DRAFT ALSF-2 LED Light Assembly Specification_01 15 2025.pdf

FAA-E-3000

January 2025

U.S. Department of Transportation

Federal Aviation Administration

PERFORMANCE SPECIFICATION

LIGHT EMITTING DIODE (LED) STEADY BURNING

LIGHT ASSEMBLY FOR THE

HIGH INTENSITY APPROACH LIGHTING SYSTEM WITH

SEQUENCED FLASHING LIGHTS (ALSF-2)

FAA Navigation Programs Visual Guidance Lighting Systems Team (AJM-3220) i January 2025

TABLE OF CONTENTS

1. SCOPE

2. APPLICABLE DOCUMENTS

2.1 General

2.2 Government Documents

2.2.1 FAA Specifications, Standards, Handbooks, and Drawings

2.2.2 Military specifications and handbooks

2.2.3 External Documents

3. LED STEADY BURNING LIGHT ASSEMBLY REQUIREMENTS

3.1 Physical Requirements

3.1.1 Elevated Light Assembly

3.1.2 Semi-Flush Light Assembly

3.2 Performance Requirements

3.2.1 Input Current

3.2.2 Elevated Light Assembly Optical Requirements

3.2.3 Semi-Flush Light Assembly Optical Requirements

3.2.4 Chromaticity Requirements

3.2.5 LED Lamp Monitoring Interface Requirements

3.3 System Requirements

3.3.1 Dielectric Protection

3.3.2 Electromagnetic Interference (EMI)

3.3.3 Electrical Requirements

3.3.4 Interchangeability

3.3.5 Derating of Electronic Parts

3.3.6 Nameplates

3.3.7 Assembly and Marking

3.4 Personnel Safety and Health

3.4.1 Electrical Safety

3.4.2 Ground Potential

3.4.3 Discharging Devices

3.4.4 Electrical Connections

3.4.5 Mechanical Interconnections

3.4.6 Hazardous and Restricted Materials

3.5 Parts, Materials, and Processes

3.5.1 Parts

3.5.2 Materials

3.5.3 Process

3.6 Environmental Requirements

3.6.1 Operational Environmental Requirements

3.6.2 Non-operating Environmental Requirements

3.7 Reliability

3.8 Maintainability

4. VERIFICATION

4.1 Verification Requirements Traceability Matrix

4.2 Test Allocation

ii January 2025

4.2.1 Development Test (DT)

4.2.2 Production Acceptance Test (PAT)

4.2.3 Type Tests

4.2.4 Operational Test (OT)

4.3 Test Procedures

4.3.1 Visual Inspection

4.3.2 Photometric Tests

4.3.3 Electrical Tests

4.3.4 Electromagnetic Interference Tests

4.3.5 Light Assembly Weight Test

4.3.6 Aiming Device Test

4.3.7 Environmental Tests

4.3.8 Additional Semi-Flush Light Assembly Tests

4.3.9 Functional Tests

4.3.10 Reliability Demonstration

4.4 Test Tools

iii January 2025

Table of Figures

Figure 3-1. Snowplow Ring

Figure 3-2. Elevated Intensity Limits

Figure 3-3. Semi-Flush Beam Pattern

Figure 3-4. Polling Pulse

Figure 3-5. Response Pulse

Figure 3-6. Lighting Loop Communication Timing

List of Tables

Table 3-1. 20A/6.6A Isolation Transformer Interface

Table 3-2. Elevated Intensity (White)

Table 3-3. Semi-Flush Intensity (White)

Table 3-4. Sand and Dust Particles

Table 3-5. Vibration Profile Parameters

Table 4-1. Development Tests

Table 4-2. Production Acceptance Tests

Table 4-3. Type Tests

Table 4-4. Elevated Intensity (White)

Table 4-5. Semi-Flush Intensity (White)

Table 4-6. Light Assembly Orientation and Test Duration

Table 4-7. Sand and Dust Particles

Table 4-8. Combined Rain and Wind

Table 4-9. Vibration Profile Parameters

1 January 2025

1. SCOPE

This FAA specification establishes the performance and verification requirements for the elevated and semi-flush steady burning light emitting diode (LED) light assemblies as direct replacements incandescent lamps used in the Dual Mode High Intensity Approach Lighting System with Sequenced Flashing Lights (ALSF-2).

2 January 2025

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-E-2689a Dual Mode High Intensity Approach Lighting System with

Sequenced Flashing Lights (ALSF-2/SSALR) Specification FAA-C-1217 FAA Construction Specification, Electrical Work, Premises

Wiring FAA-G-2100J Electronic Equipment, General Requirements FAA Engineering Brief 67D Light Sources Other than Incandescent and Xenon for

Airport and Obstruction Lighting Fixtures AC 150/5345-26 Specification for L-823 Plug and Receptacle, Cable

Connectors AC 150/5345-42 Specification for Airport Light Bases, Transformer

Housings, Junction Boxes, and Accessories

2.2.1.2 FAA Standards

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

2.2.1.3 FAA Orders

JO 3900.64.A Air Traffic Organization Electrical Safety Program

2.2.2 Military specifications and handbooks

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

3 January 2025

MIL-STD-889 Dissimilar Metals MIL-HDBK-1516 Unified Code for Coatings and Finishes for DOD Materiel MIL-STD-810H Environmental Considerations and Laboratory Tests MIL-STD-276 Impregnation of Porous Nonferrous Metal Castings MIL-STD-8625F Anodic Coatings for Aluminum and Aluminum Alloys MIL-HDBK-781A Reliability Test Methods, Plans, and Environments For

