4516351100 revaa_instructions for seatnet advanced installationx draft v1

Instructions for SeatNetTM Advanced Installation

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_____________________________________________________________________________________________________ ZODIAC ACTUATION SYSTEMS PROPRIETARY

Use, duplication or disclosure of any information contained herein is prohibited for any purposes other than relating to this project

Instructions for SeatNetTM Advanced

Installation

ZODIAC ACTUATION SYSTEMS

Bâtiment 227 45, Avenue Victor Hugo

93 538 AUBERVILLIERS Cedex – France

NSCM: F0358 Department: System and Customer Support Equipment: SeatNetTM Advanced System Airplanes: AIRBUS and BOEING airplanes


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REVISION TABLE

Rev Date Pages Description /

July 2006 All First release

A March 2007 Page 6 Section 6

Added picture of the MPB actuator Replaced picture of the ECB’x’ box Added “Recommendations for Linear Actuators” calibration

B February 2010 All General review and update of the document � particular additions: - details relative to calibration process - notes relative to ECB’x’ ARINC function - note relative to ‘clone’ KDB and DEB -details relative to MPB and LPB anti-rotation system - note relative to over ride system - note relative to electrical harnesses - PCU installation recommendations - note relative to declutching system - addition of JPB, P6B & DPB

C October 2010 Page 32 Page 34

Addition of comments related to bonding straps lug & main harnesses “ground” wire termination lug attachment to seat structure connected to ground plane (“chassis ground”)

D April 2012 All - Added RCB PNB equipments - Note relative to actuator attachment - Note relative to TTL LED fitting - Addition of Electromagnet installation chapter - Annex 2 : clip connector installation

AA March 2014 All Change of company name: PRECILEC became Zodiac Actuation Systems. - Add RPB1110; RLB; ECBA363 - Reference documents updated


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SIGNATURES

Prepared by: ________________________ Date: E. CHEVRIER/P. PASQUER System and Customer Support

Reviewed by: ________________________ Date:

S. ENGEL Reliability Manager Reviewed by: ________________________ Date:

L. CIMA Program Director & Continuous Improvement

Approved by: ________________________ Date:

P. GORDIET R&D Director Approved by: ________________________ Date:

E. MACKER Design and Sales Quality Assurance Manager


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ABBREVIATIONS

• DEB: Digital interface for Electromagnet Box • DPB : Diagnostic Power Box • ECBA : Electronic Control Box for Airbus • ECBB : Electronic Control Box for Boeing • EC/FC : Event Code/Fault Code • HRB : electrical HaRness • JPB : Junction Power Box • KDB : Keyboard Driving interface Box • LEB : Linear Elbow actuator • LED : Light Emitted Diode • LPB : Linear Pass-through actuator • LRU : Line Replaceable Unit • MPB : Micro Linear Pass-through actuator • MVB : Manual oVerride system • RPB : Rotary Pass-through actuator • P4B : Pneumatic lumbar Box – 4 ways • P6B : Pneumatic lumbar Box – 6 ways • P8B : Pneumatic lumbar Box – 8 ways • PCU : Passenger Control Unit • PNB : Passenger iNterface Box • RCB : Rs Converter Box • RLB : Rotary light / Reading light SeatNet • TTL : Take off-Taxi-Landing • ZAS : Zodiac Actuation Systems

WORDING The use of “shall”, “should”, “must”, “will” and “may” within this document observes the following rules:

- The word SHALL in the text denotes a mandatory requirement of the document. Departure from such a requirement is not permissible without formal agreement.

- The word SHOULD in the text denotes a recommendation or advice on implementing such a requirement of the document. Such recommendations or advice is expected to be followed unless good reasons are stated for not doing so.

- The word MUST in the text is used for legislative or regulatory requirements (e.g. Health and Safety) and shall be complied with. It is not used to express a requirement of the document.

- The word WILL in the text denotes a provision or service or an intention in connection with a requirement of the document.

- The word MAY in the text denotes a permissible practice or action. It does not express a requirement of the document.


