PAR-38 PAR-56 LED Light Source Specification_Update Amendment 1.pdf

FAA-E-37013

April 2022

U.S Department of Transportation Federal Aviation Administration

PERFORMANCE SPECIFICATION

PAR-38 AND PAR-56 LIGHT EMITTING DIODE (LED)

STEADY BURNING LIGHT SOURCES

FOR THE

MEDIUM INTENSITY APPROACH LIGHTING SYSTEM

WITH RUNWAY ALIGNMENT INDICATOR LIGHT

(MALSR)

FAA Visual Guidance Lighting Systems Team

AJM-3220

i April 2022

TABLE OF CONTENTS

1. SCOPE

2. APPLICABLE DOCUMENTS

2.1 General

2.2 Government Documents

2.2.1 FAA specifications, standards, handbooks, and drawings

3. REQUIREMENTS

3.1 PAR-56 LED Light Source Requirements

3.1.1 Physical Requirements

3.1.2 Optical Requirements

3.2 PAR-38 LED Light Source Requirement

3.2.1 Physical Requirements

3.2.2 Optical Requirements

3.3 Electrical Requirements

3.3.1 Power Demand

3.3.2 Input Voltage

3.3.3 Input Power Frequency

3.3.4 Power Factor

3.3.5 Power Outages

3.3.6 Response Time

3.3.7 Pulse Width Modulation

3.3.8 Electromagnetic Interference (EMI)

3.3.9 Electrostatic Discharge Protection

3.4 Environmental Requirements

3.4.1 Operational Environmental Requirements

3.4.2 Non-operating Environmental Requirements

3.5 Workmanship

3.6 Marking

3.7 Fungus-Proof Materials

3.8 Ultra-Violet Protection

3.9 Metals

3.10 Printed Circuit Boards

3.10.1 Conformal Coating of Printed Circuit Boards

3.10.2 Assembly

3.11 Reliability

4. VERIFICATION

4.1 Verification Requirements Traceability Matrix

4.2 Test Allocation

4.2.1 Development Test (DT)

4.2.2 Production Acceptance Tests (PAT)

4.2.3 Type Tests

4.2.4 Operational Test (OT)

4.3 Test Procedures

4.3.1 Visual Inspection

4.3.2 Electrical Tests

ii April 2022

4.3.3 Electromagnetic Interference Test

4.3.4 LED Light Source Weight Test

4.3.5 Aiming Device and Aiming Angle Test

4.3.6 Pulse Repetition Rate Test

4.3.7 Response Time Test

4.3.8 Environmental Tests

4.3.9 Photometric Tests

4.3.10 Functional Tests

4.3.11 Reliability Demonstration

4.4 Test Tools

5. PACKAGING

6. ADDITIONAL INFORMATION

6.1 Intended Use

6.1.1 Green Threshold LED Light Sources

6.1.2 White Steady Burning LED Light Sources

6.2 Design Considerations

6.3 LED Driver Circuit

6.4 Recycled, Recovered, or Environmentally Preferable Materials

6.5 Definitions

6.6 MALSR Systems in the National Airspace System

APPENDIX A. VERIFICATION REQUIREMENTS TRACEABILITY MATRIX (VRTM) ... 32

iii April 2022

Table of Figures

Figure 3-1. Mogul End Straight Prong Figure 3-2. Main Beam Pattern Figure 3-3. Lamp Holder Aiming Device Type FA-11507 Figure 3-4. Steady Burning Beam Pattern

List of Tables

Table 3-1. Required Levels of Average Intensity Table 3-2. Required Levels of Intensity Extremes Table 3-3. PAR-38 Lamp Holders Table 3-4. Required Levels of Steady Burning Light Average Intensity Table 3-5. Input Voltage Table 3-6. Sand and Dust Particles Table 3-7. Vibration Profile Parameters Table 4-1. Development Tests Table 4-2. Production Acceptance Tests Table 4-3. Type Tests Table 4-4. Lamp Orientation Table 4-5. Sand and Dust Particles Table 4-6. Combined Rain and Wind Table 4-7. Vibration Profile Parameters Table 4-8. Average Intensity Table 4-9. Intensity Extreme Table 4-10. Required Levels of Steady Burning Light Average Intensity Table 6-1. MALSR Systems in the NAS

1 April 2022

1. SCOPE

This FAA specification establishes the performance and verification requirements for the PAR-56 and PAR-38 Light Emitting Diode (LED) light source in the MALSR system.

2. APPLICABLE DOCUMENTS

2.1 General

The documents listed in this section are specified in sections 3, 4, or 5 of this specification. This section does not include documents cited in other sections of this specification or recommended for additional information or as examples. While every effort has been made to ensure the completeness of this list, document users are cautioned that they must meet all specified requirements of documents cited in sections 3, 4, or 5 of this specification, whether or not they are listed.

2.2 Government Documents

2.2.1 FAA specifications, standards, handbooks, and drawings

The following specifications and handbooks form a part of this document to the extent specified herein.

Unless otherwise specified, the issues and revisions of these documents are those cited in the solicitation or contract.

2.2.1.1 FAA specifications

FAA-E-928j PAR-56 Lamp holder FAA-G-2100H Electronic Equipment, General Requirements FAA Engineering Brief 67D Light Sources Other than Incandescent and Xenon for

Airport and Obstruction Lighting Fixtures

2.2.1.2 FAA standards

FAA-STD-019f, Chg 2 Lightning and Surge Protection, Grounding, Bonding, and Shielding Requirements for Facilities and Electronic Equipment

2.2.1.3 FAA drawings

AE-C-1391-15 Hoelting Aiming Device PAR-38 Mounting Ring

2.2.1.4 Military specifications and handbooks

MIL-T-152B Treatment, Moisture and Fungus Resistant, of Communications, Electronic and Associated Electrical Equipment

MIL-STD-889 Dissimilar Metals MIL-HDBK-1516 Unified Code for Coatings and Finishes for DOD Materiel

2 April 2022

MIL-STD-810H Environmental Considerations and Laboratory Tests

2.2.1.5 External documents

2.2.1.5.1 ASTM International

ASTM D295 Standard Test Methods for Varnished Cotton Fabrics Used for Electrical Insulation

