DEPARTMENT OF THE AIR FORCE HEADQUARTERS AIR FORCE CIVIL ENGINEER SUPPORT AGENCY 27 JUL 2012 FROM: HQ AFCESA/CEO 139 Barnes Drive Suite 1 Tyndall AFB FL 32403-5319 SUBJECT: Engineering Technical Letter (ETL) 12-12: Solar-Powered Light- Emitting Diode (LED) Fixture Design and Installation Criteria for Exterior Lighting Applications in Contingency Environments 1. Purpose. This ETL provides technical guidance and criteria for specifying, designing, and installing solar LED luminaire exterior lighting applications at Air Force overseas contingency locations only. For the purposes of this ETL, contingency locations are defined as locations where a named operation is the primary mission and the location utilizes expeditionary equipment for all or some of the support facilities in use. Requirements in this ETL are mandatory. Deviations require approval from the Air Force Electrical Engineering subject matter expert (SME), AFCESA/CEOA. Requests for deviations must be coordinated through the major command (MAJCOM) before submitting to AFCESA/CEOA. 2. Application. This ETL does not apply to LED airfield lighting systems, including, but not limited to, taxiway, obstruction, runway edge, threshold, or approach lighting systems (consult ETL 11-29, Use of Light-Emitting Diode (LED) Fixtures in Airfield Lighting Systems on Air Force Installations and Enduring/Contingency Locations), nor to LED fixtures for interior and exterior use covered by ETL 12-15, Light-Emitting Diode (LED) Fixture Design and Installation Criteria for Interior and Exterior Lighting Applications. 2.1. Authority: Air Force instruction (AFI) 32-1063, Electrical Power Systems Unified Facilities Criteria (UFC) 3-530-01, Interior and Exterior Lighting and Controls 2.2. Effective Date: Immediately. 2.3. Intended Users: MAJCOM engineers Base civil engineers (BCE) Base maintenance organizations All MAJCOM and base-level energy managers Contracting officers 2.4. Coordination: MAJCOM electrical engineers APPROVED FOR PUBLIC RELEASE: DISTRIBUTION UNLIMITED
3. References. 3.1. Air Force: AFI 32-1063, Electrical Power Systems, http://www.e-publishing.af.mil ETL 11-29, Use of Light-Emitting Diode (LED) Fixtures in Airfield Lighting Systems on Air Force Installations and Expeditionary Locations, http://www.wbdg.org/ccb/browse_cat.php?o=33&c=125 ETL 12-15, Light-Emitting Diode (LED) Fixture Design and Installation Criteria for Interior and Exterior Lighting Applications, http://www.wbdg.org/ccb/browse_cat.php?o=33&c=125 3.2. Joint Service: UFC 3-530-01, Design: Interior and Exterior Lighting and Controls, http://www.wbdg.org/ccb/browse_cat.php?o=29&c=4 3.3. Industry (also see Attachment 1, paragraph 1-1): NFPA 70, National Electrical Code (NEC) http://webstore.ansi.org/recorddetail.aspx?sku=nfpa+70-2011 4. Acronyms and Terms. C - degrees Celsius F - degrees Fahrenheit AC - alternating current AFCESA/CEOA - Air Force Civil Engineer Support Agency, Engineer Support Branch AFI - Air Force instruction AGM - absorbed glass mat battery ANSI - American National Standards Institute ASTM - American Society for Testing and Materials AWG - American wire gauge BCE - base civil engineer BUG - backlight, uplight, glare CCT - correlated color temperature Cd - cadmium cd - candel power CR6+ - hexavalent chromium CRI - color rendering index CSA - Canadian Standards Association DOE - Department of Energy DOT - Department of Transportation Duv - distance to the closest point on the Planckian locus on the CIE 1976 (u', v') diagram, with + sign for above and - sign for below the Planckian locus EMC - electromagnetic compatability 2
EMI EPA ETL ETL FAA FCC Hg HID IATA ICAO IEC IEEE IESNA IP K kwh LAN LED LLD LVD ma MAJCOM MSDS mw/nm NEC NEMA NFPA NIST NRTL NVLAP OSHA Pb PBB PBBE P.E. PV QUV RFI RoHS SME SSL THHN UFC UL U.S. UV - electromagnetic interference - effective projected area - Edison Testing Laboratories - Engineering Technical Letter - Federal Aviation Administration - Federal Communications Commission - mercury - high-intensity discharge - International Air Transport Association - International Civil Aviation Organization - International Electrochemical Commission - Institute of Electrical and Electronics Engineers - Illuminating Engineering Society of North America - International Protection - kelvin - kilowatt hour - local area network - light-emitting diode - lamp lumen depreciation - low voltage disconnect - milliamp - major command - material safety data sheet - milliwatt per nanometer - National Electrical Code - National Electrical Manufacturers Association - National Fire Protection Association - National Institute of Standards and Technology - nationally recognized testing laboratory - National Voluntary Laboratory Accreditation Program - Occupational Safety and Health Act - lead - polybrominated byphenyls - polybrominated byphenyl ether - Professional Engineer - photovoltaic - Q-lab ultraviolet - radio frequency interference - restriction of hazardous substances - subject matter expert - solid state lighting - thermoplastic high heat-resistant nylon-coated - Unified Facilities Criteria - Underwriters Laboratories - United States - ultraviolet 3
