3939 Mississippi Ave Cahokia, IL 62206-1043 Phone (618) 337-7800 Fax (618) 337-7976 U.S. PATENT NO. 5,647,658 Report No. INSTALLATION OPERATION MAINTENANCE MANUAL, FIBER OPTIC LIGHTING SYSTEM, SERIES AV11009 P/N AV51003 P/N AV51004 P/N AV51005 P/N AV51006 P/N 04-07-0001-XXX-YYY-ZZZ PROPRIETARY STATEMENT These technical data and the designs disclosed herein are the exclusive property of Avtec Inc. or contain proprietary rights of others and are not to be used or disclosed to others without the written consent of Avtec Inc. The recipient of this document, by its retention and use agrees to hold in confidence the technical data and design contained herein. The foregoing shall not apply to persons having proprietary rights to such technical data or such designs to the extent that such rights exist. Revision: H i
List of Effective Pages i iii 1 14 REVISION STATUS Revision Description Date Approved By N/C Original Release 20JUN98 WJZ Dir. Of Engineering A Changed Pages i, ii, 1, 2, 5, 6 and 7 16JUL98 WJZ Dir. Of Engineering B Changed Pages ii, 3 and 7 23JUL98 WJZ Dir. Of Engineering C Changed Pages ii, 4 and 7 03SEP98 JRCC Auth. Inspector D Changed Page 7 27OCT98 JRCC Auth. Inspector E Changed Pages i, ii, iii, and 1-7 Added Pages 8-13 11AUG99 W. J. Ziadi F Changed All Pages N/A Not Circulated G Changed All Pages 03DEC99 W. J. Ziadi H Changed Pages 6-8 and 14, Dwg # 05-02-0003 20MAR00 Revision: H ii
TABLE OF CONTENTS PARAGRAPH TITLE PAGE 1.0 Scope 1 2.0 General Description and Specifications 1 3.0 Product Specifications 2 4.0 FAR Compliance 3 5.0 RTCA DO-160C/D Environmental Qualification 4 6.0 Installation Instructions 6 7.0 Electrical Connections To Lighting System 9 8.0 Operation And Control 10 9.0 Maintenance And Continued Airworthiness 11 10.0 Troubleshooting 12 11.0 Lamp Replacement Procedure 13 Appendix A 14 Revision: H iii
1.0 SCOPE This document provides installation and application data for the AV11009 Fiber Optic Lighting System. Aircraft installations are to be in accordance with FAA Acceptable Methods, Techniques, and Practices. 2.0 GENERAL DESCRIPTION AND SPECIFICATIONS The Fiber Optic Lighting System, Series AV11009, is intended to provide aircraft cabin lighting, indirect upwash / downwash, galley and accent lighting. The Fiber Optic Lighting System is non-required electrical equipment and AC25-10 applies. The system is not to provide emergency egress lighting. Aircraft power to the system is controlled by dedicated resettable circuit breakers. If the Illuminator fails the 5 amp (AV51003 and AV51005) or 2 amp (AV51004 and AV51006) circuit breaker will open, thus isolating the failed unit from any aircraft power connections. The lighting system consists of the following. Illuminator: The illuminator assemblies house the lamp, ballast, cooling fan (AV51005, AV51003, AV51004 and AV51006), color wheel stepper motor, and stepper motor controller (AV51003 and AV51004). The 60-watt lamp is sealed and features a 30 second initial start up time with immediate restart capabilities following a power interruption. The ballast provides the lamp with a regulated DC output to drive the lamp (60 VDC at 1 amp) and a 27KVDC pulse for start-up. The stepper motor controller provides a regulated phased output to drive the color wheel stepper motor. The Illuminator is continuously cooled by a 28 VDC fan (AV51003 and AV51005) or a 12VDC fan (AV51004 and AV51006). Fiber Assembly: The Fiber Assembly is made up of five parts, the fiber, the quartz, the focusing head assembly, the End Cap and the lead-in heat shrink. The fiber is a continuous piece comprised of two sections, the Lead-In section and the illuminated section. The Lead-In section is covered by the Lead-In heat shrink to prevent light loss and then terminated with the quartz and the focus head assembly P/N 04-03-0001, which is inserted into the illuminator. The illuminated section provides light along its entire length and is terminated with an End Cap. The fiber has a minimum allowable bend radius of 4.0 inches. Revision: H 1
