Attachment 1 FAA-E-2756 REV B.pdf

FAA-E-2756B

May 25, 2004

DEPARTMENT OF TRANSPORTATION

FEDERAL AVIATION ADMINISTRATION

PERFORMANCE SPECIFICATION

FOUR BOX

PRECISION APPROACH PATH INDICATOR (PAPI)

WITHOUT REMOTE MONITORING SUBSYSTEM

(RMS)

DISTRIBUTION STATEMENT A. Approved for public release; distribution is unlimited

Attachment 1 i

TABLE OF CONTENTS

1.0 SCOPE

1.1 Scope

2.0 APPLICABLE DOCUMENTS

2.1 FAA Documents

2.1.1 FAA Specifications

2.1.2 FAA Standards

2.1.3 FAA Drawings

2.1.4 FAA Management Documents

2.2 Military and Federal Publications

2.2.1 Military Specifications

2.2.1.1 Military Publications

2.2.2 Military Standards

2.2.3 Federal Specifications

2.2.4 Federal Standards

2.2.5 Federal Communications Commission Rules and Regulations

2.3 Other Publications

2.3.1 National Electrical Manufacturers Association (NEMA) standards

2.3.2 American National Standards Institute

2.3.3 National Fire Protection Association Publications

2.3.4 Masters Painters Institute (MPI)

2.3.5 American Society for Testing and Materials (ASTM)

2.3.6 Institute for Printed Circuits

2.3.7 Society of Automotive Engineers

2.3.8 Underwriters Laboratories Inc

3. REQUIREMENTS

3.1 General Functional Requirements

3.2 Reserved

3.3 Lamp Housing Assembly

3.3.1 Optical Bench

3.3.2 Housing Shell

3.3.3 Lamp and Lamp Mounting

3.3.4 Filter Assembly

3.3.5 Projection Lens

3.3.6 Terminal Block

3.3.7 Power Input Cable Entrance Connector

3.3.9 Mounting Provisions

3.3.10 Lampout Feature

3.3.11 Housing Shell Finish

3.3.11 Housing Shell Finish

3.3.11.1 Interior Finish

3.3.11.2 Exterior Finish

3.3.12 Optical Bench Finish

3.3.13 Mounting Base Finish

3.3.14 Tilt Switch

3.4 Photometric Requirements

3.4.1 Light Beam

3.4.2 Light Intensity

3.4.3 Light Colors

3.4.4 Light Beam Aiming Tolerance

3.5 Power and Control Assembly

3.5.1 General

3.5.2 Operational Requirements

3.5.3 Power and Control Assembly Cabinet

3.5.3.1 Components

3.5.3.1.1 Terminal Blocks

3.5.3.1.2 Circuit Breaker

3.5.3.1.3 Thyristors

ii

3.5.3.1.4 Photoelectric Switching Circuitry

3.5.3.1.5 Photosensing Device

3.5.3.1.6 Current Control Device

3.5.3.1.7 Elapsed Time Indicator

3.5.3.1.8 Power Supply

3.5.3.1.9 RMS Output Current Meter

3.5.4 Power and Control Assembly Finish

3.6 Interchangeability

3.7 Aiming Instrument Set and Calibration Bar

3.7.1 Clinometer

3.7.2 Calibration Bar

3.7.3 Carrying and Storage Case

3.7.3.1 Carrying and Storage Case Finish

3.8 Reserved

3.9 Environmental Requirements

3.9.1 Temperature

3.9.2 Altitude

3.9.3 Temperature Shock (Thermal Shock)

3.9.4 Humidity

3.9.5 Sand and Dust

3.9.6 Rain

3.9.7 Salt Spray

3.9.8 Solar Radiation (Sunshine)

3.9.9 Vibration

3.10 Transient Suppression

3.11 Electromagnetic Interference Control

3.12 Electrical Components

3.12.1 Relays

3.12.2 Reserved

3.12.3 Reserved

3.12.4 Reserved

3.12.5 Reserved

3.12.6 Electrical Connectors

3.12.7 Printed Wiring Boards

3.12.8 Component Ratings

3.12.9 Reserved

3.13 Materials and parts

3.13.1 Metals

3.13.2 Aluminum

3.13.4 Gaskets

3.13.5 Nameplates

3.13.5.1 Instruction plate

3.14 Brazing

3.15 Soldering

3.16 Reserved

3.17 Assembly, Wiring and Marking

3.17.1 Assembly

3.17.2 Wiring

3.17.3 Marking

3.18 Workmanship

3.19 Monitored Points and Controls

3.20 Maintainability

3.20.1 Maintainability Design Criteria

3.21 Reliability Design Criteria

3.21.1 System Reliability Parameters

4 VERIFICATION

4.1 VRTM

4.2 Reserved

4.3 Reserved

4.4 Test Methods

iii

4.4.1 Design qualification test

4.4.2 Production Unit Tests

4.4.3 PAPI Requirements Testing Discussion

4.4.4 Type Tests

4.5 Test Procedures

4.5.1 Visual Inspection

4.5.2 Altitude Test

4.5.3 Temperature Test

4.5.4 Sand and Dust Test

4.5.5 Salt Fog Test

4.5.6 Rain Test

4.5.7 Humidity Test

4.5.8 Thermal Shock Test

4.5.9 Solar Radiation (Sunshine) Test

4.5.10 Vibration Test

4.5.11 Transient Suppression Test

4.5.12 Electromagnetic Interference Test

4.5.13 Power and Control Assembly Performance Test

4.5.14 1000-Hour Operational Test

4.5.15 Two-hour Operational Test

4.5.16 Lampout Operational Test

4.5.17 Production Model Photometric Test

4.5.18 Production Unit Photometric Test

4.5.19 Dielectric Test

4.5.20 Clinometer Test

4.5.21 Lamp Housing Assembly Aiming Test

4.6 Test Performance

5. PACKAGING

6. NOTES

6.1 Cross-reference with NAS-SS-1000

6.2 Mounting hardware not furnished under this contract

TABLE OF TABLES

Table V. Qualification and Production Tests (Tables I-IV not used) Table VI. Vibration Test Data