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REFERENCE DOCUMENTS ZODIAC ACTUATION SYSTEMS documentation references

[1] : #4516352193, ICD ECU ARINC485 (November 8, 2011) [2] : #4170092310AA, Clip connector detail for straight latch [3] : #4170092320AA, Clip connector detail for bent latch

Design & manufacture of some components to be linked to ZODIAC ACTUATION SYSTEMS SeatNetTM Advanced system, when not provided by ZODIAC ACTUATION SYSTEMS, as well as the integration of ZODIAC ACTUATION SYSTEMS SeatNetTM Advanced system in the seat shall comply with the following Airplanes Manufacturer Specifications. AIRBUS specifications

- 2520M1F001200 - Issue 2 - Electrical Seat Actuation System - 2520M1I001700 - Issue 8 - Seat Interface Specification for the Electrical Integration of In-

Seat Systems BOEING specifications

- D6-36440 Volume 1 - Issue F - Standard Cabin System Requirements - D283W604 - Issue E - Passenger Seat Electronic Equipment and Cable Installation

Requirements


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TABLE OF CONTENTS

1 SUBJECT ........................................................................................................................................ 8

2 RESPONSIBILITY ........................................................................................................................ 8

3 SEATNETTM ADVANCED LRUS ............................................................................................... 9

3.1 ACTUATORS ........................................................................................................................... 11 3.1.1 Actuators Restricted Positions (all types) ...................................................................... 13 3.1.2 Specific Procedure for Rotary Actuators (RPB) ............................................................ 13 3.1.3 Specific retractable shaft (RPB) ..................................................................................... 14 3.1.4 Specific Procedure for Linear / Micro Pass-through Actuators (LPB, MPB) ............... 15

3.2 MANUAL OVERRIDE SYSTEM (MVB) ..................................................................................... 16

3.2.1 Routing ........................................................................................................................... 16

3.2.2 Minimum Bend Radius ................................................................................................... 17 3.2.3 Anchorage of the MVB on actuator side ........................................................................ 17 3.2.4 Anchorage of the MVB on manual lever side ................................................................. 18 3.2.5 Override Cable Tightening ............................................................................................. 18 3.2.6 Clutch and Declutch Test ............................................................................................... 20

3.3 ELECTRICAL HARNESSES (HRB) ............................................................................................ 20

3.3.1 General recommendations ............................................................................................. 20 3.3.2 Latching blocks mounting on panels .............................................................................. 23 3.3.3 TTL light harness (HRB666C, HRB666A or equivalent) ............................................... 24

3.4 JUNCTION POWER BOX (JPB) ................................................................................................ 25

3.4.1 Junction Power Box (JPB) functionality ........................................................................ 25 3.4.2 JPB Attachment to the Seat Structure ............................................................................ 26 3.4.3 Junction Power Box (JPB) Electrical Harnesses ........................................................... 26

3.5 LUMBAR SYSTEM (P4B, P6B OR P8B) ................................................................................... 27

3.6 ELECTRONIC CONTROL BOX (ECBA OR ECBB) ................................................................... 28 3.6.1 ECB’x’ Attachment to the Seat Structure ....................................................................... 29 3.6.2 Circuit Breaker / Maintenance Connector Position ....................................................... 29

3.6.3 ECB’x’ Restricted Positions ........................................................................................... 30 3.6.4 Motor Harnesses Plugging to ECB’x’ Connectors ........................................................ 30

3.6.5 ARINC harness plugging to ECB’x’ Connectors ........................................................... 31

3.6.6 ARINC communication protocol and communication harness definition ...................... 31 3.6.6.1 Shielding and connection between ECU and IFE electrical ground .......................................................... 31 3.6.6.2 ZODIAC ACTUATION SYSTEMS ECB’x’ J400 “ARINC485” Connector ........................................... 32 3.6.6.3 ZODIAC ACTUATION SYSTEMS ECB363 J2 “POWER/ARINC485” Connector ............................... 32 3.6.6.4 Hardware address definition ...................................................................................................................... 33 3.6.6.5 Termination of the ARINC BUS line ........................................................................................................ 34

3.6.7 ECB’x’ Heat Dissipation ................................................................................................ 35 3.6.8 ECB’x’ Electrical Characteristics.................................................................................. 36

