THE AGL ENGINEERING CENTRE by Precision AGL Academy · Performance & Verification

AGL Testing & Inspection

A practical testing, inspection and verification guide for Airfield Ground Lighting. AGL testing and inspection is the process of confirming that lighting equipment and systems are physically sound, electrically safe, mechanically correct, operationally functional and optically compliant — from the power source to the final optical output.

Inspect → Test → Measure → Compare → Rectify → Re-Test → Record
Overview

What Is AGL Testing & Inspection?

AGL Inspection is the systematic examination of equipment, installation, components and physical conditions.

AGL Testing is the measurement or functional verification of defined electrical, mechanical, optical or operational parameters.

Together they answer one question: is the AGL system installed correctly, electrically healthy, mechanically sound and capable of providing the required visual performance?

Not Just "Is It ON?"

AGL testing should not be limited to checking whether a light illuminates. A complete program examines the system from the power source to the final optical output.

Four Verification Areas

A practical framework separates verification into electrical, mechanical, optical and operational dimensions — together forming complete AGL verification.

Traceable Evidence

Every inspection and test should be recorded so the system's condition and performance can be demonstrated, trended and defended.

Why It Matters

A System May Look Normal While Having an Underlying Defect

AGL systems operate in demanding environments and may experience a wide range of degrading conditions. Testing helps identify problems before they become operational failures.

Moisture Water ingress Temperature variation Lightning Cable deterioration Mechanical impact Vehicle movement Aircraft blast Vibration Corrosion Connector deterioration Optical contamination Equipment ageing
Verification Framework

Four Dimensions of AGL Verification

A practical AGL inspection framework can be divided into four major areas. Electrical + Mechanical + Optical + Operational = Complete AGL Verification.

1. Electrical

Is the electrical system healthy?

2. Mechanical

Is the physical installation secure and correctly positioned?

3. Optical

Is the light producing the required visual performance?

4. Operational

Does the complete system operate and respond correctly?

Sequence

AGL Testing Hierarchy

A useful testing sequence helps prevent unnecessary energization of defective equipment.

Visual Inspection
Mechanical Inspection
Electrical Testing
Functional Testing
Alignment Verification
Photometry
System Testing
Final Inspection
Documentation
When

When Should AGL Testing Be Performed?

The exact testing frequency should follow the applicable airport maintenance program, standards and project requirements. Testing and inspection may be required during:

Material receipt Installation Pre-energization Commissioning Acceptance testing Periodic maintenance Preventive maintenance After equipment replacement After cable repair After transformer replacement After fixture replacement After major construction After severe weather After suspected lightning damage After abnormal operational performance
Before Installation

Incoming Material Inspection

Testing starts before installation. Inspect incoming equipment thoroughly.

Inspect Incoming Equipment For

  • Correct model
  • Correct rating
  • Correct quantity
  • Correct accessories
  • Physical damage
  • Manufacturing defects
  • Identification
  • Certification
  • Packaging condition
  • Storage condition

Typical Equipment

AGL fixtures Isolation transformers CCRs Connectors Cables PAPI units Signs Control equipment
First Line of Quality Control

Visual & Mechanical Inspection

Visual inspection is the first line of AGL quality control and should be documented rather than treated as an informal walk-through. Mechanical inspection then verifies the physical integrity of the installation.

Visual Inspection — Check For

  • Broken housing
  • Cracks
  • Corrosion
  • Loose hardware
  • Missing covers
  • Damaged lenses
  • Dirty optics
  • Water ingress
  • Cable damage
  • Connector damage
  • Incorrect installation
  • Missing identification
  • Physical obstruction

Mechanical Inspection — Verify

Fixtures

MountingOrientationElevationHardwareFrangibility where applicable

Transformers

HousingMountingCable entryConnector condition

Signs

StructureFoundationMountingOrientationFrangibility

PAPI

FoundationUnit positionElevationMountingAlignment

Visual inspection in six steps.

VIEW · FROM FAR TO NEAR start with the whole pattern, finish with the single component WHAT THE EYE LOOKS FOR every look has a defect it is trying to catch LAMP OUT DIM / UNEVEN 1. lit pattern from a distance 2. walk to each marked fixture 3. isolate, then open and look closer GAPS, DIMMING, WRONG COLOUR LIT out, dim, wrong colour, gaps EXTERNAL cracks, dirt, tilt, loose or missing fasteners SURROUNDINGS sealant, covers, water, debris, growth INTERNAL corrosion, damp, heat marks, damaged seals SIX INSPECTION STEPS · IN ORDER 1 PREPARE permit, records, last defects, PPE, radio with ATC 2 LIT VIEW circuit on: judge the pattern from a distance 3 WALK fixtures and signs one by one; note what is visible 4 SURROUNDS pavement, covers, water, debris, vegetation 5 CLOSE LOOK isolated, proved dead: connectors, seals, cable entries 6 RECORD classify, photo, log and raise work orders
Figure 1. Visual inspection sequence: from a lit view, to a walk-round, to a close look once isolated.
AGL Visual Encyclopedia: Visual inspection sequence Mechanical inspection Fixture inspection
Component-Level Inspection

Fixtures, Transformers, Connectors & Cable

Component defects are a common source of intermittent AGL faults. Record defects by fixture location and inspect each component category on its own merits.