TABLE OF FIGURES

Figure 1. PAPI System Signal Presentations Figure 2. PAPI Approach Path (Side View) Figure 3. Lamp Housing Assembly (Side View) Figure 4. Lamp Housing Assembly (Front View) Figure 5. Light Intensity Requirements for PAPI Figure 6. Functional Relationship of PAPI Units

TABLE OF APPENDICES

APPENDIX A. Verification of Requirements Traceability Matrix (VRTM) APPENDIX B NAS-SS-1000 Requirements Trace

1.0 SCOPE

1.1 Scope.- This specification sets forth the requirements for a precision approach path indicator (PAPI) system that is used to provide accurate approach path guidance to pilots of landing aircraft. The PAPI system consists of four housing assemblies, a compact power and control assembly, and an aiming instrument set.

2.0 APPLICABLE DOCUMENTS

2.1 FAA Documents.- The following FAA specifications, standards, and drawings, of the issues in effect on the date of the invitation-for-bids or request-for-proposals, form a part of this specification and are applicable to the extent specified herein.

2.1.1 FAA Specifications.

FAA-D-2494 Technical Instruction Book Manuscripts: Electronic, Electrical and Mechanical Equipment, Requirement for Preparation of Manuscript and Production of Books.

FAA-G-2100 Electronic Equipment, General Requirements

2.1.2 FAA Standards.

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

2.1.3 FAA Drawings.

C-6046 Frangible Coupling, Types 1 and 1A, Details

2.1.4 FAA Management Documents. (Not Used)

2.2 Military and Federal Publications.- The following military and federal publications, of the issues in effect on the date of the invitation-for-bids or request-for-proposals, form a part of this specification and are applicable to the extent specified herein.

2.2.1 Military Specifications.

MIL-A-8625 Anodic Coatings, for Aluminum and Aluminum Alloys

MIL-C-5541 Chemical Conversion Coatings on Aluminum and Aluminum Alloys

MIL-C-7989 Covers, Light-Transmitting, for Aeronautical Lights, General Specification for

2.2.1.1 Military Publications.

MIL-HDBK- 217 Reliability Stress and Failure Rate Data for Electronic Equipment

MIL-HDBK-472 Maintainability Predictions

MIL-HDBK-781 Reliability Test Methods, Plans, and Environment for

Engineering Development, Qualification, and production

2.2.2 Military Standards.

MIL-STD-276 Impregnation of Porous Nonferrous Metal Castings

MIL-HDBK-454 Standard General Requirements for Electronic Equipment

MIL-STD-461 Electromagnetic Emission and Susceptibility Requirements for the Control of Electromagnetic Interference

MIL-STD-810 Environmental Test Methods

MIL-STD-889 Dissimilar Metals

MIL-STD-961 Department of Defense Standard Practice for Defense Specifications

MIL-STD-1472 Department of Defense Design Criteria Standard

2.2.3 Federal Specifications.

TT-P-1757 Primer Coating, Zinc Chromate, Low Moisture Sensitivity

2.2.4 Federal Standards.

FED-STD-1005 Telecommunications: Coding and Modulation Requirements for Nondiversity 56,000 Bit/Second Modems

FED-STD-595 Color

2.2.5 Federal Communications Commission Rules and Regulations

Part 15 Radio Frequency Devices, Equipment Authorization Subpart J Procedures

2.3 Other Publications.- The following publications, of the issues in effect on the date of the invitation-for-bids or request-for-proposals, form a part of this specification and are applicable to the extent specified herein.

2.3.1 National Electrical Manufacturers Association (NEMA) standards.

NEMA 4 Watertight and Dust Tight Indoors and Outdoors (Enclosure)

2.3.2 American National Standards Institute.

ANSI C61.1 Quantities and Units Used in Electricity

2.3.3 National Fire Protection Association Publications.

NFPA No. 70 National Electrical Code

2.3.4 Masters Painters Institute (MPI).

QPL-TT-E-489-48, MPI # 48 Interior Alkyd, Gloss

MPI # 49 Interior Alkyd, Flat

2.3.5 American Society for Testing and Materials (ASTM).

B26 Aluminum-Alloy Sand Castings

B85 Aluminum-Alloy Die Castings

B108 Aluminum-Alloy Permanent Mold Castings

B209 Aluminum and Aluminum-Alloy Sheet and Plate

B211 Aluminum and Aluminum-Alloy, Bar, Rod, and Wire

B221 Aluminum and Aluminum Alloy Extruded Bars, Rods, Shapes and Tubes

B241 Pipe, Seamless, and Seamless Extruded Tube, Aluminum and Aluminum-Alloy

2.3.6 Institute for Printed Circuits: IPC-2221 Generic Standard on Printed Board

Design

2.3.7 Society of Automotive Engineers.

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

2.3.8 Underwriters Laboratories Inc: UL 1059 Terminal Blocks

(Copies of applicable FAA specifications, standards, and drawings may be obtained from the Contracting Officer in the Federal Aviation Administration office issuing the invitation-for-bids or request-for-proposal, or contract involved, or other use to be made of the requested material.)

(Single copies of military specifications and standards may be obtained from the Federal Aviation Administration, Washington, D.C. 20590, ATTN: Contracting Officer. Requests should cite the invitation-for-bids, request-for-proposals, or contract for which the material is needed. Mail requests, if found acceptable, will be forwarded to a military source of supply for filling; hence, ample time should be allowed. Single copies of military specifications, standards, and publications may also be obtained directly from the Commanding Officer, Naval Publications and Forms Center, 5801 Tabor Avenue, Philadelphia, Pennsylvania 19120.)

(Information on obtaining Federal specifications and standards may be obtained from General Services Administration offices in Washington, D.C.; Atlanta; Boston; Chicago;

Denver; Kansas City, Missouri; New York; San Francisco; and Seattle.)

