Boeing SPECTROLAB SX-16 Nightsun Manual
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Boeing SPECTROLAB SX-16 Nightsun Manual

Boeing SPECTROLAB SX-16 Nightsun Manual

Junction box searchlight power cable
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SX-16 Nightsun® Searchlight
Safety and Service Bulletin # SL 0898-02
Issue Date: 09/25/98
Amended Date: 02/09/06
Subject:
SX-16 Nightsun® Junction Box Wiring Modification
Affected Products:
th
All SX-16 Nightsun® Searchlight Junction Boxes manufactured through August 4
, 1998.
The Junction Box is the power distribution box for Nightsun® Searchlight systems.
Dear Nightsun® Searchlight Product User:
Certain electrical connections in the SX-16 Junction Boxes may not have sufficient mechanical
strength to remain tight and sustain reliable electrical connections. This may cause your
Nightsun® searchlight system to malfunction.
Electrical connections that become loose or corroded can create smoke and /or cause circuit
breakers to "open" unexpectedly.
WARNING: TO AVOID A POTENTIALLY DANGEROUS SITUATION
WHICH COULD CAUSE SERIOUS PERSONAL INJURY OR PROPERTY
DAMAGE, ENSURE THAT THE JUNCTION BOX WIRING IS MODIFIED
AS DESCRIBED IN THIS BULLETIN.
Bulletin # SL 0898-02
Page 1 of 2

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Summary of Contents for Boeing SPECTROLAB SX-16 Nightsun

  • Page 1 SX-16 Nightsun® Searchlight Safety and Service Bulletin # SL 0898-02 Issue Date: 09/25/98 Amended Date: 02/09/06 Subject: SX-16 Nightsun® Junction Box Wiring Modification Affected Products: All SX-16 Nightsun® Searchlight Junction Boxes manufactured through August 4 , 1998. The Junction Box is the power distribution box for Nightsun® Searchlight systems. Dear Nightsun®...
  • Page 2 Spectrolab, Inc. Safety and Service Bulletin # SL 0898-02 dated 09/25/98 (continued) What you should do: Perform the service procedure described in document # SL 0898-02A, which follows. The procedure will guide you through the rewiring process. What is included with this bulletin: 1.
  • Page 3 Installation Wiring Instructions for SX-16 Junction Boxes Procedure 032384 Revision N/C Date: 12/06/99 INSTALLATION WIRING INSTRUCTIONS FOR SX-16 JUNCTION BOXES P/N 020706 Effective for boxes Revision V and higher, S/N 3307 and up, Manufactured after March 1, 1999 SPECTROLAB NIGHTSUN® and STARBURST® SEARCHLIGHTS O.E.M.

  • Page 4: Table Of Contents

    Installation Wiring Instructions for SX-16 Junction Boxes Procedure 032384 Revision N/C Date: 12/06/99 Table of Contents SCOPE......................2 INTRODUCTION AND PURPOSE..............3 RESPONSIBILITY ..................3 DEFINITIONS (DOES NOT APPLY)............3 REFERENCE DOCUMENTS ................ 3 PROCEDURE ....................4 6.1. Install Control Box Cable................ 4 6.2.

  • Page 5: Introduction And Purpose

    Installation Wiring Instructions for SX-16 Junction Boxes Procedure 032384 Revision N/C Date: 12/06/99 If the new style E1(+)/(-) block P/N 032199 is added to update an older 020706 junction box, installation wiring would also proceed as described below. INTRODUCTION AND PURPOSE A substantial change in the internal configuration of the SX-16 junction box was implemented with Revision V.

  • Page 6: Procedure

    Installation Wiring Instructions for SX-16 Junction Boxes Procedure 032384 Revision N/C Date: 12/06/99 WARNING LETHAL VOLTAGES EXIST IN COMPONENTS Junction box components contain hazardous AC and DC voltages up to 150 volts when powered. To reduce risk of death or serious injury: •...
  • Page 7 Installation Wiring Instructions for SX-16 Junction Boxes Procedure 032384 Revision N/C Date: 12/06/99 the box from which the grommet was removed. Reinstall the grommet with cable into the hole in the box. See Figure 1. 6.1.2. Connect all the crimp lugs on the control cable’s wires to TB1 as shown in Figure 1. They are secured under the single row of screw terminals farthest away from the main power relay K1 and closest to the large blue capacitor C1.

  • Page 8: Install Junction Box-To-Searchlight Cable

    Installation Wiring Instructions for SX-16 Junction Boxes Procedure 032384 Revision N/C Date: 12/06/99 Figure 1. Step 1. CONTROL BOX CONNECTIONS as seen when looking inside the junction box with the lid open and moved aside. Note numbered wires are connected to same numbered screws on the terminal strip row opposite the power relay K1.
  • Page 9 Installation Wiring Instructions for SX-16 Junction Boxes Procedure 032384 Revision N/C Date: 12/06/99 washer and the nut to temporarily hold the cable in place. (Another wire will be stacked onto this one in Paragraph 3.4.) See Figure 3 for E1 Terminal Block details. 6.2.4.

