BSI Training and Troubleshooting

Boeing Sky Interior LED Cabin Lighting Training

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

[email protected]

mailto:[email protected]

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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

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.

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

CONFIDENTIAL B/E Aerospace © 2014

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


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


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


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


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


737 BSI Light Construction


Typical light bar construction. Common to all BSI lighting elements.


Attendant Control Panel

FlyDubai LOPA


FlyDubai LOPA


FlyDubai LOPA


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


• 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


System Communications Overview


System Communications with LOPA Overlay


LRU Architecture


Ceiling Light Architecture


Ceiling Light Architecture with COS Light


Sidewall Light Architecture


Ceiling Light Connection Details


COS Light Connection Details


Sidewall Light Connection Details


Schematic Representation of RS-485/Token


System Architecture including both ACP’s


4 Light Modes:1) Scene selection

2) Data load

3) Configuration check

4) BIT/BITE

Communication Details (ACP Commands)


Communication Details (Data Load)


Addressing Example via Token


• 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


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


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


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


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


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


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



• 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




Improved Maintenance Screen with Red Fault Identifiers


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


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)

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

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