Driver / Ballast
Electrical interface where the existing supply arrangement requires a compatible driver or ballast for LED operation.
View Details AGL Retrofit & Replacement
AGL LED Retrofit Module
Modernise compatible existing fixtures without replacing the complete assembly
LED retrofit modules provide a route to modernise compatible existing lighting equipment using a compatible LED light source and electrical interface. Compatibility with the existing fixture, optics, supply and mechanical arrangement is confirmed before replacement.
Supplied by Precision AGL Solutions
Introduction
AGL LED Retrofit Module
What It Is
LED retrofit modules provide a route to modernise compatible existing lighting equipment without necessarily replacing the complete fixture assembly.
The AGL LED Retrofit Module is intended for refurbishment and lifecycle replacement applications where an existing airfield lighting fixture can be upgraded using a compatible LED light source and associated electrical interface.
Compatibility First
Retrofitting can help extend the useful service life of existing equipment while providing a controlled approach to LED conversion.
Compatibility between the module and the existing fixture, optics, electrical supply and mechanical arrangement should be confirmed before replacement.
Applications
Where LED Retrofit Modules Are Used
Lighting refurbishmentAirfield lighting refurbishment.
Existing fixture upgradesExisting fixture LED upgrades.
Energy-efficiency projectsEnergy-efficiency improvement projects.
Lifecycle replacementPlanned lifecycle replacement.
Obsolete lampsObsolete lamp replacement.
Maintenance-driven upgradesMaintenance-driven fixture upgrades.
Airport rehabilitationAirport lighting rehabilitation.
Phased conversionPhased LED conversion programs.
Conventional sourcesReplacement of compatible conventional light sources.
Key Features
Designed for Compatible Existing Equipment
- Designed for compatible existing airfield lighting equipment
- LED-based replacement route for selected conventional light sources
- Supports fixture refurbishment without necessarily replacing the complete assembly
- Compatibility-based mechanical and electrical interface
- Controlled optical output for the intended fixture application
- Reduced reliance on conventional replacement lamps where applicable
- Suitable for planned lifecycle replacement programs
- Supports phased airfield lighting upgrades
- Compact design for integration within compatible equipment
- Selection based on existing fixture model and configuration
Technical Data
Typical Requirements
| Parameter | Typical Requirement |
|---|---|
| Compatibility | Selected according to existing fixture model, lamp arrangement and optical configuration |
| LED Rating | Selected according to required light output and fixture application |
| Optical Output | Designed to provide the required optical performance within the compatible fixture |
| Electrical Interface | Compatible with the existing fixture electrical arrangement where specified |
| Circuit Compatibility | Series (constant-current) or parallel circuit; transformer rating, loading and power factor reviewed |
| Brightness-Step Response | Intensity follows the required ratios at each regulator step |
| Colour | Within Annex 14 / FAA chromaticity limits for the fixture application |
| Dimensions | Selected to suit the available fixture and mounting arrangement |
| Certification | Converted fixture shown to meet the applicable fixture specification |
| Thermal Characteristics | Designed for LED operating conditions within the applicable fixture enclosure |
| Environmental Performance | Suitable for the intended airfield operating environment |
| Installation | Retrofit installation into compatible existing equipment |
Retrofit Compatibility
The Most Important Selection Consideration
The Existing Fixture Should Be Assessed For
- Fixture manufacturer and model
- Existing lamp type
- Lamp rating
- Optical system
- Lamp holder or mounting arrangement
- Electrical supply
- Internal wiring
- Available installation space
- Heat dissipation arrangement
- Environmental sealing
- Existing control or monitoring interface
Not a Universal Replacement
A retrofit module should not be treated as a universal replacement for every existing fixture.
The existing fixture model and configuration should be provided for compatibility review before ordering.
LED Light Source
Solid-State Source for Compatible Equipment
Module Selection
The LED module is selected according to the intended fixture application, required optical output and existing equipment configuration.
It should operate within its specified electrical and thermal conditions to maintain stable performance.
Optics Still Matter
Where the retrofit replaces a conventional lamp, the optical characteristics of the original fixture should also be considered.
A mechanically compatible LED module is not necessarily suitable if the resulting optical distribution does not meet the requirements of the application.
Coloured fixtures need extra care: an LED spectrum differs from a filament, so the same filter can shift the colour outside the limits of ICAO Annex 14 Appendix 1.