3.0 PRODUCT SPECIFICATIONS 3.1 General Avtec, Inc. AV51003 and AV51005 are designed to operate from an input voltage of 28VDC. AV51004 is designed to operate from an input voltage of 115VAC (ballast) and 28VDC (color wheel). AV51006 is designed to operate from an input voltage of 115VAC. Ballast incorporates an on board slow-blow fuse which protects the ballast if excess current is flowing in the circuit. Ballast incorporates a thermal switch which protects the illuminator if an over heat situation occurs. Ballast incorporates Arc to Ground technology, which protects the ballast if an arc to ground occurs. Lamp life is rated at 4,000 hours. The Illuminator should be mounted with the arrow facing up and the receptacle facing down, refer to Figure 3. Install the system per installation instructions, see section 6.0. 3.2 Electrical Characteristics MODEL SYSTEM P/N MINIMUM VOLTAGE MAXIMUM VOLTAGE NOMINAL VOLTAGE NOMINAL AMPERAGE MAXIMUM STEADY STATE AMPERAGE Spectrum 1 AV51005 22.0 VDC 30.3 VDC 27.5 VDC 3.00 A 3.3 A Spectrum 4 Spectrum 1 AV51003 22.0 VDC 30.3 VDC 27.5 VDC 3.15 A 3.4 A AV51006 100.0 VAC 122.0 VAC 115.0 VAC 1.0 ARMS 1.25 ARMS Spectrum 4 AV51004 100.0 VAC 22.0 VDC 122 VAC 30.3 VDC 115.0 VAC 27.5 VDC 1.0 ARMS 130 ma 1.25 ARMS 200 ma The above input voltages assume the Fiber Optic Lighting System operating at a room temperature of 25 C, 65% RH, at sea level. Normal operating and storage temperatures are 15 C through +70 C Revision: H 2
4.0 FAR COMPLIANCE FAR Paragraph Subject Method of Compliance 25.301 (a),(b) Loads. A 25.303 Factor of safety. A 25.305 (a),(b),(c) Strength and deformation. A 25.307 (a) Proof of structure. A 25.333 (a) Flight envelope. A 25.561 (a),(c) Emergency Landing Conditions, General. A 25.853 (a) Compartment Interiors. T 25.869 (a) Fire protection systems. D,T 25.1301 Function and Installation D 25.1353 (a) Electrical equipment and installations. D,T 25.1357 (a),(c) Circuit Protective Devices. D 25.1431 Electronic equipment. D The method of compliance includes, Drawings (D), Analysis (A), or Tests (T). To meet FAR 25.1301 and other applicable FAR s, the systems was tested to RTCA DO-160C and RTCA DO-160D. Section 5.0 shows the RTCA DO-160C/D tests that were accomplished on specific Illuminator part numbers. Revision: H 3
5.0 RTCA/DO-160C/D ENVIRONMENTAL QUALIFICATION 5.1 RTCA/DO-160C Environmental Qualification NOMENCLATURE (P/N): SYSTEM COMPONENTS: LABORATORY: Fiber Optic Lighting System Series AV11009 (1) ILLUMINATOR, P/N AV51003 (By Test) (1) ILLUMINATOR, P/N AV51005 (By similarity) RADIOMETRICS 55 West 22nd Street, Suite 106 Lombard, IL 60148 FAA Test Date: August 27, 1998 CONDITIONS SECTION DESCRIPTION OF CONDUCTED TESTS CONDUCTED RF INTERFERENCE 21.3 CATEGORY Z RADIATED RF INTERFERENCE 21.4 CATEGORY Z 5.2 RTCA/DO-160D Electrical Qualification NOMENCLATURE (P/N): SYSTEM COMPONENTS: LABORATORY: Fiber Optic Lighting System Series AV11009 (1) ILLUMINATOR, P/N AV51004 (By Test) (1) ILLUMINATOR, P/N AV51006 (By similarity) RADIOMETRICS 12 East Devonwood Romeoville, IL 60446 Witnessed Test Date: July 26, 1999 CONDITIONS SECTION DESCRIPTION OF CONDUCTED TESTS MAGNETIC EFFECT 15.0 CATEGORY B POWER INPUT 16.0 CATEGORY A VOLTAGE SPIKE 17.0 CATEGORY A AUDIO FREQ. CONDUCTED SUSCEPTIBILITY 18.0 CATEGORY Z INDUCED SIGNAL SUSCEPTIBILITY 19.0 CATEGORY Z RADIO FREQ. SUSCEPTIBILITY 20.0 CATEGORY U EMISSION OF RADIO FREQ. ENERGY 21.0 CATEGORY M 5.3 RTCA/DO-160D Environmental Qualification Revision: H 4
