Specification 5100-451 April 2012 UNITED STATES DEPARTMENT OF AGRICULTURE FOREST SERVICE SPECIFICATION FOR LED HEADLAMP, FIREFIGHTER Comments and suggestions related to this standard should be addressed using the comment sheet at the end of this document. Remarks may be sent via electronic mail (mailroom_wo_sdtdc@fs.fed.us) or U.S. mail to the USDA Forest Service San Dimas Technology and Development Center, 444 E. Bonita Ave, San Dimas, CA 91773.
Comments and suggestions related to this standard should be addressed using the comment sheet at the end of this document. Remarks may be sent via electronic mail (mailroom_wo_sdtdc@fs.fed.us) or U.S. mail to the USDA Forest Service San Dimas Technology and Development Center, 444 E. Bonita Ave, San Dimas, CA 91773.
CONTENTS 1.0 SCOPE... 1 2.0 APPLICABLE DOCUMENTS... 1 2.1 Non-Government Publications... 1 2.2 Order of Precedence... 1 3.0 INTERPRETATION AND DEFINITIONS... 2 3.1 Interpretation.... 2 3.2 Definitions... 2 4.0 GENERAL REQUIREMENTS... 3 4.1 First Article... 3 4.2 Performance Requirements and Testing... 3 4.2.1 Light Emitting Diode (LED) Service Life:... 3 4.2.2 Light Output:... 3 4.2.3 Light Output Levels:... 3 4.2.4 Run Time:... 3 4.2.5 Run Time Curve:... 4 4.2.6 Beam Pattern:... 4 4.2.7 Beam Distance:... 4 4.2.8 Weight:... 4 4.3 Design Requirements:... 4 4.3.1 Integrated Unit.... 5 4.3.2 Light Operations.... 5 4.3.3 ON-OFF Switch.... 5 4.3.4 Vertical Adjustment.... 5 4.3.5 Retention Strap... 5
4.3.6 Battery Replacement.... 5 4.3.7 Protective Bag:... 5 4.4 Reliability Requirements:... 6 4.4.1 Impact Resistance:... 6 4.4.2 Enclosure Protection.... 6 4.5 Workmanship... 6 4.6 Symmetry... 6 4.7 Recoverable Materials... 6 4.8 Marking... 6 4.9 Metric Products... 6 5.0 INSPECTION AND SAMPLING PROCEDURES... 7 5.1 General Inspection and Tests... 7 5.1.1 Testing With Referenced Documents.... 7 5.2 Responsibility for Compliance.... 7 5.3 Sampling for Inspection.... 7 5.3.1 Lot... 7 5.3.2 Sampling for Visual, Functional and Dimensional Examination... 7 5.4 Inspection and Tests... 8 5.4.1 Visual, Functional and Dimensional Examination... 8 5.4.2 Lot Acceptance Tests... 8 5.4.3 First Article Inspection... 8 5.4.4 Certificates of Conformance in Lieu of Testing... 9 6.0 NOTES... 9 6.1 Intended Use... 9 6.2 Acquisition Requirements... 9 6.3 First Article... 9 6.4 Packaging, Packing and Marking... 9 6.5 Notice... 9
6.6 Preparing Activity... 10 Standardization Document Improvement Proposal... 11
1.0 SCOPE This specification establishes the minimum functional, performance and design requirements for the wildland firefighter LED headlamp. The LED headlamp described in this specification is intended to be used with a NFPA 1977 compliant wildland firefighter helmet. 2.0 APPLICABLE DOCUMENTS 2.1 Non-Government Publications The following documents form a part of this document to the extent specified herein. Unless otherwise specified, the issues of these documents are those in effect on the date of the invitation for bids or request for proposals (see 6.2). American National Standards Institute (ANSI)/National Electrical Manufacturers Association (NEMA) FL 1-2009 Flashlight Basic Performance Standard American National Standards Institute /International Electrotechnical Commission (IEC) 60529-2004 - American National Standard for Degrees of Protection Provided by Enclosures. American National Standards Institute /American Society for Quality (ASQ) Z1.4 -Sampling Procedures and Tables for Inspection by Attributes Address requests for copies to the American National Standards Institute Inc., 11 West 42nd Street, New York, NY 10036. Electronic copies may also be purchased at www.ansi.org. Alternatively, National Electrical Manufacturers Association, 1300 North 17 th Street, Suite 1762, Rosslyn, Virginia 22209. Electronic copies can be purchased at www.nema.org/std/ Non-Government standards and other publications normally are available from the organizations that prepare or distribute the documents. These documents also may be available in or through libraries or other informational services. 2.2 Order of Precedence In the event of conflict between the text of this document and the references cited herein, the text of this document takes precedence. Nothing in this document, however, supersedes 1
applicable laws and regulations unless a specific exemption has been obtained. 3.0 INTERPRETATION AND DEFINITIONS 3.1 Interpretation. To carry out the provisions of this document, the word shall is to be understood as mandatory. 