16511 Final Airfield Lighting.pdf

Offutt Air Force Base

16511-1 (Repair Taxiway Circuits A & B)

(072060) 2009 by FEI

SECTION 16511

AIRFIELD LIGHTING

PART 1 - GENERAL

1.1 RELATED DOCUMENTS

A. Drawings and general provisions of the Contract, including General and Supplementary Conditions and Division 1 Specification Sections, apply to this Section.

1.2 SUMMARY

A. This Section includes equipment for an Airfield Taxiway Lighting System including elevated L- 852T Style 3 LED taxiway edge lights, L-861T LED taxiway edge lights, L-830 insulation transformers, L-867 and L-868 light base/transformer housings, L-867 base plate and gasket, L- 867/L-868 blank steel covers and 5 kV conductors.

1.3 SUBMITTALS

A. Product Data: For each type of product indicated.

B. Shop Drawings: Show fabrication and installation details showing arrangements, characteristics, and circuit assignments of various modules. Include illustrations and dimensioned outline drawings.

1. Wiring Diagrams: Power wiring. Show connections and circuit assignments.

C. Qualification Data: For Installer and manufacturer.

D. Operation and Maintenance Data: For Lighting System and Transformers to include in emergency, operation, and maintenance manuals.

1.4 QUALITY ASSURANCE

A. Electrical Components, Devices, and Accessories: Listed and labeled as defined in NFPA 70, Article 100, by a testing agency acceptable to authorities having jurisdiction, and marked for intended use.

B. Comply with NECA 1.

C. Comply with NFPA 70.

1.5 EXTRA MATERIALS

A. Furnish extra materials described below that match products installed and that are packaged with protective covering for storage and identified with labels describing contents.

1. Twenty (20) 20/25 W isolation transformers.

2. Ten (10) 30/45 W isolation transformers.

3. Twenty (20) L-861T ETES LED lights with heaters.

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4. Ten (10) L-852T ITEL LED lights with heaters.

5. Ten (10) L-867 base plate and gasket.

6. Four (4) L-867/L-868 blank steel covers.

PART 2 - PRODUCTS

2.1 MANUFACTURERS

A. In other Part 2 articles where titles below introduce lists, the following requirements apply to product selection:

1. Available Manufacturers: Subject to compliance with requirements, manufacturers offering products that may be incorporated into the Work include, but are not limited to, manufacturers specified.

2. Siemens Airfield Solutions.

2.2 DESCRIPTION

A. This item shall consist of furnishing and installing the following:

1. L-830T series circuit isolation transformers.

2. L-861T LED elevated fixtures.

3. L-852T LED in-pavement fixtures.

4. L-867 and L-868 light base/transformer housing.

B. This item shall also include all wire and cable connections, the furnishing and installing of all necessary cable, conduits, fittings and all necessary mounting structures. It shall also include testing of the installation and all incidentals necessary to place the lights in operation as complete units to the satisfaction of the Contracting Officer’s Representative.

2.3 EQUIPMENT AND MATERIALS

A. L-830 Isolation Transformers:

1. L-830: The L-830 series circuit isolation transformer shall conform to the requirements of FAA Advisory Circular 150/5345-47 (current edition) “Isolation Transformers for Airport Lighting Systems”. The L-830 transformers shall be ETL certified. The L-830 transformers shall be as provided by Siemens Airfield Solutions 20/25 W, Style L-830-17 Cat #35A0617 and 30/45 W Style L-830-1 Cat #35C0077 (www.usa.siemens.com/airfield-solutions) or approved equal.

2. EQUIPMENT SUPPLIED: L-830 series circuit isolation transformers shall be supplied in the wattages and current ratios for the total quantity as shown on the plans. L-830 TRANSFORMERS. The L-830 series circuit isolation transformer shall isolate low-voltage lamps from the high operating voltages present on airfield series lighting circuits.

The L-830 transformer shall be quick and easy to connect via factory-molded L-823 plugs and receptacles. The L-830 transformer shall have two single-conductor primary cables (8 AWG, 5,000V) with a molded Style 2 plug on one lead and a molded Style 9 receptacle on the other lead and one two-conductor secondary cable (12 AWG 600V) with a Style 8 two-pin receptacle. The L-830 transformer shall be completely watertight – cables shall be an integral part of the transformer and their sheath shall be molded in the transformer body. The transformer shall be able to be buried directly in the ground, http://www.usa.siemens.com/airfield-solutions http://www.usa.siemens.com/airfield-solutions

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(072060) 2009 by FEI exposed to the sun, immersed in water, and exposed to other weather elements. The outer molded jacket shall be acid-, alkali- and oil-resistant and shall also resist deicing fluids, ozone, and UV radiation. The encapsulation shall not absorb water.