AGL Fixture Inspection

  • Housing, lens, optical surfaces
  • Fasteners & mounting base
  • Frangible fittings
  • Cable connection & connector
  • Sealing & drainage
  • Orientation

Inset Light Inspection

  • Fixture elevation
  • Surface condition
  • Mounting, lens, gaskets
  • Sealing & drainage
  • Cable connection & connector
  • Mechanical damage

Elevated Light Inspection

  • Base, pole/stem
  • Frangible fitting
  • Fixture head & mounting bolts
  • Orientation & stability
  • Cable & connector
  • Blast/vehicle damage

Isolation Transformer Inspection

  • Rating & identification
  • Housing & connector
  • Water ingress
  • Physical damage
  • Insulation condition
  • Installation position matches design

Connector Inspection

  • Correct type & mating
  • Mechanical locking
  • Contact condition
  • Cable termination
  • Water ingress & corrosion
  • Strain relief

Cable Inspection

  • Route & identification
  • Physical damage
  • Joint condition & termination
  • Mechanical protection
  • Water exposure
  • Signs of overheating
Where a cable cannot be visually inspected, electrical testing becomes particularly important.
Measured Verification

Electrical Testing

Electrical testing is one of the most important pillars of AGL verification. The exact test method and acceptance value must be taken from the applicable equipment standard, manufacturer instructions and project specification.

Continuity Insulation resistance Voltage Current Circuit resistance Transformer verification Earth continuity Earth resistance where applicable CCR output Control circuit testing
Circuit Health

Continuity & Insulation Resistance Testing

Continuity Test

Verifies that the intended electrical path is complete. For a series circuit, the engineer may verify the circuit path through:

CCR → Cable → Transformer → Connector → Fixture → Transformer → Cable → CCR

Record circuit number, test points, test instrument, measured result, acceptance criterion and PASS/FAIL.

Insulation Resistance Test

Can identify moisture, damaged insulation, cable deterioration, ground leakage, incorrect termination and connector problems.

Testing should be performed using the specified test voltage and procedure. Sensitive electronic equipment should be isolated where required by the manufacturer before applying insulation-test voltage.

Continuity Test Path — Loop Verification

Continuity is verified around the complete series loop — a numbered test point at each stage keeps the result traceable back to a specific segment

CCR 1 2 Cable TRANSFORMER 3 4 Connector 5 Fixture 6 · Transformer (return) 7 · Cable (return) CCR → Cable → Transformer → Connector → Fixture → Transformer → Cable → CCR Each numbered point is a recorded test location, not just a visual stop
Cable & Transformer

Cable Testing & Isolation Transformer Testing

Cable Testing — By Stage

Before Installation

Visual condition, drum condition, cable identification.

During Installation

Physical damage, routing, termination.

Before Energization

Continuity, insulation resistance, circuit identification.

After Repair

Repeat applicable electrical tests — a repaired cable should not be returned to service without verification.

Isolation Transformer Testing

Depending on the applicable procedure, inspect/test:

  • Primary continuity
  • Secondary continuity
  • Insulation
  • Physical condition
  • Connector condition
  • Rating & identification

Coordinate with the applicable manufacturer and project requirements.

Constant Current Regulator

CCR Testing

CCR testing is one of the most important AGL system tests, covering input, output, control and monitoring functions.

Input

Supply voltage, phase condition where applicable, protection.

Output

Output current, current stability, intensity steps, circuit response.

Control

Local control, remote control, ON/OFF, intensity selection.

Monitoring

Fault indication, alarm, circuit monitoring, communication where applicable.

CCR Output Current Test Record

StepSet ValueMeasured ValueStatus
Step 1As specifiedMeasuredPASS/FAIL
Step 2As specifiedMeasuredPASS/FAIL
Step 3As specifiedMeasuredPASS/FAIL
Step 4As specifiedMeasuredPASS/FAIL
Step 5As specifiedMeasuredPASS/FAIL
The applicable tolerance must come from the CCR manufacturer, applicable standard or project specification.

A CCR on test, with six checks.

CCR ON TEST · WHAT CCR TESTING PROVESINPUT SUPPLYV · phasesCCRSTEP 1-5PROTECTIONArmsINSULATIONTESTERSERIES CIRCUITor DUMMY LOADEARTH1PREPARE & ISOLATEpermit, lock out, prove dead, fit test gear2INPUT SUPPLYvoltage and phases within limits3INSULATION RESISTANCEoutput circuit tested de-energised4OUTPUT CURRENTeach brightness step vs rated value5LOAD REGULATIONcurrent holds as load or supply varies6PROTECTION & ALARMSopen circuit, overcurrent, earth leakage1 · Prepare & isolate2 · Input supply3 · Insulation resistance4 · Output current5 · Load regulation6 · Protection & alarms
Figure 2. CCR on test with supply, insulation and current meters on the output. Record each result against the acceptance criterion.
AGL Visual Encyclopedia: CCR testing CCR inspection CCR protection
An electrical systems craftsman checking a constant current regulator
Photo 1. An electrical systems craftsman checks a constant current regulator before checking the airfield lights.Credit: U.S. Air Force photo by Senior Airman Rusty Frank, Spangdahlem Air Base, Jan. 23, 2014. Public domain (US Government work). Source page
Power System