NOMENCLATURE: SYSTEM COMPONENTS: LABORATORY: Fiber Optic Lighting System Series AV11009 (1) ILLUMINATOR, P/N AV51004 (By Test) (1) ILLUMINATOR, P/N AV51006 (By similarity) Trace Laboratories 1150 West Euclid Avenue Palatine, IL 60067 Witnessed Test Date: July 26, 1999 CONDITIONS SECTION CATEGORY TEMPERATURE & ALTITUDE 4.0 CATEGORY A1 TEMPERATURE VARIATION 5.0 CATEGORY C HUMIDITY 6.0 CATEGORY B OPERATIONAL SHOCKS & CRASH SAFETY 7.0 CATEGORY B VIBRATION 8.0 CATEGORY S 5.4 Additional Testing Nomenclature (P/N): System Component: Testing Laboratory: Lumenyte Intl. Corp. FB-R Fiberescent Optical Fiber with round core OPTICAL FIBER AVTEC, INC. 18 Mark Allen Drive Sauget, IL 62206 Witnessed Test Completion: February 21, 1996 FAR Paragraph Subject Test 25.853 (a) Compartment Interiors. 12 Second Vertical Burn Revision: H 5
6.0 INSTALLATION INSTRUCTIONS Avtec, Inc. 6.1 General Layout The installation should be accomplished per acceptable methods, techniques and practices, found in FAA Advisory Circular AC43.13-1B. Before starting the installation, it is recommended that the fiber be removed from the packing box and laid out straight for at least 3 hours for ease of installation. After the fiber is straight, install the Teflon heat-shrink I.A.W. dwg # 04-07-0004 (see appendix A). Estimate the mounting location of the Fiber Assembly (P/N 04-07-0001-XXX-YYY- ZZZ) to provide the desired lighting and/or lighting effect. (See DWG # 04-07-0001 for the angle of light emission.) A straight 8 section of Lead-In from the Illuminator is required. Enough slack must be left in the Lead-In Section of the fiber assembly to be inserted into the receptacle of the Illuminator (P/N AV51003, AV51004, AV51005 or AV51006). All bends must have a radius of 4 or greater. See DWG # 05-02-0003 for details. 6.2 Illuminated Section Preparation After locating the fiber, the Illuminated Section (section with the white U - Channel backing) must be cut to the appropriate length and terminated with the supplied End Cap, P/N ES MIRROR 510. Figure 1: Typical Fiber, Single Lead-In. The fiber may have a single Lead-In or dual Lead-In s. The dual Lead-In optic has two extended Lead-In Sections and is used when an illuminator is used at both ends of the optic. Figure 1 shows a single Lead-In fiber with the 6 to 8 end tail. The end tail must be cut off prior to installation. For optic with a single Lead-In section, It is acceptable to cut up to 2 feet off the end of the Illuminated Section. To cut the fiber, use an Avtec approved cutter and cut perpendicular (90º) to the fiber at the desired length. Make sure the cut is clean and smooth. To install the End Cap (P/N ES MIRROR 510), slide the End Cap over the end of the fiber. It is not necessary to bond the End Cap to the fiber. If bonding is desired, place a small amount of glue around the inside of the End Cap after insertion of the fiber. Revision: H 6
6.3 Illuminated Section Mounting The Illuminated Section of the fiber assembly is to be secured to the interior with the Illuminated Clips (P/N 04-06-0002) I.A.W. Avtec DWG # 05-02-0003 (see Appendix A). The Illuminated Clips are to be secured to a structural member with one each #6 100 countersink screw, 60 ksi ultimate tensile strength or equivalent strength hardware. 6.4 Illuminator Mounting Ensuring that enough slack remains in the Lead-In section of the fiber assembly to insert the focusing head into the Illuminator receptacle, locate and mount the Illuminator I.A.W. DWG # 05-03-0001, with the receptacle facing downward ± 15, see Figure 2. The mounting surface chosen for the Illuminator must be shown by analysis, to have sufficient strength (with the hardware specified) to withstand the flight, ground and emergency landing conditions of the applicable regulations without failure. 15.0 Max 15.0 Max ½ Air gap) ½ Air gap) Avtec ½ Air gap) AIRFLOW ½ Air gap) UP ½ Air gap) UP Optical Fiber Figure 2: Illuminator positioning* *Recommended position for maximum lamp life. 6.5 Focus Head Assembly Once the Illuminator is securely mounted, you will need to cut any excess Lead-In Revision: H 7