3. The transformer shall operate at 60Hz for L-830 on series circuits rated up to 5,000V AC.

Transformer wattages rated 20/25W shall have a minimum efficiency of 70%.

Transformer wattages rated 30/45W shall have a minimum efficiency of 80%. The primary windings of the transformer shall be connected in a 6.6A series circuit supplied by a constant current regulator. The continuity of the series lighting loop shall be maintained even if one or more lamps supplied by individual isolation transformer secondaries are open-circuited due to lamp failures. The transformer shall be self-protected. Even with a short-circuited or open secondary winding, there shall be no damage or reduced transformer lifetime. In addition, there shall be a complete separation of the high-voltage primary and low-voltage secondary windings.

B. L-861T LED Fixtures:

1. L-861T. The L-861T LED fixtures shall conform to the requirements of FAA Advisory

Circular 150/5345-46B “Specification for Runway and Taxiway Light Fixtures” and “FAA Engineering Brief No. 67 “Light Sources other than Incandescent and Xenon for Airport Lighting and Obstruction Lighting Fixtures.” The L-861T LED fixture shall be ETL certified. The L-861T LED fixtures shall be the “ETES” fixture as manufactured by Siemens Airfield Solutions Cat # ETES-6411 ( www.usa.siemens.com/airfield-solutions) or approved equal.

2. EQUIPMENT SUPPLIED: FAA L-861T LED fixtures shall be supplied for the total quantity as shown on the plans. Each lot shipment of fixtures shall include two Instruction Manuals.

3. L-861T LED FIXTURE: The light source shall be an electroluminescent diode assembly.

A single LED shall be used in the light source. The lifetime of the LED shall be a minimum of 56,000 hours at full intensity and more than 150,000 hours in actual operating conditions. The L-861T shall use an aviation blue optical outer lens to insure high daytime visibility.

4. The light fixture, with heater, shall operate on a 6.6A circuit at 60Hz using a 20/25W, 6.6A

(secondary) isolation transformer that meets all applicable requirements of AC 150/5345-

47. The fixture load with the heater operational shall be no more than 25VA. The CCR load (which includes isolation transformer losses), with the heater operational, shall be no more than 32.5VA. The fixture load with the heater inactive shall be no more than 12VA.

The CCR load, with the heater inactive, shall be no more than 19.5VA. The heater shall be designed to insure that the light emitting area remains unobscured and clearly visible in a manner similar to existing incandescent fixtures. Activation of the heater shall be thermostatically controlled.

5. The fixture shall have an adjustment mechanism that allows ±4.5° vertical adjustment in the field. It shall be possible to install the lights on existing circuits in addition to, or in replacement of, conventional incandescent or halogen lights without having to change any other element (CCR, primary and secondary cabling, series isolation transformer, etc.). The fixture light output shall match quartz-incandescent fixtures at all brightness levels on a 5-step regulator. The required beam color shall be obtained without the use of a color filter.

6. It shall be possible to easily remove the top optical assembly without the use of tools.

Exterior, hard to remove, rubber type elements (that are subject to UV degradation;

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(072060) 2009 by FEI attack by rodents, fire ants, birds, etc) shall not be used to hold the top optical assembly on.

7. The fixture electronics shall be mounted inside the LED chamber to provide optimum protection from water and ice in the base can. No active electronic LED elements are allowed in the base can. The fixture shall use robust, solid-state internal devices that withstand damage if the fixture is knocked over. To insure long-reliability, the heater shall be mounted in the fixture column. Heater wires taped to the inside optical element, that are subject to long-term degradation, shall not be used. It shall be possible to remove the top optical assembly without unplugging any heater wiring.

8. The fixture shall have a low profile design with a maximum O.D. of 3.75 inches to reduce the risk of damage due to jet blast. The overall fixture height shall be 14 inches.