3.7 KEYBOARD DRIVING INTERFACE BOX (KDB), DIAGNOSTIC POWER BOX (DPB) AND

DIGITAL INTERFACE FOR ELECTROMAGNET BOX (DEB) ...................................................... 36 3.7.1 KDB, DPB and DEB Restricted Positions ..................................................................... 37 3.7.2 KDB functionalities ........................................................................................................ 37 3.7.3 DPB functionalities ........................................................................................................ 37

3.8 DIGITAL INTERFACE FOR ELECTROMAGNET BOX (DEB) ...................................................... 38 3.8.1 DEB functionalities ........................................................................................................ 38 3.8.2 Electromagnet installation ............................................................................................. 38

3.9 PASSENGER CONTROL UNIT (PCU) ....................................................................................... 39

3.10 PASSENGER INTERFACE BOX (PNB) AND RS CONVERTER BOX (RCB) ................................. 39


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3.10.1 PNB / RCB attachments to the seat structure................................................................. 39 3.10.2 PNB / RCB Restricted position: ..................................................................................... 40 3.10.3 PNB functionalities ........................................................................................................ 40 3.10.4 RCB functionalities ........................................................................................................ 40

3.11 ROTARY LIGHT / READING LIGHT (RLB) .............................................................................. 41

3.12 ELECTRICAL BONDING STRAPS.............................................................................................. 41

3.12.1 General bonding of system ............................................................................................. 41 3.12.2 Equipment delivered with Bonding Straps ..................................................................... 42 3.12.3 Equipment delivered without Bonding Straps (Customer request) ................................ 42

4 LRU STATUS LED ...................................................................................................................... 45

4.1 GENERAL PRINCIPLES AND DEFINITIONS ................................................................................ 45

4.2 OPERATING MODES ................................................................................................................ 45 4.3 STATUS LED TABLE ............................................................................................................ 46

5 SYSTEM TEST ON KDB OR DPB : SYSTEM STATUS LEDS ............................................. 47

5.1 GENERAL PRINCIPLES ............................................................................................................ 47 5.2 SYSTEM TEST PROCEDURE ................................................................................................. 47

5.3 SYSTEM TEST RESULTS ON SYSTEM STATUS LEDS ......................................................... 48

6 SEAT CALIBRATION................................................................................................................ 49

7 LRU REPLACEMENT ............................................................................................................... 53

8 CONFIGURATION MANAGEMENT AND RESPONSIBILITY SHARING ...................... 55

ANNEX 1 : TROUBLE SHOOTING BASED ON STATUS LED ................................................. 52

ANNEX 2 : CLIP CONNECTOR INSTALLATION ............. ......................................................... 55


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1 SUBJECT This document is an outline guide that will assist the seat manufacturer in integrating ZODIAC ACTUATION SYSTEMS SeatNetTM Advanced actuation system into the seats as well as to insure safe functioning, expected service life and high reliability. ZODIAC ACTUATION SYSTEMS SeatNetTM Advanced LRUs (as stand-alone units) shall be installed and checked according to the recommendations described in this document in regard to electrical interfaces, mechanical interfaces, and pre-use tests. This document is mostly useful during seat design phase and LRUs integration phase.

2 RESPONSIBILITY ZODIAC ACTUATION SYSTEMS is responsible for designing LRUs (electronic control units, actuators, harnesses, etc...) that are compliant with Customer specifications (if provided) and with general aircraft manufacturers’ specifications and directives applicable to electrical seat actuation systems. As result, all ZODIAC ACTUATION SYSTEMS SeatNetTM Advanced LRUs are designed and qualified as standalone units. It is Customer’s responsibility to ensure the conformity of SeatNetTM Advanced actuation system as an integrated system to the general aircraft manufacturers’ specifications and directives applicable to electrical seats and cabin interiors. It is Customer’s responsibility to ensure the conformity of all equipments connected to ZODIAC ACTUATION SYSTEMS SeatNetTM Advanced system when not provided by ZODIAC ACTUATION SYSTEMS (such as PCU, harnesses, lights, etc...) to the general aircraft manufacturers’ specifications and directives applicable to electrical seats and cabin interiors. It is Customer and / or the end user’s responsibility to ensure that the ZODIAC ACTUATION SYSTEMS SeatNetTM Advanced system remains within the settings and conditions described in this document and the ZODIAC ACTUATION SYSTEMS SeatNetTM Advanced LRUs technical drawings.