Optical Compatibility
Evaluate the LED Source Against the Existing Optics
Compatibility Review May Consider
- Light source position
- Emitting area
- Beam distribution
- Colour output and chromaticity (LED spectrum through the existing filter)
- Intensity at each brightness step
- Optical alignment
- Existing reflector or lens
- Filter arrangement
- Required viewing angles
- Fixture application
Why It Matters
Airfield lighting fixtures are designed around specific optical arrangements, including reflectors, lenses, filters and other optical components.
The review helps ensure the module is appropriate for the existing fixture rather than simply replacing the original lamp on a physical basis.
Electrical Interface
Compatible with the Existing Equipment
The Review May Include
- Supply voltage
- Current requirements
- Series-circuit current, isolating-transformer rating and brightness-step range
- Existing driver or ballast
- Electrical noise and interference from the LED driver
- Behaviour if the module fails (open or short)
- Lamp circuit configuration
- Connector arrangement
- Internal wiring
- Monitoring requirements
- Protection and control equipment
Driver / Ballast
Where an existing driver or ballast is not suitable for LED operation, an appropriate Driver / Ballast or associated electrical interface may be required.
In a series circuit the LED load is lower than the original lamp, which changes circuit loading and power factor and can affect regulator performance and lamp-out monitoring. Assess the whole circuit, not the fixture alone. A filament lamp and an LED module respond differently to the 3- or 5-step current settings, so the driver must make light output follow the required intensity ratio at every step. Mixing LED and incandescent fixtures on one circuit, or in one approach-light bar, needs separate review.
Thermal Characteristics
Manage Heat as Part of the Retrofit
Compatibility Review May Include
- Available mounting surface
- Heat transfer path
- Internal fixture temperature
- Module operating temperature
- Enclosure configuration
- Ventilation or heat dissipation provisions
Operating Range
LED modules convert electrical energy into light and heat, making thermal management an important part of retrofit design. The existing fixture enclosure, mounting arrangement and heat dissipation path should be considered.
Install in accordance with the applicable product and fixture requirements so the LED module operates within its intended temperature range.
Mechanical Integration
Secure Fit and Correct Optical Relationship
Mechanical Considerations
- Mounting dimensions
- Fixing points
- Internal clearances
- Lamp position
- Connector access
- Optical alignment
- Existing covers and seals
- Service accessibility
Identify Modifications Early
The module should fit securely within the existing fixture and maintain the intended relationship between the light source and optical components.
Where fixture modifications are required, they should be identified during the compatibility review rather than assumed during field installation.
Environmental Performance
Suitable for the Fixture's Operating Environment
Selection Should Consider Exposure To
- Rain and moisture
- Temperature variation
- Dust and contamination
- Vibration
- UV exposure
- Routine maintenance activity
Protection and Sealing
Retrofit components must be suitable for the outdoor environment in which the fixture operates.
The installation should preserve the applicable environmental protection and sealing characteristics of the original fixture wherever required.
Energy-Efficiency Upgrades
Replacing Compatible Conventional Sources
Efficiency Programs
LED retrofit modules can support energy-efficiency improvement programs by replacing compatible conventional light sources with LED technology.
The actual energy benefit depends on the existing lamp, LED module, fixture configuration, operating hours and electrical system.
Phased Implementation
For large airfield installations, retrofit programs can be implemented in phases based on fixture condition, maintenance requirements and operational priorities.
Lifecycle Replacement
An Alternative to Complete Fixture Replacement
Useful Where
- Existing fixture housings remain serviceable
- Replacement lamps are becoming difficult to source
- Existing equipment requires refurbishment
- A phased LED upgrade is preferred
- Complete fixture replacement is not immediately required
- Maintenance teams want to standardise replacement components
Assess the Fixture
Retrofit modules suit cases where existing equipment remains mechanically and optically suitable for continued service.
The condition of the existing fixture should always be assessed before deciding between retrofit and complete equipment replacement.
Installation Considerations
Identify and Check Before Installation
Important Considerations
- Existing fixture model
- Existing lamp specification
- Electrical supply
- Driver or ballast arrangement
- Optical configuration
- Mechanical fit
- Thermal conditions
- Connector compatibility
- Environmental sealing
- Maintenance access
After Installation
The existing fixture should be identified and checked against the proposed retrofit module before installation.
Afterwards, check for correct mechanical assembly, electrical operation and optical alignment as applicable.
Maintenance & Inspection
Part of the Normal Inspection Program
Maintenance Checks May Include
- Correct operation
- Light output
- Physical condition
- Mounting security
- Electrical connections
- Connector condition
- Signs of overheating
- Moisture ingress
- Optical cleanliness
- Fixture alignment
Abnormal Conditions
LED retrofit installations should be included within the normal airfield lighting inspection and maintenance program.