C. L-852T LED Fixtures:

1. LED IN-PAVEMENT FIXTURE. The LED in-pavement fixture shall be ETL certified at the time of bid according to the requirements of FAA Advisory Circular 150/5345-46B “Specification for Runway and Taxiway Light Fixtures” and the latest version of FAA Engineering Brief No. 67 “Light Sources other than Incandescent and Xenon for Airport Lighting and Obstruction Lighting Fixtures.” The LED in-pavement fixtures shall be as manufactured by Siemens Airfield Solutions Cat #ITEL-1111 (www.usa.siemens.com/ airfield-solutions) or approved equal.

2. EQUIPMENT SUPPLIED. LED in-pavement fixtures shall be supplied for the total quantity as shown on the plans. Each lot shipment of fixtures shall include two Instruction Manuals.

3. The LED in-pavement fixture light source shall be an electroluminescent diode assembly.

The lifetime of the LED shall be a minimum of 56,000 hours at full intensity and more than 150,000 hours in actual operating conditions. The MTBF of the entire fixture shall be 65,000 hours minimum. The fixture electronics shall be designed to incorporate galvanic isolation from the series circuit transformer, protecting the LED module against over voltage.

4. The light fixture, with heater shall operate on a 6.6A circuit at 60 Hz using a 30/45 W, 6.6A (secondary) isolation transformer that meets all applicable requirements of AC 150/5345-47. The fixture load with the heater operational shall be no more than 44 VA.

The CCR load (which includes isolation transformer losses), with the heater operational, shall be no more than 53 VA. The fixture load with the heater inactive shall be no more than 19.5 VA. The CCR load, with the heater inactive, shall be no more than 25.5 VA.

The heater shall be designed to insure that the light emitting area remains unobscured to existing incandescent fixtures. Activation of the heater shall be thermostatically controlled.

5. It shall be possible to install the lights on existing circuits in addition to, or in replacement of, conventional incandescent or halogen lights without having to change any other element (CCR, primary and secondary cabling, series transformer, etc.). The fixture light output shall match quartz-incandescent fixtures at all brightness levels on a 3-step and 5-step regulator. The required beam color shall be obtained without the use of a color filter.

6. The L-852T LED in-pavement fixture shall be Style 3 ( 1/4 inch above grade) and the top cover shall be of single piece construction (2 piece top covers will not be allowed) and made from an aluminum alloy to enhance fixture strength. All components shall be corrosion proof without the use of environmentally hazardous metal protective coatings, such as cadmium plating. The prisms shall be field replaceable without the use of epoxy

16511-5 (Repair Taxiway Circuits A & B)

(072060) 2009 by FEI or other sealing compounds and held in place by means of a mechanical clamping device. Grommets, in conjunction with a mechanical clamping device, shall be used for the entry and sealing of L-823 cord set wire cables to the inner cover. This will allow for cord set replacement without the use of epoxy or other sealing compounds. A test port with removable plug will be provided in the bottom cover to allow for pressure testing after fixture overhaul. To insure fixture quality, the manufacturer will production leak and dielectric strength test each individual fixture prior to shipment. The leak test will be by means of a Helium tank testing apparatus, capable of detecting minor fixture leaks due to material porosity.

D. L-867B and L-868B Light Base and Transformer Housing:

1. FAA AC 150/5345-42 type L-867 (elevated lights) and L-868 (inset lights). Provide steel bases, Class 1 size as required to accommodate the fixture or device installed thereon.

Twenty-four (24) inches overall height with 2-inch couplings (verify coupling location with installation requirements) and 1-inch dram hole. Provide potassium acetate resistant, internal coating external is galvanized.

2. L-868 load bearing bases shall be provided with four (4) side mounted, anti-rotation fins in 90° pattern.

3. Provide base plates, cover plates and adapter plates to accommodate various sizes of fixtures. Bolts shall be stainless steel. Base plate finish shall be oxide primer and aviation yellow enamel. Provide with steel cable clamp and screws for securing L-823 connector.

E. Airfield Lighting Cable:

1. FAA AC 150/5345-7, type L-824 No. 8 AWG copper, cross linked polyethylene, type C, 5000 volt cable. Series airfield lighting cable shall be unshielded.

F. Counterpoise Wire:

1. ASTM B3, ASTM B8 No. 4 AWG base stranded copper, annealed or soft drawn.

G. Equipment Grounding Wire:

1. UL 44, type XHHW-2, 600 volt for equipment grounding conductor.

H. Cable Tags:

1. Provide cable tags for each cable or wire at duct entrances entering or leaving manhole, handhole and at each terminal within the lighting vault. Provide stainless steel, bronze or copper strip tags approximately 1/16 inch (1.55 mm) thick or hard plastic 1/8 inch (3.17

mm) thick suitable for immersion in salt water and impervious to petroleum products.