Circuit Monitoring, Voltage & Earthing

Circuit Current Monitoring

Compare actual circuit current against expected system performance. Abnormal current may indicate:

  • Short circuit
  • Incorrect load
  • Transformer problem
  • Fixture failure
  • Cable problem
  • Incorrect connection
  • Circuit configuration error

Voltage Measurement & Earthing

Possible measurement points: CCR input/output, transformer input/output, equipment supply. Consider nominal voltage, operating voltage, variation and drop.

Earthing & bonding: equipment grounding, panel grounding, bonding, metal structures, cable protection, PAPI/sign grounding, surge protection. Test earth continuity and earth resistance where required.

Current Monitoring — Where Abnormal Current Points

The current is the same everywhere on a healthy series loop — where the clamp reading departs from the expected value narrows down which segment to investigate

CCR Clamp meter XFMR Reading = 0 → open circuit / break Reading unstable → loose connector / bad transformer Reading below expected → fixture failure / partial short Compare the measured value against the applicable design current — not against a value assumed to be normal
Do not compare results against arbitrary values — use the applicable design and equipment requirements.
Actual Operation

Functional Testing

Functional testing verifies actual operation, and the test should reproduce the intended operating conditions.

ON/OFF Intensity control Local control Remote control Monitoring Fault indication Interlocks Automatic functions Emergency functions where applicable

Five operating checks on the live system.

FUNCTIONAL TESTING · DOES IT DO ITS JOB LIVE SYSTEM · OPERATED AS A USER WOULD 1 CIRCUITS Each circuit selected Right fixtures lit Colour & direction RECORD: lit check 2 BRIGHTNESS Every step selected Lamps respond evenly Current matches step RECORD: steps 3 CONTROLS Local control Remote control Selector & interlocks RECORD: controls 4 MONITORING Status indications Alarm responses Fail-safe behaviour RECORD: alarms 5 SEQUENCES Flashing & sequence Stop-bar selection Where fitted RECORD: modes FUNCTION VERIFIED EVERY CIRCUIT · EVERY MODE 6 DEFECT ISOLATE · FIX · RE-TEST PASSED READY FOR INTEGRATION SCHEMATIC · CHECKS SHORTENED · NOT TO SCALE
Figure 3. Functional testing: circuits, brightness steps, controls, monitoring and sequences.
AGL Visual Encyclopedia: Functional testing Commissioning sequence Load testing
An electrical systems craftsman activating airfield lights at an air base
Photo 2. An electrical systems craftsman activates airfield lights at Shaw Air Force Base. Function is tested on the live system.Credit: U.S. Air Force photo by Airman 1st Class Jensen Stidham, Shaw Air Force Base, July 16, 2014. Public domain (US Government work). Source page
By Lighting System

Runway, Taxiway, Approach, PAPI & Sign Inspection

Approach lighting and PAPI should be inspected as complete visual systems — verifying both physical and operational condition, not just individual fixtures.

Runway Lighting

Edge lights, centreline, threshold, runway end and touchdown zone lights.

  • Location & spacing
  • Orientation, colour, intensity
  • Circuit operation
  • Physical condition

Taxiway Lighting

Edge, centreline, stop bars, runway guard, lead-on/off and intersection lighting.

  • Physical condition
  • Operational condition

Approach Lighting

Fixture position, structure, elevation, alignment, output, sequencing and colour.

  • Cable, transformer, connector
  • Control

PAPI Inspection & Testing

Mechanical

Foundation, position, elevation, mounting, frangibility.

Electrical

Supply, current, cable, connector, earthing.

Optical

Aiming, alignment, colour, intensity, photometric performance.

Airfield Sign Testing

  • Legend, location, orientation
  • Structure & illumination
  • Brightness & power
  • Control & monitoring
  • Photometric performance where applicable

Verify the installed legend matches the approved sign schedule.

A PAPI that illuminates but has incorrect alignment should not be considered fully verified.

Six stages of an inspection.