ASTM D3955 Standard Specification for Electrical Insulating Varnishes ASTM E308-01 Standard Practice for Computing the Colors of Objects by

Using the CIE System

2.2.1.5.2 National Electrical Manufacturers Association (NEMA)

ANSI C81.61 American National Standard for Electric Lamp Bases – Specifications for Bases (Caps) for Electric Lamps

ANSI/ESD STM11.11 Surface Resistance Measurements of Static Dissipative Planar Materials

2.2.1.5.3 Institute of Printed Circuits

IPC-A-600 Acceptability of Printed Boards IPC-CC-830 Qualification and Performance of Electrical Insulating

Compound for Printed Wiring Assemblies IPC-A-610 Acceptability of Electronic Assemblies J-STD-001 Requirements for Soldered Electrical and Electronic

Assemblies

2.2.1.5.4 International Civil Aviation Organization (ICAO)

Annex 14 Aerodromes

2.2.1.5.5 Society of Automotive Engineers (SAE)

SAE-AS25050 Colors, Aeronautical Lights, and Lighting Equipment, General Requirements for

3 April 2022

3. REQUIREMENTS

The green steady burning light emitting diode (LED) light source shall be a direct replacement for the Medium Intensity Approach Lighting System with Runway Alignment Indicator Lights (MALSR) elevated green-filtered incandescent PAR-56 lamp. The individual requirements for PAR-56 are specified in Section 3.1.

The white steady burning light emitting diode (LED) light source shall be a direct replacement for the MALSR elevated incandescent PAR-38 lamp. The individual requirements for PAR-38 are specified in Section 3.2.

Requirements in Sections 3.3 through 3.11 are applicable to both light sources.

3.1 PAR-56 LED Light Source Requirements

The green threshold LED light source shall interface, mechanically and electrically, with the current PAR-56 lamp holder specified in FAA-E-982j. No modification to the PAR-56 lamp holder shall be required to install and operate the green threshold LED light source. The green threshold LED light source shall properly operate using the existing voltages provided by the

MALSR.

3.1.1 Physical Requirements

3.1.1.1 PAR-56 Electrical Interface

The PAR-56 LED light source shall have a ceramic Mogul End, Straight Prong connector fitting a GX16D connector as specified in FAA-E-2408b, paragraph 3.6.4 and Figure 3-1 below.

Figure 3-1. Mogul End Straight Prong

4 April 2022

3.1.1.2 Size

3.1.1.2.1 LED Light Source Base

The green threshold LED light source shall occupy the available volume allocated to the standard incandescent PAR-56 lamp used in the PAR-56 lamp holder.

3.1.1.2.2 LED Light Source Lens

The outer edge of the LED light source shall fit securely into the mounting clip specified in section

3.3.1.1 of FAA-E-982j. No part of the LED light source lens shall protrude more than 1 inch from the lamp holder.

3.1.1.3 Weight

The green PAR-56 LED light source shall weigh no greater than three (3) pounds (lbs).

3.1.1.4 Center of Gravity

The location of the center of gravity for the green threshold LED light source shall not adversely affect the ability of the PAR-56 Light Assembly to remain locked at an aiming angle while exposed to the combined wind and rain conditions specified in section 3.4.1.6.

3.1.1.5 Vertical Adjustment

The green threshold LED light source shall operate over the entire vertical alignment range from 0° horizontal to 25° above horizontal.

3.1.2 Optical Requirements

The green threshold LED light sources shall meet all the following requirements under the operating environmental conditions specified in Section 3.4.1.

3.1.2.1 Beam Pattern

The green PAR-56 LED light source beam shall exhibit an elliptical shape defined by the standard ellipse equation:

b Y a X where X is the horizontal axis coordinate and Y is the vertical axis coordinate. The outer bounds of the light beam shall be no closer than ±6° from the optical centerline along the horizontal axis (a = 6) and shall be no closer than ±4° from the optical centerline along the vertical axis (b = 4).

(shown in Figure 3-4)

5 April 2022

Figure 3-2. Main Beam Pattern

The aviation green output of the steady burning LED light sources shall produce three intensity steps that are determined by input voltages in Table 3-5. Input Voltage. Within the steady burning main beam pattern described in Section 3.1.2.1, the average intensity shall be within the required levels as stated in Table 3-1. Required Levels of Average Intensity.

Table 3-1. Required Levels of Average Intensity

Pattern Average Intensity (Candela) Low Medium High

Main Beam 145 ± 30 715 ± 145 5,000 ± 1,000

3.1.2.3 Intensity Extremes

Within the light beam pattern described in 3.1.2.1, no measured intensity shall be less than the minimum allowable intensity listed in Table 3-2. Required Levels of Intensity Extremes for each intensity step. Within the light beam pattern described in 3.1.2.1, the maximum measured intensity shall be no greater than the maximum allowable intensity listed in Table 3-2. Required Levels of Intensity Extremes for each intensity step. The maximum measured light intensity shall reside within ± 3°circle of the light unit centerline (see Figure 3-2. Main Beam Pattern).

Table 3-2. Required Levels of Intensity Extremes

Light Source Intensity Extremes (Candela) Low Medium High

Minimum Maximum Minimum Maximum Minimum Maximum 80 360 400 1,800 2,000 9,000

6 April 2022

3.1.2.4 Chromaticity

The color of the light emitted from the PAR-56 LED light source shall be Aviation Green according to the boundaries listed below for LED Chromaticity Boundaries, as plotted in the CIE 1931 (x, y) Chromaticity Diagram. If multiple LEDs are used within a light source, each LED shall meet the same specification.

• Green (ICAO Modified) with chromaticity boundaries in the CIE 1931 (x, y):

o Blue boundary: y = 0.768 - 1.306x o White boundary: y = 0.600 o Yellow boundary: y = 3.470 - 9.200x

• Boundary Intersection Points for aviation green:

o x = 0.014, y = 0.750 o x = 0.129, y = 0.600 o x = 0.302, y = 0.692 o x = 0.312, y = 0.600

3.2 PAR-38 LED Light Source Requirement

The white steady burning LED light source shall interface, mechanically and electrically, with the current PAR-38 lamp holders specified in Table 3-3. No modification to the PAR-38 lamp holder shall be required to install and operate the white steady burning LED light source. The white steady burning LED light source shall properly operate using the existing electrical and control signals provided by the MALSR. The white steady burning LED light source shall fit securely into the lamp holders.