Provide sufficient length for imprinting the legend on one line using raised letters not less than 1/4 inch (6.35 mm) in size. Permanently mark or stamp with identification as noted on the drawings. Two-color laminated plastic is acceptable. Provide dark colored plastic tag with marking of light color to provide contrast so that identification can be easily read.

Provide fasting material of a type that will not deteriorate when exposed to water with a high saline content and petroleum products.

I. Cable Connectors:

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1. FAA AC 150/5345-26, FAA Type L-823 connectors for use with FAA Type L-824 airfield lighting cable.

PART 3 - EXECUTION

3.1 INSTALLATION

A. L-830 Isolation Transformers:

1. Placing the L-830 Transformers: The contractor shall furnish and install each L-830 series circuit isolation transformer as specified and shown in the plans.

2. Tests: All L-830 series circuit isolation transformers shall be fully tested by continuous operation for not less than 24 hours as completed system prior to acceptance. The test shall include operating the constrant current regulator in each step not less than 10 times at the beginning and end of the 24 hour test. The fixtures shall illuminate properly during each portion of the test. A dielectric strength test shall be performed at the beginning and end of the 24 hour test to insure that the total circuit is 50M ohms minimum.

B. L-861T LED Fixtures:

1. Placing the L-861T LED Fixtures: The contractor shall furnish and install each L-861T

LED fixture as specified and shown on the plans. The L-861T LED fixtures shall be mounted on an industry standard 2-inch slip fit hubbed frangible coupling. The fixture shall then be mated to a standard FAA L-867 base at the locations shown on the plans.

2. Tests: All taxiway edge lights shall be fully tested by continuous operation for not less than 24 hours as a completed system prior to acceptance. The test shall include operating the constant current regulator in each stop not less than 10 times at the beginning and end of the 24 hour test. The fixtures shall illuminate properly during each portion of the test.

C. L-852T LED Fixtures:

1. Placing the LED In-Pavement Fixture: The contractor shall furnish and install each L- 852T LED in-pavement fixture as specified and shown on in the plans. The L-852T LED in-pavement fixtures shall be mounted on industry standard FAA L-868 base cans as specified and shown by location on the plants

2. Tests: Each fixture shall be connected to the series circuit using the manufacturer’s recommended isolation transformer. The constant current regulator (CCR) shall then be tested to verify the correct output current is present at each step. The output current shall be checked using the CCR manufacturer’s instructions using a True RMS meter.

The entire circuit shall then be fully tested by continuous operation for not less than 24 hours prior to acceptance. The test shall include operating the (CCR) in each step (Local and Remote) not less than 10 times at the beginning and end of the 24 hours test.

D. Mount light fixtures on bases installed in a concrete envelope. Use a jig or holding device for installing each light fixture base to ensure positioning to the proper elevation. alignment, level control and azimuth control. For elevated lights level the outermost edge of the base with the surrounding pavement for inset lights recess the base below the surrounding pavement as required. Leave the holding device in place until concrete reaches its initial set.

E. Airfield Lighting Cable:

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1. Use kit type connectors to splice 5 kV single-conductor series lighting cables. During installation keep mating surfaces of connectors covered until connected and clean when plugged together. At ajoint where connectors come together, install heat shrinkable tubing with waterproof sealant.

2. Lay counterpoise wire for entire length of circuits supplying airfield lighting. Provide wire in one piece, except where distances exceed the length usually supplied, and install 6 inches above directional duct lines. Where trenches or duct lines intersect electrically interconnect counterpoise wires by exothermic welding. Connect counterpoise wires together and to existing counterpoise wires. Provide 5/8” x 10’ copper clad ground rod exothermically welded to counterpoise installation at least every 300 meters (1000 ft.) Do not connect counterpoise system to light bases. Lay the counterpoise around light bases, provide not less than 12 inch separation. Do not connect the counterpoise to the lighting vault power grounding system.

3. Equipment grounding system: Install #6 AWG green jacketed wires identified as an equipment ground, in ducts with primary circuit and connect to all light bases and to the lighting vault power grounding system.