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3 SEATNETTM ADVANCED LRUs

Every ZODIAC ACTUATION SYSTEMS SeatNetTM Advanced system could include the following components:

RPB (Rotary Pass-through actuator) MVB (Manual oVerride system) LEB (Linear Elbow actuator) HRB (electrical HaRness) MPB (Micro Linear Pass-through actuator) LPB (Linear Pass-through actuator) P4B (Pneumatic lumbar Box – 4 ways) ECBA (Electronic Control Box for Airbus) P6B (Pneumatic lumbar Box – 6 ways) ECBB (Electronic Control Box for Boeing) P8B (Pneumatic lumbar Box – 8 ways) KDB (Keyboard Driving interface Box) JPB (Junction Power Box) DPB (Diagnostic Power Box) PCU (Passenger Control Unit) DEB (Digital interface for Electromagnet Box) PNB (Passenger iNterface Box) RCB (Rs Converter Box)

Instructions for SeatNet

_____________________________________________________________________________________________________ZODIAC ACTUATION SYSTEMS

Use, duplication or disclosure of any informa

LEB

DEB

KDB

DPB

PNB/RCB

JPB


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ECB’x’

P4B / P6B / P8B ECB363

RLB

LPB

Advanced Installation Page: 10/60 March 2014

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_____________________________________________________________________________________________________

other than relating to this project

P4B / P6B / P8B

RPB

HRB

PCU

MVB

MPB


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3.1 ACTUATORS

CAUTION: The seat shall have a mechanical stop at the end of the actuator stroke travel. The seat shall be designed to incorporate mechanical ends over rotary actuators stroke to hold the seat mechanism in place at both ends when manually operated but also before linear actuators both mechanical ends (at least few millimeters before actuator internal mechanical end is reached both ways). ZODIAC ACTUATION SYSTEMS cannot be liable for linear actuators damages in case of repetitive reaches of actuator internal mechanical end strokes

Before use, the following operations shall be performed: 1. Attach carefully the actuator to the seat structure. 2. Secure axle at rod-end and actuator anchorage.

Do not torque over 6,5N.m on actuator attachment anchorage and / or shaft

3. Make sure there is no interference between seat structure and the actuator (especially actuator moving parts, actuator connectors and actuator harness pigtail when applicable).

4. Make sure there is full alignment between actuator and seat parts in any position over the seat

stroke. Should the seat structure be out of alignment and, as result, causes load or torque to the actuator, ZODIAC ACTUATION SYSTEMS will not be responsible for any actuator abnormal functioning (i.e. lower reversibility, abnormal noise, reduced performances, wearing, etc…). 5. Plug the motor harnesses to the actuator’s electrical connector according to the ZODIAC

ACTUATION SYSTEMS applicable system wiring diagram. 6. Make sure there is sufficient room around harnesses connectors to allow easy plugging and

unplugging in case of maintenance. 7. Fit the override cable into the override mechanism and adjust the override cable according to

section 3.2. 8. Attach the grounding strap to the seat structure or the dedicated main harness wire to the actuator

ground stud when applicable. Should the seat design architecture require a dedicated wire from the main harness to be connected to the actuator ground stud, apply protective blue varnish (NYCOTE® 7-11 / PPG coating – base material 4125/6407 & hardening material 0613/9000 - or equivalent) both on the stud & lug after connection and on the actuator casing 5 mm minimum around the ground stud (refer to section 3.8).


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9. Both motor harness connector spring latches shall firmly hooked up to the actuator’s electrical connector latching blocks (see picture below).

The installation shall ensure that the harnesses connectors spring latches cannot be entrapped into any seat moving parts during the complete seat motion.