Table 3-3. PAR-38 Lamp Holders

TYPE NUMBER MANUFACTURER

FA-10290/5 AVW

FA-11506 DME

FA-10267/5 Godfrey FA-10097/5 Godfrey FA-9877 Unit-3 Multi-Electric FA-9426/3 Multi-Electric FA-8767/LH Multi-Electric FA-8091/LH Multi-Electric

3.2.1 Physical Requirements

3.2.1.1 Light Source Socket

The white steady burning LED Light Sources shall have a Medium Screw, Skirted Base (E26) as specified in ANSI/IEC C81.61.

7 April 2022

3.2.1.2 Size

3.2.1.2.1 Light Source Length

The total length of the PAR-38 LED light source shall not exceed 6.0 inches.

3.2.1.2.2 Light Source Lens

The outer edge of the LED light source shall fit securely into the mounting ring of the lamp holder aiming device using the dimensions specified in Figure 3-3 below. Maximum diameter of the LED light source shall be no larger than 4.92 inches. No part of the LED light source lens shall protrude through the center of the mounting ring more than ¼ of an inch.

Figure 3-3. Lamp Holder Aiming Device Type FA-11507

3.2.1.3 Weight

The white steady burning LED light source shall weigh no greater than two and a half (2.5) lbs.

with a goal of one and a half (1.5) lbs.

8 April 2022

3.2.1.4 Center of Gravity

The location of the center of gravity for the white steady burning LED light source shall not adversely affect the ability of the PAR-38 Light Assembly to remain locked at an aiming angle while exposed to the combined wind and rain conditions specified in Section 3.4.1.6.

3.2.1.5 Vertical Adjustment

The white steady burning LED light source shall operate over the entire vertical alignment range from 0° horizontal to 25° above horizontal.

3.2.2 Optical Requirements

The white steady burning LED light sources shall meet all the following requirements over the operating environmental conditions specified in Section 3.4.1.

3.2.2.1 Beam Pattern

The white steady burning LED light beam pattern shall be circular in shape (shown in Figure 3-4) along the optical centerline of the LED light source. The outer bounds of the main-beam pattern shall be ±8 degrees.

Figure 3-4. Steady Burning Beam Pattern

3.2.2.2 Main Beam Average Intensity

The aviation white output of the steady burning LED light sources shall produce three intensity steps that are determined by the input voltages as specified in Table 3-5. Within the steady burning

9 April 2022 main beam pattern described in Section 3.2.2.1, the average intensity shall be within the required levels as stated in Table 3-4.

Table 3-4. Required Levels of Steady Burning Light Average Intensity

Pattern Steady Burning Average Intensity (Candela) Low Medium High

Main Beam (±8°) 250 ± 40 1,250 ± 200 10,000 ± 1500

3.2.2.3 Intensity Extremes

Within the main-beam (±8°), no measured intensity point shall be greater than 15,000 Candela.

3.2.2.4 Chromaticity

The color of the light emitted from the elevated steady burning LED light source shall be within the boundaries listed below for LED Chromaticity Boundaries, as plotted in the CIE 1931 (x, y) Chromaticity Diagram.

• Boundary Intersection Points:

o x = 0.4003, y = 0.4034 o x = 0.3737, y = 0.3879 o x = 0.3671, y = 0.3583 o x = 0.3895, y = 0.3708

3.3 Electrical Requirements

3.3.1 Power Demand

The average wattage rating of the LED light sources shall be no greater than 25W, with a goal of 20W.

3.3.2 Input Voltage

The PAR-38 and PAR-56 LED light sources shall produce three light intensities at three discrete input line voltages as described in Table 3-5 below. The LED light source shall operate properly and not be damaged by voltage variations of ±5% VAC at each intensity level.

Table 3-5. Input Voltage

Intensity Level

PAR-38 Average Light Intensity

PAR-56 Average Light Intensity Input Voltage

Low 250 ± 40 Candela 145 ± 30 Candela 50 ± 5% VAC Medium 1,250 ± 200 Candela 715 ± 145 Candela 75 ± 5%VAC

High 10,000 ± 1500 Candela 5,000 ± 1,000 Candela 120 ± 5% VAC

10 April 2022

3.3.3 Input Power Frequency

The LED light source shall accept input power at a frequency of 60Hz. The LED light source shall not be damaged or experience performance degradation with steady state or momentary deviation in input frequency, as specified:

Frequency:

(1) Steady State

(a) Steady state 60 Hz ±3 Hz

(b) Steady state rate of change 1.5 Hz/sec

(c) Steady state frequency variation ±0.5 Hz

(2) Momentary deviations (.5 seconds to 3 seconds)

(a) 60 Hz +5 Hz, -7 Hz

(b) Rate of change 5 Hz per sec.

3.3.4 Power Factor

The LED light source power factor shall be ≥ 0.9.

3.3.5 Power Outages

The LED light source performance shall not be damaged by MALSR facility power outage conditions. Any solid-state devices within the LED light source shall remain active for 100 ms following a power interruption to avoid an inadvertent light source outage. The LED light source shall automatically reset, if necessary, on power restoration in the event of a power interruption.

3.3.6 Response Time

The LED light source driver circuit shall respond to an intensity step change in less than one (1) second after receiving the change of input voltage.

3.3.7 Pulse Width Modulation

If Pulse Width Modulation is used, the pulse repetition rate shall be greater than 120 Hz.

3.3.8 Electromagnetic Interference (EMI)

3.3.8.1 Radiated Emission Interference

The LED light source and associated on-board circuitry shall meet the Radiated Emission Interference requirements of the Federal Communications Commission (FCC) Title 47, Subpart B, Section 15, “Unintentional Radiators”, 47 CFR 15.109 Class B Radiated emission limits, regulations concerning the emission of electronic noise. The frequency range is 30 MHz to 1000 MHz with the field strength limits identified in the FCC reference above.

11 April 2022

3.3.8.2 Radiated Susceptibility

The LED light source shall meet the Radiated Susceptibility requirements of RS103 defined in MIL-STD-461G. The frequency range shall be 2 MHz to 18 GHz. The electric field intensity limits shall be as specified in Table XI RS103 for Navy ground equipment of MIL-STD-461G.