V VA W - volt - volt-ampere - watt 5. Background. This ETL is required to support installation of solar-powered, energyefficient LED light sources at contingency locations. 6. Exterior Solar LED Luminaire Applications. 6.1. Solar LED luminaires are authorized for walkway, roadway, and vehicular parking areas only when there is no existing power source available within 250 feet and the conditions of paragraph 8 are met. 6.2. Solar LED luminaires are not authorized for: airfield ramp lighting security lighting (e.g., munitions storage areas) supplemental task lighting 7. Exterior Solar LED Luminaire Installation Requirements. 7.1. Use of solar-powered lighting to replace powered lights in retrofit or replacement applications is prohibited. Note 1: Retrofit project installations are defined as inserting LED technology into existing fixture housings. Note 2: Replacement project installations are defined as replacing existing luminaires with new LED luminaires. 7.2. Solar LED luminaire specifications shall comply with Attachment 1. 7.3. Local area network (LAN), wireless, radio, modem, power line carrier, or other communication methods used for LED light fixture control are prohibited. 7.4. LED drivers, controllers, time switchs, and sequencers may be mounted remotely within a separate enclosure outside the luminaire, provided such devices are rated for Ingress Protection Rating (IP) of IP-65 or enclosed in an IP-65 rated enclosure. 8. LED Project Considerations. Prior to authorizing any solar LED lighting project in a contingency environment, the BCE and MAJCOM electrical engineer shall review and approve the calculation methods, assumptions, and resulting justification for the proposed solar LED lighting project, and review the project for compliance with paragraphs 8.1 through 8.3. 8.1. Approval for a solar LED lighting project shall be based on the following calculation: 4
Total Installed Solar Lighting System Cost (Total Installed Grid Connected System Light Cost + Projected Grid Connected Lighting System 2-Year Electricity Cost) Note 1: For contingency locations where grid power is supplied by the local utility, use the actual billed electrical cost in the calculation. Note 2: For contingency locations where grid power is supplied by a generator plant, use $0.15/kWh to calculate the 2-year electricity cost. 8.2. Use of solar LED lighting systems in areas receiving less than 2.5 sun hours at the optimal photovoltaic (PV) tilt during the worst month for solar exposure is not allowed. 8.3. Solar lighting assemblies must be approved by a Professional Engineer (P.E.) to be in compliance with indicated maximum wind ratings for the installation s location. 9. Design and Siting Requirements. 9.1. Design Criteria. Solar LED lighting installations in contingency environments shall incorporate a lighting design certified to meet criteria in applicable AFIs, UFCs, ETLs, and Illuminating Engineering Society of North America (IESNA) standards. Note: Design is any calculation, analysis, field testing, or other engineering methodology that ensures products and installation (LED lighting system) meet applicable statutes, standards, and criteria, including field measurement and verification requirements within this ETL. 9.2. Projects must be certified by an individual qualified in lighting design. This may include the design agent, installation contractor, or vendor. Note: A qualified individual is one who has the skills and knowledge related to the calculation, design, construction, installation, and operation of lighting systems, and has received training concerning types and application of light sources, field measurement equipment, luminaires, and their placement, to comply with applicable standards and criteria, including this ETL. 9.2. Technical Specifications. LED fixture design, component specifications, submittals, and installation criteria shall comply with UFC 3-530-01, IESNA standards, and the requirements in Attachment 1. Note: For replacement projects, ensure the supporting infrastructure (e.g., light poles, exterior structural walls) is capable of supporting replacement luminaires. Facilty modifications or unnecessary penetrations shall be minimized. 5