Any abnormal operating condition should be investigated before continued service.
Replacement & Rehabilitation
When Fixture Bodies Remain Suitable
Staged Replacement
LED retrofit modules are particularly useful during rehabilitation where existing fixture bodies remain suitable but the installed light source requires replacement or modernisation.
They can support staged programs in which compatible fixtures are upgraded during scheduled maintenance rather than removed solely because of conventional lamp availability.
When to Replace the Fixture
Where fixture condition is poor or compatibility cannot be established, complete fixture replacement may be more appropriate.
Compatibility Review
Information to Provide
- Manufacturer
- Fixture model
- Existing lamp type and rating
- Fixture photographs
- Electrical supply information
- Existing driver or ballast details
- Optical configuration
- Quantity of fixtures
- Current application and location
This allows the retrofit arrangement to be evaluated against the existing equipment rather than relying on a generic LED replacement.
Safety
Electrical Safety — Isolation and Lock-Out
WARNING — never open a live series circuit. An open series circuit driven by a constant-current regulator can produce dangerously high voltage. Opening, cutting or disconnecting any part of an energised circuit can cause serious injury or death and damage equipment.
- De-energise the circuit at the regulator and apply the site lock-out / tag-out (LOTO) procedure before any work
- Where the circuit must be isolated or shorted, use the series circuit cut-out switch or approved isolation device — not an improvised bypass
- Verify the circuit is de-energised and the output is isolated before touching conductors, connectors, splices or transformers
- Work only under the airport's permit-to-work system, using qualified personnel and the manufacturer's instructions
- Follow the applicable national electrical safety regulations and site procedures
Standards & References
A Retrofit Must Still Meet the Fixture Requirement
Principal References
- FAA Engineering Brief 67 (light sources other than incandescent and xenon for airport and obstruction lighting fixtures)
- FAA AC 150/5345-53D (Airport Lighting Equipment Certification Program)
- FAA AC 150/5345-46F (runway and taxiway light fixtures)
- FAA AC 150/5345-47C (isolation transformers)
- ICAO Annex 14 Vol. I, Chapter 5 and Appendices 1 and 2 (light colours and light characteristics)
- ICAO Doc 9157 Aerodrome Design Manual, Parts 4 and 5
- DGCA India CAR Section 4 and airport authority specifications
Use the edition current at the time of your project.
Verify the Converted Fixture
An LED module changes the light source, its relationship to the optics and the electrical load. The converted fixture should be shown to meet the required intensity, beam distribution and colour for its application, and the series circuit should be re-checked for loading, power factor and monitoring.
Where equipment must be certified (for example FAA-funded projects), fitting a module can take the fixture outside its original approval. Confirm with the airport authority that the converted fixture is accepted, and ask for test evidence.
FAQ
AGL LED Retrofit Module — Frequently Asked Questions
What is an AGL LED retrofit module?
An LED retrofit module is a route to modernise compatible existing airfield lighting equipment, using a compatible LED light source and electrical interface, without necessarily replacing the complete fixture assembly. It is intended for refurbishment and lifecycle replacement, where the existing fixture can be upgraded and its useful service life extended.
Is an LED retrofit module a universal replacement?
No. A retrofit module should not be treated as a universal replacement for every existing fixture. The existing fixture model and configuration should be provided for compatibility review before ordering, so that the retrofit arrangement is evaluated against the actual equipment rather than relying on a generic LED replacement.
What is assessed on the existing fixture?
The review covers the fixture manufacturer and model, the existing lamp type and rating, the optical system, the lamp holder or mounting arrangement, the electrical supply, internal wiring, available installation space, heat dissipation, environmental sealing and any existing control or monitoring interface. LED modules produce heat as well as light, so the mounting surface, heat transfer path and internal fixture temperature also matter.
Why do the optics and colour need checking?
A mechanically compatible LED module is not necessarily suitable if the resulting optical distribution does not meet the requirements of the application. The review considers light source position, emitting area, beam distribution, colour and intensity at each brightness step. Coloured fixtures need extra care: an LED spectrum differs from a filament, so the same filter can shift the colour outside the limits of ICAO Annex 14 Appendix 1.
How does an LED retrofit affect a series circuit?