10. Note: If necessary, spring latches of D-SUB connector can be secured by using clip connector

For details regarding clips connector installation, refer to Annex 2 attached

11. Ensure that there is no mechanical interference with seat parts / structure during the complete

motion.

Harness connector spring latches shall be correctly hooked up to actuator connector latching blocks

Harness connector spring latches

Actuator connector latching blocks

Press on both side to latch/unlatch

Press on both side to latch/unlatch

Clip connector firmly press the latch on

the block


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3.1.1 Actuators Restricted Positions (all types)

The actuators connector shall not be placed in the upward position as on the picture below. Further, every practical precaution shall be taken to protect the actuators connector against liquid contamination / spillage.

3.1.2 Specific Procedure for Rotary Actuators (RPB)

The rotary actuators have no mechanical end stops by design. If a potentiometer internal mechanical end stop is reached during actuator installation / integration in the seat, it will slide to prevent any internal damage. This technology has two main advantages:

� no fixed position for the delivery

� no risk to break the potentiometer with an over-travel during actuator installation / integration in the seat or during maintenance

After installation of the actuator in the seat and before seat calibration, move manually (not electrically) each rotary actuator from the minimum seat mechanical end stroke to the maximum seat end stroke (using override mechanism) in order to adjust the position of the internal potentiometer with the real stroke of the associated rotary actuator in the seat.

NOT RECOMMENDED

UP

DOWN


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3.1.3 Specific retractable shaft (RPB)

A specific RPB design is also available in order to ease the actuator installation on seat by mean of a telescopic shaft. One side of the shaft is retractable when unlocked by removing a circlip. The other side of the shaft remains with a fix length. An internal spring ensures that the extended shaft position is reached when installed.

1. Remove the circlip from the telescopic shaft.

2. Reduce the shaft length by pushing on the shaft end as shown on the picture above (red arrow). 3. Install the actuator on the seat structure by placing the fix shaft's extremity into the dedicated

bearing with its washer. The pinion shall be engaged on the seat gear. 4. Extend the shaft until the second extremity is into its bearing with its washer placed between

bearing and pinion. 5. Reinstall the circlip into the shaft groove in order to lock the shaft length. 6. Finalize the actuator’s body installation by screwing the dedicated mechanical interfaces 7. Check that both washers are in position between pinions and seat structure.

Check that the circlip is properly installed and the shaft is locked.

Spring load

Retractable pinion Circlip

Washer

Actuator’s body

Shaft


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3.1.4 Specific Procedure for Linear / Micro Pass-through Actuators (LPB, MPB)

CAUTION: Pay special attention to the anti-rotation rod during installation (refer to pictures below).

8. Do not bend or remove the anti-rotation rod during installation. The anti-rotation device is part of

the actuator and shall not be damaged or removed. 9. Make sure there is no interference between any seat parts and the anti-rotation rod during the

actuator entire stroke in the seat. 10. Make sure there is no falling of liquids, graphite, glue, grease, oil, etc…on the anti-rotation rod

before, during and after the actuator installation (the anti-rotation rod must remain clean before, during and after the actuator installation into the seat).

11. Do not apply a rotation movement on ball screw during actuator installation in the seat or during

ball screw override off the seat. 12. Do not remove clamps or screws, whatever applicable, that secure the anti-rotation plate. Any actuator returned without or with a damaged anti-rotation device will be Customer’s liability.

Anti -rotation Rod

Anti-rotation plate

Anti-rotation mechanical key

Securing screw

Anti -rotation Rod

Securing clamp


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3.2 MANUAL OVERRIDE SYSTEM (MVB) A manual override mechanism is installed on each actuator to manually stow the seat headrest, recline, seatpan, legrest, etc…when power supply to the seat is interrupted. By activating the override mechanism, the clutch is disengaged allowing free movement of the actuator and the respective seat part (headrest, legrest, etc..). Multiple mock up tests are strongly recommended during seat design phase. Note: In order to ease in seat integration and to get a reliable operation, ZODIAC ACTUATION SYSTEMS do not recommend locating the override lever on Legrest assembly. Should ZODIAC ACTUATION SYSTEMS not supply the manual override system, ZODIAC ACTUATION SYSTEMS will not be responsible if the used manual override system is defective or non compatible with ZODIAC ACTUATION SYSTEMS actuation system (refer to associated actuator ZODIAC ACTUATION SYSTEMS Overall Drawing for actuator interfaces characteristics). In this case, ZODIAC ACTUATION SYSTEMS cannot take on the responsibility if manual override systems are cause of damage to ZODIAC ACTUATION SYSTEMS parts, to seat or create unsafe conditions for passenger.