10. Contracting Requirements. 10.1. Requirements and specifications in this ETL shall be incorporated into applicable contracting documents. 10.2. LED fixture manufacturers shall submit written certification that their luminaires comply with Attachment 1. The certification shall be included in the first submittal from the contractor. Incomplete and/or incorrect information is unacceptable and will result in the light fixture failing to meet Air Force requirements. 10.3. Materials and equipment shall be sourced from manufacturers who are regularly engaged in production of LED lighting products. The manufacturers products shall have been in satisfactory commercial or industrial use for two years prior to bid opening. The two-year period shall include applications of equipment and materials under similar circumstances and of similar size. Technology used may be less than two years old. The manufacturers products shall have been on sale on the commercial market through advertisements, manufacturers' catalogs, or brochures during the two-year period. All components shall be supplied from one manufacturer. 11. Warranties. LED fixture construction and installation warranties shall be provided in accordance with Attachment 1 and paragraphs 11.1 and 11.2. 11.1. The contractor shall install luminaires in accordance with the design engineer s and manufacturer s requirements. 11.2. LED luminaire warranties shall begin on the date of final acceptance of the installation by the contracting officer or designated representative, as executed by DD Form 1354, Transfer and Acceptance of DOD Real Property. 12. Point of Contact. The authority having waiver jurisdiction and interpretive authority for this ETL is the Air Force Electrical Engineering SME, HQ AFCESA/CEOA. To reach the Air Force Electrical Engineering SME, call DSN 523-6352 or commercial (850) 283-6352, email: AFCESA.CEO3333@afnsep.af.mil, or mail to 139 Barnes Drive, Suite 1, Tyndall AFB, FL 32403-5319. ANDREW A. LAMBERT, Colonel, USAF Chief, Operations & Programs Support Division 2 Atch 1. Solar LED Technology Technical Specification Information and Requirements 2. Distribution List 6
PART 1 GENERAL SOLAR LED TECHNOLOGY TECHNICAL SPECIFICATION INFORMATION AND REQUIREMENTS Note: The electrical designer must edit the bracketed information within this attachment for the requirements of the project. 1-1 REFERENCES The publications listed below form a part of this specification to the extent referenced. Publications are referenced within the text by their basic designation only. AMERICAN NATIONAL STANDARDS INSTITUTE (ANSI) ANSI C62.41.1-2002 ANSI C62.41.2-2002 ANSI C78.377-2011 ANSI C136.31-2010 IEEE Guide on the Surge Environment in Low-Voltage (1000 V and less) AC Power Circuits IEEE Recommended Practice on Characterization of Surges in Low-Voltage (1000 V and less) AC Power Circuits Specifications for the Chromaticity of Solid State Lighting Products Roadway and Area Lighting Equipment Luminaire Vibration AMERICAN SOCIETY FOR TESTING AND MATERIALS INTERNATIONAL (ASTM) ASTM B117-11 ASTM E1038-10 ASTM G154-06 Standard Practice for Operating Salt Spray (Fog) Apparatus Standard Test Method for Determining Resistance of Photovoltaic Modules to Hail by Impact with Propelled Ice Balls Standard Practice for Operating Fluorescent Light Apparatus for UV Exposure of Nonmetallic Materials FEDERAL COMMUNICATIONS COMMISSION (FCC) (FCC) Title 47, Part 15, Subpart B, Section 15.109 Radiated emission limites ILLUMINATING ENGINEERING SOCIETY OF NORTH AMERICA (IESNA) HB-10-11 The Lighting Handbook (1 of 14)