(Information on obtaining NEMA standards may be obtained from the National Electrical Manufacturers Association, 155 East 44th Street, New York, New York 10017.)

(Copies of ANSI standards may be obtained from the American National Standards Institute, 70 East 45th Street, and New York 10017)

(Information on obtaining the National Electrical Code may be obtained from the National Fire Protection Association, Battery March Park, and Quincy Massachusetts 02269.)

3. REQUIREMENTS.

3.1 General Functional Requirements.- The precision approach path indicator (PAPI) system will be installed alongside a runway or at a heliport to provide accurate visual approach path information to pilots of landing aircraft, either day or night. The PAPI system shall meet the requirements specified herein, and shall consist of:

(a) Four LHAs, with integral mounting and adjustment hardware (3.3).

(b) One Power and control assembly (3.5).

(c) One Aiming instrument set (3.7).

The PAPI signal presentations are shown in Figure 1 and the PAPI approach path (side view) in Figure 2 ).

Figure 1. PAPI System Signal Presentations

Figure 2. PAPI Approach Path (Side View)

3.2 Reserved.-

3.3 Lamp Housing Assembly.- The lamp housing assembly (LHA) shall consist of:

(a) An optical bench that will permit the mounting of lamps, red glass filters, projection lenses, and adjustment hardware for the lamps. The optical bench shall be integral with aluminum walls or barriers that will compartmentalize the optical bench into sections (one for each lamp and its associated optical components). A transverse leveling pad and aiming pad compatible with the clinometer specified in Section 3.7.1 shall be an integral part of the optical bench.

(b) A removable housing shell will be integral with a deflection plate (figures 3 and 4).

The deflection plate is to prevent the pilot from seeing light reflected off the back of the PAPI and shall have a minimum height of 7% of the length of the housing shell (adequate protection up to 4 degrees above flight path).

The LHA shall be designed to maintain the required light beam orientation and photometric requirements as in Section 3.4 performing under the environmental conditions specified in 3.9.

Figure 3. Lamp Housing Assembly (Side View)

Figure 4. Lamp Housing Assembly (Front View)

3.3.1 Optical Bench.- The optical bench shall be constructed of non-corrosive metal and shall be of sufficient thickness, in conjunction with the structural design, to provide rigidity.

3.3.2 Housing Shell.- The optical bench shall be enclosed by a housing shell made of non-corrosive metal. The thickness of the housing shell material, in conjunction with the structural design, shall meet the requirements of 3.9.9. The maximum dimension of any drain hole shall be not greater than ¼ inch (6.35 millimeters (mm)) in diameter to prevent intrusion of foreign objects. Removal of the housing shall permit easy access to the lamps, filter-lens assemblies, and electrical components mounted on the optical bench. The housing shell shall be installed on a mounting base to maintain the requirements of 3.4.4 over the expected life of the product, (see figures 3 and 4 by means of fasteners to discourage unauthorized persons from tampering with the equipment. The housing may be raised, instead of removed, to gain access to the optical and electrical components provided the raised housing can withstand winds of 100 MPH.

3.3.3 Lamp and Lamp Mounting.- The lamp shall have a rated life of 1000 hours when operated in the LHA on the high intensity setting. The lamps shall be quartz halogen 6.4A to 6.6A. The lamp leads shall be No. 16 American Wire Gauge (AWG) (minimum) insulated copper conductors. The lamp mounting shall permit firm and positive positioning of the three lamps. The lamp mounting shall be designed to facilitate lamp removal and replacement to meet the required Mean Time To Repair (MTTR) stated in Section 3.20.1(a) .

The lamp removal must not exceed 5 minutes by a technician wearing gloves. Focusing of the optical system may be accomplished by adjusting the lamp, reflector, or filter.

3.3.4 Filter Assembly. – Three red, glass filter assemblies shall be supplied with each lamp housing assembly. The filters shall have a transmittance of at least 15 percent when the lamps are operated at full intensity. The filters and retaining hardware shall be positively keyed to ensure correct mounting in relation to the lamps. The filter assemblies shall be easily removable for replacement purposes.

3.3.5 Projection Lens.- The glass projection lenses shall be mounted in a vertical cast aluminum or stainless steel frame that will prevent any stray light from entering the LHA (figure 4). The lenses shall be recessed under an overhang to minimize the direct impingement or splash-back of rain or snow on the lenses. The overhang shall protrude beyond the front of the unit by a distance equal to or greater than the height of the housing shell.

3.3.6 Terminal Block.- A terminal block shall be provided in the rear of the lamp housing assembly. The terminal block shall provide non-corroding type terminals rated to carry 10 amperes (A) at 250 volts alternating current (VAC). Electrical contact surfaces of terminals shall be brass, bronze or copper that satisfy UL 1059 standard . Pressure screws of the electrical terminals shall be brass, bronze, or stainless steel that satisfy UL 1059 standard.

The terminal block shall have sufficient terminals to accommodate all internal connections, plus connection of external power cables. External connections will be made using conductors ranging in size from No. 12 AWG to No. 8 AWG for power wiring and No. 18 or No. 20 AWG for signal wiring.

3.3.7 Power Input Cable Entrance Connector.- Space shall be reserved in the rear of the lamp housing assembly to permit connection of the incoming power cable to the terminal block. The cable shall enter through one hole located in the bottom rear of the housing. The hole shall be provided with a cable strain relief connector, firmly secured to the housing, and shall be designed to firmly secure a cable having a diameter of 0.3 to 0.5 inches (7.62 to 12.7 mm). The strain relief connector shall have a neoprene grommet to provide a compressive surface on the cable.

3.3.8 Weight.- The weight of the lamp housing assembly, excluding lamps and mounting legs, shall be not greater than 100 pounds (45 kilograms (kg)). This must be in accordance with MIL-STD-1472F section 5.9.11.3.

