BRITISH STANDARD AUTOMOBILE SERIES CONFIRMED APRIL 1987 BS AU 40 4a 1966 Incorporating Amendment No 1 Specification for Motor vehicle lighting and signalling equipment — Part 4a Sealed beam headlamps[.]
BRITISH STANDARD AUTOMOBILE SERIES BS AU 40-4a:1 966 Incorp orating C O NFI RME D APRI L 987 Specification for Motor vehicle lighting and signalling equipment — Part 4a: Sealed beam headlamps UD C 62 1 8: 65 8: 62 1 6: 62 Reprodu ced by I H S u n d er l i cen se wi th BSI - U n trol l ed Copy Am endm ent No BS AU 40-4a:1 966 Co-operating organizations The Illumination Industry Standards Committee under whose supervision this British Standard was prepared, consists of representatives from the following Government departments and scientific and industrial organizations: Association of Public Lighting Engineers* British Electrical and Allied Manufacturers’ Association British Glass Industry Research Association British Railways Board* Electric Lamp Industry Council* Electric Light Fittings Association* Electricity Council, the Generating Board and the Area Boards in England and Wales* Gas Council Glass Manufacturers’ Federation Illuminating Engineering Society* Independent Lamp Manufacturers’ Export Group* Institution of Electrical Engineers* Institution of Gas Engineers Institution of Municipal Engineers London Transport Board* Medical Research Council Ministry of Aviation* Ministry of Defence, Navy Department* Ministry of Housing and Local Government Ministry of Labour (H.M Factory Inspectorate) Ministry of Public Building & Works* Ministry of Technology — Building Research Station Ministry of Transport* National Physical Laboratory (Ministry of Technology)* Post Office* Royal Institute of British Architects Society of British Gas Industries Society of Glass Technology* The Government departments and scientific and industrial organizations marked with an asterisk in the above list, together with the following, were directly represented on the committee entrusted with the preparation of this standard British Cycle & Motor Cycle Industries Association Ltd Electrical Contractors Association (Incorporated) Greater London Council Municipal Passenger Transport Association (Incorporated) Public Transport Association (Incorporated) Society of Motor Manufacturers & Traders Ltd This British Standard, having been approved by the Illumination Industry Standards Committee and endorsed by the Chairman of the Engineering Divisional Council, was published under the authority of the General Council on 27 April 1966 © BSI 02-2000 The following BSI references relate to the work on this standard: Committee references LGE/6, LGG/6/3 Draft for comment D64/1958 ISBN 80 345 X Reprodu ced by I H S u n d er l i cen se wi th BSI - U n trol l ed Copy Amendments issued since publication Amd No 2188 Date of issue December 1976 Comments Indicated by a sideline in the margin BS AU 40-4a:1 966 Contents Page Co- operating organizations Inside front cover Foreword ii Section General Scope Definitions Marking Section Tests Sampling and testing procedure Dimensions Thermal shock Current limits Photometric requirements and test Visual aim 10 Life 11 Conditions of compliance 10 Figure — in diameter sealed beam headlamp unit 11 Figure — 12 # in diameter sealed beam headlamp unit Type Figure — # in diameter sealed beam headlamp unit Type Table — inch volt 60/45 watt right hand drive unit (Dip left) Table — Table — # inch volt 37" watt Type # inch volt 37" /50 W Type right hand drive unit (Dip left) Table — inch volt 75/50 watt right hand drive unit (Dip left) © BSI 02- 2000 13 Table — inch volt 60/50 watt right hand drive unit (Dip left) Table — # inch volt 37" /60 watt right hand drive unit (Type 2) Table — # inch, volt, 75 watt (Type ) Reprodu ced by I H S u n d er l i cen se wi th BSI - U n trol l ed Copy Appendix A Statistical basis i BS AU 40-4a:1 966 Foreword This British Standard has been prepared under the authority of the Illumination Industry Standards Committee after consultation with the Automobile Industry Standards Committee, and it is based upon data- sheets SMMT 74: 960 and SMMT 77: 962 of the Society of Motor Manufacturers and Traders Ltd This standard forms Part of BS AU 40; other parts are: — Part 1: Side, rear, parking and stop lamps, and direction indicators; — Part 2: Reflex reflectors for vehicles, including cycles; Part 3: Headlamps with prefocused filament lamps (in course of preparation); — — Part 5: Rotating beacons (in course of preparation) It will be seen that compliance with this specification is checked by the testing of samples from batches of units The statistical