3.2.1 Routing

1. During routing of the cables, special care should be taken to ensure that no moving seat parts or seat components hit the cables.

2. Each cable shall be routed and secured in such a way to prevent excessive bending, kinking,

pinching and pulling. 3. Each cable shall have sufficient slack to allow full travel without tension or deterioration. 4. When seat parts can rotate between each other, the cable routing shall be parallel to the rotation

axis. 5. Whenever possible, a cable loop should be preferred to a sharp bend radius. 6. Make sure to secure cables to prevent abrasion between articulated devices or potential cable trap.


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3.2.2 Minimum Bend Radius

1. Curves of the override cables have negative influence on the clutch normal operations and requires higher force applied on the override lever to declutch the override mechanism.

2. The sharpest curves shall not present less than 100 mm-bend radius, whatever the seat motion or

configuration is.

3.2.3 Anchorage of the MVB on actuator side

Routing shall be aligned with the cable output axis during at least 50 mm (refer to pictures below)

ACCEPTABLE

50 mm

50 mm

UNACCEPTABLE : cable output has not been screwed to the actuator support

50 mm

50 mm

50 mm 50 mm

ACCEPTABLE

ACCEPTABLE UNACCEPTABLE

UNACCEPTABLE

LPB / MPB Actuators

LEB Actuators

RPB Actuators


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3.2.4 Anchorage of the MVB on manual lever side

1. Routing shall be parallel to the manual lever box output during at least 25mm (refer to pictures below).

2. Adjust the length to maintain a few mm free play on the manual lever side, when seat is clutched,

regardless the seat position. 3. Tighten threaded cable tube-end to manual lever box, if any.

3.2.5 Override Cable Tightening

CAUTION: the cable adjustment shall be performed in the worst case of bending (sharpest bend radius during seat operation conditions).

Step 1: Fit the cable ball in the actuator declutching lever

Step 2: Fit the over ride end in the actuator threaded hole

25 mm

ACCEPTABLE

Free rotation between cable and end of cable

Free rotation between cable and end of cable


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Step 3: Tighten the cable end in the actuator over ride support (1,2 N.m 0 / - 20%) DO NOT EXCEED TORQUE, the over ride support could be broken

Step 4 : Turn the cable tightener to adjust the cable tension to obtain a gap between cable ball and

actuator lever 1 mm<x<2 mm

Step 5 : Tighten the nut to lock the cable tightener (1,2 N.m 0 / - 20%)

Step 6 : Check the correct operation of the declutching system

The operation of the lever on the manual lever box shall allow the full stroke of actuator lever (actuator lever in contact with over ride support in over ride position)

Cable End Over ride support

Cable tightener Cable

Cable ball

Actuator lever

Nut

Torque

1.2 N.m 0 / -20%

Torque

1.2 N.m 0 / -20%


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Note : In order to get full declutching position, nothing shall be added between override lever and override cable support

3.2.6 Clutch and Declutch Test

1. Check the seat for confirmation that a safe clutched position is in place in every intermediate seat position: headrest, recline, tracking, leg rest and footrest shall not move. Make sure to check in several seat positions.

2. Check the sensibility on manual lever: there should be no hard point, good free play.

Note: Actuator lever will not declutch actuator internal mechanism up to half stroke. 3. Ensure that the lever operation will provide a full de-clutching of the respective actuator. Make

sure to check in several seat positions. 4. Check that the lever comes back freely and smoothly once released.

Note: Before the mechanism re-clutches, the actuator may have to move a little to allow pin re-engagement (few millimeters or degrees on actuator stroke).