off and install the Focus Head Assembly. (P/N 04-03-0001) Once cut, remove approximately 2 of the white heat shrink from the end of the Lead-In section. (CAUTION: DO NOT CUT INTO THE JACKETING OF THE FIBER.) To install the Focus Head Assembly ensure that the quartz glass rod (P/N 465-FF12-1) is inside the assembly, slide the Focus Head Assembly onto the Lead-In and tighten with a 1 and a ¾ wrench. (DO NOT OVER TIGHTEN.) (See DWG # 04-07-0004 for details.) If done correctly there will be no rattling of the quartz when shaken. 6.6 Lead-In Section Mounting Insert the Focus Head Assembly into the Illuminator and tighten the screw. Secure the Lead-In section of the fiber assembly with the Lead-In Clips (P/N MS21919WDG12) I.A.W. Avtec DWG # 05-02-0003 (see Appendix A). The first section must be straight for a minimum of 8 and must be secured with a Lead-In Clip. All bends must be smooth and secured with clamps. (Refer to DWG # 05-02- 0003 for detailed mounting instructions.) The Lead-In Clips are to be secured to a structural member with one each #10 pan head screw, 55 ksi minimum ultimate tensile strength (or equivalent strength hardware). The fiber assembly, Lead-In Clips and Illuminated Clips should be installed per FAA acceptable methods, techniques, and practices, reference AC43.13-1B. The FAA approved installation information is referenced in the Installation Drawing List for the particular Supplemental Type Certificate being used. If the installer wishes to deviate from the approved installation, the local FAA Flight Standards Office or Aircraft Certification Office should be contacted for their approval of the planned deviation/s. Revision: H 8
7.0 ELECTRICAL CONNECTIONS TO LIGHTING SYSTEM There is one electrical connection to be made to the Illuminator. Use one MS3126E12-10S connector to connect aircraft power to the Illuminator I.A.W. the appropriate Avtec drawing for the wiring diagram for your particular Fiber Optic Illuminator (05-01-0001 for AV51006, 05-01-0002 for AV51005, 05-01-0003 for AV51004, 05-01-0004 for AV51003). (See appendix A) The drawings have recommended wire type, wire size, circuit breakers and switches for your particular installation. Depending on the type of switches used during installation and the configuration of the system, one to six switches may be used for each illuminator. The system must tie into aircraft s 28 VDC or 115 VAC or both busses (depending on Illuminator type). Any aircraft buss or circuit breaker, which is being tied into, should have a load analysis done to insure that the total load is not exceeding 80% of the rated load. In addition, the Fiber Optic Lighting System should not be tied into any buss that is reserved for critical flight functions. If the new Fiber Optic Lighting System is replacing an existing system, and the old system used more power off the same bus that the new system is being tied into, then a load analysis is not necessary. WARNING High output voltage. Insure that the appropriate circuit protection devices are "open" when working on the Illuminator. Revision: H 9
8.0 OPERATION AND CONTROL Avtec, Inc. Power must be supplied to the illuminator through the installation and use of one or two (depending on Illuminator model), single pole switches, which control the ON/OFF function of the illuminator. The ON/OFF function switches that are required are as follows: AV51003 & AV51005 require the use of one 5 A single pole switch (connected through Pin A); AV51004 requires the use of two single pole switches (one 0.5 A for 28 VDC input (through Pin A) and one 1.0 ARMS for 115VAC input (through Pin J); AV51006 requires the use of one 1.0 ARMS single pole switch (connected through Pin J). Dimming is accomplished through the installation and use of two 0.5 amp - single pole/momentary switches. One switch is for control of the BRIGHT function (connected through Pin C) and one switch is for control of the DIM function (connected through Pin D). Color change is accomplished through the installation and use of three 0.5 amp - single pole switches. Each individual Color switch controls the individual COLOR function, i.e. Switch one ON (switches two and three OFF ) = MAGENTA (connected through Pin E); switch two ON (switches one and three OFF ) = YELLOW (connected through Pin F) and switch three ON (switches one and two OFF ) = BLUE. The normal WHITE/CLEAR position is obtained when switches one two and three are in the OFF position. If an integrated switch is used, configure it to break before make during each color selection. Revision: H 10
