Download - BSI Training and Troubleshooting
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Boeing Sky Interior LED Cabin Lighting Training
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737 BSI Lighting System
- B/E Lighting Systems Overview- Contacts- Fluorescent vs. LED lighting- Description of Lights- 737 BSI Light Architecture- Attendant Control Panel- LOPA Overview - System Overview- LRU System Architecture- System Communication Overview- Troubleshooting- Generation II Lighting System Review-Document References
Agenda
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Bohemia, NY – Lighting Systems
Located ~50 miles east of New York City on Long Island.
New 60,000 sq. ft manufacturing, engineering, and administration offices.
Fully equipped FAA/EASA repair station (EO1R120K)
LED lighting used throughout offices and manufacturing space.
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Contacts
• Product Support – Lighting Systems– Contact for any lighting related technical or warranty related concerns with in-service
products• Sharon Harbauer
Global Customer Support Manager – Lighting Systems
Bohemia, NY
Office: +1-631-563-6400
Direct: +1-631-256-2175
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Contacts• Customer Service– Lighting Systems
– Contact for any lighting warranty related concerns with in-service products• Janet Rosado
Customer Service Assistant– Lighting Systems
Bohemia, NY 11716
Office: +1-631-256-2163
email: [email protected] or [email protected]
• Spares Sales– Lighting Systems– Contact for any lighting spares orders:
• Diane Spooner
Inside Sales Representative – Commercial Spares
Bohemia, NY 11716
Office: +1-256-2179
email: [email protected]
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Scope of Work
• All product and field service returns• Customer complaints• Repair Station• Warranty claims and validation• Technical Product support• Field support work – troubleshooting, upgrading, etc.• Component analysis• Trend analysis• Customer training• RSPL• AOG
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Fluorescent vs. LED Lighting
Fluorescent:•Fluorescent systems usually consist of a lighting ballast and a fluorescent bulb.•Control may include dimming functionality, but no color selection or scene selection•Maintenance is straightforward, mechanical issues only
LED:•Advanced LED lighting systems are PCB based systems with control boards that contain power and data signals.•Lighting scenes are controlled via RS485 (communication protocol) and must be addressed after removal and replacement so the light and the ACP knows where the light “lives” on the aircraft.•Maintenance requires additional steps to complete versus fluorescent, even if just a remove and replace so the replacement light is addressed and has lighting scenes downloaded to it.
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Direct Light
Direct Light (Gen I: 9500-13-0000, -0001/ Gen II: 9501-13-0000, -0001):The LED Direct Light shall supply lighting of the cabin interior beneath the forward and aft lowered ceilings. This includes entry areas, galley areas, and continuation into the main passenger cabin.
WWA
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Cove Light
Cove Light (Gen I: 9550-26-0000, -0001/ Gen II: 9551-26-0000, -0001):The Cove Light shall have a ceiling illumination component only. It will be located in the crown of the aircraft, both in the FWD and AFT ceiling coves and will provide White and Color LED lighting.
RGBW
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Ceiling Light
Ceiling Light (Gen I: 9600-XX-0000/ Gen II: 9601-XX-0000):The LED Ceiling Lights shall provide indirect light to the cabin. The Ceiling Lights shall be able to set a decorative color. One of these colors is sky blue, but other colors may be defined for specific scenes. The ceiling lights shall be mounted to the top inboard surface of the stow bin strong backs behind a valance. This LRU also includes the cross-bin lights which shall provide cabin illumination by reflecting light off the opposite stow bin face. They are replaced as an assembly.
WWARGBW
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Sidewall Light
Sidewall Light (Gen I: 9650-XX-000X/ Gen II: 9651-XX-000X):Sidewall Lights shall be mounted into the Air Conditioning extrusion located below and outboard of the stow bins and outboard of the passenger service units. The purpose of the Sidewall Light is to illuminate the side walls to give a brighter feel to the cabin.
RGBW
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Overwing Exit Light
Overwing Exit Light (Gen I: 9700-14-0000, -0001/ Gen II: 9701-14-0000, -0001):The Over-Wing Exit Down light provides white and color sidewall illuminance at the over-wing exit doors, providing an extension of sidewall lighting and in the event of an emergency situation will provide white lighting on the OWE door hatch handle via a 6VDC battery circuit.
RGBW
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Center Overhead Stowage Light
Center Stowage Light (Gen I: 9750-41-0000/ Gen II: 9751-41-0000): Center Overhead Stowage Light is mounted on the COS box and provides illumination to the stow bins on either side of the cabin.
WWA
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737 BSI Light Construction
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Typical light bar construction. Common to all BSI lighting elements.
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CONFIDENTIAL B/E Aerospace © 2014
Attendant Control Panel
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FlyDubai LOPA
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FlyDubai LOPA
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FlyDubai LOPA
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Operation:
• The attendant control panel (ACP) provides scene, zone and brightness selections for the cabin lights
• Power for the light operation is from the 115VAC ground service bus.
• Power for the overwing exit lights (when emergency power is supplied), and emergency aisle lights during is supplied via the 6VDC power supplies.