3.3 ELECTRICAL HARNESSES (HRB)

3.3.1 General recommendations

If ZODIAC ACTUATION SYSTEMS does not supply the seat electrical harnesses, ZODIAC ACTUATION SYSTEMS will not be responsible if the used electrical harnesses are defective or non compatible with ZODIAC ACTUATION SYSTEMS actuation system. In this case, ZODIAC ACTUATION SYSTEMS cannot take on the responsibility if electrical harnesses are cause of damage of ZODIAC ACTUATION SYSTEMS parts, seat or create unsafe conditions for passengers.

CAUTION: If ZODIAC ACTUATION SYSTEMS does not supply the seat electrical harnesses, the

electrical harnesses shall be designed according to ZODIAC ACTUATION SYSTEMS applicable system wiring diagram but also aircraft manufacturer applicable specifications (refer to applicable documents).


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1. During routing of electrical harnesses, special care should be paid to ensure that no moving seat parts or seat components hit the harnesses or rub against them.

2. Each harness must be routed and secured in such a way to prevent excessive bending, kinking,

pinching and pulling. 3. The harnesses connected to moving seat or actuators parts shall have sufficient slack to allow full

travel without tension (straight or radial) on the bundle or deterioration of the wiring or potential harness entrapment.

4. The harness connectors shall not be installed upwards in order to avoid liquid intrusion / spillage. 5. Adequate standoff support must be provided to prevent chafing / wearing of cables where routed

over sharp edges or through a structural part. 6. Grommets must be used to protect and support the harnesses bundles where necessary.

The harnesses bundles shall never be fixed directly to the seat structure (refer to schematic below).

7. A minimum bend radius of 6 times bundle diameter shall be respected for each harness (refer to

applicable harness Overall Drawing).

8. All harnesses bundles shall be secured all over their routing.

Seat

ACCEPTABLE

Seat

UNACCEPTABLE

Ø 6mm

Min. 36 mm

In this example, with a 6mm diameter bundle, the minimum bend radius musn’t be less than 6×6=36mm


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9. The harnesses and their connectors shall be protected, supported and secured to prevent any interference with the seat structure and its moving parts.

10. The harnesses shall be routed in such a way that they are not likely to be used as handholds or

damaged by passenger. 11. Every harness connector’s engagement shall be carefully checked after routing.


Note: If necessary, D-SUB connector attachment can be secured by using clip connector. For details regarding clips connector installation, refer to Annex 2 attached


motion. 13. Make sure there is sufficient room around harnesses connectors to allow easy plugging and

unplugging during maintenance. Note: ZODIAC ACTUATION SYSTEMS SeatNetTM Advanced system electrical architecture

includes a BUS line whose daisy chaining is done through each actuator / box connector. As a result, there shall not be any intermediate flying connector on the main harness (connector from the main harness not used on an actuator or on a box).

Harness connector spring latches shall be correctly hooked up to equipment connector latching blocks

Equipment Connector Latching Block

Harness Connector Spring Latches

bonding strap torque : 1 to 1.2N.m


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3.3.2 Latching blocks mounting on panels

Mounting for 1,52mm panels :

Mounting for 2,29mm panels :

Latching block (TYCO) ref : 745403-8-3 hole thread size : 4-40UNC

Screw CHC 4-40UNC2A inox A2 L≥ 6,35

Latching block (TYCO) ref : 747080-2

Screw CHC 4-40UNC2A inox A2 L6,35 (ref ZODIAC ACTUATION SYSTEMS: 1980554708)


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3.3.3 TTL light harness (HRB666C, HRB666A or equivalent)

� HRB666C :

The LED is fully protected by a plastic cap which is designed to be fixed through the shell panel.

� HRB666A :

The LED goes through a rubber grommet is not protected at his end. So seat monument shall include specific TTL LED location to prevent any shock that could damage the LED

Example:

Therefore, it’s seat manufacturer responsibility to ensure this protection.

shell panel

rubber grommet

LED

LED

outside shell panel


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3.4 JUNCTION POWER BOX (JPB)

If ZODIAC ACTUATION SYSTEMS does not supply the seat junction power box, ZODIAC ACTUATION SYSTEMS will not be responsible if the used power box is defective or non compatible with ZODIAC ACTUATION SYSTEMS actuation system. In this case, ZODIAC ACTUATION SYSTEMS cannot take on the responsibility if the junction power box is cause of damage of ZODIAC ACTUATION SYSTEMS parts, seat or create unsafe conditions for passengers.