basis for the sampling system is explained in Appendix A to the standard All materials and components used in the construction of these units are required to comply with relevant British Standards A British Standard does not purport to include all the necessary provisions of a contract Users of British Standards are responsible for their correct application Compliance with a British Standard does not of itself confer immunity from legal obligations Summary of pages This document comprises a front cover, an inside front cover, pages i and ii, pages to and a back cover This standard has been updated (see copyright date) and may have had amendments incorporated This will be indicated in the amendment table on the inside front cover ii Reprodu ced by I H S u n d er l i cen se wi th BSI - U n trol l ed Copy © BSI 02- 2000 BS AU 40-4a:1 966 Section General 2.6 7-inch two-headlamp system Scope two similar inch sealed beam units used together This standard specifies requirements for volt on a vehicle sealed beam headlamp units for use on vehicles, and 2.7 tests for photometric properties, visual aim, current, four-headlamp system life and resistance to thermal shock NOTE In general, the inch dimensions given in this specification are the standard Where dimensions are given in both systems, the first figure is four units used together on a vehicle and lit to provide the main beam, two units only being lit to provide the dipped beam the standard and the second is an approximate conversion For NOTE Two systems are employed at present The first uses accurate conversions reference should be made to BS 350, four inch units, two being Type and two Type and the “ Conversion factors and tables” # second system is a mixed one using two inch units and two # Definitions 2.8 For the purposes of this specification the following batch inch (Type ) units definitions apply: all the lamps of one type put forward at one time for 2.1 acceptance mechanically aimable sealed beam units a sealed unit having three pads on the face of the Marking lens, pre- aimed during manufacture to form an The lamp shall be legibly and durably marked with aiming plane the following information: NOTE The unit is pre- aimed during manufacture to form an aiming plane normal to the vehicle axis when the beam is correctly aimed 2.2 main (driving or upper) beam a beam of light intended primarily for distant a) Nominal voltage b) Nominal wattage c) Trade mark d) Where appropriate, a mark indicating the rule- of- the- road illumination of the road, when no other vehicle is e) With the number of this British Standard, approaching i e BS AU 40 2.3 dipped (meeting or lower) beam a beam of light intended for illumination of the road ahead of the vehicle when meeting other road users 2.4 7-inch sealed beam unit a unit inches in diameter having two filaments, one providing a main beam and the other a dipped beam 2.5 # -inch sealed beam unit a unit # inches in diameter Type has a single NOTE The mark BS AU 40 on or in relation to the product is a claim by the manufacturer that it complies with the requirements of the standard The British Standards Institution is the owner of a registered certification trade mark This is shown below, enclosed in the words “Approved to British Standard” This mark can be used only by manufacturers licensed under the certification mark scheme operated by the BSI The presence of this mark on or in relation to a product is an assurance that the goods have been produced to comply with the requirements of the British Standard under a system of supervision, control and testing operated during manufacture and including periodical inspection at the manufacturer’s works in accordance with the certification mark scheme of the BSI Further particulars of the terms of licence may be obtained from the Director, British Standards Institution, 2, Park Street, London, W filament which contributes to the main beam and Type has two filaments, one of which contributes to the main beam and the other provides the dipped beam © BSI 02- 2000 Reprodu ced by I H S u n d er l i cen se wi th BSI - U n trol l ed Copy BS AU 40-4a:1 966 Section Tests Photometric requirements and test Sampling and testing procedure Following the ageing prescribed in Clause the photometric test voltage (given in the The units for testing shall be selected so as to ensure appropriate table) shall then be applied to the proper representation of the batch, as follows: terminals of the unit a) The units shall be mounted in such a way that the Metho d of sam p ling i) A b atch of A 000 units or less photo- cell and centre of the unit This