HOW REQUIREMENTS TRAVEL INTO INSPECTION 1 REQUIREMENT LIST Checkable requirements from design and governing documents OUTPUT: INSPECTION ITEMS 2 INSPECTION PLAN What, where, how often, who and the pass criteria OUTPUT: CHECKLIST AND SCHEDULE 3 CARRY OUT Visual, mechanical and electrical checks, under permit and isolation as required OUTPUT: OBSERVATIONS 4 RECORD FINDINGS Values, photos, location, date and inspector OUTPUT: INSPECTION RECORD 5 CLASSIFY & DECIDE Compare with criteria; grade condition and defects OUTPUT: ACCEPT, REPAIR OR ESCALATE 6 CLOSE OUT Action done, re-inspect, update the matrix OUTPUT: CLOSED RECORD FEEDBACK LOOP A defect goes to repair and then back to re-inspection; recurring findings feed back to the requirement list and the plan. CRITERIA FIRST · THEN CHECK, RECORD, CLASSIFY AND CLOSE SIMPLIFIED SEQUENCE · FOLLOW YOUR SITE PERMIT AND ISOLATION PROCEDURE
Figure 4. Inspection flow: requirement list, plan, carry out, record, classify and decide, close out.
AGL Visual Encyclopedia: Inspection requirement flow Inspection decision flow PAPI inspection Sign inspection
An airman inspecting strobe lights on an airfield
Photo 3. An electrical systems journeyman inspects strobe lights on the airfield. The team inspects all lights, including the runway and all taxiways.Credit: U.S. Air Force photo by Senior Airman Rusty Frank, Spangdahlem Air Base, Jan. 23, 2014. Public domain (US Government work). Source page
Optical Verification

Optical Inspection & Photometry

Optical Inspection

Evaluates the visual condition of the light. Check the lens, reflector, optical chamber, LED module, lamp, colour, contamination, damage and condensation.

Optical contamination can reduce performance even when the electrical system remains healthy.

AGL Photometry

Provides quantitative verification of optical performance — intensity, distribution, colour, beam characteristics, alignment and uniformity — using suitable calibrated equipment and the applicable measurement procedure.

Open the full AGL Photometry guide →
Optical Path — Why a Healthy Circuit Can Still Fail Optically

The electrical circuit only proves the lamp is energized — contamination, damage or a shifted reflector between the source and the beam still reduces the light actually delivered

LED / lamp source Reflector Lens — contamination Design beam — full intensity Actual beam — reduced by contamination Observer / pilot eye Electrical testing confirms the source is powered — only optical inspection and photometry confirm the beam reaching the pilot is correct
Comparisons

Electrical Testing vs Photometry, Inspection vs Testing

A system can pass electrical testing and fail photometry. Both inspection and testing are required — inspection identifies visible problems, testing identifies measurable problems.

Electrical TestingPhotometry
Checks powerChecks optical output
Measures voltage/currentMeasures light
Checks insulationChecks intensity
Checks continuityChecks distribution
Checks electrical healthChecks visual performance
Finds cable faultsFinds optical deficiencies
InspectionTesting
Looks for visible defectsMeasures performance
Housing conditionElectrical values
Lens conditionInsulation
Cable damageContinuity
MountingCurrent
CorrosionVoltage
Water ingressPhotometry
Reference

Testing by Equipment

EquipmentTypical Verification
CCRInput, output current, steps, control, monitoring
Series circuitContinuity, insulation, current
Isolation transformerRating, condition, continuity, insulation
ConnectorCondition, mating, termination
Runway lightPhysical, electrical, optical
Taxiway lightPhysical, electrical, optical
Approach lightPosition, alignment, electrical, optical
PAPIPosition, elevation, alignment, electrical, optical
SignLegend, structure, electrical, illumination
CableContinuity, insulation, physical condition
EarthingContinuity and applicable earth measurements
Frequency

AGL Inspection Frequency

The actual frequency should be defined by the airport's approved maintenance program and applicable requirements.

Routine Inspection

Regular visual inspection during normal airport operations/maintenance.

Detailed Inspection

More comprehensive equipment and installation inspection.

Electrical Testing

Scheduled testing of cables, circuits and equipment.

Photometric Inspection

Periodic measurement of optical performance as required.

Special Inspection

Triggered by an event — see the cards below.

Airfield lights lit at night at an air base
Photo 4. Airfield lights at night. At this base a night-shift team checks all the lights on the airfield, including taxiways, every two hours.Credit: U.S. Air Force photo by Airman 1st Class Sean Campbell, Fairchild Air Force Base, Oct. 21, 2015. Public domain (US Government work). Source page
Event-Triggered

Special Inspection After an Event

Click a card to see what to check.

After Lightning

Inspect & Look For

  • CCR, control system, surge protection
  • Cables, transformers, fixtures, PAPI, signs, earthing, monitoring
  • Burn marks, electronic failure
  • Insulation damage, abnormal current
  • Multiple fixture failures

After Heavy Rain / Flooding

Check For

  • Water ingress, flooded transformer pits
  • Cable insulation deterioration
  • Connector moisture, fixture condensation
  • Damaged seals, corrosion, earthing problems

After Fixture Replacement

Verify Sequence

  • Correct fixture → correct transformer → correct connector
  • Correct installation → electrical test → functional test
  • Alignment → photometry where applicable

After Cable Repair

Nine-Step Sequence

  • Inspect the repair
  • Verify termination
  • Verify continuity
  • Verify insulation
  • Verify circuit condition
  • Energize under controlled conditions
  • Verify current
  • Inspect fixtures
  • Record results
Traceability

Test Instruments & Result Recording

A measurement without traceability has limited engineering value. All measurement equipment should be suitable for the application and maintained/calibrated according to the applicable quality system.