F. Frangibility and Accident-Avoidance Construction: In the areas around the runway, including approach zone, and taxiways all above ground structures must be light weight and of a frangible or low impact resistant construction using breakaway sections to minimize hazards to aircraft.

Concrete foundations or mounting slabs must not extend above the finished grade of the surrounding surface.

3.2 IDENTIFICATION

A. Identify components, power, and control wiring according to Division 16 Section "Electrical Identification."

B. Label each fixture.

3.3 FIELD QUALITY CONTROL

A. Give the Contracting Officer’s Representative five (5) working days notice prior to test(s).

Correct deficiencies found and repeat tests.

B. Visual and Mechanical Tests and Inspections:

1. Inspect each fixture and device for defects, finish failure, corrosion, physical damage, labeling by nationally recognized testing laboratory, and nameplate.

2. Record results of tests and inspections.

C. Operating Test:

1. After installation has been completed, conduct an operating test. Demonstrate equipment to operate in accordance with the requirements of this section. Conduct tests one (1) day and one (1) night for the Contracting Officer’s Representative.

D. Progress Testing for Series Airfield Lighting Circuits:

1. Conduct a megger test on each section of circuit or progressive combinations of sections as they are installed. Check each section or progressive combination of sections with a megohmeter providing a voltage of approximately 1000 volts to provide a direct reading

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(072060) 2009 by FEI in resistance, and document results. Locate any faults indicated by these tests and eliminate before proceeding with the circuit installation.

2. Electrical Acceptance Tests:

a. Perform acceptance tests for series airfield lighting circuits only on complete lighting circuits. Subject each series lighting circuit to a high voltage insulation resistance test.

3. Low Voltage Continuity Tests:

a. Test each series circuit for electrical continuity. Locate faults indicated by this test and eliminate before proceeding with the high voltage insulation resistance test.

4. High Voltage Insulation Resistance Test:

a. Subject each series lighting circuit to a high voltage insulation resistance test by measurement of the insulation leakage current. Provide a suitable high voltage test instrument which has a steady, filtered direct current output voltage and limited current. High voltage tester shall include an accurate voltmeter and microammenter for reading voltage applied to the circuit and resultant insulation leakage current. Do not apply voltages in excess of test values specified below.

1) Test Procedures: Disconnect both leads from regulator output terminals and support so that air gaps of several inches existing between bare conductors and ground. Clean and dry cable sheaths, for a distance of 305 mm one foot from ends of cables and exposed insulation at ends of cables.

Connect ends of both conductors of the circuit together and to high-voltage terminals of test equipment, and apply test voltage specified in the following tabulation between conductors and ground for a period of 5 minutes.

Test Voltage, dc

First Test Test on Series on New Existing Lighting Circuits Circuits Circuits

Medium intensity series 6000 3000 lighting circuits (5000volt leads, 20/25 watt to 30/45 watt transformers)

When additions are made to existing circuit, test only new sections in accordance with “First Test on New Circuits” in table above. To ensure reliable operation test complete circuit at reduced voltage indicated above.

b. Leakage Current: Measure and record insulation leakage current in microamperes for each circuit for each minute application of test voltage. Do not exceed the value of the insulation leakage current calculated on the basis of the following leakage current allowances for cable and connected equipment for each circuit:

1) 3 microamperes for each 305 meter 1000 feet of cable.

2) 2 microamperes for each 30/45 watt 5000 volt series transformer.

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If measured value of insulation leakage current exceeds calculated value, sectionalize the circuit and repeat specified test for each section. Locate defective components and repair or replace until repeated tests indicated an acceptable value of leakage current for the entire circuit.

E. Operating Test:

1. Upon completion of tests, show by demonstration in service that lights covered by the contract are in good operating condition. During this process, observe lights and associated equipment to determine that each switch controls properly corresponding circuit. Provide telephone or radio communication between the operator and the observers. Test each lighting circuit by operating the lamps at maximum brightness for not less than 30 minutes. Visually examine at the beginning and at the end of this test to ensure that the correct number of lights are burning at full brightness. Conductor one day and e night operating test for the Contract Officer.

F. Correct deficiencies disclosed by tests and inspections, and retest deficient items. Verify that specified requirements are met.

G. Test Labeling. After satisfactory completion of tests and inspections, apply a label to tested components indicating test results, date and responsible organization and person.

END OF SECTION