Engineering, Development Qualification, and Production MIL-DTL-7989C General Specification for Cover, Light-Transmitting For

Aeronautical Lights

2.2.3 External Documents

2.2.3.1 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 ATSM-A890 Castings, Iron-Chromium-Nickel-Molybdenum Corrosion

Resistant, Duplex (Austenite-Ferrite) for General Application

2.2.3.2 American National Standards Institute (ANSI)

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

ANSI/ESD STM11.11 ESD Association Standard For Protection Of Electrostatic Discharge Susceptible Items - Surface Resistance Measurement Of Planar Materials

ANSI/ASME B46.1 Surface Texture (Surface Roughness, Waviness, and Lay)

2.2.3.3 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

2.2.3.4 International Civil Aviation Organization (ICAO)

Annex 14 Aerodromes

4 January 2025

2.2.3.5 Society of Automotive Engineers (SAE)

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

SAE AMS-QQ-A-200/9 Aluminum Alloy 6063, Bar, Rod, Shapes, Tube, and Wire, Extruded

2.2.3.6 Code of Federal Regulations (CFR)

CFR Title 47 Federal Communications Commission (FCC), Telecommunications

CFR Title 29, Part 1910 Occupation Safety and Health Standards (OSHA), Labor

5 January 2025

3. LED STEADY BURNING LIGHT ASSEMBLY REQUIREMENTS

The elevated steady burning light emitting diode (LED) light assembly shall be a direct replacement for the elevated incandescent PAR-56 light assembly used in the Dual Mode High Intensity Approach Lighting System with Sequenced Flashing Lights (ALSF-2/SSALR) (i.e., no new cabling or wiring required). The semi-flush steady burning LED light assembly shall be a direct replacement for the in-pavement incandescent light assembly used in the ALSF-2/SSALR.

The elevated and semi-flush LED steady burning light assemblies consist of either white, red, or green light sources and associated light fixtures. The LED light assemblies shall interface with the FA-10703 Control and Monitoring (CM) cabinet and FA-10724 Replacement Lamp Monitoring System (RLMS) control cabinet (Unit 1). When replacing a light assembly, it is allowable to replace the existing isolation transformer with a size and configuration approved by the FAA.

3.1 Physical Requirements

3.1.1 Elevated Light Assembly

3.1.1.1 Programmable Heating Element

The elevated LED light assembly shall include a programmable heating element capable of dissipating ice off the face of the lens.

3.1.1.2 Aiming Device

The elevated LED light source aiming device shall meet the requirements specified in the following subsections.

3.1.1.2.1 Aiming Device Accuracy

The aiming device shall indicate the aiming angle on a scale calibrated in at least 1° increments and be accurate to within ±0.5° of the actual angle with the device attached. The aiming device shall provide light source vertical alignment to within ±1° of the desired aiming angle following the removal of the aiming device. The aiming device shall permit field aiming of the light beam at any angle from 0° to +25° above the horizontal. The scale shall be capable of indicating the light assembly angle relative to the Low-Impact Resistance (LIR) pole in the up or down position.

3.1.1.2.2 Aiming Device Operation

The aiming device shall allow the operator to aim lights without the need for tools. The aiming device shall not require the disassembly of any part of the light assembly to complete the aiming activity. The aiming device shall be capable of aiming the light assembly when mounted on Electrical Metallic Tubing (EMT) and LIR structures.

When mounted on LIR structures, the aiming device shall retain its reading when the pole is lowered. Starting with the structure in the elevated position, the aiming device shall permit aiming from the ground after lowering the structure parallel to the runway centerline a maximum of two

(2) times (including installation and removal of the aiming device).

6 January 2025

3.1.1.2.3 Aiming Device Physical Requirements

The aiming device shall weigh no greater than two (2) lbs. The aiming device construction shall be of non-corrosive material. The aiming device shall have no loose parts. The assembly of aiming device parts shall use self-retaining fastening devices. The aiming device shall provide means to retain an aiming reading when subject to movement or transport. The aiming device may be electronic, mechanical, or a combination of both. If the aiming device is mechanical, it shall have an enclosed dial and stop brake to hold the reading. If the aiming device is electronic, it shall be battery powered.

3.1.1.2.4 Aiming Device Storage and Transport

The alignment device stored in its transport case shall be transportable by one person. The transport case shall protect the aiming device from damage when dropped from a height of four

(4) feet at any angle on any axis.

3.1.1.3 Vertical Adjustment

The elevated light assembly shall provide continuous vertical adjustment of the light beam axis from 0° horizontal to 25° above horizontal. The light assembly shall permit vertical alignment of the light beam to any vertical angle within ±0.5°. A locking mechanism shall be provided to securely lock each light assembly in its set position. The light assembly shall operate over the entire vertical alignment range. The light assembly locking mechanism shall keep the light aligned while exposed to the specified requirements for Ice Dissipation (Section 3.6.1.10) and Combined Wind and Ice Loading (Section 3.6.1.11).

3.1.1.4 Mounting Base

The elevated light assembly-mounting base shall provide rigid mechanical support for one (1) light source. The light assembly-mounting base shall have an internal wire-way that provides an interface to power wires from the bottom of the light mounting base. Three (3) equally spaced (120°) 3/8-inch cup point set or machine stainless steel screws shall be used to secure the bottom of the light assembly-mounting base to the support structure, per FAA-E-982.