  • Page 10: Figure 2. Searchlight Cable Control Wire Connections

    Installation Wiring Instructions for SX-16 Junction Boxes Procedure 032384 Revision N/C Date: 12/06/99 Searchlight cable wires Booster transformer (on j/b lid) Figure 2 Step 2. SEARCHLIGHT CABLE CONTROL WIRE CONNECTIONS to terminal strip TB1. Numbered AWG 20 wires are connected to the row of screws across from control cable wire connections.

  • Page 11: Figure 3. Close Up View Of E1 Terminal Block

    Installation Wiring Instructions for SX-16 Junction Boxes Procedure 032384 Revision N/C Date: 12/06/99 6.3.2. Insert the 4-conductor gimbal cable into the grommet, one lug at a time. 6.3.3. After the cable is fed through the grommet, reinstall the grommet into the hole in the side of the junction box.

  • Page 12: Figure 4. Connecting Searchlight Power Cables

    Installation Wiring Instructions for SX-16 Junction Boxes Procedure 032384 Revision N/C Date: 12/06/99 place and the lamp(+) wire is installed on top of them, under the same washers and nut. To install the negative wires, remove the nut and washers from the negative terminal, stack the added heavy wires onto the existing ones and reinstall washers and nut.

  • Page 13: Connect Input Power (+) And (-) Cables To Junction Box

    Installation Wiring Instructions for SX-16 Junction Boxes Procedure 032384 Revision N/C Date: 12/06/99 6.4. Connect Input Power (+) and (-) Cables to Junction Box WARNING HAZARDOUS VOLTAGES Aircraft bus contains hazardous voltages when powered up To reduce the risk of death or serious injury: •...

  • Page 14: Verification, Quality Assurance Check And Full Functional Tests

    Installation Wiring Instructions for SX-16 Junction Boxes Procedure 032384 Revision N/C Date: 12/06/99 the flat washer, lock washer and nut in this order. Neatly dress the wires and tighten the nut fully. See Figure 5. Airframe ground wire is connected to E1(-) terminal.
  • Page 15 Installation Wiring Instructions for SX-16 Junction Boxes Procedure 032384 Revision N/C Date: 12/06/99 6.5.1. Verify all connections to the terminal strip TB1, circuit breaker CB1 and terminal block E1 (POS) and E1 (NEG) are tight. 6.5.2. VERIFY THAT NO WIRES FROM THE SEARCHLIGHT CABLE ARE DIRECTLY ATTACHED TO THE LARGE BLUE CAPACITOR.

  • Page 16: Final Routing Of Wires In Junction Box Before Closing Cover

    Installation Wiring Instructions for SX-16 Junction Boxes Procedure 032384 Revision N/C Date: 12/06/99 Route this wire behind this capacitor Figure 6. Step 5. FINAL ROUTING OF WIRES IN JUNCTION BOX BEFORE CLOSING COVER. Routing the (+) wire from the top of the booster diode behind the large blue capacitor is necessary to prevent damaging the wire or its insulation.
  • Page 17 Installation Wiring Instructions for SX-16 Junction Boxes Procedure 032384 Revision N/C Date: 12/06/99 system, the searchlight may not start and could be damaged by continuous repeated attempts to start it. 6.5.7. Install and connect the rest of the SX-16 searchlight system. 6.5.8.
  • Page 18 Installation Wiring Instructions for SX-16 Junction Boxes Procedure 032384 Revision N/C Date: 12/06/99 6.5.10. Perform full start and operational test of the searchlight as follows: WARNING HAZARDOUS AC AND DC VOLTAGES AC and DC voltages up to 150 volts exist within the junction box during the lamp start cycle To reduce the risk of death or serious injury: •...
  • Page 19 Installation Wiring Instructions for SX-16 Junction Boxes Procedure 032384 Revision N/C Date: 12/06/99 • Always wear protective eyewear when looking at closely illuminated objects • Prior to starting searchlight, verify it is pointed down and not toward any objects that may be damaged by the high intensity light beam WARNING HAZARDOUS INFRARED LIGHT BEAM...

  • Page 20: Control Plan (Does Not Apply)

    Installation Wiring Instructions for SX-16 Junction Boxes Procedure 032384 Revision N/C Date: 12/06/99 objects. Reposition or redirect the searchlight if required. Let the light continue to run and warm up. If the searchlight will not start, check the Inspection and Maintenance manual for troubleshooting information.
  • Page 21 Installation Wiring Instructions for SX-16 Junction Boxes Procedure 032384 Revision N/C Date: 12/06/99 If you have any problems or questions, do not hesitate to call Spectrolab’s Customer Service Department at 1-800-936-4888 or 1-818-898-2895, or fax us at 1–818-361- 5102, or contact us by E-mail at customerservice@spectrolab.com. SPECTROLAB NIGHTSUN®...

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