LM-79-08 LM-80-08 RP-8-00 TM-15-11 TM-21-11 Approved Method: Electrical and Photometric Measurements of Solid-Sate Lighting Products Approved Method: Measuring Lumen Maintenance of LED Light Roadway Lighting Luminaire Classification System for Outdoor Luminaires Projecting Long Term Lumen Maintenance of LED Light Sources INSTITUTE OF ELECTRICAL AND ELECTRONICS ENGINEERS (IEEE) IEEE STDSPCD1155 IEEE Standards Dictionary: Glossary of Terms & Definitions INTERNATIONAL ELECTROTECHNICAL COMMISSION (IEC) IEC 60529-2004 ed2.1 Degrees of Protection Provided by Enclosures (IP Code) IEC 60068-2-14 ed6.0 Environmental Testing Part 2-14: Tests - Test N: Change of temperature IEC 60068-2-30 ed3.0 Environmental Testing - Part 2-30: Tests - Test Db: Damp heat, cyclic (12 h + 12 h cycle) IEC 61215-2005 ed2.0 Crystalline silicon terrestrial photovoltaic (PV) modules Design qualification and type approval IEC 61000-4-2 ed2.0 Electromagnetic compatability (EMC) Part 4-2 Testing and measurement techniques Electrostatic discharge immunity test IEC 60896-11 ed1.0 Stationary lead-acid batteries Part 11: Vented types General requirements and methods of tests NATIONAL FIRE PROTECTION ASSOCIATION (NFPA) NFPA 70 National Electrical Code (NEC) UNDERWRITERS LABORATORIES (UL) UL 1703 UL 1741 Standard forflat-plate Photovoltaic Modules and Panels Standard for Inverters, Converters, Controllers and Interconnection System Equipment for Use With Distributed Energy Resources (2 of 14)
1-2 DEFINITIONS Unless otherwise specified or indicated, electrical and electronics terms used in specifications and on the drawings shall be as defined in IEEE STDSPCD1155. a. Useful Life the operating hours before reaching 70% of the initial rated lumen output point with no catastrophic failures under normal conditions. b. Correlated Color Temperature (CCT) a visible light characteristic of comparing a light source to a theoretical, heated black body radiator (measured in kelvin). c. Effective Projected Area (EPA) the wind loading of the fixture. d. International Protection (IP) Rating delineates the level at which foreign objects and water can intrude inside a device. e. Restriction of Hazardous Substances (RoHS) products that are RoHScompliant do not contain any of the following materials: lead (Pb), mercury (Hg), cadmium (Cd), hexavalent chromium (Cr6+), polybrominated byphenyls (PBB), and polybrominated byphenyl ether (PBBE). 1-3 SUBMITTALS. Government approval is required for items (a) through (d). a. Shop drawings. b. Certified lighting design incorporating requirements outlined in ETL 12-12, paragraph 9, where applicable. Consider possible snow and ice buildup. The luminaire fixture weight and effective projected area shall not exceed the pole s requirements for all dynamic loading; e.g., wind, snow, ice. c. IESNA LM-79 report on manufacturer s standard production model luminaire, to include: Testing agency, report number, date, manufacturer s name, catalog number, LED driver, drive current, ambient temperature. Luminaire efficacy (lumens/watt), minimum light output, zonal lumen density. Color qualities (CCT, CRI, chromaticity). ANSI C78.377 Duv. Electrical measurements (input voltage, input current, input power [watts]). Spectral distribution over visible wavelengths (mw/nm). Absolute intensity candlepower (cd) summary table. Isocandela plot. Luminance summary table. Illuminance point to point. (3 of 14)
Illuminance cone of light plot. Illuminance isofootcandle plot. Illuminance roadway isofootcandle plot (if street light). Picture of sample. Photometric file, including BUG rating. d. IESNA LM-80 report on LED package, array, or module, to include: Testing agency, report number, date, type of equipment, and LED light source being tested. All data required by IESNA LM-80. Note: Test laboratories for the IESNA LM-79 and IESNA LM-80 reports shall be one of the following: - National Voluntary Laboratory Accreditation Program (NVLAP) - accredited for solid-state lighting testing as part of the Energy-Efficient Lighting Products laboratory accreditation program. - One of the qualified labs listed on the Department of Energy (DOE) SSL web site (http://www1.eere.energy.gov/buildings/ssl/test_labs.html). - Manufacturer s in-house lab that meets the following criteria: (1) Manufacturer has been regularly engaged in the design and production of HID roadway and area luminaires and the manufacturer s lab has been successfully certifying these fixtures for a minimum of 15 years, (2) Annual equipment calibration, including photometer calibration, in accordance with NIST. e. Computer-generated photometric analysis of the designed-to values for the end of useful life of the lighting installation, using an LLD value of 0.7. Submittal shall include the following: Horizontal illuminance measurements at finished grade. Spacing between computer calculation points shall be 10 feet. Vertical illuminance measurements at 5-foot intervals above finished grade. Minimum footcandle level. Maximum footcandle level. Average maintained footcandle level. Maximum and minimum ratio (horizontal). f. Distribution data according to IESNA classification type as defined in IESNA HB-10-11. g. Product Certificates: Submitted by the installing contractor, certification from the manufacturer indicating the expected useful life of the provided luminaires. The useful life (4 of 14)