Typical AGL Test Instruments

Digital multimeter Clamp meter Insulation resistance tester Earth resistance tester Continuity tester Current measurement equipment Voltage tester Cable fault-location equipment Photometer Colour measurement equipment Alignment equipment Survey equipment

For Every Important Measurement, Record

  • Instrument name & ID
  • Model & serial number
  • Calibration status & due date
  • Test range
  • Test date & technician

Test Result Record — Required Fields

FieldRequirement
ProjectAirport/project name
LocationExact location
EquipmentEquipment under test
CircuitCircuit number
TestTest performed
InstrumentInstrument ID
RequirementApplicable criterion
ResultMeasured value
StatusPASS/FAIL
TechnicianPerson performing test
DateTest date
RemarksAdditional information
Result Philosophy

PASS / FAIL Philosophy & Defect Classification

A test result should be compared with a defined acceptance criterion. Avoid declaring PASS merely because the equipment appears operational.

PASS

Measured result satisfies the applicable requirement.

FAIL

Measured result does not satisfy the applicable requirement.

HOLD / INVESTIGATION

Result is abnormal, inconclusive or requires additional investigation.

Defect Classification

CRITICAL

Potential impact on operational safety or major system availability.

MAJOR

Significant equipment or system defect requiring corrective action.

MINOR

Defect that does not immediately prevent operation but requires correction.

OBSERVATION

Condition requiring monitoring or future action.

The airport/project quality plan should define the formal classification system.
Quality Cycle

Defect → Test → Rectification → Re-Test

DEFECT IDENTIFIED
CAUSE INVESTIGATION
CORRECTIVE ACTION
INSPECTION
RE-TEST
PASS
CLOSE DEFECT
Never close an engineering defect solely because corrective work has been reported as completed.
Diagnosis

AGL Testing Troubleshooting Logic

When a test fails, work through the sequence below. This prevents incorrect component replacement.

STEP 1

Confirm the Test Method

STEP 2

Confirm the Test Instrument

STEP 3

Repeat the Measurement

STEP 4

Compare with Historical Results

STEP 5

Check Upstream Equipment

STEP 6

Check the Circuit

STEP 7

Check the Individual Component

STEP 8

Rectify the Cause

STEP 9

Re-Test

Records

Historical Test Data & Documentation

Historical Test Data — Track

CCR current Insulation resistance Earth measurements Transformer condition Fixture failures Photometry Connector failures Cable faults

Trend analysis can reveal deterioration before complete failure occurs.

A Complete Testing File May Include

  • Inspection checklists
  • Electrical, cable, transformer & CCR test reports
  • Earthing reports
  • Functional test reports
  • Alignment records & photometry reports
  • Calibration certificates
  • Defect reports & re-test records
  • Final acceptance records
Keyword Reference

AGL Circuit Resistance, Continuity Test & Insulation Resistance Test

The core electrical checks on an airfield lighting series circuit, and what a poor result usually means.

AGL circuit resistance

AGL circuit resistance is the total resistance of the series loop, from the CCR output, through the primary cable and connections, and back. It is compared with the expected value from the cable length and size. A reading that is much higher than expected can point to a poor joint, a damaged conductor or a loose connection. Acceptance limits come from the project specification.

AGL circuit continuity test

An AGL circuit continuity test confirms that the series loop is complete with no open circuit. It is done with the circuit isolated and the CCR disconnected, using a suitable meter. If continuity is lost, the circuit can be split into sections to find where the break is. Continuity alone does not show that insulation is healthy, so it should be followed by insulation testing. See Continuity & Insulation Resistance Testing above.

Airfield lighting insulation resistance test

An airfield lighting insulation resistance test measures how well the cable and connected equipment resist leakage to earth. It is one of the most important checks for finding moisture and insulation damage before they cause faults. Record the result, with conditions such as temperature and weather, so it can be trended over time.

Airfield lighting low insulation resistance

Low insulation resistance in an airfield lighting circuit usually points to water ingress, damaged cable insulation, a poor connector or a failing isolation transformer. Locate the fault by isolating the circuit into sections and testing each, then repair, dry out where needed and re-test. Persistent low readings should be treated as a defect, not a trend to monitor.

Testing a complete series loop with the CCR isolated.

SERIES CIRCUIT · COMMISSIONING TESTS WHOLE LOOP · CCR ISOLATED 1 · ISOLATE 2 · LOOP Ω 3 · INSULATION 4 · ENERGISE ISOLATING TRANSFORMER + FIXTURE, ALL IN SERIES TXTXTXTX CCR ISOLATED LOCKED OFF OUTPUT DISCONNECTED LOW-RESISTANCE OHMMETER Ω INSULATION TESTER MΩ EARTH CLAMP AMMETER (ENERGISED STEP) SERIES LOOP (PRIMARY CABLE) LOOP RESISTANCEcompare with the design value INSULATION TO EARTHwhole loop, high and steady CURRENT AT EACH STEPstart on the lowest step NEVER OPEN A LIVE LOOPisolate and prove dead first SCHEMATIC · NOT TO SCALE · LIMITS COME FROM THE DESIGN, THE CCR DATA AND THE SPECIFICATION
Figure 5. Series-loop test: loop resistance with a low-resistance ohmmeter, insulation resistance with a tester. Limits come from the project specification.
AGL Visual Encyclopedia: Series-circuit testing Circuit continuity Insulation-resistance testing
Keyword Reference

AGL FAT Testing & Testing Procedures

Testing at the factory and how a testing procedure is written for airfield, airport and ground lighting work.