3.3.9 Electrostatic Discharge Protection

The LED light source shall provide Electrostatic Discharge (ESD) protection to reduce the frequency of ESD events and to minimize the effects as specified below. All electronic circuitry that contain miniaturized or solid-state components shall be considered ESD susceptible.

• Electrostatic shielding materials are a subset of conductive materials with a surface resistance equal to or less than 1.0 x 103 ohms when tested per ANSI/ESD STM 11.11.

• Electrostatic shielding materials are permitted as barriers for protection of ESD sensitive items from electrostatic fields.

3.4 Environmental Requirements

3.4.1 Operational Environmental Requirements

The LED light source shall operate properly under the environmental conditions specified below.

3.4.1.1 Temperature

The LED light source shall exhibit no adverse effects during operation at temperature ranges between -40°C to +67.2°C.

3.4.1.2 Humidity

The LED light source shall exhibit no adverse effects during operation at relative humidity levels between 0 to 100% humidity over the temperature range of -40°C to +67.2°C.

3.4.1.3 Altitude

The LED light source shall exhibit no adverse effects during operations at an altitude range from zero feet (0, +300) to 10,000 feet Mean Sea Level (MSL).

3.4.1.4 Sand and Dust

The LED light source shall exhibit no adverse effects during exposure to windblown sand and dust particles in accordance with Table 3-6.

12 April 2022

Table 3-6. Sand and Dust Particles Blowing Dust

Mean % by weight Particle size Wind Speed

100% Particles < 150μm

(140 mesh silica flour or equivalent)

1750 feet/minute (8.9 meters/second)

Blowing Sand Mean % by weight Particle size Wind Speed

90 ± 5% 150μm < Particles < 600μm 5700 feet/minute (29 meters/second)

5% 600μm <= Particles < 850μm 5700 feet/minute (29 meters/second)

3.4.1.5 Salt Fog

The LED light source shall operate under exposure to salt-laden atmosphere of 5.0 ±1% sodium chloride by weight with relative humidity of 0 to 100% humidity.

3.4.1.6 Combined Rain and Wind

The LED light source shall operate under exposure to windblown rain at rain rates up to 6 inches/hour and wind velocities up to 40mph using drop sizes of 0.02 in. to 0.18 in.

3.4.1.7 Thermal Shock

The LED light source shall withstand exposure of external surfaces (including the light window) to a sudden application of cold (0°C to 5°C) water when the light source reaches stable temperatures in the high intensity mode.

3.4.1.8 Solar Radiation (Sunshine)

The LED light source shall withstand 1,120 watts per meter squared (355 British Thermal Units per square foot per hour) of sunshine intensity.

3.4.1.9 Vibration

The LED light source installed the lamp holder shall be capable of withstanding vibrations on all three axes in the frequency range of 10 to 2,000 Hz in the transverse, longitudinal, and vertical directions with the parameters presented in Table 3-7. Following the vibration test, the LED light source shall be thoroughly examined for mechanical failure of any component, loosening of any part, cracked or broken seals, continuity of electrical circuits, and possible damage to supports, etc.

13 April 2022

Table 3-7. Vibration Profile Parameters

Vibration Test Data Acceleration in G's Frequency (Hz)

0.020 inch (0.5mm) double amplitude (Peak to Peak displacement) 10-70

3 70-200 3 200-500 3 500-2,000

3.4.1.10 Ice Dissipation

The energized LED light source shall dissipate the accumulation of ice on the face of the light source within 10 minutes when exposed to an ambient air temperature of -10⁰C, ±2⁰C and water droplet temperature of 0°C to +3°C.

3.4.1.11 Combined Wind and Ice Loading

The LED light source shall operate normally with 0.5-inch radial ice load in winds of 100 mph.

3.4.1.12 Internal Condensation

The LED light source design shall prevent internal condensation and accumulation of moisture.

3.4.2 Non-operating Environmental Requirements

The LED light source shall not be damaged when stored or transported under conditions delineated in the non-operating conditions specified below:

• Temperature -50°C to +67.2°C

• Relative humidity 0% to 100% including condensation due to temperature changes

• Altitude 0 to 50,000 feet above sea level

3.5 Workmanship

Each LED light source shall be free of blemishes and defects. Soldering, welding, brazing, cementing, and wiring shall be thorough. Alignment of parts shall be accurate. The mogul end prongs shall be straight, without bends, twists, or burrs. Loose, spattered or excess solder, metal chips, flux, and other foreign material shall be removed during and after final assembly of the LED light source.

3.6 Marking

Each LED light source shall be marked in the back with:

• Manufacturer

• Serial Number

• Part Number

• Wattage

14 April 2022

The marking shall be permanent and remain legible for the life of the light source. Stick on labels shall be unacceptable.

3.7 Fungus-Proof Materials

Materials that are nutrients for fungi shall not be used. Fungus protection shall be provided based on the environmental conditions.

3.8 Ultra-Violet Protection

Materials that degrade or deteriorate when subjected to ultra-violet radiation shall be protected with the appropriate coating.

3.9 Metals

If metals are used in the housing of the LED light source, they shall be compatible with the material used in their respective lamp holder. Metals shall be corrosion resistant or shall be coated or metallurgically processed to resist oxidation and environmental conditions in the Section 3.4.

• Materials and processes for metallic parts shall conform to applicable requirements in MIL-STD-889 and MIL-HDBK-1516.

• Coatings shall be selected from MIL-HDBK-1516.

• Non-corrosion resistant steel alloys, except where specifically required for electronic purposes shall not be used.

3.10 Printed Circuit Boards

Printed circuit boards shall be in accordance with IPC-A-600E.

3.10.1 Conformal Coating of Printed Circuit Boards

Printed circuit boards shall be conformally coated in accordance with ANSI/IPC CC-830.

3.10.2 Assembly

Assembly shall be in accordance with ANSI/IPC-A-610 and ANSI/J-STD-001B.

3.11 Reliability

The LED light source shall have a Mean Time Between Failures (MTBF) of greater than or equal to 50,000 hours as a serial reliability model. The Reliability Demonstration shall be conducted in accordance with MIL-HDBK-781A, Paragraph 4.