The adaptable light assembly mounting base mechanical solution shall be such that the light mounting base will have a universal interchangeable interface for a frangible coupling, frangible coupling/EMT, or LIR mounting arrangement. The elevated light assembly mounting base shall allow for the elevated mounting of the assembly on a two (2) inch diameter EMT/LIR conduit.

3.1.1.5 Weight

The elevated light assembly shall weigh no greater than six (6) pounds.

3.1.1.6 Assembly Finish

The finish of the elevated light assembly shall be Aviation Orange in accordance with FED-STD- 595 (excluding heat sink, if required). The LED light assembly finish shall include means to identify the color of the light output when not illuminated.

7 January 2025

3.1.2 Semi-Flush Light Assembly

The semi-flush light assembly shall consist of a top cover assembly, optical assembly and bottom cover assembly. The semi-flush light assembly shall be constructed so that adjustments and repairs can be made easily. The semi-flush light assembly shall include the items below:

1. Steady Burning Semi-Flush Light Fixture

2. L-823 Receptacle Plug Kits

3. Snowplow Rings

4. Mounting Hardware (bolts, O-rings, washers, and lock washers)

5. Anti-Seize Compound

The anti-seize compound shall be Loctite Nickel Anti-Seize Lubricant 771, or equivalent (28 grams minimum).

3.1.2.1 Programmable Heating Element

The semi-flush LED light assembly shall include a programmable heating element capable of dissipating ice off the face of the lens.

3.1.2.2 Assembly Configuration

3.1.2.2.1 Interconnecting Wiring

The semi-flush light assembly shall have two separate sections of interconnecting wiring, in accordance with AC 150/5345-26:

a. The first interconnecting wiring section shall have no less than 12 inches of electrical conductor to connect the light fixture to the L-823 Plug (“Plug A”). The cables shall clamp to the base of the light fixture to provide strain relief.

b. The second interconnecting wiring section shall have no less than 30 inches of electrical conductor, starting with a L-823 Receptacle (“Receptacle B” to mate with “Plug A”), and ending with exposed leads for field installation.

The semi-flush light assembly shall have a minimum insulation resistance of 50 Megohms lead-to-case when dry or while soaking in salt water. Leads shall be stranded copper, 600 VAC insulated with a material suitable for the electrical and temperature requirements. Moisture shall not wick into the fixture through the leads.

3.1.2.2.2 Assembly Dimensions

The semi-flush light assembly shall be designed to fit into an L-868C light base using a snowplow ring without degrading the photometric output. The semi-flush light assembly shall have an outside diameter of 11.94 inches (+/-0.05 inches). The semi-flush light assembly shall be mounted into the light base with six (6) 0.375-inch diameter, high-strength stainless steel bolts and two-part locking washers. A silicone or neoprene O-ring shall be used between the light fixture and the snowplow ring. The AC 150/5345-42 shows interface details and dimensions of the L-868C light

8 January 2025 base. Critical interface areas of the light fixture are the outer diameter, top flange, bolt-holes, and throat projection.

The semi-flush light assembly shall have a projection that extends at least 0.25 inches down through the top flange of the L-868C light base. The diameter of this projection shall be 0.06-inch (+0.00 /-0.01 inch) less than the nominal diameter of the top flange cutout of the L-868C light base. The thickness of outer edge of the light assembly top cover shall be a maximum of 0.77 inches when installed in the light base. The outer edge of the light assembly top cover shall be rounded to no less than 0.0625-inch radius. The light assembly when installed shall not exceed

1.25 inches above the mating surface of the L-868C base.

The light assembly bolt-hole configuration shall match the top flange of the light base. In addition, the axis between one pair of bolt holes on opposite sides of the light fixture shall be perpendicular to the direction of the runway centerline.

3.1.2.2.3 Light Fixture Hardware

Fabrication of all bolts, studs, nuts, and other similar fasteners shall be from 18-8 stainless steel, passivated, and free from discoloration. Lock washers shall be made of 410 stainless steel and shall have a black oxide finish in accordance with MIL-DTL-13924E, Class 3.

3.1.2.3 Top Cover Assembly

The top cover assembly shall withstand pressure from tires, mechanical impact, thermal shock, and vibration without damage or loss of the watertight seal. O-ring grooves shall have a surface finish of 64 micro-inches RMS maximum, as defined in ASME B46.1. The top surface of the light assembly may be stainless steel, anodized aluminum, or bare aluminum with a low copper content.

The top surface of the light assembly shall be smooth and free of sharp projections. The surface on the light assembly that mates with the light base flange shall have a smooth finish to provide good load transfer and sealing. The surfaces of mating parts shall be flat to ensure proper seating without rocking prior to assembly. The top surface (excluding recesses, light windows, and light channels) shall have a slope less than 12 degrees. Means shall be provided on the light unit to permit its removal for maintenance purposes, i.e. pry bar slots, indentations, extraction devices or other suitable provisions.

3.1.2.3.1 Gaskets and O-Rings

Gaskets and O-Rings used at joints shall be capable of sustained operation at environmental conditions specified in Section 3.6. Gaskets and O-Rings shall withstand deterioration caused by de-icing and anti-icing fluids. Gaskets and O-Rings shall be neoprene or silicone rubber. If used, silicone rubber shall be of low compression set and conform to Class 2B, Grade 60, as specified in A-A-59588.

