P-422-0432 RevB 12vdc Marine Lamps.doc

Revision __B__ Mar 2008

SPECIFICATION

OR

STATEMENT OF WORK

COVER SHEET

TITLE

SPECIFICATION

FOR

AIDS TO NAVIGATION

12-VOLT MARINE SIGNAL LAMPS

SPECIFICATION NUMBER:

P-422-0432

(FORMERLY HQ SPECIFICATION NO. 487A)

ORIGINATED BY: D. W. White_____ _ DATE: Mar 2008 ORIGINATOR’S COMMAND: Engineering Logistics Center Baltimore

INTERNAL REVIEWER: __ _____ __ DATE:

DEPARTMENT/DIVISION: _____022_____

SOWRB APPROVAL: _____________________________ DATE:

1.

Scope. This specification describes 12 volt DC (VDC) lamps of various current/wattage ratings and constructions for use in standard U. S. Coast Guard marine signal lanterns installed on aids-to-navigation buoys and fixed structures.

1.1.

Classification of Lamps.

Type I: C-8 Filament

3.05 A

Type II: CC-8 Filament

2. APPLICABLE DOCUMENTS:

2.1 General. Sections 3 and 4 of this specification reference the documents listed in this section. This section does not include documents cited in other sections of this specification. Those documents are recommended for additional information or are used as examples. Every effort was made to ensure the completeness of this list. However, document users are cautioned that they must meet all specified requirements cited in sections 3 and 4 of this specification, whether or not the referenced documents are listed here.

SPECIFICATIONS

2.2 Government Documents. The following documents form a part of this specification to the extent referenced herein. Suffixes denoting the specific issue of each document are omitted from future references to the documents in this specification.

MIL-STD-129P (3)

Standard Practice for Military Marking

10/29/2004

2.3.1 Industry Publications. The following documents of the issues specified form a part of this specification to the extent referenced herein. Suffixes denoting the specific issue of each document will be omitted from future references to the document in this specification.

AMERICAN SOCIETY FOR TESTING AND MATERIALS (ASTM)

ASTM D 3951 (2004)

Standard Practice for Commercial Packaging

AMERICAN SOCIETY FOR QUALITY CONTROL (ASQC)

ANSI/ASQC

Quality Systems - Model for Quality Assurance in

Q9002-1994 Production, Inspection, and Servicing

ANSI/NSCL

Calibration Laboratories & Measuring and Test Equipment Requirements

Z540-1-1994

AIM BC 1-95

Uniform Symbology Specification Code 39

DRAWINGS

G-ECV 121059, G-ECV 121114, SK1401-A

2.4 Precedence. Any ambiguity or conflict between the specification and applicable documents shall be resolved by utilizing the following documents in the precedence shown:

a. This specification

b. Applicable documents 3.

Requirements:

3.1.

Mechanical: Lamps offered under this specification shall meet the requirements for dimensions, material, and configuration described in this specification and as illustrated in the attached drawings.

3.1.1.

Dimensions: The dimensions and tolerances of the lamps; including base, bulb, filament, filament axis, filament support orientation, and light center length (LCL), shall be in accordance with Table 1 of this specification and the attached drawings.

3.1.2.

Bulb: Lamp bulbs shall be clear glass or quartz. Bulb sizes for the various lamps are specified in Table 1 of this specification. There shall be no markings on the lamp bulb.

3.1.3.

Base: The lamps shall have a single contact candelabra base with a prefocus collar. The dimensions, tolerances, material, and orientation of the base and prefocus collar shall comply with the attached drawings.

3.1.4.

Alignment: The filament axis is defined as a straight line centered in the filament coil and running the entire length of the filament. The prefocus collar axis is defined as a straight line originating in the geometric center of the collar and extending perpendicular to the plane of the collar. The prefocus collar and filament axes shall coincide, within ± 0.4mm, along the entire filament length. This requirement is met if every part of the filament is within a cylinder of radius 0.4mm plus ½ the allowable width of the filament, which is centered on the prefocus collar axis.

Table 1A

Table 1B

Tolerances:

Rating ±7%;

Filament Height ±20%;

Filament Width ±25%;

Luminous Flux –15% (no upper limit);

LCL ±0.41mm.

3.1.5.

Lamp Marking: The rated current/wattage and voltage, and the manufacturer’s name or trademark shall be marked on the top (bulb) side of the prefocus collar of each lamp, or on the upper section of the lamp base (between the bulb and the prefocus collar).

3.1.6.