In a series circuit the LED load is lower than the original lamp, which changes circuit loading and power factor and can affect regulator performance and lamp-out monitoring. Because a filament lamp and an LED respond differently to the 3- or 5-step current settings, the driver must make light output follow the required intensity ratio at every step. Mixing LED and incandescent fixtures on one circuit, or in one approach-light bar, needs separate review.
Is a driver or ballast needed?
Where an existing driver or ballast is not suitable for LED operation, an appropriate driver, ballast or associated electrical interface may be required. The review should also consider supply voltage, current, electrical noise and interference from the LED driver, and the behaviour of the module if it fails open or short.
What should be checked on 50 Hz series circuits in India?
Confirm the circuit frequency and transformer type, since 50 Hz circuits use the L-831 and a 60 Hz L-830 is not an equivalent substitute. Work out the new total circuit load, because lower-wattage LED units can fall below the regulator minimum load or regulation range, and avoid leaving a large transformer lightly loaded. Check circuit current at every brightness step, confirm compatibility with existing lamp-out or circuit monitoring, and record before-and-after readings at handover.
Does a retrofitted fixture still need to meet the fixture requirement?
Yes. The converted fixture should be shown to meet the required intensity, beam distribution and colour for its application, and the series circuit should be re-checked for loading, power factor and monitoring. Where equipment must be certified, for example on FAA-funded projects, fitting a module can take the fixture outside its original approval, so confirm with the airport authority that the converted fixture is accepted and ask for test evidence.
When is a retrofit better than replacing the whole fixture?
A retrofit suits cases where existing fixture housings remain serviceable, replacement lamps are becoming difficult to source, and a phased LED upgrade is preferred. Where fixture condition is poor or compatibility cannot be established, complete fixture replacement may be more appropriate.
What information is needed for a compatibility review?
Provide the manufacturer, fixture model, existing lamp type and rating, fixture photographs, electrical supply information, existing driver or ballast details, optical configuration, quantity of fixtures and the current application and location.
Is it safe to retrofit a fixture on an energised series circuit?
No. An open series circuit driven by a constant-current regulator can produce dangerously high voltage, and opening, cutting or disconnecting any part of an energised circuit can cause serious injury or death. De-energise the circuit at the regulator, apply the site lock-out / tag-out procedure, use the series circuit cut-out switch or an approved isolation device and work under the permit-to-work system. See the electrical safety warning on this page.
50 Hz Series Circuits (India): Check Before You Order
Indian airfield series circuits run from a 50 Hz supply. Replacing lamps or fixtures changes the load on the regulator and transformers, so check the whole circuit, not only the new unit.
- Confirm the circuit frequency and the transformer type. 50 Hz circuits use the L-831; a 60 Hz L-830 is not an equivalent substitute.
- Work out the new total circuit load. Lower-wattage LED units can fall below the regulator's minimum load or regulation range; confirm limits with the CCR manufacturer.
- Do not leave a large transformer lightly loaded. Match the transformer rating to the new fixture load.
- Check circuit current at every brightness step after the change, including the regulator's current tolerance.
- Confirm compatibility with existing lamp-out or circuit monitoring.
- Record before-and-after readings (circuit current, secondary current, insulation resistance) at handover.
Procurement Information for Indian Projects
Indian public tenders commonly ask for the documents below. State which ones your tender requires when you send the enquiry, so they are covered in the quotation.
- Manufacturer / OEM authorisation
- Country of origin and local-content declaration (for Make in India purchase preference)
- Type-test and routine-test certificates, and the FAA / ICAO / IEC compliance documents named in the specification
- Datasheets, drawings and installation instructions
- Warranty, delivery period and spares support
- GeM catalogue or tender-portal requirements, where applicable
Share Fixture Model for Compatibility Review
Precision AGL Solutions can support LED retrofit selection based on the existing fixture model, lamp configuration and installation requirements. Share your existing fixture model for a retrofit compatibility review.
Share the fixture manufacturer, model, lamp type, supply details and quantity for review.
- Emailprecisionaglsolutions@gmail.com
- Websiterahulsharmaagl.in
- LinkedInPrecision AGL Solutions
- Phone+91 98214 96412
Product Disclaimer
Product availability, configuration, dimensions, electrical characteristics, photometric performance, certifications and compliance status depend on the selected manufacturer and project specification. The technical values published on this page should not be treated as a substitute for the manufacturer's current approved Technical Data Sheet.
Final selection shall be based on the approved project specification, applicable aviation standards, authority requirements, manufacturer documentation and site conditions. Use of this page is also subject to the Legal Notice, Disclaimer & Terms of Use.
Standards and editions referenced on this site are listed on the Standards Reference page.