15 April 2022

4. VERIFICATION

4.1 Verification Requirements Traceability Matrix

Appendix A contains the Verification Requirements Traceability Matrix (VRTM) applicable to this specification. Methods utilized to accomplish verification include:

1. Demonstration (D): Demonstration is a method of verification that is accomplished by operation, adjustment, or reconfiguration of items performing their designed functions under specific scenarios. The items may be instrumented, and quantitative limits of performance monitored, but only observational data rather than actual performance data is required to be recorded for verification. Demonstration is often used to verify compliance with requirements in servicing, reliability, maintainability, transportability, and human factors engineering.

2. Test (T): Test is a method of verification that is accomplished, with or without instrumentation, through systematic exercising of the application item under appropriate conditions with the collection, analysis, and evaluation of quantitative data.

3. Analysis (A): Analysis is a method of verification that consists of comparing hardware or software design with known scientific and technical principles, technical data, models, or procedures and practices to verify that the proposed design will meet the specified functional/performance requirements.

4. Inspection (I): Inspection is a method of verification that is accomplished by a visual examination of the item, reviewing descriptive documentation, and comparing the appropriate characteristics with predetermined standards to determine conformance to requirements without the use of laboratory equipment or procedures.

4.2 Test Allocation

4.2.1 Development Test (DT)

The primary objective of DT is to demonstrate that all specified technical and performance requirements for a system or service have been met. DT is typically conducted within a controlled test environment and may include the use of third-party test facilities or laboratories.

First article units shall be used for performing the DT of the product. If multiple first article units are required for initial DT, then all members of that group will be referred to herein as part of the first article. DT is conducted prior to FAA acceptance of first article units.

All First Article systems shall be subjected to the following tests specified in Section 4.3. An overall visual inspection (i.e., inspect for any mechanical and structural failure, or degradation of the system) and a Minimum Function Test shall be performed before and after all DT, PAT, and Type Test activities to prove that the LED light sources are operating as intended as specified in Table 4-1 below.

16 April 2022

Table 4-1. Development Tests

Test Para. Reference Visual Inspection (before and after each test) 4.3.1 Electrical Tests 4.3.2 Electromagnetic Interference Test 4.3.3 LED Light Source Weight Test 4.3.4 Aiming Device and Aiming Angle Test 4.3.5 Pulse Repetition Rate Test 4.3.6 Response Time Test 4.3.7 Environmental Tests 4.3.8 Photometric Tests 4.3.9 150-Hour Test 4.3.10.1 Minimum Function Test (before and after each test) 4.3.10.2

4.2.1.1 Pre-test and Post-test Condition

The Visual Inspection (see Section 4.3.1) and Minimum Function Test (see Section 4.3.10.2) shall be performed prior to and after any DT procedure.

4.2.1.2 Cause for Rejection

Any deformation, discoloration, deterioration, malfunction, or operation of the equipment outside of the prescribed conditions or limits of Section 3 during or after the conduct of each test shall be cause for rejection.

4.2.2 Production Acceptance Tests (PAT)

4.2.2.1 Applicability

All LED light sources produced for field installation will be referred to herein as “Production Units”. All Production Units, and site and depot spares, shall pass the PAT prior to delivery.

4.2.2.2 Pre-test and Post-test Condition

The Visual Inspection (see Section 4.3.1) and Minimum Function Test (see Section 4.3.10.2) shall be performed prior to and after any PAT procedure.

4.2.2.3 Cause for Rejection

Any deformation, discoloration, deterioration, malfunction, or operation of the equipment outside of the prescribed conditions or limits of Section 3 during or after the conduct of each test shall be cause for rejection.

17 April 2022

4.2.2.4 Required Tests

The following tests shown in Table 4-2 shall be required for all Production Units, and site and depot spares.

Table 4-2. Production Acceptance Tests

Test Para. Reference

24-hour Test 4.3.10.1

Visual Inspection 4.3.1

Photometric Tests 4.3.9

Power Consumption Test 4.3.2.4

Water Soaking Test 4.3.8.6

4.2.3 Type Tests

4.2.3.1 Applicability

Tests shall be performed on regular production equipment or systems in accordance with FAA-G- 2100H, paragraph 4.2.2.2. All Production Units shall be subjected to the PAT prior to performing Type Tests.

4.2.3.2 Pre-test and Post-test Condition

The Visual Inspection (see Section 4.3.1) and Minimum Function Test (see Section 4.3.10.2) shall be performed prior to and after any Type Test procedure.

4.2.3.3 Cause for Rejection

Any deformation, discoloration, deterioration, malfunction, or operation of the equipment outside of the prescribed conditions or limits of Section 3 during or after the conduct of each test shall be cause for rejection.

4.2.3.4 Required Tests

The tests shown in Table 4-3. Type Tests shall be required for Type Tests.

Table 4-3. Type Tests

Test Para. Reference Photometric Tests

(chromaticity included) 4.3.9

24-hour Test 4.3.10.1

18 April 2022

Test Para. Reference

Temperature Tests 4.3.8.1

Humidity Test 4.3.8.2

Visual Inspection 4.3.1

Electrical Tests 4.3.2

Water Soak Test 4.3.8.6

4.2.4 Operational Test (OT)

OT encompasses the test and evaluation of the operational requirements of a system or service.

The primary objective of OT is to examine performance and, determine operational readiness (effectiveness and suitability) of a new or modified system for use in the NAS, and verify that the NAS infrastructure is ready to accept the system. OT is conducted by the FAA on a fully installed system at the William J. Hughes Technical Center and other designated operational sites.

4.3 Test Procedures

4.3.1 Visual Inspection

The LED light source shall be visually inspected for workmanship, fabrication, finishing, painting, adequacy of selected parts, damage, discoloration, and burn marks.

4.3.2 Electrical Tests

Unless otherwise noted, the LED light source shall be tested to the following requirements while installed in its lamp holder and operating on high intensity.

4.3.2.1 Power Interruption Test

Reference Section 3.3.5

Tests shall be performed with the LED light sources operating at the high intensity level. The LED light sources shall restart automatically and in the same state of service before the interruption or shutdown is experienced due to the surges or transients. Power interruption test shall include missing half cycles, and whole cycles, for a short term power interruption, and then tested with a longer term power interruption of 0.2, 0.5, 1.0, 2.0, and 5.0 seconds. The LED light source shall still be illuminated 100 ms after the interruption. This test shall be performed using a digital oscilloscope. Testing shall be done at all intensity levels (low, medium, and high).