AGL FAT testing

AGL FAT testing is factory acceptance testing, done at the manufacturer's works before equipment is shipped. It normally covers CCRs, fixtures, transformers and control equipment, and checks electrical, mechanical and, where relevant, photometric performance against the order specification. It is often witnessed by the client or their representative, and passing it is a condition for shipment.

Airfield ground lighting testing procedure

An airfield ground lighting testing procedure sets out what is tested, in what order, with which instruments, and what counts as pass or fail. It normally runs from visual and mechanical inspection through electrical testing to functional and optical checks, with each result recorded. See the AGL Testing Hierarchy section above.

Airfield lighting testing procedure

An airfield lighting testing procedure is the same idea from the aerodrome operator's view: a written, approved method that anyone qualified can follow and get the same result. It should include safety precautions, isolation steps, test equipment and records. Intervals and limits come from your maintenance plan and standards.

Airport lighting testing procedure

An airport lighting testing procedure covers all airside lighting systems, including runway, taxiway, approach, PAPI and signs. A common procedure format keeps results comparable across systems, and each system's specific tests are added as appendices or sub-procedures. Please confirm test criteria with the standard your aerodrome follows.

Testing in six stages, with a failed-test loop.

HOW REQUIREMENTS TRAVEL INTO TESTING 1 REQUIREMENT LIST Requirements that must be proved by measurement or operation OUTPUT: TEST ITEMS 2 TEST PLAN Test type, method, instruments and acceptance criteria OUTPUT: TEST PROCEDURES 3 PREPARE Calibrated instruments, isolation, permits and safe access OUTPUT: READY TO TEST 4 CARRY OUT TESTS Factory, site and commissioning tests OUTPUT: MEASURED RESULTS 5 EVALUATE Compare each result with its acceptance criterion OUTPUT: PASS, RETEST OR NON-CONFORMANCE 6 RECORD & CLOSE Signed records, matrix updated, items closed OUTPUT: TEST RECORDS FEEDBACK LOOP A failed test goes to investigation and repair, then back to retest; the acceptance criterion is never changed without formal approval. CRITERIA FIRST · THEN PREPARE, TEST, EVALUATE AND RECORD SIMPLIFIED SEQUENCE · FOLLOW YOUR SITE PERMIT AND ISOLATION PROCEDURE
Figure 6. Testing requirement flow: requirement list, test plan, prepare, test, evaluate, record and close. A failed test goes to investigation and retest.
AGL Visual Encyclopedia: Testing requirement flow Test documentation Pre-commissioning
Interactive

AGL Inspection Checklist Structure

A good field checklist should contain six phases. Tick items off as you work through a project — this resets on reload.

Identification

Airport
Project
Area
Circuit
Equipment ID
0 / 5 complete

Physical

Housing
Lens
Mounting
Cable / Connector
Foundation
Water ingress
0 / 6 complete

Electrical

Voltage
Current
Continuity
Insulation
Earthing
0 / 5 complete

Optical

Colour
Intensity
Alignment
Photometry
0 / 4 complete

Operational

ON/OFF
Intensity
Control
Monitoring
Fault indication
0 / 5 complete

Documentation

Result recorded
Defects recorded
Corrective action
Re-test
Final status
0 / 5 complete
Handover

AGL Acceptance Testing

Acceptance testing establishes whether the installed system meets the approved requirements. It should normally verify: Equipment → Installation → Electrical → Mechanical → Functional → Optical → Documentation.

Acceptance criteria should come from approved project specifications, applicable standards, manufacturer requirements, approved drawings and airport requirements.

Installation InspectionAcceptance Testing
Checks workmanshipChecks final performance
During installationNear completion
Physical conditionMeasured results
PositionElectrical performance
MountingFunctional performance
ConnectionsOptical performance
MaterialsFinal compliance

Five steps to a system-accepted decision.

FINAL ACCEPTANCE · IS IT READY TO HAND OVER REVIEWED · WITNESSED · CLOSED · SIGNED 1 RECORDS All test results in Within the limits Nothing missing RECORD: review 2 WITNESS Key tests shown Owner watches Matches records RECORD: witnessed 3 PUNCH LIST Open items listed Each one closed Re-tested, ticked RECORD: closure 4 HANDOVER As-built drawings O&M manuals Spares & training RECORD: documents 5 SIGN-OFF Certificate drawn up Owner signs Warranty starts RECORD: certificate SYSTEM ACCEPTED OWNER SATISFIED · CERTIFICATE SIGNED 6 NOT ACCEPTED CORRECT · RE-TEST · RE-SUBMIT ACCEPTED READY FOR SERVICE SCHEMATIC · STEPS SHORTENED · NOT TO SCALE
Figure 7. Final acceptance: review test records, witness key tests, close the punch list, hand over documents, sign off.
AGL Visual Encyclopedia: Final acceptance Commissioning sequence Commissioning
Full Sequence

AGL Quality Control Workflow

Material Inspection
Installation Inspection
Pre-Energization Inspection
Electrical Testing
Functional Testing
Optical Verification
Photometry
Defect Identification
Rectification
Re-Test
Final Acceptance
Matrix

AGL Testing Matrix

The exact scope depends on the equipment and project requirements.