shall be directly correlated to the IESNA LM-80 test data, interpreted for IESNA TM-21. Minimum LED life shall be 50,000 hours. Manufacturer certification that fixture meets recyclability requirements. Manufacturer certification that the luminaires satisfy Part 1-4 General Requirements and Part 2 Products portions of this specification. Luminaires: - Distribution data according to IESNA classification type as defined in IESNA HB-10-11. - Shielding as defined by BUG rating for the installed position as defined by IESNA TM-15. - Safety certification and file number as required for the luminaire family, listed, labeled or identified per NFPA 70. Applicable testing bodies are determined by OSHA as nationally recognized testing laboratories (NRTL) and include CSA (Canadian Standards Association), ETL (Edison Testing Laboratory), and UL. PV modules: - Module manufacture, country of origin, and complete component rating such as Pmax, Isc, Ioc. - UL 1703 certification. Energy storage batteries: - Battery rating at C20 and C100 rate. - Safety certification and file number as required for the battery family, listed, labeled or identified per NFPA 70. Applicable testing bodies are determined by OSHA as NRTL and include CSA, ETL, and UL. - MSDS sheets for handling and storing batteries. - IATA and FAA certification for battery handling. Charge controller and LED driver: - Maximum voltage, current, and power rating at maximum operating temperature of 50 C. - Maximum and minimum input voltage for the LED driver. - Safety certification and file number as required for the luminaire family,listed, labeled, or identified per NFPA 70. Applicable testing bodies are determined by OSHA as NRTL and include CSA, ETL, and UL. PV support structure and battery enclosure: - PV structure reviewed and certified by an independent Professional Engineer (P.E.) to be rated for a maximum wind loading for the specific installation site or not less than 150 miles per hour. - Battery enclosure holds a NEMA rating of 3. - All structure materials are certified to be US-manufactured galvanized steel, stainless steel, or aluminum. 1-4 GENERAL REQUIREMENTS Solar light system drawings shall include: (5 of 14)
Dimensions of all components; e.g., fixture, solar panel, pole, base, battery compartment. Effective projected area (EPA). Complete list of accessories and installation and construction details. Overall system weight. Electrical access points; e.g., hand holes. 1-5 SAFETY CERTIFICATION Provide safety certification and file number as required for the luminaire family, listed, labeled, or identified per NFPA 70. Applicable testing bodies are determined by OSHA as NRTL and include CSA, ETL, and UL. 1-6 MATERIAL AND EQUIPMENT MANUFACTURING DATE Products manufactured more than one (1) year prior to date of delivery to site shall not be used, unless specified otherwise. 1-7 WARRANTY LED luminaires and replacement lamps available today claim long life (e.g., 50,000 hours or more), which exceeds the life ratings of nearly all other light sources (except for some electrodeless sources). These claims are based on the estimated lumen depreciation of the LED used in the product and often do not account for other components or failure modes. Projected life of LED luminaires is a key component to payback scenarios in project evaluations; therefore, it is critical that products perform as promised and anticipated. Since life claims provided by suppliers are typically 50,000 hours or more and the initial cost of exterior LED luminaires may be significant, warranties shall include product performance as claimed in terms of useful life. Life claims by LED luminaire manufacturers shall take into account the whole system, not just the LEDs. A key lesson learned from early market introduction of compact fluorescent lamps was that long-life claims need to be credible and backed up with adequate manufacturer warranties. Equipment items shall be supported by service organizations that are reasonably convenient to the equipment installation so as to render satisfactory service to the equipment on a regular and emergency basis during the warranty period of the contract. a. The solar LED fixture manufacturer shall provide a written five-year replacement finish warranty for luminaires. Finish warranty shall include warranty against failure or substantial deterioration such as blistering, cracking, peeling, chalking, or fading. b. The solar LED fixture manufacturer shall provide a written five-year replacement warranty for defective or non-starting power supply units and LED (6 of 14)