3.1.2.3.2 Sealing Compounds

Sealing compounds shall be run-proof. Sealing compounds shall not harden or crack (i.e., lose water-sealing properties) after exposure to the environmental conditions specified in Section 3.6.

9 January 2025

Sealing compounds shall withstand deterioration caused by de-icing and anti-icing fluids. There shall be sealing compounds applied to all silicone gaskets or seals.

3.1.2.4 Bottom Cover Assembly

The bottom cover shall be airtight and watertight. Seals used shall prevent breathing with internal pressure changes due to varying lamp heat. Pressure within the light fixture shall not exceed 20 psi under any operating condition. Pressurization of the sealed optical assembly shall be possible through a supplied stainless-steel valve (e.g., Schrader valve) integral to the assembly. The fitting may be permanent, or a plug may replace it for installation. An external ground lug of an appropriate type, based on the manufacturer’s design, shall be an integral part of the external bottom cover of the light assembly. The external ground lug shall accommodate at least 6 AWG.

The external ground lug shall be located so as not to interfere with light base insertion/extraction.

3.1.2.5 Optical Assembly

The light window of the light assembly shall have an internal flange that will prevent external forces from pushing the lens back into the interior of the light fixture. The clearances between the lens and the metal surfaces of the light shall prevent cracking of the lens. The clearance shall be chosen such that the possibility is minimized for shards of the Teflon/rubber snowplow blade edges to penetrate the area between the lens and the adjacent metal surfaces and cause leakage. Optical assembly components shall be keyed to prevent incorrect reassembly.

3.1.2.6 Weight

The semi-flush light assembly shall weigh no greater than 20 lb.

3.1.2.7 Snowplow Ring

If a new snowplow ring is required, the design shall meet the following requirements: The snowplow ring shall not interfere with installation of the light fixture in the light base or degrade the photometric performance of the light fixture below minimum requirements. Snowplow rings shall meet all environmental and structural requirements within this specification. The light assembly can be used with or without the snowplow ring. Figure 3-1 provides detailed measurements of the existing snowplow ring.

10 January 2025

Figure 3-1. Snowplow Ring

3.1.2.8 Structural Integrity Requirements

The semi-flush light assembly shall withstand the mechanical stresses described below without damage or deterioration of performance.

3.1.2.8.1 Static Load

The light assembly shall withstand a static load (lb) of 500 times the top area of the light fixture (in2) distributed uniformly over the top surface of the light fixture.

3.1.2.8.2 Dynamic Load

The light assembly when installed with a snowplow ring, shall withstand snowplow impacts without deterioration in materials or operational degradation.

3.1.2.8.3 Shear Load

The light assembly shall withstand shear loads of 6,000 lbs. imposed by aircraft during their operational phases (i.e., taxiing, taking off, landing, and stopping) uniformly applied to the top of the light fixture in any direction parallel to the mounting surface.

11 January 2025

3.1.2.8.4 Torque Load

The light assembly shall withstand a torque load of 8,000 ft/lb (±5%) applied to the top surface of the light fixture in any direction parallel to the mounting surface. This requirement approximates the twisting torque generated upon the center of a light fixture by an aircraft tire inflated to 250 psi in a locked-wheel turn.

3.1.2.8.5 Hydraulic Load

The light assembly shall withstand momentary hydraulic pressure of 250 psi created by aircraft tires moving at high speeds during operations in wet weather.

3.1.2.8.6 Mechanical Impact

The light assembly shall withstand the repeated impact of a steel ball with 30 ft/lb (40 J) of energy.

3.1.2.8.7 Light Window Load

The light window shall support a load of 500 psi over the area of the opening when applied directly to the light window surface.

3.2 Performance Requirements

3.2.1 Input Current

The LED light assemblies (elevated and semi-flush) are powered by Constant Current Regulators (CCRs) that have an output range from 8.5 Amps to 19.8 Amps to operate the five brightness levels (1-5). A single 300W 20A/6.6A isolation transformer is capable of interfacing with multiple elevated LED light assemblies.

The steady burning LED light assembly shall produce five brightness levels (1-5) at the five current levels as provided in Table 3-1. If the isolation transformers are included as part of the design, the transformers shall not attenuate the 3840 Hz and 7680 Hz signal being transmitted over the power line as part of the Lamp Monitoring.

Table 3-1. 20A/6.6A Isolation Transformer Interface

BRIGHTNESS

LEVEL

NOMINAL OUTPUT

(AMP/RMS)

ALLOWABLE RANGE

(AMP/RMS)

5 6.6 6.5 – 6.7 4 5.2 5.1 – 5.3 3 4.1 4.0 – 4.2 2 3.4 3.3 – 3.5 1 2.8 2.7 – 2.9

12 January 2025

3.2.2 Elevated Light Assembly Optical Requirements

The elevated light assembly shall meet all the following requirements under the operating environmental conditions specified in Section 3.6.1.

3.2.2.1 Beam Pattern

The light assembly beam shall exhibit a circular shape defined by the standard equation for a circle:

𝑥𝑥2 + 𝑦𝑦2 = 72 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 ±7° from the optical centerline along the vertical or horizontal axis (a = 7, b = 7) as shown in Figure 3-2.

Figure 3-2. Elevated Intensity Limits

3.2.2.2 Photometric Intensity

The measured intensity of the white LED elevated light assembly shall have a maximum allowable intensity as listed in Table 3-2 for each brightness level (+0%, -20%).