specifies A b atch p acked in o r less containers Units shall be selected from detailed above, when measured at 60 ft (1 m) A b atch p acked in m ore than containers Units shall be selected from at least one half of the total number of containers, with a minimum of ii) A b atch of m ore than 000 units Lamps shall be selected as far as possible from b) the H—V point (see Note below) The light intensities from a unit mounted as each container B aiming plane is perpendicular to a line through the from the unit face shall comply with the values given in the appropriate table ! ° is permissible for any test point NOTE A tolerance of ± NOTE In locating the test points, the line formed by the intersection of a vertical plane through the lamp axis with the test screen is designated as V The line formed by the intersection of a horizontal plane through the unit centre and the test screen one third of the number of containers, with a is designated as H The point at the intersection of these two lines maximum of is designated as H—V The other points on the screen are designated by similar symbols to indicate the number of degrees Tests i) For single filam ent units of arc above or below H and the number of degrees of arc to the left or right of V for an observer facing the screen, for example, 4D—3L is a point degrees below H and degrees to shall be selected from the batch, units the left of V, and U—V is a point degree above H in the median shall be tested in accordance with vertical plane Clauses, , , and The remaining units shall be tested in accordance with Clauses , , and ii) For doub le filam ent units 25 shall be selected from the batch, of these shall be tested in accordance with Clauses , and 20 of these, including the referred to above, shall be tested in accordance with Clause , being tested on the main beam filament and on the dipped beam filament The remaining units shall be tested in accordance with Clauses , and Visual aim When the unit is mounted as in Clause , it shall be possible for the high intensity zone of the main beam of inch and # inch Type units to be set by three experienced observers to within maximum vertical and horizontal deviations of ± and ± degrees respectively at a distance of 25 ft (7 m) Life When mounted in the position of normal use the units shall be tested on an a c supply at the life test Dimensions The units shall comply with the dimensions given in Figure , Figure or Figure as appropriate voltage given in the appropriate table, at a nominal frequency of 50 c/s The momentary fluctuations of the test voltage during the test shall not exceed ± per cent and Thermal shock The higher- wattage filament shall be operated for five minutes in the normal- operating position of the unit at volts The unit shall then be quickly immersed, lens first, in water at ° C until cool there shall be no sensible departure of the average value throughout the test from the specified value Lamps shall be switched off twice daily for periods of not less than minutes, such periods not being considered as part of the life of the lamp After this test there shall be neither evidence of Lamps which are accidentally broken before the moisture in the unit nor sign of failure in the glass completion of the test shall, when necessary, be Current limits lamps complete the test Any such broken lamps replaced to ensure that the required number of The units shall be aged at the life- test voltage shall be neglected in calculating the results given in Table to Table as appropriate for at The test shall be considered to have terminated least 30 minutes The current passed shall then be when the requirements of the tables have been measured with the specified voltage applied to the satisfied terminals of the unit Reprodu ced by I H S u n d er l i cen se wi th BSI - U n trol l ed Copy © BSI 02- 2000 BS AU 40-4a:1 966 1 Conditions of compliance A batch shall be considered as complying with this specification if the requirements contained in a) to e) inclusive below are satisfied If the batch fails to satisfy the requirements of any of these clauses, it shall be deemed not to comply with the specification a) Not more than unit of the sample tested shall fail any one of the requirements described in Clauses and b) Not more than two units of the sample tested shall fail any one of the tests described in Clauses and NOTE Clause is applicable only to 7-inch and 5# -inch Type units c) The average of the currents passed by the unit in the sample tested under Clause shall lie within the appropriate limits shown in the appropriate tables d) No unit shall fail the test prescribed