source assemblies, which include, but are not limited to, LED packages, LED arrays, LED modules, LED dies, encapsulates, and phosphors. c. The solar LED fixture manufacturer shall provide a written five-year replacement warranty for any LED source assembly, package, array, or module, which does not include the power supply, against 10% or more of the individual LEDs in that assembly, package, array, or module failing to illuminate. d. The solar LED fixture manufacturer shall provide a 20-year replacement warranty for defective photovoltaic (PV) modules where defective is defined as PV module power output depreciation/reduction greater than 10% of label rating from 0-10 years and 20% of label rating from 11-20 years. e. The solar LED fixture manufacturer shall provide a written seven (7) year warranty with 100% replacement cost covered for five-years for defective batteries that do not maintain at least 80% state of charge following one night of operation and prorated in years 6 and 7 as follows: 40% of battery(ies) cost in year 6; and 20% of battery(ies) cost in year 7. f. The solar LED fixture manufacturer shall provide a written 5-year replacement warranty for defective charge controllers. g. The solar LED manufacturer warranty period shall begin on the date of final acceptance, as executed by DD Form 1354. The contractor will provide the contracting officer with the signed warranty certificates prior to final payment. PART 2 PRODUCTS CONSTRUCTION AND PERFORMANCE REQUIREMENTS 2-1 LUMINAIRES Provide luminaires complete with LED light source and power supply unit. Details, shapes, and dimensions are indicative of the general type desired but are not intended to restrict selection to luminaires of a particular manufacturer. Luminaires of similar design, light distribution and brightness characteristics, and of equal finish and quality will be acceptable. 2-1.1 GENERAL PRODUCT REQUIREMENTS a. Complete luminaires shall be provided, which include factory-installed LED light source, PV panels, power supply, battery, and charging components. (7 of 14)
b. Luminaires shall be UL-listed for wet locations and wiring cavities shall be fieldaccessible for service or repair needs. c. Luminaires must be rated for operation in ambient temperatures from -30 C to +50 C. d. Luminaires shall be full-cutoff or fully shielded as defined by IESNA RP-8-00. Alternatively, the full cutoff can be validated by meeting the following IESNA TM-15 BUG (backlight, uplight, and glare) ratings: Maximum backlight (B) rating of B1. Maximum uplight (U) rating of U1. Maximum glare (G) rating equal to G2. e. Optical systems for roadway and area luminaires, including the driver, shall be sealed and rated for IP 66 as defined in IEC 60529. f. Luminaires shall be fully assembled and electrically tested prior to shipment from the factory. g. For all mast-arm-mounted luminaires, a wildlife shield shall be included on the fixture to prevent wildlife access. h. The color of the luminaires shall be bronze, unless specified otherwise. i. Coatings shall be capable of surviving ASTM B117 salt fog environment for 1000 hours minimum without blistering or peeling. j. Coatings shall demonstrate gloss retention greater than or equal to 90% for 1000 hours exposure QUV test per ASTM G154 UV-B313, 4-hour UV-B 60 C/4-hour condensation 50 C. k. Luminaires shall be fully functional after testing for thermal shock according to IEC 60068-2-14 and be fully functional after testing. l. Luminaires shall be tested according to IEC 60068-2-30, damp heat, steady state, for high humidity and high temperatures, and be fully functional after testing. m. Luminaire arm bolts shall be 304 stainless steel or zinc-plated steel. n. If a lens not integral to the luminaire is used, the optical enclosure (lens/window) shall be constructed from clear and UV-resistant acrylic, polycarbonate, or UV-treated tempered glass. (8 of 14)