Table 3-2. Elevated Intensity (White)

ELEVATED WHITE LIGHT SOURCE INTENSITY

Brightness Level Amperage (A) Candela (cd)

13 January 2025

B1 2.8 77 B2 3.4 384 B3 4.1 1,920 B4 5.2 9,600 B5 6.6 48,000

The green LED elevated light assembly shall be measured at 50% intensity of the white as shown in Table 3-2. The red LED elevated light assembly shall be measured at 20% intensity of the white as shown in Table 3-2.

3.2.3 Semi-Flush Light Assembly Optical Requirements

The semi-flush light assembly shall meet all the following requirements under the operating environmental conditions specified in Section 3.6.

3.2.3.1 Beam Pattern

The semi-flush light assembly beam shall exhibit an elliptical shape defined by the standard ellipse equation:

𝑥𝑥2 𝑎𝑎2

(𝑦𝑦 − 7)2 𝑏𝑏2 = 1 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 ±15° from the optical centerline along the horizontal axis (a = 15) and shall be no closer than ±5° from the optical centerline along the vertical axis (b = 5).

(shown in Figure 3-3). The light output from the top cover window shall have no negative slope.

Figure 3-3. Semi-Flush Beam Pattern

3.2.3.2 Photometric Intensity

The measured intensity of the white LED semi-flush light assembly shall have a maximum allowable intensity as listed in Table 3-3 for each brightness level (+0%, -20%).

14 January 2025

Table 3-3. Semi-Flush Intensity (White)

WHITE LIGHT SOURCE INTENSITY

Brightness Level Amperage (A) Candela (cd)

B1 2.8 77 B2 3.4 384 B3 4.1 1,920 B4 5.2 9,600 B5 6.6 48,000

The green LED semi-flush light assembly shall be measured at 50% intensity of the white as shown in Table 3-3. The red LED semi-flush light assembly shall be measured at 20% intensity of the white as shown in Table 3-3.

3.2.4 Chromaticity Requirements

3.2.4.1 White LED

The color of the light emitted from the white LED light assembly 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 = 0.3366, y = 0.3369 o x = 0.3376, y = 0.3616 o x = 0.4006, y = 0.4044 o x = 0.3889, y = 0.3690

3.2.4.2 Green LED

The color of the light emitted from the green LED light assembly shall be 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.

• 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

15 January 2025

3.2.4.3 Red LED

The color of the light emitted from the red LED light assembly shall be 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.

• Red boundary intersection points:

o x = 0.680, y = 0.320 o x = 0.660, y = 0.320 o x = 0.690, y = 0.290 o x = 0.710, y = 0.290

3.2.5 LED Lamp Monitoring Interface Requirements

The LED light assembly shall operate as part of the ALSF-2 system in accordance with the requirements specified below.

3.2.5.1 Lighting Loop Characteristics

There are two ALSF-2 loop configurations: the FA-10700 (NBP) ALSF-2 loop configuration consists of five (5) lighting loops and the FA-10048 (Airflo) and FA-9993 (Godfrey) loop configurations consist of three (3) lighting loops. The maximum number of failed light assemblies per lighting loop prior to a failure alarm is 28. Each loop is monitored by the FA-10703 CM cabinet and the FA-10724 RLMS control cabinet (Unit 1). The CM (FA-10703) and RLMS control cabinet (Unit 1) send a 16.67 msec polling pulse every five seconds in the 5-loop configuration or three seconds in the 3-loop configuration.

3.2.5.2 Light Assembly Addressing

Each LED light assembly shall be addressable by either hardware or software means. Each LED light assembly shall have a unique address from of one (1) through 127. The addressing of the light assembly shall be designed that it can be performed at the ALSF site. Field addressing shall not affect the environmental requirements of the light assembly.

3.2.5.3 Shorting Device Characteristics

Each LED light assembly shall be fitted with a shorting device that will activate when the LED light assembly fails to avoid an open loop condition. If multiple LED devices are used to produce a single light source, the light assembly shall be considered failed if more than 25% of the LEDs fail.

3.2.5.4 Polling Pulse

The ALSF-2 LED light assembly shall accept the polling pulse from the CM cabinet (FA-10703) or RLMS control cabinet (Unit 1) transmitted over each of the current power loops in accordance with Figure 3-4 and the following parameters:

16 January 2025

Frequency: 3840 Hz (±0.4 Hz)

Pulse Duration: 16.67 msec (±0.002 msec)

Peak to Peak Amplitude: 76 VAC (±7.6 VAC)

Figure 3-4. Polling Pulse

3.2.5.5 Light Assembly Response

The ALSF-2 LED light assembly shall respond to the polling signal, based on its assigned address, over each of its associated current power loops (i.e., the response for lamp 3 on a loop shall occur during the 3rd positive half-cycle of the 60Hz cycle) in accordance with Figure 3-5 and the following characteristics:

Frequency: 7680 Hz (±0.8 Hz)

Response Duration: 8.33 msec (+0, -1.7 msec) on the positive half of 60 Hz cycle

Peak Amplitude: 0.75 VAC (±0.075 VAC); 5 W (±0.25 W)

17 January 2025

Figure 3-5. Response Pulse

The LED light assembly response shall synchronize to the 60 Hz (+0.01 Hz) polling signal in the order (i.e., sequentially) of each light assembly’s individual address, as shown in Figure 3-6. Each LED light assembly shall transmit its response back based on its address number.