9.0 MAINTENANCE AND CONTINUED AIRWORTHINESS The Avtec are non required non essential equipment items and therefore have no effect on the airworthiness of an aircraft. With this in mind, the practice of ON CONDITION/CONDITION MONITORING applies. The concept of on condition/condition monitoring as it applies to the Avtec requires that NO system components are removed for servicing, as long as the systems output light and dimming and color change (if applicable) function correctly. The Avtec systems are designed to provide many years of safe, continuous and worry free operation. There are NO component overhaul or replacement HARD TIME limitations imposed upon any of the system components at this time. Suggested Routine Maintenance Components Maintenance Procedure Frequency Illuminators: AV51003, AV51004, AV51005, AV51006 Optical Fiber: 04-07-0001-XXX-YYY-ZZZ Verify that the Fan inlet and cooling exhaust ports are F.O.D. free. Clean as necessary. Wipe with a soft, clean cloth lightly moistened with fresh water. Prior to closing panels, after units have been exposed during performance of a routine inspection and maintenance. As required or when normal interior compartment cleaning operations are performed. Revision: H 11
10.0 TROUBLESHOOTING Avtec, Inc. The following table is provided to enable a crewmember or technician to find the cause of a failure and to correct minor defects. Defect Verification Corrective Action Item 1. Illuminator does not light Item 2. Illuminator shuts down Item 3. Dimming does not work Item 4. Color change does not work Item 5. System is dim. Light appears weak Item 6. Color of light is different between fibers. Check C/B. Turn system on and listen for high voltage arc inside the lamp. Check C/B. Wait for unit to cool down and then cycle the power switch. If unit does not restart, see item 1. Check C/B. If unit restarts after cool down period and after the power switch has been cycled, verify that the cooling fan is operating. Check switches and switch grounds from Illuminator to switch (Pins B, C & D) and grounds from switch to terminal strip. Check switches and switch grounds from Illuminator to switch (Pins E, F & G) and grounds from switch to terminal strip. Check focus head assembly for correct insertion into illuminator. Also, check for any quartz endplay between fiber and head and for any FOD in the assembly. Check focus head assembly for correct insertion into illuminator. Also, check for any quartz endplay between fiber and head and for any FOD in the assembly. Can hear arc: Lamp has failed. Replace Lamp with new. No arc heard: Internal ballast unit failed. Return Illuminator to Avtec for replacement. Cooling fan operates: Illuminator is mounted in an unventilated area. Either provide cooling air circulation or re mount the Illuminator in a ventilated area. Cooling fan has failed: Return Illuminator to Avtec for replacement. If a high resistance is found on any of the ground circuits (> 0.2 ): Remake the ground connections. If ground circuits resistance and switches are okay: Return Illuminator to Avtec for replacement. If a high resistance is found on any of the ground circuits (> 0.2 ): Remake the ground connections. If ground circuits resistance and switches are okay: Return Illuminator to Avtec for replacement. If focus head assembly is loose or there is rattle or there is FOD: Clean and tighten the assembly and correctly insert into the illuminator. If focus head assembly is okay: Replace Lamp with new. If focus head assembly is loose or there is rattle or there is FOD: Clean and tighten the assembly and correctly insert into the illuminator. If focus head assembly is okay: If installation is new, lamps may require a minimum burnin period of 2 to 3 hours before correct color is output. If the installation is existing prior to problem, replace Lamp with new. Revision: H 12