StageInspectionElectricalFunctionalOptical
Material Receipt✓As required——
Installation✓As required——
Pre-Energization✓✓——
Commissioning✓✓✓✓
Periodic Maintenance✓✓✓As required
After Repair✓✓✓As required
Final Acceptance✓✓✓✓
Avoid These

Common AGL Testing Mistakes

1. Testing only when something fails

Testing should also be preventive.

2. Checking only voltage

Correct voltage does not prove complete system health.

3. Ignoring insulation

A circuit can operate today and still have deteriorating insulation.

4. Skipping photometry

Electrical health does not guarantee optical compliance.

5. Using unverified instruments

Poor measurement equipment can produce unreliable conclusions.

6. Not recording results

Unrecorded testing provides little historical value.

7. Not re-testing after repair

Repair completion does not automatically prove system compliance.

8. Comparing against arbitrary values

Use the applicable technical requirement.

9. Testing components without checking the system

AGL is an integrated system.

10. Declaring PASS because the light is ON

ON does not equal compliant.

Philosophy

The AGL Testing Philosophy

Every AGL test should answer three questions:

What are we measuring?

Electrical / Mechanical / Optical / Operational parameter.

What should it be?

Applicable acceptance criterion.

What did we actually measure?

Recorded result.

Measurement + Requirement + Result = Engineering Verification. A reliable AGL testing program does not ask only "is the light working?" — it asks whether the complete AGL system is physically correct, electrically healthy, mechanically secure, optically compliant and operationally reliable. That is the difference between basic inspection and engineering verification.

Standards & References

Standards & References

AGL testing and inspection should always be based on the current applicable edition of the relevant requirements. Exact test values, tolerances and frequencies should not be assumed universally.

ICAO

Annex 14 and applicable ICAO aerodrome guidance.

FAA

AC 150/5340 series, equipment specifications & maintenance guidance.

IEC / IS

Applicable IEC standards and Indian Standards; DGCA requirements.

Project

Airport-specific specifications, manufacturer procedures & approved ITP/drawings.

Test Yourself

Quick Knowledge Check

Q1. Which statement best captures the AGL testing philosophy?

A. If the light is ON, it has passed
B. Only electrical values matter
C. Measurement + Requirement + Result = Engineering Verification
D. Photometry is only needed at commissioning

Q2. A circuit is electrically healthy but a fixture is misaligned. Which test is most likely to catch this?

A. Insulation resistance test
B. Photometry / alignment verification
C. Continuity test
D. Earth resistance test

Q3. What is the correct sequence after a defect is identified?

A. Cause investigation → corrective action → inspection → re-test → close defect
B. Close defect → investigate cause
C. Replace the component immediately, no re-test needed
D. Record the defect and take no further action
Explore More

AGL Testing & Inspection Knowledge Hub

AGL Electrical Testing

Cable, transformer, CCR and circuit testing.

AGL Insulation Resistance Testing

Understanding insulation testing and interpretation.

AGL Cable Testing

Continuity, insulation and fault investigation.

AGL CCR Testing

Output current, steps, control and monitoring.

AGL Transformer Testing

Isolation transformer inspection and verification.

AGL Connector Inspection

Primary and secondary connector quality checks.

AGL Fixture Inspection

Elevated and inset fixture inspection.

AGL Photometry

Quantitative verification of optical performance.

Open guide →

AGL Alignment Verification

Checking fixture and PAPI alignment.

AGL Acceptance Testing

Final verification before handover.

AGL Inspection Checklists

Structured field inspection forms.

AGL Troubleshooting Engine

Diagnosis after abnormal test results.

Summary

Final AGL Testing Model

INSPECT

Find visible and physical defects.

TEST

Measure electrical and system parameters.

MEASURE

Verify optical performance.

COMPARE

Evaluate against the applicable requirement.

RECTIFY

Correct the identified defect.

RE-TEST

Confirm corrective action.

RECORD

Create traceable engineering evidence.

VERIFY

Confirm final system performance.

Inspect the installation. Test the circuit. Measure the light. Verify the system. Document the result.

Inspect → Test → Measure → Compare → Rectify → Re-Test → Record

Inspect. Test. Verify.

AGL Testing & Inspection turns visible and measured evidence into engineering verification. Explore the principles, test methods, checklists and standards.