Figure 3-6. Lighting Loop Communication Timing

3.2.5.6 Signal Attenuation

The proposed isolation transformers shall not attenuate the polling pulse signal (3840 Hz (±0.4 Hz)) more than -0.445 dB. The proposed isolation transformers shall not attenuate the light assembly responses (7680 Hz (+0.8 Hz)) more than -0.445 dB.

18 January 2025

3.3 System Requirements

3.3.1 Dielectric Protection

Insulation and insulating materials used in the elevated and semi-flush LED light assemblies shall be rated for at least 5,000 VAC service. Insulation resistance shall be greater than 50 megohms, when measured using 10 kV DC. Designs shall be consistent with the surge withstand capability of ANSI C37.90.

3.3.2 Electromagnetic Interference (EMI)

3.3.2.1 Radiated Emissions

The light assembly 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.

3.3.2.2 Radiated Susceptibility

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

3.3.2.3 Electrostatic Discharge Protection

The light assembly 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 contains 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 IEC 61000-4-2 Level 4 with direct and indirect discharge applications.

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

3.3.3 Electrical Requirements

3.3.3.1 Power Demand

The average wattage rating of the LED light assembly shall be no greater than 60W.

3.3.3.2 Response Time

The light assembly driver circuit shall respond to a brightness step change in less than one (1) second after receiving the change of input current (with an exception of initial start-up).

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3.3.3.3 Pulse Width Modulation

If Pulse Width Modulation is used, the pulse repetition rate shall be greater than 200 Hz.

3.3.4 Interchangeability

LRUs shall be interchangeable in form, fit, and function without mechanical adjustment. LRUs are defined as any top assemblies and subassemblies.

3.3.5 Derating of Electronic Parts

The use of electronic parts and materials selected shall be within their electrical ratings and environmental capabilities (e.g., any ambient or hot spot temperatures, voltage, current, or power dissipation). Derating shall be implemented as necessary to assure the required equipment reliability within the specified operating conditions.

3.3.5.1 Semi-Flush Light Assembly Current-Carrying Components

Current-carrying components in the semi-flush light assembly shall be fabricated of non-corrosive, high-conductivity materials. All current-carrying components in the light assembly requiring insulation shall be insulated for at least 1.5 times the operating voltage and shall be designed for a current-carrying capacity of 1.5 times the maximum operating current. All interconnecting cables shall be rated for a minimum of 1.5 times the maximum expected voltages in the circuits.

3.3.6 Nameplates

The equipment shall have nameplates in accordance with FAA-G-2100, Section 3.3.3. Nameplates for the elevated light assemblies shall be attached to the outside surface of the equipment using 18-8, type 4-40 stainless steel screws. The nameplates for the semi-flush light assemblies shall be attached on the outside of the base of the light assembly by a permanent self-adhesive backing.

Serial numbers shall start with one (1) for each equipment unit having an individual nameplate and continue consecutively up to the total number of such equipment units required. Serial numbers for a given part number shall not be duplicated or reassigned.

3.3.6.1 Additional Semi-Flush Requirements

A plate, similar to the nameplate, shall be attached to the outside of the base of the semi-flush light assembly directing the installer to:

1. Apply anti-seize compound to each of the bolts attaching the light assembly to the light base;

2. Torque the bolts to a value of from 175 to 200 inch-pounds, or the contractor’s recommended value, if different; and

3. Not use an impact wrench to tighten the bolts.

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3.3.7 Assembly and Marking

All components shall be properly assembled and marked. Each electrical/electronic component or part thereof shall be identified by a reference designation marked adjacent to the physical location of the part of the equipment and readily visible to maintenance personnel. Such identification shall be identical to reference designations used in instruction books for equipment.

3.3.7.1 Marking

a. Marking shall be permanent and legible during normal operation and maintenance usage.

b. Marking shall be as specified in ANSI/IEEE-200.

3.3.7.2 Visibility of Parts and Labels

All LRU parts that have labels or markings identifying data or ratings, shall be mounted so that the data is visible to maintenance personnel without the necessity for disassembly of parts or of adjacent functional or structural parts.

3.3.7.3 Fuse Positions

All fuse positions shall be marked with the rated current capacity of the fuse to be employed therein and approved by the FAA.

3.3.7.4 Terminal Strips, Blocks, and Wafer Switches

All terminal strips, blocks, and wafer switches shall be identified.

3.4 Personnel Safety and Health

a. The equipment design shall meet or exceed OSHA regulations for personnel safety, as identified in CFR Title 29, Part 1910 and Part 1926, FAA-C-1217, and JO 3900.64.

b. Personnel shall be protected from injury by sharp edges of equipment or cabinets during maintenance.

3.4.1 Electrical Safety

a. Covers or caps shall be provided to protect personnel from accidental contact with voltages in excess of 5 V RMS or DC during normal operations or maintenance of the equipment:

1. After power to the equipment is turned off, the equipment shall discharge all potential stored power within 2 seconds.

2. Personnel shall be protected from circuits carrying currents greater than 21mA AC and 80mA DC.

b. The power input side of the switch and the incoming power line connections shall be given physical protection against accidental contact.

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3.4.2 Ground Potential

a. The design and construction of the equipment shall ensure that all external parts, surfaces, and shields, exclusive of transmission line terminals, are at ground potential at all times during normal operation.

b. All outer metal cases of components shall be at ground potential or covered by an external casing made of insulating material.

c. A point on the electrically conductive chassis or equipment frame shall serve as the common tie point for the static or power ground.