o. If the lens is integral to the luminaire, the lens shall be UV-treated tempered glass. p. At least 80% of the luminaire material by weight shall be recyclable at the manufacturer s stated end of life. q. LED luminaires shall produce a minimum efficacy of 60 lumens per watt driven at a maximum 600 ma, tested per IESNA LM-79. Theoretical models of initial raw LED lumens per watt are not acceptable. r. Luminaires shall incorporate modular electrical connections and be constructed to allow replacement of all or part of the optics, heat sinks, power supply units, and electrical components using only a simple tool, such as a screwdriver. s. Luminaires shall bear a nameplate inscribed with the manufacturer's name, address, model number, date of manufacture, and serial number, securely affixed in a conspicuous place. The nameplate of the distributing agent will not be acceptable. t. The rated voltage and rated power in watts (W) and volt-amperes (VA) shall be permanently marked inside each unit. u. Luminaires must pass 3G vibration testing in accordance with ANSI C136.31. 2-1.2 WIRING Twist-style wire nuts and tap-style stripless connectors are not acceptable for factory electrical connections. 2-1.3 POWER SUPPLY UNITS a. Minimum efficiency of 85%. b. Rated to operate between -30 C to +50 C. c. Comply with FCC 47 CFR Section 15, Class B, non-consumer RFI/EMI standards. d. Reduction of hazardous substances (RoHS) -compliant. 2-1.4 LED LIGHT SOURCE Note 1: Select CCT values and CRI bracketed options based on application. If a design strategy is to blend with traditional lighting systems in the local area, pick a CCT in the 4,000 5,000 K range. This temperature is a warmer light source than 6500 K and provides a balance between color temperature, color rendering, and efficacy of the light (9 of 14)
source. LED chips are manufactured to achieve maximum efficacy related to a specific color temperature and this varies with chip manufacturer and binning. Note 2: High pressure sodium is 2700 K, warm metal halide is 3200 K, clear metal halide is 4000 K, and moonlight is 4100 K. Note 3: 6500 K is a cooler temperature and should only be used when color rendering or environmental concerns such as sky glow are not a factor. Objects appear bluish and items in the red color spectrum may appear distorted. a. Correlated color temperature (CCT) shall be in accordance with ANSI C78.377. [Nominal CCT: 3000 K: 3045 ± 175 K] [Nominal CCT 3500 K: 3465 ± 245 K] [Nominal CCT: 4000 K: 3985 ± 275 K] [Nominal CCT 4500 K: 4503 ± 243 K] [Nominal CCT 5000 K: 5028 ± 283 K] [Nominal CCT 5700 K: 5665 ± 355 K] [Nominal CCT: 6500 K: 6530 ± 510 K] b. Color Rendering Index (CRI) shall be: [ 80 for 3000 K 3500 K] [ 70 for 4000 K 6500 K] c. Thermal management shall be passive by design and shall consist of heat sinks with no fans, pumps, or liquids. 2-2 PV MODULES 2-2.1 CONSTRUCTION a. Comprised of crystalline silicon solar cells. b. Framed in an all-aluminum structure. c. Sealed behind UV-stabilized, tempered glass. d. Meet or exceed IEC 61215-2005. e. UL 1703 listed. f. RoHS compliant. g. Harnessing and cabling: minimum 12 AWG THHN stranded wire with overmolded insulation and UV-stabilized polymer rated for exterior use. (10 of 14)
h. Electrically joined to the system via watertight junction box and sealed ULrecognized PV connectors (Type MC4). 2-2.2 PERFORMANCE a. PV panel shall be rated to withstand hail stone impact described in ASTM E1039-10 and surface-cut susceptibility tests (UL 1703). b. Supplemental protection by 0.125 inch (1/8 ) aluminum panel backer color matched to the solar light system shall be provided. c. PV panel shall generate adequate power to fully recharge system battery(ies) within three (3) days at the installation s location s expected minimum insolation. d. PV panels shall be fastened to the PV support system in a minimum of four locations. 2-3 SOLAR CONTROLLER AND LED DRIVER 2-3.1 CONSTRUCTION a. Enclosed within the light system with touch-proof covers to prevent damage. b. Conformal coated or potted to IP-65 to prevent corrosion and failure due to water intrusion, humidity, or dust. c. Charge controller shall be UL 1741 listed. d. Charge controller and LED driver are constructed without electrolytic capacitors. e. All other capacitor devices are de-rated by at least 20 C below the capacitor s maximum temperature rating under fully loaded conditions and ambient temperature of 30 C. f. LED driver shall be UL-listed. g. Single unit shall be capable of controlling and dimming one or two luminaires. h. Integrated surge protection and noise reduction. i. Complies with FCC Title 47, Subpart B, Section 15 noise threshold requirements. j. Ten day/night memory averaging to ensure accurate turn on and turn off of (11 of 14)