AGL Engineering Hub

Explore the AGL Engineering Knowledge Hub

Fundamentals

Standards & Compliance

Runway, Taxiway & Approach Lighting

Surface Movement & Safety

PAPI

Electrical Engineering & Power

Photometry & Testing

Maintenance, Inspection & Safety

Resources, Documentation & Careers

FAQ

Frequently Asked Questions

Q1What is AGL testing and inspection?

AGL inspection is the systematic examination of equipment, installation, components and physical conditions. AGL testing is the measurement or functional verification of defined electrical, mechanical, optical or operational parameters. Together they confirm the system is installed correctly, electrically healthy, mechanically sound and capable of providing the required visual performance.

Q2What are the four dimensions of AGL verification?

Electrical, mechanical, optical and operational. Electrical asks whether the electrical system is healthy, mechanical whether the installation is secure and correctly positioned, optical whether the light produces the required visual performance, and operational whether the complete system operates and responds correctly.

Q3What is the recommended AGL testing sequence?

A useful hierarchy runs from visual inspection and mechanical inspection through electrical testing, functional testing, alignment verification, photometry, system testing and final inspection, and ends with documentation. The sequence helps prevent unnecessary energization of defective equipment.

Q4When should AGL testing be performed?

Exact frequency should follow the applicable airport maintenance program, standards and project requirements. Testing may be required at material receipt, installation, pre-energization, commissioning, acceptance and periodic maintenance, and after equipment replacement, cable repair, major construction, severe weather, suspected lightning damage or abnormal operational performance.

Q5Why inspect equipment before installation?

Testing starts before installation. Incoming fixtures, transformers, CCRs, connectors, cables, PAPI units, signs and control equipment should be checked for correct model, rating, quantity, accessories, physical damage, manufacturing defects, identification, certification, packaging and storage condition.

Q6What does a visual inspection check?

Visual inspection is the first line of AGL quality control and should be documented rather than treated as an informal walk-through. It looks for broken housings, cracks, corrosion, loose hardware, missing covers, damaged lenses, dirty optics, water ingress, cable and connector damage, incorrect installation, missing identification and physical obstruction.

Q7What electrical tests are used in AGL verification?

Electrical testing can include continuity, insulation resistance, voltage, current, circuit resistance, transformer verification, earth continuity, earth resistance where applicable, CCR output and control circuit testing. The exact method and acceptance value must come from the applicable equipment standard, manufacturer instructions and project specification.

Q8What is the difference between a continuity test and an insulation resistance test?

A continuity test verifies that the intended electrical path is complete, for example CCR to cable to transformer to connector to fixture and back. An insulation resistance test can identify moisture, damaged insulation, cable deterioration, ground leakage, incorrect termination and connector problems, and should be performed using the specified test voltage.

Q9Why can an AGL system look normal while having an underlying defect?

AGL systems face moisture, water ingress, temperature variation, lightning, cable deterioration, mechanical impact, vehicle movement, aircraft blast, vibration, corrosion, connector deterioration, optical contamination and equipment ageing. Testing helps identify problems before they become operational failures.

Q10What should be recorded during AGL testing?

Every inspection and test should be recorded so system condition and performance can be demonstrated, trended and defended. For a continuity test, record the circuit number, test points, test instrument, measured result, acceptance criterion and pass or fail.

Q11How to measure insulation resistance in AGL?

Isolate and de-energise the circuit under your site's permit-to-work, lock it out and disconnect the CCR and any equipment the procedure says to disconnect. Use a calibrated insulation resistance tester at the test voltage set by your specification and the cable rating. Connect between the conductor and earth, apply the voltage for the specified time, then read and record the value with the date, circuit and conditions. Discharge the circuit afterwards. Compare the result with the acceptance limit and with earlier readings, and treat a low or falling reading as a defect to investigate.

Field Insight

Engineering & Expert Notes

Visual Inspection Still Finds Many Defects
Visual

Damaged seals, loose fixings and contamination are often visible. Allow time for careful observation before instruments come out.

Insulation Tests Need Proper Preparation
Electrical

Isolate and discharge circuits, choose the correct test voltage for the equipment, and record temperature and conditions.

Compare Readings With History
Trending

A passing number can hide a downward trend. Compare against previous results as well as the acceptance limit.

Verify Optical Performance Where Required
Photometry

Electrical acceptance does not prove light quality. Include photometric and alignment checks in the scope.

Define Pass and Fail Criteria Before Testing
Criteria

Agree acceptance values and responsibilities in advance so results are interpreted consistently.

File Reports Where the Next Team Can Find Them
Records

Test reports are most valuable years later during fault finding. Store them with clear identifiers and revision control.

Precision AGL Academy

Understand AGL. Build Your Engineering Skills.

You now understand how testing and inspection verify that AGL systems perform correctly — electrically, photometrically, mechanically and operationally.

Take the next step with Precision AGL Academy.

Learn AGL Step by Step

Build your knowledge through structured technical learning covering:

AGL Fundamentals Components Electrical Systems Design Photometry Testing Troubleshooting Maintenance

Move from understanding how AGL works to developing the practical knowledge needed to analyse, operate and maintain complete AGL systems.

Understand the system. Build the knowledge. Apply the engineering.