3.4.3 Discharging Devices

a. Discharging devices shall be provided to discharge high voltage circuits and capacitors unless they discharge to 30V within two seconds or less after power removal.

b. These protective devices shall be positive acting, highly reliable, and shall actuate automatically when the case or rack is opened.

c. When resistive bleeder networks are used to discharge capacitors, the bleeder network shall consist of at least two equal valued resistors in parallel.

d. The particular discharging device that is chosen shall ensure that the capacitor is discharged to 30V or less within two seconds.

3.4.4 Electrical Connections

a. The design of the connector shall be such that the operator is not exposed to electrical shock or burns when normal disconnection methods are used.

b. Exposed pin contacts shall not be energized (hot) after being disconnected from the socket contacts.

3.4.5 Mechanical Interconnections

a. The design shall provide positive means to prevent the inadvertent reversing or mismatching of instrument leads and electrical connections.

b. When prevention of mismatching by design considerations is not feasible, coding or marking shall be employed when approved by FAA.

3.4.6 Hazardous and Restricted Materials

a. Assessment of the hazard potential of a substance and its decomposition products shall be performed prior to material selection.

b. The assessment shall include the relative toxicity of the substance (and decomposition products) as well as the nature of the potential exposure to personnel and equipment.

c. Before using any materials that might contain these chemicals, they shall be evaluated in accordance with the 29 CFR 1990.

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3.5 Parts, Materials, and Processes

Parts, materials, and processes selected for use in this equipment shall be in conformity with specific requirements herein. Parts and materials shall be selected based on the environmental conditions, as specified in Section 3.6.

3.5.1 Parts

Parts shall be as specified herein.

3.5.1.1 Electrical Connectors

a. All electrical connectors shall be Underwriters Laboratories (UL), Electrical Testing Laboratories (ETL), or Canadian Standards Association (CSA) listed for their application and use.

b. Contact crimp, installing, and removal tools shall be in accordance with the individual connector specifications.

3.5.1.2 Fastener Hardware

a. Fasteners shall be able to be removed and installed without damage to hardware.

b. Fasteners shall remain secure when exposed to equipment operational and environmental stresses.

c. Except for those items designed to be affixed with one fastener, parts shall be secured so failure of a single fastener will not free the part completely.

d. Friction between mating surfaces shall not be employed as the sole means of preventing fixed parts from rotating or shifting.

e. Fasteners shall be selected to minimize the number of standard tools used during maintenance.

3.5.2 Materials

Materials shall be specified herein. When materials are used, for which no specification is provided, they shall be of the commercial quality and suitable for the purpose.

3.5.2.1 Glass

3.5.2.1.1 Elevated LED Light Assembly

All light transmitting surfaces must meet MIL-C-7989B, Class B, C, or D.

3.5.2.1.2 Semi-Flush LED Light Assembly

Glass used as an optical or structural part shall meet all requirements of this specification, which includes the requirements of MIL-DTL-7989C for Class B glass. Class C glass may be used, if required, for impact strength. The light output window shall be of borosilicate glass, or equivalent, having an average Young’s Modulus of 9.1 x 106 and a Poisson’s Ratio of 0.2. The glass shall be tempered to withstand thermal shock. Supports shall protect glass from damage due to vibration, physical shocks, or deflection of any component parts.

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3.5.2.2 Printed Circuit Boards

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

3.5.2.2.1 Conformal Coating of Printed Circuit Boards

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

3.5.2.2.2 Assembly

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

3.5.2.3 Wiring

Solid wire shall not be used. Wire shall be continuous from point of origin, on a discrete device or terminal, to the point of destination, on a discrete device or terminal. All wiring shall be in accordance with the subsections below.

3.5.2.3.1 Wiring – Marking

All signal, control, and power wiring shall be uniquely identified to and within the enclosure along the wire and at each termination by either permanent, insulation markings or by heat shrink labels.

3.5.2.3.2 Wiring – Protection

The wiring shall be secured and protected against chafing due to vibration or movement.

3.5.2.3.3 Wiring – Sleeving

a. Flexible plastic sleeving, nonflammable, self-extinguishing, or flame retardant shall be used on cables subject to flexing.

b. The sleeving shall be secured under cable clamps at each end.

c. The cable shall be formed and secured so the cable will not be subject to abrasion in its normal flexing motion.

d. In cases where abrasion cannot be avoided, additional protection shall be provided.

3.5.2.3.4 Wiring – Through Hole Protection

a. Whenever wires are run through openings in metal partitions, shields, and the like, which are less than 1/8 inch in thickness, the holes shall be equipped with suitable mechanical protection (grommet) or insulation.

b. Openings in panels 1/8 inch or more in thickness shall have either grommets or the edges of the openings rounded to a minimum radius of 1/16 inch.

3.5.2.3.5 Wiring – Arrangement

a. All wiring shall be arranged in a manner to allow access to and maintenance of all components.

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b. Materials used for binding, sleeving, and strapping shall be compatible with the conductor or cable insulation or jacket, and shall meet the same flame retardant and self-extinguishing requirements.

3.5.2.3.6 Wiring – Slack

Discretely terminated wires and cables shall be as short as practicable and still allow for maintenance and operation without damage or crimping of the wires.

3.5.2.3.7 Wiring – Entrance Cabling and Wiring

Wiring from cable entrances to terminal boards, plugs, jacks, and similar devices shall be harnessed and clamped.