3.3.9 Mounting Provisions.- The lamp housing assembly shall be installed on the mounting base as shown in figures 3 and 4. The mounting base shall have three adjustable legs to permit aiming of the light beam to any vertical angle from 1.5º up to 6°. Also, the mounting and adjustment hardware shall permit transverse leveling where any mounting leg may be up to 1 inch (2.54 cm) higher or lower than any other leg after installation. The legs shall consist of mounting and adjusting hardware, 2-inch electrical metallic tubing (emt), frangible couplings conforming to FAA Drawing C-6046, and aluminum flanges.

3.3.10 Lampout Feature.- If series-connected lamps are used in the system design, switching devices shall be provided in the lamp housing assembly to automatically maintain circuit continuity when a lamp(s) fails, and to ensure continued operation of the remaining series-connected lamps.

3.3.11 Housing Shell Finish.- All aluminum exterior and interior surfaces of the lamp housing shell shall be pretreated with a chemical film in accordance with MIL-C-5541E, Class 1A or MIL-STD 8625F, and shall be sprayed with one coat of zinc chromate primer in accordance with Federal Specification No. TT-P-1757, composition L, color Y. As an alternate, the housing may be black anodized per MIL-A-8625 in lieu of painting the interior and prior to painting the exterior. Alternative finishing methods that provide the same level of protection or greater may be used upon approval of the agency.

3.3.11.1 Interior Finish.- The deflection plate and all interior surfaces of the aluminum housing shell, including the interior surface of the overhang, shall be painted with not less than a body coat and a finish coat of alkyd enamel in accordance with Master Painters Institute reference #49 , Black, color No. 37038 of FED-STD-595. The paint shall be applied to at least 2.5 mils (63.5 microns) thickness and the final painted surfaces shall be free of blotches, scratches, and runs. . Alternative finishing methods that provide the same level of protection or greater may be used upon approval of the agency.

3.3.11.2 Exterior Finish.- All exterior surfaces of the housing shell, shall be painted with not less than a body coat and two finish coats of alkyd baking enamel in accordance with QPL- TT-E-489-48, MPI # 48 , Class B, International Orange, Color No. 12197 of FED-STD-595.

The paint shall be applied to at least 3.0 mil (76.2 microns) thickness and the final painted surfaces shall be free of blotches, scratches, and runs. Alternative finishing methods that provide the same level of protection or greater may be used upon approval of the agency.

3.3.12 Optical Bench Finish.- The optical bench including the lamps and projector mounting frames shall be painted as described in 3.3.11.1. As an alternate, the optical bench may be black anodized per MIL-A-8625 in lieu of painting.

3.3.13 Mounting Base Finish.- The LHA mounting base shall be painted as described in 3.3.11.1.

3.3.14 Tilt Switch.- Each lamp housing assembly unit shall have a tilt switch in the unit. The tilt switch system shall de-energize the lamps when the optical pattern is lowered between 1/4 and 1/2 degree or raised between 1/2 and 1 degree with respect to the preset aiming angle.

The tilt switch shall have a time delay of at least 10 seconds that will prevent intermittent tilt switch activation due to vibration. The tilt switch shall have fail-safe operation so that any malfunction of the tilt switch, including loss of input power, shall de-energize the lamp circuit in all indicators.

3.4 Photometric Requirements.

3.4.1 Light Beam.- The LHAs shall provide a split beam of light consisting of white light in the top sector and red light in the bottom sector as viewed from the front. The transition from red light to white light shall occur within an angle of 3 minutes of arc at the beam center and within an angle of 5 minutes of arc at the beam edges. The transition band shall be flat to within 3 minutes of arc. The PAPI shall provide usable visual approach guidance out to at least ± 10 degrees either side of the extended runway centerline.

3.4.2 Light Intensity.- Each LHA shall contain three lamps. Each LHA shall meet the minimum intensity requirements, as shown in figure 5, while operating at 6.4A root mean square (rms) (high intensity). The method of controlling the lamp intensity shall not decrease the lamp manufacturers 1000-hour sinusoidal waveform life expectancy for the lamps.

Figure 5. Light Intensity Requirements for PAPI

3.4.3 Light Colors.- The light colors shall be aviation white and aviation red as defined in SAE-AS25050, Colors, Aeronautical Lights and Lighting Equipment, General Requirements for, paragraph 3.1, Aviation Colors.

3.4.4 Light Beam Aiming Tolerance.- The centerline of the transition zone (i.e. the vertical area of change from red light to white light) of each LHA projected light signal shall be parallel to the zero aiming angle projection within plus or minus five (5) minutes of arc. This is to be interpreted to mean that the projected vertical transition zone signal angle will be coincident with the LHA aiming angle to the tolerance stated, and is a measure of the aiming accuracy of the LHA/Aiming device combination.

3.5 Power and Control Assembly.

3.5.1 General.- The power and control assembly shall control the supply of 4.5A rms (low intensity) or 6.4A rms (high intensity) service to the lamps (Figure 6). The power and control assembly shall form one compact, light weight, self-cooled unit that will be installed adjacent to the LHA furthest from the runway. Detailed description of components and requirements are provided in the following subparagraphs. The weight of the power and control assembly shall not exceed 50 pounds (22.67 kg).

Figure 6. Functional Relationship of PAPI Units

3.5.2 Operational Requirements.- The power and control assembly shall supply power for operation of the PAPI system at two light intensity steps as follows: 95 to 100 percent (6.4A rms) for daytime operation and approximately 8.5 percent (4.5A rms) for night operation.

