on the previous page Part n°



Description of part names



1



Aluminium cover



2



Front protection glass



3



Outer lens



4



Inner lens



5



Retaining spring for filter



6



Red filter



7



Specular finish aluminium reflector



8



Pre-focus halogen lamp



9



Lamp holding fixture



10



Folded aluminium housing with lockable latches



11



Mounting top leg assembly



12



Differential setting sleeves



13



Aluminium anchoring leg



14



Breakable coupling and height adjustable leg assembly (optional)



15



Compression bushing PGW 13,5



16



2-core cable with 2-pole plug



17



Flange ring



18



Anchor bolts (optional)



19



Gasket for front glass



48



N.V. ADB S.A. Leuvensesteenweg, 585 – B 1930 Zaventem – Belgium Tel. : 32/2/722.17.11 – Fax : 32/2/722.17.64



49