• Pass through power is fused (3A) to protect from downstream shorts
• Local power is fused (0.75A) separately
BSI System Overview
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• RS-485 parallel bus at 57,600 bps
• 10 bit word (1 start, 8 data, 1 stop)
• 400’ max bus length
• 100Ω differential impedance with end node terminations
• Token signal is isolated (floating) with a 2.7K pull up
Communication Details
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System Communications Overview
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System Communications with LOPA Overlay
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LRU Architecture
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Ceiling Light Architecture
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Ceiling Light Architecture with COS Light
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Sidewall Light Architecture
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Ceiling Light Connection Details
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COS Light Connection Details
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Sidewall Light Connection Details
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Schematic Representation of RS-485/Token
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System Architecture including both ACP’s
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4 Light Modes:1) Scene selection
2) Data load
3) Configuration check
4) BIT/BITE
Communication Details (ACP Commands)
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Communication Details (Data Load)
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Addressing Example via Token
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• Lights that have lost communication with the ACP will go to a white bright mode and not respond to scene commands.
• Lights that are dark are not receiving AC power and standard troubleshooting should apply (check connections, etc.)
• Sidewall lights are daisy chained for power, so the light that is out may not be the light that has a problem.
• Jumper harness may be employed to skip over suspect light to continue power/communication
• Lamps test mode can help to determine power vs. communication/LED failures
• Lights experiencing a surge may experience an open fuse as TVS protects power supply (LED lights are electronic devices, not transformers)
Troubleshooting
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Sidewall (window) lights:
• If a string of sidewall lights will not turn on, check power connections from the upstream light next to the first light that does not come on. The upstream light may be forward or aft of the light that does not come on, depending on where power is applied to that string
• A maximum of six lights may be connected in a string
Ceiling Lights:
• Ceiling lights have communication passed around aft and then forward through the same LRU twice
• Cross bin light failure may not be apparent due to lens
Troubleshooting
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RS-485:
• RS-485 signals follow transmission line rules for termination, reflections and stubs
• Un-terminated lines will have positive reflections and may cause intermittent communications
• Shorted line will have negative reflections and create nodes/antinodes that will cause faults remotely
• ½ of a RS-485 signal may function up to a certain length
• Breaking the system is the best way to isolate these failures
Token:
• Token failure may be caused by the sending or receiving light
RS-485 quick check (Power off):50-60 ohms acrossHigh impedance to ground
Troubleshooting
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Introduced Gen 2 lights and controls beginning L/N 4590 in September 2013
More robust lighting power supplies to withstand ground power transients
Increased communication signal levels to resolve unpredictable lighting behavior
Improved error messages to help pinpoint faulted light assemblies
In-Service Issues and initial Boeing and supplier actions were described in documents
737NG-FTD-33-12001 Boeing Service Letter 737-33-066 – Describes Generation II
lights and improved troubleshooting and maintenance
Gen II Lighting System
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V4 layout V5 layout
Save Data to Data Loader
Improved Menu
One-step config load
Scroll Bar
Version 5 (V5) Improved Screen Layout
Gen II Lighting System cont’d
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Improved fault message layout with recommended actions and FIM fault codes.
Version 5 (V5) Attendant Control Panel Sample Fault Messages
Version 5 (V5) Improved Screen LayoutGen II Lighting System cont’d
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Version 5 (V5) Attendant Control Panel Scene Preview(Available with complete set of Gen 2 lights only)
Allows airlines to test out lighting scene colors before creating a new lighting
database
Gen II Lighting System cont’d
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• The following improvements are available only with V5 ACP Operating software used with complete set of Gen 2 lights:
• Maintenance Message Fault Reporting with FIM codes and recommended actions (Gen 2 only as Gen 1 lights cannot send fault data)
• Red text for errors during addressing, zoning, scene download to the Lights
• New graphical menu layout for Maintenance.• Additional Maintenance Lighting Checks including Token
On, Token Off, and Health Check (Maintenance check passes a token through the system. Wire or communications faults appear when specific lights do not change color)
• Scene Preview
Gen II Lighting System cont’d
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Gen II Lighting System cont’d
Improved Maintenance Screen with Red Fault Identifiers
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Document references
CMM’s:33-20-25 (9120/9125)33-20-26 (9130)33-20-27 (9500)33-20-28 (9550)33-20-29 (9600)33-20-30 (9650)33-20-31 (9700)33-20-32 (9750)33-20-33 (9800)33-20-34 (9900)
Drawings:9120PD, 9125PD, 9130PD, 9500PD, 9501PD, 9550PD, 9551PD, 9600PD, 9601PD, 9650PD, 9651PD, 9700PD, 9701PD, 9750PD, 9751PD, 9800PD, 9801PD, 9900PD, 9901PD
CONFIDENTIAL B/E Aerospace © 2014
Gen II CMM’s33-20-40 (9501) 33-20-41 (9551)33-20-42 (9601)33-20-43 (9651)33-20-44 (9701)33-20-45 (9751)33-20-46 (9801)33-20-47 (9901)
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Appendix – GSE equipment power surges
45CONFIDENTIAL B/E Aerospace © 2014
0 0.002 0.004 0.006 0.008 0.01 0.012 0.014 0.016
-300
-200
-100
0
100
200
300
Voltage PHA Volts
Voltage PHB Volts
Voltage PHC Volts
P91 SERV 115V PHA Volts
P91 SERV 115V PHB Volts
P91 SERV 115V PHC Volts