4.3.2.2 Voltage Variation Test

Reference Section 3.3.2

19 April 2022

This test shall be performed using a variable transformer that will test the line voltage and the voltage variation extremes for each of the input voltages specified in Table 3-5. The average intensity of the LED light source shall be within the specified range (see Table 3-1 or Table 3-4) at the line voltage and at the voltage variation extremes specified in 3.3.2. The LED light source shall operate properly and not be damaged by voltage variations of ±5% VAC at each intensity level.

4.3.2.3 Power Factor Test

Reference Section 3.3.4

This test shall be performed using a line power analyzer to measure the power factor at the input of the LED light source. Measurement shall be taken for each of the input voltages specified in Table 3-5.

4.3.2.4 Power Consumption Test

Reference Section 3.3.1

The LED light source power demand shall be tested at the terminal inputs on the lamp holder while the LED light source is operating on high intensity.

4.3.2.5 Power Outages Test

Reference Section 3.3.5

This test shall be performed with the LED light source operating in three intensities: Low, Medium, and High for 2 hours. The LED light source input power shall be interrupted at least 10 times in succession at each intensity. There shall be a minimum of 10 seconds between each interruption.

4.3.3 Electromagnetic Interference Test

Reference Section 3.3.8

The LED light sources shall be connected as they would be operationally. The LED light sources shall be tested at all intensity levels. Measurement of the radiated emissions shall be as specified in the Radiated Emission Interference requirements of the Federal Communications Commission (FCC) Title 47, Subpart B, Section 15, “Unintentional Radiators”. Measurement of the radiated susceptibility shall be as specified in test method RS103 of MIL-STD-461G. The LED Lamps shall be tested for conformance to the electromagnetic interference control requirements defined in MIL-STD-461G (Navy ground equipment) for the MIL tests.

4.3.3.1 Radiated Emissions

Reference Section 3.3.8.1

Measurement of the radiated emissions shall be as specified in test method in the Radiated Emission Interference requirements of the Federal Communications Commission (FCC) Title 47, 20 April 2022

Subpart B, Section 15, “Unintentional Radiators.” The measurement shall be made at 3 meters with the field strength limits identified in the above FCC reference for that distance as identified in Section 15, paragraph 15.109(a) for a Class B device.

4.3.3.2 Radiated Susceptibility

Reference Section 3.3.8.2

Radiated susceptibility shall be not greater than the limit for RS103 as defined in MIL-STD- 461G using a frequency range of 2 MHz to 18 GHz.

4.3.3.3 Electrostatic Discharge Test

Reference Section 3.3.9

The LED light source shall withstand a static discharge of 15,000 volts as specified in ANSI/ESD

STM 5.1.

4.3.4 LED Light Source Weight Test

Reference Sections 3.1.1.3 and 3.2.1.3

Using a digital scale with an accuracy of 0.1 lbs., the LED light source shall be weighed. The LED light source shall not exceed the applicable weight requirements.

4.3.5 Aiming Device and Aiming Angle Test

Reference Sections 3.1.1.5 and 3.2.1.5

With the LED light source mounted in its lamp holder, the aiming device shall be attached. The LED light source shall not interfere with the mounting of the aiming device. The light assembly (LED light source and lamp holder) shall be aimed at 0°, 3°, 5°, 10°, 15°, 20°, and 25° above horizontal.

4.3.6 Pulse Repetition Rate Test

Reference Section 3.3.7

If Pulse Width Modulation is implemented, measure the pulse repetition rate of the LED light source either electrically or optically. The pulse repetition rate shall be greater than 120 Hz.

Testing shall be done at all intensity levels (low, medium, and high).

4.3.7 Response Time Test

Reference Section 3.3.6

This test shall be performed with the LED light source operating in three intensities: Low, Medium, and High. The LED light source driver circuit shall respond to an intensity step change in less than one (1) second after receiving the change of input voltage.

21 April 2022

4.3.8 Environmental Tests

Reference Section 3.4

Unless otherwise noted, the LED light source shall be tested while installed in its lamp holder and operating on high intensity. A Water Soaking Test (Section 4.3.8.6) shall be performed after each of the following Environmental Tests: Solar Radiation, Altitude Test, Vibration Test, High Temperature Test, and Low Temperature Test.

4.3.8.1 Temperature Tests

Reference Section 3.4.1.1

4.3.8.1.1 Low Temperature Test

The low temperature test shall be in accordance with Procedure I (Storage) and Procedure II (Operation) of Method 502.7 of MIL-STD-810H, except that the temperature for Procedure I shall be -50oC and the temperature for Procedure II shall be -40°C. The lamp is held at the low temperature for two hours and then it is turned “ON” for data acquisition.

4.3.8.1.2 High Temperature Test

The high temperature test shall be as specified in Procedure I (Storage) and Procedure II (Operation), Method 501.7 of MIL-STD-810H, except that the temperature for both procedures shall be +67.2°C. The lamp is held at the high temperature for two hours and then it is turned “ON” for data acquisition, including light intensity output. There shall be three cycles of the High Temperature Test. Photometric Tests (see Section 4.3.9) shall be conducted on all LED light sources prior to and following the High Temperature Test. The LED light source intensity shall not decrease by more than 30% of the original measured intensity.

4.3.8.2 Humidity Test

Reference Section 3.4.1.2

The procedure for humidity testing shall be as specified in Method 507.6 Procedure II and Figure 507.6-7 of MIL‑STD‑810H. The temperature range is identified in paragraph 3.6.1.2. The equipment shall be subjected to 10 cycles. The temperature ranges of Figure 507.6-7 and Table 507.6-IX shall be modified to be from +30oC to +67.2oC.

4.3.8.3 Altitude Test

Reference Section 3.4.1.3

The Altitude test shall be as specified in Procedure II, Method 500.6 of MIL-STD-810H. The LED light source shall be tested at atmospheric pressures corresponding to zero feet (-0, +300 feet) and 10,000 feet altitude (MSL) at -40°C and +67.2°C.

