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
Bohemia, NY Lighting Systems
3
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.
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
sharon_harbauer@beaerospace.com


4
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: janet_rosado@beaerospace.com or
lightingsupport@beaerospace.com

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: diane_spooner@beaerospace.com


5
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

6
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
CONFIDENTIAL B/E Aerospace 2014
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.
WWA
RGBW
CONFIDENTIAL B/E Aerospace 2014
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
CONFIDENTIAL B/E Aerospace 2014
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
CONFIDENTIAL B/E Aerospace 2014
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
CONFIDENTIAL B/E Aerospace 2014
737 BSI Light Construction
CONFIDENTIAL B/E Aerospace 2014
Typical light bar construction. Common to all BSI lighting elements.
CONFIDENTIAL B/E Aerospace 2014
Attendant Control Panel
FlyDubai LOPA
CONFIDENTIAL B/E Aerospace 2014
FlyDubai LOPA
CONFIDENTIAL B/E Aerospace 2014
FlyDubai LOPA
CONFIDENTIAL B/E Aerospace 2014
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
CONFIDENTIAL B/E Aerospace 2014
RS-485 parallel bus at 57,600 bps
10 bit word (1 start, 8 data, 1 stop)
400 max bus length
100 differential impedance with end node terminations
Token signal is isolated (floating) with a 2.7K pull up

Communication Details
CONFIDENTIAL B/E Aerospace 2014
System Communications Overview
CONFIDENTIAL B/E Aerospace 2014
System Communications with LOPA Overlay
CONFIDENTIAL B/E Aerospace 2014
LRU Architecture
CONFIDENTIAL B/E Aerospace 2014
Ceiling Light Architecture
CONFIDENTIAL B/E Aerospace 2014
Ceiling Light Architecture with COS Light
CONFIDENTIAL B/E Aerospace 2014
Sidewall Light Architecture
CONFIDENTIAL B/E Aerospace 2014
Ceiling Light Connection Details

CONFIDENTIAL B/E Aerospace 2014
COS Light Connection Details
CONFIDENTIAL B/E Aerospace 2014
Sidewall Light Connection Details
CONFIDENTIAL B/E Aerospace 2014
Schematic Representation of RS-485/Token
CONFIDENTIAL B/E Aerospace 2014

System Architecture including both ACPs
CONFIDENTIAL B/E Aerospace 2014
4 Light Modes:
1) Scene selection
2) Data load
3) Configuration
check
4) BIT/BITE
Communication Details (ACP Commands)
CONFIDENTIAL B/E Aerospace 2014
Communication Details (Data Load)
CONFIDENTIAL B/E Aerospace 2014
Addressing Example via Token
CONFIDENTIAL B/E Aerospace 2014
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
CONFIDENTIAL B/E Aerospace 2014
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
CONFIDENTIAL B/E Aerospace 2014
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
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 across
High impedance to ground
Troubleshooting
CONFIDENTIAL B/E Aerospace 2014
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
CONFIDENTIAL B/E Aerospace 2014
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 contd
CONFIDENTIAL B/E Aerospace 2014
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 Layout
Gen II Lighting System contd
CONFIDENTIAL B/E Aerospace 2014
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 contd
CONFIDENTIAL B/E Aerospace 2014

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 contd
CONFIDENTIAL B/E Aerospace 2014
Gen II Lighting System contd
Improved Maintenance Screen with Red Fault Identifiers
CONFIDENTIAL B/E Aerospace 2014
Document references
CMMs:
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 CMMs
33-20-40 (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
45
CONFIDENTIAL B/E Aerospace 2014
-300
-200
-100
0
100
200
300
0 0.002 0.004 0.006 0.008 0.01 0.012 0.014 0.016
Voltage PHA Volts
Voltage PHB Volts
Voltage PHC Volts
P91 SERV 115V PHA Volts
P91 SERV 115V PHB Volts
P91 SERV 115V PHC Volts