Shadowing: The filament support for lamps with S-8 or S-11 bulbs (see sketch SK 1401A, attachment (1)) shall spiral about the filament as illustrated in drawing G-ECV 121059, attachment (2). Filament supports for lamps in T-3.5 bulbs may be vertically oriented as illustrated in drawing G-ECV 121114, attachment (3), with a thickness less than 14% of the filament width and with a filament surface to support separation of at least 1.8 mm.

3.2.

Electrical: All lamps described in this specification shall have a rated operating voltage of 12 VDC. Lamps shall be capable of being operated in base down (± 15°) and horizontal (± 15°) orientations, with no reduction in the required performance or service life.

3.2.1.

Power Rating: When operated at 12.00 ± 0.01 VDC, the tolerance for lamp current/ wattage tolerance shall be ± 7% of rated current/wattage.

3.2.2.

Luminous Flux: All lamps shall meet the requirements for total luminous flux, outlined in Table 1 of this specification, when operated at 12.00 ± 0.01 VDC.

3.3.

Service Life.

3.3.1.

Fixed-on Lamp Life: The average lamp life for all fixed-on burning lamps shall meet or exceed the rated lamp life values in Table 1, disregarding the initial burn-in.

3.3.2.

Flashed Lamp Life: Lamps operating in a flashed mode shall meet or exceed a lamp life calculated by:

(Equation 1) disregarding the initial burn-in. The duty cycle is the contact closure time (power applied) during a flash characteristic period, divided by the total length of the period. The flash characteristic period is the total time for a flashing rhythm to repeat.

3.3.3.

Luminous Flux: The luminous flux of all lamps shall exceed 88% of the initial total luminous flux, after lamps have operated an equivalent of 58% of rated lamp life.

3.4.

Environment: Each lamp, when properly installed in standard U. S. Coast Guard marine signal lanterns, shall meet or exceed all the requirements of this document under the environmental conditions outlined below.

3.4.1.

Extreme Temperature: Exposure to temperatures from –30 to +65 degrees C.

3.4.2.

Humidity: Exposure to relative humidity from 0 to 100%.

3.4.3.

Salt Air: Continuous exposure to salt air.

3.4.4.

Shock and Vibration: Continuous exposure to the shock and vibration experienced in transportation on vehicles (including cars, trucks, boats and ships) and in service on marine aids-to-navigation, including on buoys and wooden, single-pile structures. Exposure to the shock caused by operation of a spring-loaded CG-6P lampchanger.

3.5 Documentation.

3.5.1 Quality Assurance Inspection Form. The Contractor shall develop and provide a Quality Assurance Inspection Form (QAIF). The QAIF shall be used to document the inspections and tests performed on every item throughout its fabrication process. The form shall be typewritten on standard (i.e., 8½x11 inch) white paper, whenever the scope of required information permits. Inspection results may be handwritten on the form. The form shall be prepared in the Contractor's format and shall be legible, in English, and suitable for reproduction. The form shall be made available to the Contracting Officer’s Technical Representative (COTR) for review.

QAIF Content. At a minimum the QAIF shall include:

a) Item serial number.

b) Date of test or inspection.

c) Test or inspection to be performed (list every test and inspection required by section 4.0).

d) Result of test or inspection.

e) Accept/Reject criteria for each test or inspection.

f) Corrective action taken (if any).

g) Notes.

h) Initials or signatures of Contractor’s test personnel.

3.5.2 Material Inspection and Receiving Report (DHS Form 700). A form DHS-700 shall be used as a certification of product quality assurance, as a packing list, and as a certification of acceptance. The Contractor shall prepare a separate DHS-700 for each shipping lot. Prior to shipment, a CG representative of the Contracting Officer (KO) must sign the DHS-700.

4.

QUALITY ASSURANCE PROVISIONS.

4.1.

General. The Contractor's quality assurance program shall meet the requirements of

ANSI/ASQC Q9002. However, the Contractor does not have to be Q9002 certified.

4.2 Contractor's Calibration System. The contractor shall maintain a calibration and maintenance system to control the accuracy of measurement and test equipment used in the fulfillment of this specification. The system shall include, as a minimum, prescribed calibration intervals and the source of calibration. A monitoring system to this requirement shall be readily available to the Coast Guard Inspector. Calibration shall be traceable to the National Institute of Standards and Technology.

4.3 Classification of Inspections. The inspection requirements specified herein are classified as follows:

a. First Article Inspection (paragraph 4.4)

b. Contractor Production Inspection (paragraph 4.5)

c. Coast Guard Production Inspection (paragraph 4.6) 4.4 First Article Inspection. When first article samples are required, the Contractor shall perform a first article inspection in accordance with paragraph 4.4.5.