22 April 2022

4.3.8.4 Sand and Dust Test

Reference Section 3.4.1.4

The Sand and Dust test shall be in accordance with Procedure I, Method 510.7, of MIL-STD-810H for Dust and Procedure II for Sand. The LED light sources, with their lamp holders, shall be installed on a 2-inch electrical metallic tubing (EMT). The LED light sources shall begin the tests with the lamp face facing the source of the sand or dust (orientation 0⁰). The LED light source shall be rotated 120 degrees twice in the same direction, and after each rotation the feed is maintained for six hours for the dust test and six hours for the sand as specified in Table 4-4. For blowing dust and sand, the test media particle sizes, mix, and wind speed shall be used as specified in Table 4-5.

Photometric Tests (see Section 4.3.9) shall be conducted on all LED light sources prior to and following the Sand and Dust Test. The LED light source intensity shall not decrease by more than 30% of the original measured intensity.

Table 4-4. Lamp Orientation

Enclosure Orientation Test Duration Dust (hours) Sand (minutes)

0° (lamp face) 6 90 120° 6 90 240° 6 90

Table 4-5. Sand and Dust Particles Blowing Dust

Mean % by weight Particle size Wind Speed

100% Particles < 150μm

(140 mesh silica flour or equivalent)

1750 feet/minute (8.9 meters/second)

Blowing Sand Mean % by weight Particle size Wind Speed

90 ± 5% 150μm < Particles < 600μm 5700 feet/minute (29 meters/second)

5% 600μm <= Particles < 850μm 5700 feet/minute (29 meters/second)

4.3.8.5 Salt Fog Test

Reference Section 3.4.1.5

The salt fog test shall be in accordance with MIL-STD-810H, Method 509.7. The LED light source shall be exposed for four (4) 48-hour cycles of exposure and drying. One cycle consists of a 24-hour period of salt exposure followed by 24 hours of drying. Salt accumulation shall not be removed during the first three drying periods. At the conclusion of the test, salt build-up may be removed with tap water. The salt spray shall have a concentration of 5 ±1 percent sodium chloride, by weight.

23 April 2022

4.3.8.6 Water Soaking Test

Reference Section 3.4.1.12

The LED light source, except for the electrical connector portion, shall be submerged under water for 15 minutes. After water soaking, the outer of the LED light source shall be dried off. The LED light source shall be operating normally in 3 different intensities after the water soaking. Any leakage or water intrusion shall be cause for rejection.

4.3.8.7 Combined Rain and Wind Test

Reference Section 3.4.1.6

The rain test shall be as specified in Procedure I, Method 506.6 of MIL‑STD-810H (per Table 4-6).

The rain exposure shall be on each of the four sides, horizontally, for 30 minutes each with the initial orientation being with the wind aimed directly at the lens. The LED light source shall be turned on and brought to stable operating temperature for each exposure before starting rainfall and operated during the exposure. Water temperature shall be room ambient; 25ºC ±10ºC (77ºF ±18ºF). The test item temperature shall be at least 10º ±3°C (50º ± 5.4°F) higher than the rain temperature at the beginning of each 30-minute exposure period.

Table 4-6. Combined Rain and Wind

Rain Rate Droplet Size (diameter) Wind Velocity

2.55 mm/min (0.1 in/min)

0.5 mm (0.02 in)

64.4 km/h (40 mph)

4.3.8.8 Thermal Shock Test

Reference Section 3.4.1.7

The temperature shock test shall be in accordance with Procedure I-A, Method 503.7 of MIL-STD- 810H. The LED light source shall be installed as in normal use and operated at maximum intensity at ambient temperature until the temperatures have stabilized (minimum of two hours). At least 3 gallons of water at a temperature of 0°C to +5°C shall be sprayed on the surface and directly on the lenses or window. There shall be no cracking of glass or metal.

4.3.8.9 Solar Radiation (Sunshine) Test

Reference Section 3.4.1.8

The solar radiation test shall be as specified in MIL-STD-810H, Procedure II, Method 505.7. The test shall be conducted for a total of fifty-six (56) 24-hour cycles. The intensity is defined in MIL- STD-810H Figure 505.7-2 with spectral components and tolerances as defined in Tables 505.7-I and 505.7-II of MIL-STD-810H. The LED light source shall be operated on high intensity for 8 hours, every seven days when the test item has reached its peak temperature.

24 April 2022

Photometric Tests (see Section 4.3.9) shall be conducted on all LED light sources prior to and following the Solar Radiation Test. The LED light source intensity shall not decrease by more than 30% of the original measured intensity.

4.3.8.10 Vibration Test

Reference Section 3.4.1.9

The LED light source unit shall be tested in its non-operational state as described in the following paragraphs:

(a) Vibration planes. The test assembly shall be vibrated in three planes or directions as follows:

1. In a direction, perpendicular to the test table (vertically);

2. Horizontally, parallel to the light beam axis (where applicable); and

3. Horizontally, at right angles to the light beam (where applicable) axis.

(b) Frequencies. The test assembly shall be vibrated through a frequency range of 10 to 2,000 cycles per second (cps) in each plane until the acceleration shown in Table 4-7 is reached. Duration of each sweep shall be 10 minutes. A sweep shall be defined as the vibration of the test assembly through a frequency range as shown in Table 4-7.

Table 4-7. Vibration Profile Parameters

Vibration Test Data Acceleration in G's Frequency (CPS)

0.020 inch (0.5mm) double amplitude (Peak to Peak displacement) 10-70

3 70-200 3 200-500 3 500-2,000

Following the vibration test, the LED light source shall be thoroughly examined for all damage including, but not limited to, mechanical failure of any component, loosening of any part, cracked or broken seals, continuity of electrical circuits, and possible damage to the LED light source. The LED light source shall be retested following the vibration test for compliance with the photometric requirements.