3.2 Definitions Beam Distance: The distance from the headlamp at which the light beam has a surface light intensity of 0.25 lux. Central Spot: The area covered by all light measuring between 100 percent and 50 percent of the surface light intensity of the brightest light in the beam. Certificate of Conformance: Certificates that provide legal documentation of the conformance of material and test requirements. Enclosure Protection Against Water Penetration Rating - Water Resistance IPX4: As defined by the ANSI/IEC 60529 standard. Water splashed against the device from any direction shall have no harmful effects. Impact Resistance: The degree to which a device resists damage from dropping on a solid surface. Integrating Sphere: A measurement device with an entrance port that can accept all the directional light output of a lighting device under test, or can totally enclose the lighting device itself. The walls of the sphere should be highly diffused with high reflectivity (>80%) and the spectroradiometer should be shielded from direct view of the device under test by a baffle system. Light Measuring Device: A light measuring device is a commercially available device that is used to measure the amount of light striking a surface from a given source. Light Output (total luminous flux): The total quantity of emitted overall light energy as measured by integrating the entire angular output of the headlamp. Light output in this specification is expressed in units of lumens. 2
Run Time: The duration of time from initial light output value defined as1 minute after the point the device is first turned on using fresh batteries, until the light output reached 10% of the initial value. Run Time Curve: A 2-dimensional graphical representation in Cartesian coordinates of light output on the Y-axis (vertical) and time on the x-axis (horizontal). Surface Light Intensity: Surface illuminance and is measured in lux. 4.0 GENERAL REQUIREMENTS 4.1 First Article Unless otherwise specified, first article inspection shall be performed on five (5) product samples in accordance with 5.4.3. 4.2 Performance Requirements and Testing Performance testing include light output, run time, light output levels, run time curve, beam pattern, beam distance and weight. Performance tests may be conducted concurrently. 4.2.1 Light Emitting Diode (LED) Lumen Maintenance: The LED shall at minimum have 50 percent lumen maintenance after 50,000 hours. 4.2.2 Light Output: The headlamp shall have at a minimum light output of 50 lumens when tested at the highest light setting. Light output shall be measured using the procedures specified in ANSI/FL1 2009, section 2.5. The initial light output measurement shall be recorded after 1 minute of continuous operation after turning on the device. 4.2.3 Light Output Levels: The headlamp shall have a minimum of two light output levels. 4.2.4 Run Time: Run time will be a minimum of five (5) hours at the 50 lumen setting using alkaline batteries with a maximum capacity (under a 500 ma constant drain) of 2600 mah. Headlamps with discrete light output levels shall be tested at the maximum light output 3
level. Run time shall be measured using the ANSI FL1-2009 test procedure starting at 50 lumens or the highest light output setting for the entire test. The measurement will start after one (1) minute of continuous operations after the device has been turned on and end when the output value reaches 10 percent of the initial value. The exact time measurement shall be reported in hours and minutes without any rounding. 4.2.5 Run Time Curve: The light output shall diminish no more than 20 percent of the maximum light output (measure after 1 minute) after the first five (5) hours of operation. The light output setting shall remain in the same position for the duration of this test. The run time curve shall be presented in a two dimensional graph using Cartesian coordinates. The light output shall be on the Y-axis and time on the X-axis. 4.2.6 Beam Pattern: The beam shall be composed of a central spot and a wide beam that is symmetrical about the vertical axis (perpendicular to the axis of the cone of light). The central spot shall have a diameter of at least 6 inches minimum at a distance of 15 feet. The wide beam will compose remainder of the beam up to 0.25 lux. 4.2.7 Beam Distance: The total beam distance will be a minimum of 60 feet.. The total beam distance shall be measured using the test procedure outline ANSI FL1-2009 section 2.2. Measurement will be taken after 1 minute of continuous operation. 4.2.8 Weight: The complete headlamp assembly (retention strap and batteries) shall weigh a maximum of 6.5 oz. for a single integrated unit or 9.5 oz. for headlamps with a separate battery pack Weight shall be distributed between the light assembly and the battery pack such that the complete headlamp assembly is balanced when worn by a fire fighter on a NFPA 1977 compliant wildland fire helmet. 4.3 Design Requirements: Testing for design requirements includes functional or operational test for light operations, ON-OFF switch, vertical adjustment, retention strap, and battery replacement. Testing entails actual actuation of features or dimensional measurement. The following features 4