The intensity of the lights shall be controlled by the photoelectric switching circuitry (3.5.3.1.4). The ON/OFF operation of the PAPI system will be controlled by the remote control input signal (120 VAC, 60Hz). The 120/240 volt, 60Hz input power lines (with Neutral grounded in accordance with National Electric Code) shall terminate at the input terminal block (3.5.3.1.1), and shall be connected to internal circuitry of the power and control assembly through a 2-pole main circuit breaker (3.5.3.1.2). The power and control assembly shall provide two separate, constant, root mean square output currents (of 6.4A or 4.5A) to each of two respective, two-wire output circuits, as determined by the photoelectric switching circuitry. The crest factor of the output voltage waveform shall be no greater than

1.1 and the voltage distortion relative to a sine wave shall be not greater than 10 percent of Total Harmonic Distortion Voltage (THDV). The system shall recover automatically from momentary power interruptions.

3.5.3 Power and Control Assembly Cabinet.-The power and control assembly cabinet shall contain all power and control components (3.5.3.1), including terminal blocks, cable clamps, grounding lugs, and protective devices. The cabinet shall be an outdoor, liquid-tight, aluminum National Electrical Manufacturers Association (NEMA-4X) type enclosure of sufficient size. All plane surfaces of the control cabinet shall intersect at 90°. If used, the thyristors shall be mounted within the enclosures and adequate heat sinks shall be provided.

Proper high-temperature wire in accordance with National Electric Code Article 310 (see Tables 310-13 and 310-61) shall be used throughout the cabinet. Sufficient wiring space shall be provided in the bottom of the cabinet for all wiring (input, output, and internal) and for all terminal blocks. Access to the interior of the cabinet shall be provided through one hinged and gasketed door, equipped with a three point latch set with provision for padlocking. The padlock hasp shall have a 7/16 inch (11.1 mm) hole. (Padlocks are not furnished under this specification). The door shall open a minimum of 110° and shall be equipped with a mechanism to ensure the door remains open and can withstand winds of 100MPH. The internal face portion of the door shall be provided with a pocket to hold a wiring diagram (3.17.3). The door of the cabinet shall be bonded to the body of the cabinet in accordance with National Electric Code (NEC) Article 250-90 (2002). An internal ground lug shall be provided in the cabinet for grounding purposes. The ground lug shall have a slotted, green-colored head suitable for a No. 6 American Wire Gauge bare copper ground wire. Electronic components shall be mounted on plug-in printed wiring boards whenever practicable. All adjustments located on printed wiring boards shall be readily accessible to the operator. Adjustments shall be made without the need to use extender card or cable.

3.5.3.1 Components.

3.5.3.1.1 Terminal Blocks.- One input/output terminal block of the enclosed base type, with screw-pressure terminal, shall be provided. The three input positions shall be suitable for No.

4 AWG through No. 8 AWG standard conductors. Signal wiring from the LHA to the PCA shall be No. 18 AWG or No. 20 AWG. Each pressure- type terminal shall be equipped with a pressure plate to prevent the tip of the screw from turning directly on the wire. Separators are required between the terminals; the separators shall be integrally molded with the base material. The separators shall be of adequate design to prevent current leakage due to humidity. Marking shall be provided in accordance with 3.17.3.

3.5.3.1.2 Circuit Breaker.- A properly rated two-pole, molded-case, Thermal-magnetic circuit breaker or electronic solid state type shall be provided as a main circuit breaker and power switch. The circuit breaker shall have an arc quenching chamber and shall have a minimum rating of Asymmetrical interrupting capacity (AIC) of 10,000 A (10KA) at 250V, 60Hz.

3.5.3.1.3 Thyristors.- Thyristors, if used, shall have a minimum peak repetitive off-state voltage (VDRM) rating of 600V and a minimum rms on-state current (IT) rating of 25A.

Thyristors shall have suitable heatsinks to ensure operation within the thermal constraints of the particular device selected. The thyristors selected shall not be damaged by the currents or voltages encountered when one or more lamps fails.

3.5.3.1.4 Photoelectric Switching Circuitry.- A photoelectric switching circuitry shall be provided to change automatically the intensity of the lights in two steps as described below.

All operating components of the switching circuitry, except the photo sensing device (3.5.3.1.5) and any associated signal conditioning circuitry, shall be mounted on a printed wiring board mounted within the cabinet. The photoelectric switching circuitry shall set the output current to 6.4A rms when the illumination on a vertical surface facing north reaches 58±2 foot-candles (624±21.5 lux), and shall set the output current to 4.5A rms when the illumination falls to 35±2 foot-candles(377 ±21.5 lux). The on-off points shall vary not greater than ±2 foot-candles (±21.5 lux), at any ambient temperature ranging from -55° Centigrade (C) (-67° Fahrenheit (F)) to + 70° C (+158°F) with line voltage variations from 115V to 125V. Similarly, the on-off points shall vary not greater than 3 foot-candles (32.28 lux) with line voltage variations from 108V to 115V and from 125V to 132V. A symmetrical time delay of 5 to 8 seconds shall be provided to prevent the output current from changing due to transient light conditions. A fail-safe feature shall set the output current to 4.5A in the event the photo sensing device fails.

3.5.3.1.5 Photo sensing Device.- The photo sensing device shall be mounted on the top surface of the PCA cabinet and shall be able to rotate and to lock in position. The device shall be hermetically sealed, and shall have a spectral response which peaks in the 5500 - 6000 angstroms (0.021 - 0.023 mil) region. The device shall meet the temperature requirements of the photoelectric switching circuitry (3.5.3.1.4). The device shall activate the photoelectric switching circuitry (3.5.3.1.4).

3.5.3.1.6 Current Control Device.- A load current-sensing control device shall be provided to vary automatically the conduction of the thyristors in order to maintain a constant rms load current through the lamps of the lamp housing assemblies. All operating components shall be mounted on plug-in printed wiring boards, whenever practicable. The boards shall be mounted within the cabinet. Potentiometers shall be provided for setting the load currents.