4.3.8.11 Ice Dissipation Test

Reference Section 3.4.1.10

The un-energized LED light source shall be set up in the appropriate chamber and tested in accordance with MIL-STD-810H, Method 521.4 and tailored as follows. The lamps shall be placed in an environment with the front of the lamps angled at +25 degrees to the horizontal, facing the water dispenser and with an air temperature of 0°C ± 2° C. The air temperature shall be stabilized at 0°C for two (2) hours. Water shall then be introduced by suitable means at a temperature of 0°C to +3°C with the exposure time being one (1) hour. Water droplet size shall be 1 mm to 1.5 mm in

25 April 2022 diameter. The water density shall be 5.5 ± 1 gram/cubic centimeter (g/cm3). The water delivery rate shall be 25 ± 2 millimeters/hour (mm/hr). After one hour, reset the chamber to -10°C ± 2°C and continue the water exposure for an ice thickness of 12.7 mm on the face of the lamp. Turn the lamp ON in Low intensity and measure the time for the ice to dissipate from the lamp face. In a second test, repeat the test as above but turn the lamp ON Low after the air temperature has been reset to -10°C. No ice shall accumulate on the face of the lamp.

4.3.8.12 Wind and Ice Loading Test

Reference Section 3.4.1.11

The LED light source shall operate on Low while subjected to the combined wind and ice conditions specified in 3.4.1.10 using the procedure described in MIL-STD-810H, Method 521.4.

The vertical angle of the light assembly shall be measured before and after the test. The test shall consist of a lamp mounted to a 2-inch EMT conduit and subjected to a radial glaze ice accumulation of 0.5 inch in accordance with Method 521.4 Procedure-Ice Accretion. After the ice has accumulated, apply the wind velocity of 100 mph to the face of the lamp lens for 30 minutes.

A second test shall be conducted with the 100 mph wind applied perpendicular to the glass face of the lamp. The wind portion of the test shall be in accordance with Procedure I, Method 506.6 (Rain Test) of MIL-STD-810H, except no water will be used. Electrical or physical damage to any part of the LED light source shall be cause for rejection.

4.3.9 Photometric Tests

Reference Sections 3.1.2 and 3.2.2

Photometric tests shall be performed on the LED light sources to verify conformance with the requirements. All Candela measurements shall be made according to a 0.5° rectangular grid (similar to Figure A2-11 of ICAO Annex 14). Measurements shall be made at each of these grid-points inside of the specified beam patterns (see Figure 3-2 and Figure 3-4).

4.3.9.1 Green Threshold LED Light Source Tests

Reference Sections 3.1.2

All photometric testing of the green threshold LED light source units shall incorporate a 15-minute warm-up period. Table 4-8 specifies the average intensity, and Table 4-9 specifies intensity extreme for the green threshold LED light source.

Table 4-8. Average Intensity

Pattern Average Intensity (Candela) Low Medium High

Main Beam 145 ± 30 715 ± 145 5,000 ± 1,000

26 April 2022

Table 4-9. Intensity Extreme

Light Source Intensity Extremes (Candela) Low Medium High

Minimum Maximum Minimum Maximum Minimum Maximum 80 360 400 1,800 2,000 9,000

4.3.9.1.1 Beam Pattern Test

Reference Section 3.1.2.1

Intensity, in Candela, shall be measured at each of the grid-points described as above within the beam pattern of ±10° in all directions. The grid point intensities for the green threshold LED light source shall be measured at all three (3) intensity steps: Low, Medium, and High.

4.3.9.1.2 Intensity Test

Reference Section 3.1.2.3

The minimum grid point intensity measured from the Beam Pattern Test on the green threshold LED light source, shall be no less than the minimum allowable intensities stated in Table 4-9. The maximum grid point intensity shall reside within ±3° circle of the LED light source unit centerline and shall be less than the maximum allowable intensities stated in Table 4-9.

4.3.9.1.3 Average Intensity Test

Reference Section 3.1.2.2

The green threshold LED light source average intensity shall be calculated as the arithmetic mean of all intensities measured at the grid-points as specified above during the Beam Pattern Test. The Average Intensity shall reside within the maximum and minimum allowable intensities specified in Table 4-8. Average intensity shall be calculated for all three (3) intensity steps: Low, Medium, and High.

4.3.9.1.4 Chromaticity Test

Reference Section 3.1.2.4

The threshold light source shall be tested for conformance to the aviation green color requirements defined in Chromaticity according to the International Commission on Illumination (CIE) system defined in ASTM E308 using the test procedures in Paragraph 4 of SAE AS25050. This chromaticity test shall be performed at all three (3) operating intensity levels.

27 April 2022

4.3.9.2 White Steady Burning LED Light Source Tests

Reference Section 3.2.2

All photometric testing of the white steady burning LED light source units shall incorporate a 15-minute warm-up period.

4.3.9.2.1 Beam Pattern Test

Reference Section 3.2.2.1

Intensity, in Candela, shall be measured at each of the grid-points described in Section 4.3.9, within the beam pattern of ±8° in all directions. The grid point intensities for the white steady burning LED light source shall be measured at all three (3) intensity steps: Low, Medium, and High.

4.3.9.2.2 Intensity Test

Reference Section 3.2.2.3

No measured intensity point within the specified beam pattern above shall be greater than 15,000 Candela.

4.3.9.2.3 Average Intensity Test

Reference Section 3.2.2.2

The white steady burning LED light source average intensity shall be calculated for the main beam pattern only. The average intensity shall be calculated as the arithmetic mean of all intensities measured at the grid-points within the main beam pattern during the Beam Pattern Test. The average intensity shall reside within the maximum and minimum allowable intensities specified in Table 4-10. Average Intensity shall be calculated for all three (3) intensity steps:

Low, Medium, and High.

Table 4-10. Required Levels of Steady Burning Light Average Intensity

Pattern Steady Burning Average Intensity (Candela) Low Medium High

Main Beam (±8°) 250 ± 40 1,250 ± 200 10,000 ± 1500

4.3.9.2.4 Chromaticity Test

Reference Section 3.2.2.4

The white steady burning LED light source shall be tested for conformance to the aviation white color requirements defined in Chromaticity according to the CIE system defined in ASTM E308 using the test procedures in Paragraph 4 of SAE AS25050. This chromaticity test shall be performed at all three (3) operating intensity levels.

28 April 2022

4.3.10 Functional Tests

Reference Sections 3.1 and 3.2

All operating requirements of the LED light sources shall be checked over the full range of voltage input variations.

4.3.10.1 24-Hour Burn-in Test

All LED light sources shall complete a 24-hour burn-in at ambient…