describe the headlamp: 4.3.1 Form Factor. The headlamp will either be a single integrated self-contained unit or a two component headlamp consisting of a light assembly and a battery pack. Wires connecting the two components must be secured to the head strap to prevent snagging. 4.3.2 Light Operations. The user must be able to turn the light ON and OFF, switch between light outputs levels, and adjust the position of the headlamp while wearing NFPA 1977 compliant wildland glove. 4.3.3 ON-OFF Switch. The ON-OFF switch shall be designed to prevent inadvertent activation of the light or drain on the battery when not in use. 4.3.4 Vertical Adjustment. The total vertical adjustment shall be 110 degrees minimum (90 degrees minimum above horizontal and 20 degrees minimum below the horizontal). The light shall securely hold any selected position within the specified range. Multiple discrete positions are acceptable provided the range is covered. 4.3.5 Retention Strap The headlamp shall be mounted on a NFPA 1977 compliant firefighter helmet with an adjustable retention strap. The retention strap shall be made of a non-slip material or have features designed to prevent the light from coming off the helmet. Additional clips or modifications to the helmet are not allowed. The user must be able to attach the headlamp to or remove it from a helmet by hand, without the use of tools. 4.3.6 Battery Replacement. The user must be able to replace the batteries without special tools. All removable battery compartment access doors must be secured (captured) to prevent loss. 4.3.7 Protective Bag: Each headlamp shall be supplied with a fabric bag to protect the headlamp when not in 5
use. A drawstring enclosure or equivalent is acceptable. 4.4 Reliability Requirements: Reliability testing is comprised of Impact Resistance testing followed by Enclosure Protection Against Water Penetration testing. Testing shall be conducted in the order specified above. 4.4.1 Impact Resistance: Headlamp shall meet impact resistance requirements specified in ANSI/NEMA FL1-2009, section 2.6. 4.4.2 Enclosure Protection. The headlamp shall be rated water resistant IPX4 or better when tested using the ANSI/IEC 60529 standard, Section 14.2.4 for IPX4. All test samples shall function normally, after both the test and 30 minutes after the test. Water ingress is allowed as long as above conditions are met. 4.5 Workmanship Workmanship shall be equal to the best commercial practices consistent with the highest engineering standards in the industry and shall be free from any nonconformity that may impair serviceability or detract from the product s appearance. 4.6 Symmetry All parts intended to be symmetrical shall be symmetrical. 4.7 Recoverable Materials The contractor is encouraged to use recovered materials to the maximum extent practicable, in accordance with paragraph 23.403 of the Federal Acquisition Regulation (FAR), provided all performance requirements of this specification are met. 4.8 Marking Use of icons or marking indicating performance of the headlamp shall be consistent with Section 3 of ANSI/NEMA FL1-2009. 4.9 Metric Products Products manufactured to metric dimensions will be considered on an equal basis with those 6
manufactured using inch-pound units, provided they fall within the tolerances specified using conversion tables contained in the latest revision of ASTM E 380, and all other requirements of this specification are met. 5.0 INSPECTION AND SAMPLING PROCEDURES 5.1 General Inspection and Tests Unless otherwise specified in the contract or purchase order, the contractor is responsible for performance of all inspection requirements prior to submission for Government acceptance. The contractors may use their own facilities or any commercial laboratory acceptable to the Government. Inspection records of the examination and tests shall be kept complete and available to the Government. The Government reserves the right to perform any of the inspections or tests specified herein when such inspections are deemed necessary to ensure supplies conform to prescribed requirements. 5.1.1 Testing With Referenced Documents. The contractor is responsible for ensuring that components and materials used were manufactured, examined, and tested in accordance with referenced specifications and standards. 5.2 Responsibility for Compliance. All items shall meet all requirements of sections 4. The inspection set forth in this specification shall become a part of the contractor s overall inspection system or quality program. The absence of any inspection requirements in this specification shall not relieve the contractor of the responsibility of ensuring that all products or supplies submitted to the Government for acceptance comply with all requirements of the contract. Sampling inspection, as part of manufacturing operations, is an acceptable practice to ascertain conformance to requirements, however, this does not authorize submission of known non-conforming material, either indicated or actual, nor does it commit the Government to accept non-conforming material. 5.3 Sampling for Inspection. 5.3.1 Lot All headlamps presented together in one delivery shall be considered a lot for the purpose of inspection. A sample unit shall be one headlamp. 5.3.2 Sampling for Visual, Functional and Dimensional Examination 7