One potentiometer shall be provided for adjusting the 6.4A current and a separate, independent potentiometer shall be provided for setting the 4.5A current. The potentiometers shall have a control range to accommodate a ±10 percent minimum variation in load. Each thyristor shall have a separate current control device. Monitor points shall be provided to monitor the output current, and shall drive the true rms output current indicating meter (3.5.3.1.9). The output of the monitor device shall be scaled to read equivalent rms current with a high input impedance (1 megohm minimum) digital voltohmmeter (vom) when adjusting the current control potentiometer. The current control device shall regulate the true rms values of each level of the two separate output currents to within ±4 percent under the following conditions: (a) for any combination of the environmental conditions set forth in 3.9, (b) for power line input voltage variation between 216 V and 264 V and the transient recovery requirements of 3.10, and (c) when two lamps fail or when two lamps are removed from a loop. The current control device shall limit the maximum rms value of the output current to no more than 1±10 percent of the nominal load current of 6.4A rms, regardless of the output current and voltage waveform, input current and voltage transients, and ±10 percent variation from nominal input voltage. An overcurrent protection feature shall be incorporated into the design of the current control device.

3.5.3.1.7 Elapsed Time Indicator.- An elapsed time indicator shall be provided to register the number of hours of operation during the high-intensity setting. The meter shall operate on 120 V, 60 Hz power and shall indicate total time in hours and l0ths of hours. The meter shall be recyclable and shall have a minimum indicator range of 9,999.9 hours. The meter shall be mounted within the cabinet.

3.5.3.1.8 Power Supply.- A power supply shall be provided to supply the proper voltages and currents necessary to operate the power and control assembly circuits within the tolerances and conditions set forth in this specification. Wherever practicable, all electronic components shall be mounted on a plug-in printed wiring board mounted within the cabinet.

3.5.3.1.9 RMS Output Current Meter.- One panel-mounted true rms indicating meter with calibration marks at 6.4A and 4.5A shall be provided for the series-connected lamps. There shall be a provision to calibrate the meter. The 6.4A indication shall be in the upper 60 percent of the meter scale. The meter shall have an accuracy of ±2 percent of reading. The meter scale from zero to full scale shall be 120° with 0.1A markings that will be highlighted by a reflective mirror. The rms output current meter shall indicate the output current from the power and control assembly. A three position switch shall be provided that will switch the meter to either one of the two output circuits or to the off position.

3.5.4 Power and Control Assembly Finish.- All aluminum exterior and interior surfaces of the power and control assembly shall be pretreated with a chemical film in accordance with MIL-C-5541, Class lA. All aluminum exterior surfaces of the control cabinet shall be sprayed with one coat of zinc chromate primer in accordance with Federal Specification No.

TT-P-1757, composition L, color Y. Following the application of the primer, the exterior surfaces of the control cabinet shall be painted with not less than a body coat and two finish coats of alkyd baking enamel (in accordance with QPL-TT-E-489-48, MPI # 48, Aviation White, Color No. 17875 (in accordance with FED-STD-595). The paint shall be applied to at least 3.0 mil (76.2 microns) thickness and the final painted surfaces shall be free of blotches, scratches, and runs. The interior surfaces of the control cabinet shall be painted with not less than a body coat and two finish coats of alkyd baking enamel (in accordance with QPL-TT- E-489-48, MPI #48), Aviation White, Color No. 17875 (in accordance with FED-STD-595).

Aluminum surfaces that are clear anodized in accordance with MIL-A-8625, Type II do not require painting. Alternative finishing methods that provide the same level of protection or greater may be used upon approval of the agency.

3.6 Interchangeability.- All parts of the unit furnished under a single procurement shall be manufactured to a tolerance that shall permit interchangeability of any part with like part of any other unit. Identical components shall be identified with identical parts numbers and unlike parts shall not have the same part number. This requirement does not prevent the readjustment or calibration of exchanged modules nor does it prohibit exchange of control panels due to the runway identification number. Interchangeability shall be in accordance with MIL-HDBK-454, Requirement 7.

3.7 Aiming Instrument Set and Calibration Bar.- An aiming instrument set, consists of a clinometer, calibration bar and a portable storage case.

3.7.1 Clinometer.- The clinometer shall be used to adjust accurately the LHA during cross-leveling (lateral), longitudinal leveling, and elevation setting. The base of the clinometer shall be rustproof. The clinometer shall be constructed of non-corrosive metal to provide a light-weight 10 lbs (4.5kg) maximum rugged instrument. Design and construction of the clinometer shall be such that deviation from true position due to its own weight shall be not greater than 3 minutes of arc when the clinometer is placed on the optical bench (3.3.1). An accurate direct-reading dial shall be provided for setting the LHA to the desired angle. The reading dial shall indicate angles from 1.5° to 6° in graduated increments of 0.10°. The spacing between each degree mark shall be at least 1/2 inch (12.7 mm). A 0.00° setting shall be provided on the dial for calibration purposes and shall have an accuracy of ±2 minutes of arc and a repeatability of ±1 minute of arc while on the calibration bar. Alternate designs using a vernier dial may be used, so long as the vernier dial is provided with equivalent graduations as specified for the direct reading dial. The clinometer shall be designed so that repeated changing of the dial setting will not cause excessive wear that could deteriorate the accuracy of the instrument. Aluminum and other soft metals shall not be used where subject to metal-to-metal rubbing. The clinometer shall have provisions for firmly securing the dial setting after factory calibration, but shall permit field adjustment to the 0.00° position by the user. The clinometer shall utilize a 6-inch (15.24 cm) (maximum) level having an accuracy of ±2 minutes. The level shall be permanently attached to the clinometer to permit fine adjustments to calibrate the instrument. The level shall have a protective device to minimize possible damage.

3.7.2 Calibration Bar.- A calibration bar shall be provided with each clinometer to permit field checking and calibration. The calibration bar shall be designed for laying on a flat surface or in the carrying case (see 3.7.3) and shall have adjustment features to permit it being leveled to a horizontal plane. The tolerance for the flatness of the calibration bar shall be <=.005”. A portable level, not attached to the bar, shall be provided with each calibration bar to permit leveling. The level shall be the same type as used on the clinometer in 3.7.1, with a metal base meeting the requirements of paragraph 3.13.1. The level shall be used to verify the calibration of the clinometer.