lights to prevent false response due to weather variations. k. LED output shall be short circuit-protected. l. Unit incorporates internal PV disconnect (no external diodes required). m. Test button and diagnostic indicators shall be provided. n. Self-test mode. o. PV reverse battery polarity protection. p. Self-calibrating load, timing, and charging circuitry. q. Enclosed within the lighting system to prevent contact damage. 2-3.2 Performance a. Minimum 10-year operational life when operating at minimum or maximum rated system environmental specifications (10 C to 50 C at 0 100% relative humidity, non-condensing) b. Designed and tested to withstand electrostatic discharges up to 15,000 V without impairment, per IEC 61000-4-2. c. Withstand up to a 6,000-volt surge without impairment of performance as defined by ANSI C62.41.1 and C62.41.2 Category A. d. Connects to all system components via a quick-connect/latching connector. e. Capable of one of the following operating modes: Dusk-to- dawn. Programmed run Light operates for [10] [8] [6] [4] hours after dusk. Split night with dimming Light operates at [10] [8] [6] [4] [2] hours, dims at the customer s option from 10% to 50% then returns to full light for [1] [2] [3] [4] hours before dawn. Split night - Light operates at [10] [8] [6] [4] [2] hours, turns off then returns to full light for [1] [2] hours before dawn. Split night mode where during the off or dimmed period a motion sensor activates the light to full intensity for [2] [5] [10] minutes. f. Factory pre-programmed for a selected operating mode g. Charge controller operates with temperature-compensated limits ensuring battery charging algorithm protects battery(ies) from over- and under-voltage (12 of 14)
stress. h. Charge controller adapts maximum (charged) voltage based on temperature (14V maximum at 21 C). i. Charge controller prevents discharge below temperature-compensated battery low voltage disconnect (LVD) limit (11.5V at 21 C). j. Operate the light for at least five (5) nights without adequate insolation during the day to charge the batteries. k. Charge controller never discharges more than 20% depth of discharge per night. 2-4 ENERGY STORAGE BATTERIES 2-4.1 CONSTRUCTION a. Sealed valve regulated gel cell type or AGM type. b. UL-recognized. c. Maintenance-free. d. Air-shippable. e. Rated non-spillable by ICAO/IATA/DOT. f. 100% recyclable. g. Built to comply with IEC 60896-2. h. Connected with wire harnessing that uses a ring lug or spade-type connect with a positive spring force and surface area to terminal of at least 1 square inch for both the anode and cathode. i. Input shall be fused. Battery fuses shall not be rated higher than 30 amperes. 2-4.2 PERFORMANCE a. Capable of over 2000 charge/discharge cycles. b. Feature deep-cycle technology. c. Maintain over 80% of charge after 2 months if left disconnected. (13 of 14)
d. Provide no less than 5 days of backup in no-sun conditions. 2-5 BATTERY ENCLOSURE, PV SUPPORT, AND LUMINAIRE ARMS 2-5.1 CONSTRUCTION a. All system metals shall be aluminum, 6061 T6, powdercoated bronze (unless otherwise specified), and fastened together using stainless-steel hardware. b. PV support structure shall be low profile and engineered and reviewed by a PE to adequately support the PV modules in the maximum wind rating for the location where the lighting is installed c. Battery enclosure shall be NEMA 3R rated. 2-5.2 PERFORMANCE a. PV support structure shall allow at least five tilt positions for optimized solar harvesting (5 degrees, 15 degrees, 30 degrees, 45 degrees, and 60 degrees below the horizontal). b. No self-tilting, rotating, solar tracking, or other moving components to adjust the PV modules is allowed. c. Battery enclosure shall interface to both round, square, and octagonal poles. d. Battery enclosure shall be lockable and locatable at the top or bottom of the pole structure. 2-6 DAYLIGHTING CONTROLS a. All solar powered LED luminaires shall be controlled such that exterior luminaires shall not operate during daylight. b. Controls may include a combination photocell plus time switch. Remote control is prohibited. c. Controls shall allow automatic on and off settings based on daylighting, plus timed off settings after expected activity ends. (14 of 14)
DISTRIBUTION LIST DEPARTMENT OF DEFENSE Defense Commissary Agency (1) AAFES (1) Design and Construction Division ATTN: RE-C 2250 Foulois St., Suite 2 PO Box 660202 Lackland AFB, TX 78236 Dallas, TX 75266-0202 SPECIAL INTEREST ORGANIZATIONS Information Handling Services (1) Construction Criteria Base (1) 15 Inverness Way East National Institute of Bldg Sciences Englewood, CO 80150 Washington, DC 2000 Atch 2 (1 of 1)