4.4.1 Sample Submission. The manufacturer shall prepare for submittal one box of ten lamps of each lamp type for First Article Inspection and notify the government of their desire to conduct First Article Testing. The lamps shall be representative of the manufacturer’s proposed normal production.

4.4.2 First Article Tests and Inspections Notification. The Contractor shall notify the Contracting Officer in writing at least 7 calendar days prior to the scheduled commencement of any inspections and tests required by this specification.

4.4.3 Waiver of First Article Requirements. The Contracting Officer reserves the right to waive all or part of the first article requirements specified herein.

4.4.4 First Article Tests and Inspections. The following tests and inspections shall be conducted for each first article unit:

a. Visual Inspection

b. Electrical Testing

c. Service Life Testing

d. Environmental Testing

e. Documentation Review

4.4.4.1 Visual Inspection: Each lamp in the sample lot shall be examined for conformance to design, dimensions and workmanship, as stated in section 3.1 above. A lamp that fails to comply with any of the mechanical requirements (material selection, dimensions, etc.) of this specification or has any defects that will interfere with its use or decrease its life expectancy shall be deemed a failure.

4.4.4.2 Electrical Testing: All lamps that undergo testing shall be conditioned by undergoing a five-hour burn-in period, at a voltage of 12.00 ± 0.05 VDC. After cooling for 5 ± 1 minute, each lamp shall be mechanically rotated in a standard U. S. Coast Guard CG-6P lampchanger for ten complete revolutions, rewinding the CG-6P after each revolution, to verify that the filament does not break or separate from the filament support.

4.4.4.2.1 Power Rating: The power consumption of the lamps shall be measured and recorded while the lamps are operated at 12.00 ± 0.01 VDC, and with lamps burning in both base-down (±15°) and horizontal (±15°) orientations.

4.4.4.2.2 Luminous Flux: An intergrading sphere shall be used to measure and record the total luminous flux of the lamps while operated at 12.00 ± 0.01 VDC, and with the lamps burning in both base-down (±15°) and horizontal (±15°) orientations.

4.4.4.3 Service Life Testing.

4.4.4.3.1 Fixed-on Lamp Life: Lamps shall be burned, fixed-on, in both base-down (±15°) and horizontal (±15°) orientations, at 12.00 ± 0.05 VDC until filament failure. The total lamp life, in hours, shall be recorded.

4.4.4.3.2 Flashed Lamp Life: Lamps shall be burned, with a 1 second contact closure and a duty cycle of 50% (Isophase 2 seconds), in both base-down (±15°) and horizontal (±15°) orientations, at 12.00 ± 0.05 VDC until filament failure. The total lamp life, in hours, shall be calculated and recorded.

4.4.4.3.3 Luminous Flux: All lamps that survive to 58% of rated service life during the fixed-on and flashed lamp life tests shall be subject to luminance testing using an intergrading sphere. Luminance output shall read 88% + of each sample lamp’s initial luminous flux. See Paragraph 3.3.3 4.4.4.4 Environmental Testing: For the test described in paragraph 4.4.4.4.1, lamps shall be operated bases down, at an input voltage of 12.00 ± 0.01 VDC.

4.4.4.4.1 Extreme Temperature: Place lamps with a measured total luminous flux in a black box with an aperture of 2.0 ± 0.5 mm. Place the black box in an environmental chamber with a window (Tenney Junior or equivalent). The aperture should be level with and facing the window. Power leads should be wired to the lamp, but not energized. Apply power to the lamp. After the lamp has operated for 15 ± 1 minutes, record current consumption and luminous output emitted from the aperture. The ammeter and photometer shall be outside of the chamber, under ambient room conditions. Disconnect power to the lamp and record the background illumination. (Note: background lighting should provide no more than 50% of the value recorded when the lamp is energized.) Disconnect power and lower the chamber temperature to –30 ± 2 degrees C. The chamber shall be maintained at that temperature for a period of 24 ± 1 hours. Apply power to the lamp. After the lamp has operated for 15 ± 1 minutes, record current consumption and luminous output emitted from the aperture. Disconnect power to the lamp and record the background illumination. Raise the chamber temperature to +65 ± 2 degrees C over a period of 8 ± 1 hour. Maintain that temperature for 5 ± 1 hour. Apply power to the lamp. Current consumption and luminous output shall be recorded, after the lamp has operated for 15 ± 1 minute. Disconnect power to the lamp and record the background illumination. Subtract the background luminous intensity measurements from the measurement of luminous output emitted from the aperture when the lamps where energized. The ratios of the resultant luminous output at the extreme temperatures to the resultant luminous output at room temperature shall be multiplied by the previously measured total luminous flux to calculate the total luminous flux at the extreme temperatures.