Sampling for visual, functional and dimensional examination shall be in accordance with ANSI/ASQ Z1.4, inspection level S-3, with an Acceptable Quality Level (AQL) of 2.5 percent nonconforming. 5.3.3 Sampling for Performance and Reliability Tests Sampling for performance and reliability tests shall be performed in accordance with ANSI/NEMA FL1-2009, Section 1.3. 5.4 Inspection and Tests 5.4.1 Visual, Functional and Dimensional Examination When selected in accordance with 5.3.2, each headlamp shall be visually, functionally, and dimensionally examined to determine conformance with this specification. Visual or dimensional non-conformities shall be classified as major or minor. A nonconformity not listed in Table 1 shall be classified as a minor nonconformity. Table 1 Classification of Nonconformities Classification Nonconformity Major Minor 1. Headlamp not complete X 2. 50% lumen maintenance X 3. Light Operations X 4. ON-OFF Switch X 5. Light output settings less than 2 settings X 6. Vertical adjustment not as specified X 7. Retention strap not as specified X 8. Battery replacement not as specified X 9. Weight exceeds 6.5 ounces for an integrated X unit or 9.5 ounces for a two component system 10. Protective bag missing X 11. Workmanship not as specified X 12. Markings not as specified X 5.4.2 Lot Acceptance Tests Each of the samples selected in accordance with 5.3.3 shall be tested in accordance with 4.2, 4.3, and 4.4 to determine conformance with the requirements of this specification. Any failure constitutes rejection. 5.4.3 First Article Inspection Unless otherwise specified (see 6.2), the first article sample(s) indicated in 4.1, shall be inspected as specified in 4.2, 4.3, and 4.4. All inspection and testing of the first article 8
sample(s) shall stop upon a single failure and the sample(s) shall not be accepted. The contractor will be informed as to the nature of the failure, but the Government shall not be obligated to continue testing a non-conforming item, once it is known to be nonconforming or when it is considered in the best interest of the Government. 5.4.4 Certificates of Conformance in Lieu of Testing Unless otherwise specified, certificates of conformance may be acceptable in lieu of testing end items for lot acceptance. The Government reserves the right to verify test any such items to determine the validity of certification. 6.0 NOTES 6.1 Intended Use The headlamp described in this specification is used to provide a light source to wildland fire fighters for nighttime or reduced lighting operations. The headlamp is intended to worn on the NFPA 1977 compliant wildland firefighter helmet. The headlamp is carried inside the fire fighter s line gear when not in use. 6.2 Acquisition Requirements Acquisition documents should specify the following: a. Title, number, and date of this specification. b. If a first article sampling and inspection is not required, (see 4.1 and 5.4.3). c. Packaging, packing, and marking (see 6.4). d. Date of the invitation for bids or request for proposals (see 2.1). 6.3 First Article When a first article sample(s) is required, it shall be inspected and approved in accordance with the First Article clauses set forth in the solicitation. Specific instructions shall be included regarding arrangements for selection, inspection, and approval of the first article sample(s). 6.4 Packaging, Packing and Marking The packaging, packing and marking shall be as specified in the contract or order. 6.5 Notice When Government drawings, specifications, or other data are used for any purpose other than in connection with a related Government procurement operation, the United States Government 9
thereby incurs neither responsibility nor any obligation whatsoever. 6.6 Preparing Activity USDA Forest Service, San Dimas Technology and Development Center, 444 East Bonita Avenue, San Dimas, CA 91773-3198. 10
United States Department of Agriculture, Forest Service Standardization Document Improvement Proposal Instructions: This form is provided to solicit beneficial comments that may improve this document and enhance its use. Contractors, government activities, manufacturers, vendors, or other prospective users of this document are invited to submit comments to the USDA Forest Service, San Dimas Technology and Development Center, 444 East Bonita Avenue, San Dimas, California 91773-3198. Attach any pertinent data that may be used in improving this document. If there is additional documentation, attach it to the form and place both in an envelope addressed to the preparing activity. A response will be provided when a name and address are included. Note: This form shall not be used to submit request for waivers, deviation, or for clarification of requirements on current contracts. Comments submitted on this form do not constitute or imply authorization to waive any portion of the referenced document(s) or to amend contractual requirements. Standard Number and Title: Specification 5100-451, Headlamp. Firefighter Name of Organization and Address: Vendor User Manufacturer Has any part of this document created problems or required interpretation in procurement use? Is any part of this document too rigid, restrictive, loose or ambiguous? Please explain below. Give paragraph number and wording: Recommended change(s): Reason for recommended change(s) Date: Remarks: Submitted by: (Print or type name and address Optional) Telephone number: (Optional) 11