11.0 LAMP REPLACEMENT PROCEDURE The only component change that may be accomplished in the field by the user/installer of the Avtec is the Xenon Metal Halide Lamp, P/N 18043, 04-05-0002, 04-05-0003, or 04-05-0004. This lamp must be replaced I.A.W. the following procedure: Tools & Parts Required: # 1 Phillips Head Screwdriver # 2 Phillips Head Screwdriver Medium pair of Side Cutter Pliers 1 each Cable Tie Rap, P/N TY28M 1 each Replacement Lamp, P/N 18043, 04-05-0002, 04-05-0003, or 04-05-0004 Note: It is unnecessary for the Illuminator to be removed from the aircraft or the Fiber Assembly to be removed from the Illuminator to accomplish Lamp replacement. Remove the (4 each) # 1 Phillips countersunk head screws, P/N AN507C440R4 that secure the Box Lid to the Illuminator Housing Body. Carefully remove the Box Lid from the Illuminator Housing. While supporting the Box Lid with one hand, use the other hand to disconnect the Lamp Plug from the Ballast. This is accomplished by withdrawing the female (Lamp/Box Lid end) AMP plug from the male AMP connector (mounted to Illuminator Housing). Gently grasp the Lamp Assembly by its Frame between your fingers and remove the (2 each) # 2 Phillips countersunk head screws, P/N AN507C632R4 that secure the Lamp to the Assembly Box Lid. DO NOT APPLY ANY PRESSURE TO THE LAMP BASE (CERAMIC). Carefully remove the Lamp Assembly from the Assembly Box Lid. Cut and remove the cable tie rap, P/N TY28M that secures the Lamp Cable to the Lamp Holder at the Standoff. Gently grasp the Lamp Assembly by its Frame between your fingers and loosen the (2 each) Phillips pan head screws, P/N AN526C632R6 located on the back of the Lamp Assembly that hold the open ended portion of both Lamp Retaining Spring Clips, P/N 04-06-0001. Pinch both Retaining Spring Clips together and lift (enough to clear retaining screws) and rotate away from the Lamp Base. DO NOT APPLY ANY PRESSURE TO THE LAMP BASE (CERAMIC). Remove the old Lamp and install a new Lamp. DO NOT TOUCH THE GLASS FILTER INSTALLED IN THE HOLDER. If the Glass Filter is marked with fingerprints or dirt, use a lint free, clean soft rag to remove any contamination (a camera lens tissue is ideal for this operation). Re assembly and reinstallation is to be performed in reverse order of the given procedure above. DO NOT APPLY EXCESSIVE TORQUE TO ANY OF THE SCREWS. Record the new Lamp serial number and retain for your records and then return the Illuminator to service. The old lamp should be mailed to Avtec, Inc. for recycling and disposal. There is no charge for disposal. Revision: H 13
Appendix A Title Drawing Number Rev. Date Assembly, Final, ½ Fiber, P/N 04-07-0001-XXX-YYY-ZZZ 04-07-0001 D 10MAR00 Fiber Assembly/Installation Overview, ½ Fiber, P/N 04-07-0001-XXX-YYY-ZZZ 04-07-0004 C 10MAR00 Electrical Installation for 115VAC Spectrum 1 P/N AV51006 05-01-0001 B 01SEP99 Electrical Installation for 28VDC Spectrum 1 P/N AV51005 05-01-0002 B 01SEP99 Electrical Installation for 115VAC Spectrum 4 P/N AV51004 05-01-0003 B 01SEP99 Electrical Installation for 28VDC Spectrum 4 P/N AV51003 05-01-0004 B 01SEP99 Fiber Mounting Description 05-02-0003 A 10MAR00 Mechanical Outline Description Spectrum 4, 115VAC 01-03-0003 N/C --- Mechanical Outline Description Spectrum 4, 28VDC 01-03-0002 N/C --- Mechanical Outline Description Spectrum 1, 115VAC 01-04-0002 N/C --- Mechanical Outline Description Spectrum 1, 28VDC 01-04-0003 N/C --- Avtec Illuminator Mounting Description. 05-03-0001 N/C --- Revision: H 14