3.7.3 Carrying and Storage Case.- A rigid portable non-corrosive metal or fiberglass case shall be provided for carrying and storing the clinometer. The case shall have a carrying handle and shall have a suitable latch for securing the cover in the closed position. The interior shall be designed to accommodate the clinometer so that it will be held and cushioned firmly in place.

3.7.3.1 Carrying and Storage Case Finish.- All aluminum exterior and interior surfaces of the carrying and storage case shall be pretreated with a chemical film in accordance with MIL-C- 5541, Class 1A. All aluminum exterior surfaces shall be sprayed with one coat of zinc chromate primer in accordance with Federal Specification No. TT-P-1757, composition L, color Y. Following the application of the primer, the exterior surfaces of the carrying case shall be painted with not less than a body coat and two finish coats of alkyd baking enamel in accordance with QPL-TT-E-489-48, MPI # 48, Class B, International Orange, Color No.

12197 of FED-STD-595. The paint shall be applied to at least 2.0 mil (76.2 microns) thickness and the final painted surfaces shall be free of blotches, scratches, and runs. As an alternate, the aluminum carrying and storage case may be anodized in accordance with MIL-A-8625, Type II, Clear, or a plastic case may be used instead of an aluminum case.

3.8 Reserved.

3.9 Environmental Requirements.- The equipment shall be designed for outdoor installation and continuous or intermittent operation under the environmental conditions specified below.

3.9.1 Temperature.- The temperature range shall be from -55°C (-67°F) to +65°C (+149°F).

The clinometer (Para 3.7.1) shall meet all the performance requirements of 3.7.1 when operated over this temperature range.

3.9.2 Altitude.- The pressure altitude shall range from sea level to 10,000 feet (3,048 meters).

3.9.3 Temperature Shock (Thermal Shock).- The system external surfaces (including projection lenses) shall be exposed to a sudden application of cold water at a temperature of 0° to +5 ° C when the lights reach stable operating temperatures at 20°C ambient temperature.

3.9.4 Humidity.- Relative humidity shall be up to 100 percent, including conditions where condensation takes place in the form of both water and frost.

3.9.5 Sand and Dust.- The system shall be exposed to windblown sand and dust particles as may be encountered in arid regions.

3.9.6 Rain.- The system shall be capable of withstanding windblown rain.

3.9.7 Salt Spray.- The system shall be exposed to salt-laden atmosphere with relative humidity as stated in 3.9.4.

3.9.8 Solar Radiation (Sunshine).- The system shall be exposed to sunshine with ambient temperatures as stated in 3.9.1.

3.9.9 Vibration.- The LHAs and the PCA shall be capable of withstanding vibrations in the frequency range of 10 to 2,000 Hertz. See paragraph 4.5.10(b) for limits.

3.10 Transient Suppression.- The equipment shall be designed to suppress switching transients, and to withstand transient increases superimposed on the 120/240 VAC rms power line input voltage that reach a peak value of 500 V for as long as 50 milliseconds. In addition, the equipment shall be designed to withstand lightning transients superimposed on each input power line. These transients shall be characterized as 8 by 20 microseconds (wave form) current surges of 10,000 amperes with the subsequent power-follow currents and voltage surges of up to 10 kV/microsecond (minimum). The current surge waveforms are described in ANSI Standard C61.1. The equipment shall recover and resume normal operation automatically within 3 seconds (transient recovery time) when an interruption or a shutdown is experienced due to a lightning transient. Equipment performance and operational functions shall not be degraded beyond the specification requirements by the above transients when each type of transient is superimposed a minimum of five times on each power input terminal while the equipment is energized. Transient suppression devices shall be provided for all power lines at their first point of interface with the equipment. The return for the lightning transient protection devices shall be connected to earth ground via a separate dedicated ground lug that will accommodate not less than a No. 6 AWG conductor.

The transient protection for signal lines and the LHA power lines shall be in accordance with FAA-STD-019, Lightning and Surge Protection, Grounding, Bonding and Shielding Requirements for Facilities and Electronic equipment.

3.11 Electromagnetic Interference Control.- Conducted interference levels on incoming ac power leads, control leads, and signals leads shall be not greater than the limits for CE102 as defined in MIL-STD-461E, except that above 150 kilohertz (kHz) the limits are allowed to be 20 (dB) below the prescribed values. Similarly, radiated emission over the frequency range of 30 kHz to 400 megahertz (MHz), at a distance of 20 feet (6.1 meters) shall be no greater than the limit for RE102 of MIL-STD-461E.

3.12 Electrical Components.- Electrical components must meet the requirement specified herein unless otherwise noted.

3.12.1 Reserved.

3.12.2 Reserved.

3.12.3 Reserved.

3.12.4 Reserved.

3.12.5 Reserved.

3.12.6 Electrical Connectors.- Electrical connectors shall be in accordance with FAA-G-2100G section 3.3.1.3.3.

3.12.7 Printed Wiring Boards.- Printed wiring boards, assemblies and components mounting shall conform to FAA-G-2100G, paragraphs 3.2.2.1 and 3.2.2.2, with the exception of paper base copper-clad laminates which are prohibited. Conformal coating is required and shall be in accordance with FAA-G-2100G paragraph 3.3.1.3.7b.

3.12.8 Component Ratings.- When component ratings are not specified, they shall be selected to ensure that the components are not operated in excess of 80 percent of their normally derated maximum values for the temperatures encountered under the specified equipment environmental conditions. Derating of electronic components shall be in accordance with MIL-STD-454, Requirement 18.

3.12.9 Reserved.

3.13 Materials and parts.- Materials and parts shall be as specified herein. Materials and parts not specifically designated by standard or specification shall meet the requirements of FAA-G-2100G Section 3.3.1. All materials and parts shall be suitable for operation under the environmental conditions specified in 3.9.

