Elite leads the way in lightning testing with new Thermo Scientific ECAT lightning system.

Posted on: April 1st, 2009

In the U.S., direct lightning strikes to aircraft occur on average at least once per year for every commercial passenger plane. Despite their relatively frequent occurrence, lightning strikes rarely cause damage or upset to aircraft electrical systems. Credit for this robust immunity can be attributed to good engineering and design practices, as well as to rigorous systems analysis and lightning testing. But with the expanding use of electronic systems in aircraft and more composite airframe construction, the need for comprehensive lightning testing has become even more important to ensure reliable and safe airline travel.

While certain external aircraft systems are required to be evaluated for direct lightning effects, almost all aircraft electronics (internal and external) are tested to evaluate the indirect effects of lightning. The indirect effects are the secondary currents and voltages which develop on cabling and electronic circuitry as a result of the primary lightning currents passing along the skin and frame of the aircraft. Indirect lightning effects are applied via direct contact pin injection, or transformer coupled to cable bundles, as well as through equipment ground leads.

Elite Electronic Engineering has long recognized the importance of indirect effects lightning testing. Beginning as early as 1960, Elite engineers developed surge pulses using custom networks consisting of arrangements of resistors, capacitors, and inductors. Surge testing was further enhanced in the 1980’s and 90’s using commercial surge generators and wave shaping plug-in modules.

As customer demands for more stringent testing exceeded the capabilities of Elite’s commercial equipment, staff lightning experts at Elite developed surge generators to deliver the evolving pulse waveforms and higher test levels. In 2004, Elite engineers developed two sets of lightning systems each capable of achieving the RTCA DO-160E pulses at level 5 for all waveforms.

Most recently, Elite began a collaborative working arrangement with Thermo Scientific, a manufacturer of surge test equipment. The relationship began with Elite consulting on lightning test processes as well as sharing expertise and information on the construction of Elite's lightning test equipment. This effort resulted with the development of the Thermo ECAT Lightning Test System. Elite has since purchased one of the first ECAT lighting test systems capable of achieving level 5 pulses.

Elite’s new ECAT system is designed to provide a modular test platform based on the lightning requirements of RTCA DO-160E/F Section 22. The system is expandable to meet Boeing, Airbus, EUROCAE, SAE, and other special requirements, and because of its modular configuration can be easily upgraded as test standards change.

This new test system features single-stroke, multiple-stroke, and multi-burst testing on all waveforms to Level 5, including Waveforms 3H and 6H for multi-burst testing. Test waveforms for composite aircraft, which include Waveform 5B, are also available.

With its fully-automated test operations, the ECAT system provides fast test setup, intuitive programming, built-in voltage and current monitoring, and front panel and remote computer control. Since arriving at Elite in February 2009, the ECAT system has streamlined test processes and has quickly demonstrated its ability to provide more efficient, repeatable, and accurate test results.

Today, Elite stands above all other laboratories as a leader in indirect lightning testing services. In addition to having three sets of Level 5 lightning equipment, Elite supports client test needs with highly experienced EMC personnel. Elite’s staff have extensive knowledge of the standards and test methods and they bring years of experience to correctly apply lightning test pulses. Our recognized industry experts provide guidance on the latest lightning test requirements and are available to prepare test procedures and test plans along with engineering consulting to support qualification programs.

For additional information on Elite’s lightning services, contact our sales staff at 1-800-ELITE-11 or email us at sales@elitetest.com

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