4.4.5 Rejection Criteria. The Contracting Officer, to determine compliance with the requirements of this specification, will review the first article inspection results. Failure of any of the tests or inspections described herein will be cause for rejection of the first article. If the first article is rejected, the Contractor will be notified in writing by the Contracting Officer and allowed 14 calendar days to fix or resubmit a new first article. Repair or replacement of the first article shall be by the Contractor at the Contractor's expense.

4.4.6 Authorization to Proceed. Upon successful completion of the first article inspection, the Contracting Officer will provide the Contractor with written authorization to begin fabricating production quantities.

4.4.7 Standardization. Materials, parts, design, and fabrication methods used in the production quantities shall be identical to those used in the first articles, unless otherwise authorized in writing by the Contracting Officer.

4.5 Contractor Production Inspection. The tests and inspections required by this specification are not intended to supplant any controls, examinations, inspections, or tests normally employed by the Contractor to assure product quality. The Contractor shall perform the examinations, tests and inspections specified in paragraph 4.6.1 and 4.6.2 to ensure conformance to this specification. The Contractor shall provide space, personnel, and test equipment to conduct all inspection and test requirements.

4.6 Coast Guard Production Inspection. The Coast Guard reserves the right to observe, verify, or perform the tests and inspections outlined in paragraph 4.5. A random sample of lamps (the number and type to be specified by ANSI/ASQC Z1.4, Table IIA, based on General Inspection Level II from Table I) shall be selected from each production lot. A production lot shall be all of the lamps from an identifiable production period from one manufacturer and one plant and submitted for acceptance at one time. Lots shall be rejected when the percent of nonconformance is in excess of ANSI/ASQC Z1.4. (Minimum sample size shall be Level II, normal, AQL = 0.10.) Production inspection shall consist of the examinations and tests of paragraph 4.6.1.

4.6.1 Tests and Inspections. Production samples shall be subject to the following tests and inspections:

a. Visual inspection (Paragraph 4.6.1.1)

b. Electrical Test (Paragraph 4.6.1.2)

c. Documentation Review (Paragraph 4.6.1.3) 4.6.1.1 Visual Inspection. Each lamp in the sample lot shall be examined for conformance to design, dimensions and workmanship, as stated in section 3.1 above and associated drawings. Samples shall be measured and checked for the following features:

a. Conformance to specified physical dimensions (Section 3.1)

b. Lamp marking is complete, legible and properly placed (Paragraph 3.1.5)

c. Filament support orientation is correct (Paragraph 3.1.6)

d. Conformance to required packaging and marking (Paragraph 5)

4.6.1.2 Electrical Tests. Each sample lamp shall be tested per paragraph 4.4.4.2 for compliance to amperage/wattage requirements in paragraph 3.2.1 and luminance requirements in paragraph 3.2.2.

4.6.1.3 Documentation Review. The documentation required in paragraph 3.5 shall be reviewed for conformance with this specification and provided to a CG representative of the Contracting Officer (KO) upon request.

4.6.2 Rejection for Defects. The Coast Guard will reject all items which do not conform to the requirements of this specification. Repair or replacement of the rejected items shall be by the Contractor at the Contractor's expense. All rejected items shall be resubmitted for inspection only when they conform to the requirements of this specification. Resubmitted items shall be identified as such, and shall be kept separate from new items. If defective items are found, the Coast Guard will accept no further items until the Contractor has demonstrated that the defects have been corrected and that the cause of the defects has been eliminated from the production process.

5.0

PREPARATION FOR DELIVERY.

5.1 Packaging. Lamps shall be packaged ten to a box in a cardboard carton. The preservation and packing shall conform to ASTM D 3951.

5.2 Marking. Marking shall be in accordance with MIL-STD-129. Each box shall be barcoded in accordance with ANSI/AIM BC 1.

USCG ENGINEERING LOGISTICS CENTER

SPECIFICATION FOR AIDS TO NAVIGATION

12-VOLY MARINE SIGNAL LAMPS

Specification Number: P-422-0432 Drafted By: Signature on File .

David W. White

Approved By: Signature on File .

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