3.13.1 Metals.- Metals shall be either inherently corrosion resistant or suitably protected to resist corrosion or oxidation. The use of dissimilar metals shall be in accordance with MIL-STD-889B section 5.1 Parts may be suitably coated to prevent corrosion or seizing of parts that require removal for servicing.

3.13.2 Aluminum.- Aluminum shall be in accordance with American Society for Testing and Materials (ASTM) B241, B221and B211. Aluminum alloy plate and sheet, aluminum alloy die castings, and aluminum alloy sand castings shall be in accordance with ASTM B 209, B26, B108, B85. Aluminum alloy castings, if used, shall be impregnated in accordance with

MIL-STD-276.

3.13.3 Optical covers.- Light transmitting covers shall conform to the requirements of MIL- C-7989B section 3.5.2.

3.13.4 Gaskets.- Gaskets used at separable joints for cushioning and sealing purposes shall be made of neoprene and shall be suitable for use at ambient temperatures of -55°C(-67°F) to + 65°C (+149°F)

3.13.5 Nameplates.- Nameplates conforming to FAA-E-2100G paragraph 3.3.3.1 shall be installed at convenient locations on the LHA, the carrying and storage case, and the power and the control assembly. Each nameplate shall be attached to each assembly with four aluminum rivets or drive screws.

3.13.5.1 Instruction plate.- The carrying case shall have an instruction plate installed on the inside of the cover in a location easily viewed by the user and shall contain all necessary instructions for calibration and use of the aiming instrument set. The instruction plate shall be made of aluminum.

3.14 Brazing.- Brazing shall be in accordance with MIL-HDBK-454, Requirement 59, except that electrical connections shall not be brazed. Paragraph 3.3 of Requirement 59 is not applicable.

3.15 Soldering.- Soldering shall be in accordance with MIL-HDBK-454, Requirement 5.

3.16 Reserved.

3.17 Assembly, Wiring and Marking.

3.17.1 Assembly.- Assembly of all units shall be in a permanent manner with the components accessible for servicing, replacement, or repairs. Bolts used in assembling units shall be equipped with captive nuts; bolts shall be of sufficient length so that at least three full threads will show over the nut after tightening. Lock washers of the internal tooth type shall be used on all bolts where good electrical continuity is required for grounding. The chassis shall not be used as a current-carrying part of the electrical circuitry.

3.17.2 Wiring.- Connecting wires shall be copper and shall have the proper insulation rating and be of adequate AWG size for the application, as specified in National Electric Code Article 310. Unless otherwise specified, the wires and wiring shall conform to the National Electrical Code for panel-board wiring. Insulated conductors may be closely grouped together, with the bundles secured by flame-retardant lacing or wiring clips and properly trained and supported to avoid strain on the connections. Wire bends with short radii shall be taken to avoid nicking or cutting the conductors.

3.17.3 Marking.- All equipment components shall be clearly identified by nameplates or bold permanent type stencils. Identification markings shall agree with designations on the wiring diagram and parts list. All control wires shall be provided with end identification in the form of a plastic band around the wire with identifying markings permanently stamped thereon, or with the markings permanently stamped into the wire itself. All power conductors shall be similarly marked, except that a permanently stamped rigid laminate tag may be attached near the cable ends in lieu of the above. The terminating points for all wires and cables at terminal blocks, as well as the terminal blocks, shall be clearly identified. The identification shall correspond to the circuit and terminal designations as shown on the interconnection wiring diagram and on applicable diagrams contained in the instruction book.

3.18 Workmanship.- Workmanship shall be in accordance with MIL-HDBK-454, Requirement 9.

3.19 Monitored Points and Controls.- Test points shall be provided on all signals that are required to be monitored during checkouts, alignment, and calibration, or during preventive maintenance procedures. Test points shall not be located in compartments with voltage points of 500 volts or more, and all test points shall be located so as to preclude accidental shock to personnel engaged in normal operating or maintenance activities. The removal of components, modules, or circuit cards shall not be required to gain access to test points or adjustments. Test point controls and indicators mounted on printed wiring boards shall be accessible from the front of the circuit cage assembly without the use of extender boards.

3.20 Maintainability

3.20.1 Maintainability Design Criteria.- The following maintenance parameters must be met by the system :

(a) Mean time to repair (MTTR) - The PAPI system shall have a MTTR of not more than

30 minutes and 99% of all repair times shall be less than two (2) hours. The contractor will demonstrate conformance of this requirement by performing maintainability analysis by using MIL-HDBK-472 as guidance.

(b) Mean periodic maintenance time (MPMT) - The PAPI system MPMT shall be not greater than 2 hours per 3 months, including routine inspection.

3.21 Reliability Design Criteria.

3.21.1 System Reliability Parameters.- The following reliability parameter must be incorporated into the system:

(a) Mean time between failures (MTBF) of the system, except for the lamps shall be not less than 2,500 hours. A system failure occurs when any component in the system prevents the system from meeting any requirement detailed in this specification.

(b) The contractor shall demonstrate conformance with the above requirements by performing a reliability analysis using data and techniques in accordance with MIL-HDBK-217F and MIL-HDBK-781. If the periodic maintenance replaces component (s) prior to their failure, this may be included in the analysis.

4 VERIFICATION

4.1 VRTM. Appendix A contains the Verification of Requirements Traceability Matrix (VRTM) for the PAPI. Methods utilized to accomplish verification include:

a. Analysis. An element of verification that utilizes established technical or mathematical models or simulations, algorithms, charts, graphs, circuit diagrams, or other scientific principles and procedures to provide evidence that stated requirements were met.

b. Demonstration. An element of verification which generally denotes the actual operation, adjustment, or re-configuration of items to provide evidence that the designed functions were accomplished under specific scenarios. The items may be instrumented and quantitative limits of performance monitored.

c. Inspection. An element of verification consisting of investigation, without the use of special laboratory appliances or procedures, of items to determine conformance to those specified requirements…