in Clause e) The average life of the sample selected for the test shall not fall below the minimum average value specified in the appropriate tables f) The number of units in the sample having lives shorter than 60 per cent of the specified minimum average shall not exceed the value given in the appropriate table Table — inch volt 60/45 watt right hand drive unit (Dip left) A Photometric requirements at 2.8 V on the unit terminals Main beam Position 2U—3R & 3L 1U—3R & 3L " D—V Dipped beam Cd Max Cd Min " D—3R & 3L " D—6R & 6L " D—9R & 9L " D—12R & 12L 2D—V 2D—9R & 9L 3D—V 3D—12R—12L 4D—V 000 Position Cd Max 250 000 36 000 " U—1L to L 1U—1R to R " U—1L to 3L 12 000 000 000 " U—1R to R 800 " D—1L to L 10 000 " D—2L " D—1R to R 000 1D—1R to 6R " D—2L " D—9L " D—9R 12 500 4D—4L 125 10U—90Ua 500 000 000 500 000 a From the normally exposed surface of the lens 000 500 000 Cd Min 750 750 10 000 500 750 B Current limits at 2.8 V on the unit terminals Average current limits for units Minimum Main filament: Dipped filament: Maximum 4.41 amp 3.31 amp 4.97 amp 3.73 amp C Life test at 4.0 V on the unit terminals Maximum number of Minimum average life of 10 units Main filament: Dipped filament: © BSI 02-2000 Reprodu ced by I H S u n d er l i cen se wi th BSI - U n trol l ed Copy 138 h 221 h units failing Design life 200 h 320 h before 60 per cent of 2 design life BS AU 40-4a:1 966 Table — # inch volt 37" watt Type 2A Photometric requirements at 2.8 V on the unit terminals Main beam Position 3U—3L & 3R 2U—3L & 3R 1U—3L & 3R Cd Max " D—V " D—3L & 3R " D—6L & 6R " D—9L & 9R Cd Min Position 450 750 000 " D—12L & 12R 2D—V 2D—9L & 9R 25 000 12 000 000 000 3D—V 3D—12D & 12R 4D—V Cd Max 500 Cd Min 750 000 250 500 600 2B Current limits at 2.8 V on the unit terminals Average current limits for units Minimum 2.75 amp Maximum 3.11 amp 2C Life test at 4.0 V on the unit terminals (Main Beam) Maximum number of units failing Minimum average life of 138 h 10 units Design life 200 h Reprodu ced by I H S u n d er l i cen se wi th BSI - U n trol l ed Copy before 60 per cent of design life © BSI 02-2000 BS AU 40-4a:1 966 Table — # inch volt 37" /50 W Type right hand drive unit (Dip left) 3A Photometric requirements at 2.8 V on the unit terminals Main beam Position Dipped beam Cd Max 3U—3L & 3R 2U—3L & 3R 1U—3L & 3R " D—V " D—3L & 3R " D—6L & 6R " D—9L & 9R " D—12L & 12R 2D—V 2D—9L & 9R 3D—V 3D—12L & 12R 4D—V Cd Min Position 300 750 000 1U—1R to R " U—1R to R " D—1R to R 000 000 000 " U—1L to L 000 " U—1L to 3L 000 000 750 000 " D—2L 1D—6R " D—2L " D—9L " D—9R 4D—4L 10U to 90Ua 750 000 400 500 Cd Max 650 850 000 10 000 12 500 125 Cd Min 750 750 12 000 500 750 a From the normally exposed surface of the lens 3B Current limits at 2.8 V on the unit terminals Average current limits for units Minimum Main filament Dipped filament 2.75 amp 3.68 amp Maximum 3.11 amp 4.14 amp 3C Life test at 4.0 V on the unit terminals Minimum Design failing before 60 per cent of life of design life 10 units Main filament 138 h Dipped filament 221 h © BSI 02-2000 Reprodu ced by I H S u n d er l i cen se wi th BSI - U n trol l ed Copy Maximum number of units average life 200 h 320 h BS AU 40-4a:1 966 Table — inch volt 75/50 watt right hand drive unit (Dip left) 4A Photometric requirements at 2.8 V on the unit terminals Main beam Position 2U—3R & 3L 1U—3R & 3L " D—V Cd Max " D—3R " D—3L " D—6L & 6R " D—9R & 9L " D—12R & 12L 2D—V 2D—9R & 9L 3D—V 3D—12R & 12L 4D—V 000 Dipped beam Cd Min Position Cd Max 750 000 40 000 " U—1L to L 1U—1R to R " U—1L to 3L 000 500 000 20 000 16 000 500 " U—1R to R " D—1L to L 800 10 000 000 000 000 " D—2L " D—1R to R 1D—1R to 6R " D—2L " D—9L " D—9R 4D—4L 10U—90Ua 000 000 250 a From the normally exposed surface of the lens 000 12 500 125 Cd Min 200 800 11 000 700 800 4B Current limits at 2.8 V on the unit terminals Average current limits for units Minimum Main filament Dipped filament Maximum 5.51 amp 3.68 amp 6.22 amp 4.14 amp 4C Life test at 4.0 V on the unit terminals Minimum Main filament Dipped filament Maximum number average Design of units failing life of life before 60 per cent of 10 units 105 h 221 h Reprodu ced by I H S u n d er l i cen se wi th BSI - U n trol l ed Copy 150 h 320 h 2 design life © BSI 02-2000 BS AU 40-4a:1 966 Table — inch volt 60/50 watt right hand drive unit (Dip left) 5A Photometric requirements at 2.8 V on the unit terminals Main beam Position Dipped beam Cd Max 2U—V 1U—3L & 3R H—V Cd Min 000 000 20 000 10 000 250 500 750 H—3L & 3R H—6L & 6R H—9L & 9R H—12L & 12R " D—V " D—9L & 9R " D—V " D—12L & 12R 4D—V 000 500 500 750 000 Position Cd Max 10U to 90Ua 1U—1 " R to R " U—1 " R to R " D—1 " R to R " U—1L to L 125 700 000 500 400 " U—1L to 3L " D—1 " L 1D—6R " D—2L 700 20 000 " D—9R & 9L 2D—15R & 15L 4D—4L 12 500 Cd Min 000 750 15 000 750 700 a From the normally exposed surface of the lens 5B Current limits at 2.8 V on the unit terminals Average current limits for units Minimum Main filament Dipped filament 4.41 amp 3.68 amp Maximum 4.97 amp 4.14 amp 5C Life test at 4.0 V on the unit terminals Minimum Main filament Dipped filament © BSI 02-2000 Reprodu ced by I H S u n d er l i cen se wi th BSI - U n trol l ed Copy Maximum number of units average life Design failing before 60 per cent of of life design life 10 units 138 h 221 h 200 h 320 h BS AU 40-4a:1 966 Table — # inch volt 37 " /60 watt right hand drive unit (Type 2) 6A Photometric requirements at 2.8 V on the unit terminals Main beam Position 3U—3L & 3R 2U—3L & 3R 1U—3L & 3R Cd Max Dipped beam Cd Min Position Cd Max 300 750 000 1U—1R to R " U—1R to R " D—1R to R 650 850 000 " D—V " D—3L & 3R " D—6L & 6R " D—9L & 9R " D—12L & 12R 2D—V 2D—9L & 9R 000 000 000 " U—1L to L " U—1L to 3L 000 000 000 750 000 3D—V 3D—12L & 12R 4D—V 000 400 " D—2L 1D—6R " D—2L " D—9L " D—9R 4D—4L 10U to 90Ua 750 500 15 000 Cd Min 000 750 15 000 500 750 12 500 125 a From the normally exposed surface of the lens 6B Current limits at 2.8 V on the unit terminals Average current limits for units Minimum Main filament Dipped filament Maximum 2.75 amp 4.41 amp 3.11 amp 4.97 amp 6C Life test at 4.0 V on the unit terminals Minimum Design failing before 60 per cent of of life design life 10 units Main filament 138 h Dipped filament 221 h Maximum number of units average life Reprodu ced by I H S u n d er l i cen se wi th BSI - U n trol l ed Copy 200 h 320 h © BSI 02-2000 BS AU 40-4a:1 966 Table — # inch, volt, 75 watt (Type ) 7A Photometric requirements at 2.8 V on the unit terminals Main beam Position Cd Max Cd Min 2U—3R 2U—3L 1U—3R Position " D—9L " D—12R " D—12L 250 250 500 1U—3L D—V D—3R " " " D—3L " D—6R " D—6L " D—9R Cd Max Cd Min 000 750 750 500 65 000 28 000 2D—V 2D—12R 2D—12L 500 500 500 28 000 000 000 3D—V 3D—12R 3D—12L 500 200 200 000 4D—V 500 * From the normally exposed surface of the lens 7B Current limits at 2.8 V on the unit terminals Average current limits for units Minimum Main filament 5.50 amp Maximum 6.20 amp 7C Life test at 4.0 V on the unit terminals Minimum Design failing before 60 per cent of of life design life 10 units Main filament © BSI 02-2000 Reprodu ced by I H S u n d er l i cen se wi th BSI - U n trol l ed Copy Maximum number of units average life 35 h 50 h BS AU 40-4a:1 966 Appendix A Statistical basis 2) 98 per cent of the lamps satisfy each single It is impracticable and uneconomic to test every 3) 90 per cent of the lamps satisfy each single lamp in a batch but, by the use of statistical requirement (Clauses and ) requirement (Clauses and ) sampling theory, it is possible to design tests on small samples which will determine whether the quality of a batch is acceptable Accordingly, test quantities, quality limits and compliance numbers have been so specified that if the whole of a batch had been tested and found to comply with each of the following quality statements, there would be a 975 (39/40) probability that such a batch, if tested (by sampling) in accordance with the specification, would be found to comply with the standard The quality statements are: ) 99 per cent of the lamps satisfy each single requirement (Clause ) 10 Reprodu ced by I H S u n d er l i cen se wi th BSI - U n trol l ed Copy 4) The average values satisfy the requirements for initial current (Clause ) A batch of lamps complies with this standard if, when a sample is tested according to the standard, in all the test quantities, the numbers of lamps outside the specified quality limits (such lamps are not necessarily failures or faulty lamps) are not greater than the related compliance numbers, and the average life is not less than the related minimum average life Individual lamps are deemed to comply with the requirements of the standard if they belong to, and comply consequently upon belonging to, a batch which complies with the standard © BSI 02- 2000 © BSI 02 - 000 11 Reprodu ced by I H S u n d er l i cen se wi th BSI - U n trol l ed Copy Figure — in diameter sealed beam headlamp unit BS AU 40-4a:1 966 12 © BSI 02 - 000 Reprodu ced by I H S u n d er l i cen se wi th BSI - U n trol l ed Copy Figure — # in diameter sealed beam headlamp unit Type BS AU 40-4a:1 966 © BSI 02 - 000 13 Reprodu ced by I H S u n d er l i cen se wi th BSI - 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