3.5.2.3.8 Wiring – Support

a. Wire and cable shall be supported and secured to prevent stress on the conductors and terminals and change in position of the wire or cable during and after subjection of the equipment to specified service conditions, or after service or repair of the equipment in a normal manner.

b. Twine or tape shall not be used for securing wire and cable.

3.5.2.3.9 Wiring – Conductor Insulation Sleeving

Insulation sleeving of conductors shall be UL, ETL, or CSA listed for the application.

3.5.2.3.10 Wiring – Aluminum Conductors

Aluminum conductors shall not be used.

3.5.2.3.11 Wiring – Strain Relief

Each part lead terminating at a connection point shall have allowance for strain relief to minimize tensile or shear stress.

3.5.2.4 Metals

Metals shall withstand the mechanical stress involved and shall be inherently corrosion resistant or suitably protected after fabrication, to prevent corrosion or oxidation under the service conditions.

3.5.2.4.1 Dissimilar Metals

Selection of metals for use in electronic equipment shall be made in accordance with the requirements of MIL-STD-889. Where electronic design requirements preclude the isolation from one another of incompatible metal combinations as identified in MIL-STD-889, the incompatible materials shall be isolated from exterior environments.

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3.5.2.4.2 Stainless Steel

Stainless steel shall meet the requirements of ASTM A890/A890M-18a. Type 18-8 stainless steel shall be used for all bolts, nuts, and washers not subject to high stress requirements.

3.5.2.4.3 Aluminum

Aluminum shall be in accordance with Federal Specifications QQ-A-200/9 and QQ-A-225.

Aluminum alloy plate and sheet, aluminum alloy die-castings, and aluminum alloy sand castings shall be in accordance with Federal Specifications QQ-A-250, QQ-A-591, and QQ-A-601, respectively. Aluminum alloy castings, if used, shall be impregnated in accordance with MIL-

STD-276.

3.5.2.4.4 Plating

All iron and steel parts shall be zinc or cadmium plated in accordance with ASTM B633-19 or

AMS-QQ-P-416.

3.5.2.4.5 Protective Coatings

Protective coatings used for prevention of corrosion shall be as specified below:

a. Metals shall be corrosion resistant or shall be coated or metallurgically processed to resist corrosion.

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

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

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

3.5.2.4.6 Painted Finishes

a. Surface preparation shall include masking, covering, or otherwise protecting surfaces not to be painted or primed, including contact surfaces requiring electrical continuity for grounding purposes.

b. The painted surfaces shall withstand the environmental conditions specified in Section 3.6 for the entire service life of the equipment without flaking, cracking, or allowing any corrosion of the underlying surface.

c. The primer color shall be different from the intermediate coat to provide a color contrast between coats.

3.5.2.5 Gasket

Gaskets used at separable joints for cushioning and sealing purposes shall be capable of sustained operation at ambient temperatures of -40⁰ F (-40⁰ C) to +158⁰ F (+70⁰ C). Adhesives, if used, shall be in accordance with MIL-HDBK-454B, Guideline 23.

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3.5.2.6 Adhesive

Adhesives, if used, shall be in accordance with MIL-HDBK-454B, Guideline 23.

3.5.2.7 Fungus-inert Materials

Materials used shall be fungus-inert, except within a hermetically sealed assembly. If the materials used are not fungus-inert, they shall be rendered fungus-inert by compounding with a permanently effective fungicide or by suitable surface treatment.

3.5.2.8 Ultra-Violet Protection

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

3.5.3 Process

3.5.3.1 Brazing

Brazing shall be in accordance with MIL-HDBK-454B, Guideline 59 except that electrical connections shall not be brazed.

3.5.3.2 Soldering

Soldering shall be in accordance with MIL-HDBK-454B, Guideline 5.

3.5.3.3 Lugs Connected to Screw Terminals

Where wires are connected to solderless or solder lugs which are clamped under screw terminals so as to be removable by loosening or removing the screws, not more than one wire shall be attached to each lug, so that each wire can be removed individually from the screw terminals. Not more than three lugs shall be attached to each screw terminal.

3.5.3.4 Cable Connector Wiring

Not more than one wire shall be attached to each contact of each cable connector, except that two wires may be attached to a crimp-type contact. The two wires connected together shall not exceed the size of the connector pin.

3.5.3.5 Splices

Wires and cables shall not be spliced.

3.5.3.6 Workmanship

Each light assembly 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

27 January 2025 chips, flux, and other foreign material shall be removed during and after final assembly of the light assembly.

3.6 Environmental Requirements

3.6.1 Operational Environmental Requirements

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

3.6.1.1 Temperature

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

3.6.1.2 Humidity

The light assembly shall exhibit no adverse effects during operation at relative humidity levels between 0 to 100% humidity at +67.2°C.

3.6.1.3 Altitude

The light assembly shall exhibit no adverse effects during operations at an altitude range from test facility altitude to 10,000 feet Mean Sea Level (MSL).

3.6.1.4 Sand and Dust

The light assembly shall exhibit no adverse effects during exposure to windblown sand and dust particles in accordance with Table 3-4.

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Table 3-4. 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)

3.6.1.5 Salt Fog

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

3.6.1.6 Combined Rain and Wind

The elevated light assembly 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.

3.6.1.7 Thermal Shock

The light assembly 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.

3.6.1.8 Solar Radiation

The light assembly shall…