CAUTION: If ZODIAC ACTUATION SYSTEMS does not supply the seat junction power box, it

shall be designed according to ZODIAC ACTUATION SYSTEMS applicable system wiring diagram but also aircraft manufacturer applicable specifications (refer to applicable documents).

3.4.1 Junction Power Box (JPB) functionality

The JPB provides the following fixtures: - it connects the seat actuation system to aircraft power supplier (straight connection or through

the IFE distribution box) - it allows to switch the seat actuation system OFF through the allocated switch or 5A circuit

breaker (only the power distributed to the connected ECB’x’ is switched OFF) - it allows the daisy chaining of all electrical phases according to the aircraft manufacturers

applicable specifications The Junction Power Box (JPB) shall be placed in such a location and / or shrouded to protect it against damage from luggages, passenger feet, or direct drink / food spillage. The power switch shall be placed in a location easily accessible to flight crew or maintenance staff but shall remain out of access for the passengers.

115V to the ECB’x’ (J2)

Seat actuation system power switch or 5A breaker, accessible to flight crew or maintenance staff.

Power ‘ON’ / Power ‘OFF’ 115V to the ECB’x’

115V ‘IN’ from aircraft

115V ‘OUT’ To possibly another ECB’x’

JPB


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3.4.2 JPB Attachment to the Seat Structure

The Junction Power Box has been qualified by using screws as attachment means. Should the Customer decide not to use screws to attach the JPB to the seat structure (i.e. nylatches, etc…) ZODIAC ACTUATION SYSTEMS will not be responsible for JPB damage or malfunctioning caused by vibrations. As result ZODIAC ACTUATION SYSTEMS firmly recommends to use 4 screws (2 screws on ‘switch’ assembly and 2 screws on ‘Power distribution box’) to attach the JPB to the seat structure. The JPB 2 grounding straps shall be attached to the seat structure.

3.4.3 Junction Power Box (JPB) Electrical Harnesses

1. During routing of JPB electrical harnesses, special care should be paid to ensure that no moving seat parts or seat components hit the harnesses or rub against them.

2. Each harness must be routed and secured in such a way to prevent excessive bending, kinking,

pinching and pulling. 3. The harnesses connected to moving seat parts shall have sufficient slack to allow full travel

without tension (straight or radial) on the bundle or deterioration of the wiring or potential harness entrapment.

4. The harness connectors shall not be installed upwards in order to avoid liquid intrusion / spillage. 5. Adequate standoff support must be provided to prevent chafing / wearing of cables where routed

over sharp edges or through a structural part. 6. Grommets must be used to protect and support the harnesses bundles where necessary.

The harnesses bundles shall never be fixed directly to the seat. 7. A minimum bend radius of 6 times bundle diameter shall be respected for each harness (refer to

applicable harness Outline Drawing). 8. All harnesses bundles shall be secured all over their routing. 9. The harnesses and their connectors shall be protected, supported and secured to prevent any

interference with the seat structure and its moving parts. 10. The harnesses shall be routed in such a way that they are not likely to be used as handholds or

damaged by passenger. 11. Every harness connector’s engagement shall be carefully checked after routing. 12. Make sure there is sufficient room around harnesses connectors to allow easy plugging and

unplugging during maintenance.


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3.5 LUMBAR SYSTEM (P4B, P6B OR P8B)

The P’x’B has been qualified by using 4 screws as attachment means. Should the Customer decide not to use screws to attach the P’x’B to the seat structure (i.e. nylatches, etc…) ZODIAC ACTUATION SYSTEMS will not be responsible for P’x’B damage or malfunctioning caused by vibrations. As result ZODIAC ACTUATION SYSTEMS firmly recommends to use 4 screws to attach the P’x’B to the seat structure.

Special attention should be paid to remove any sharp edges in the lumbar system installation area.

1. Attach the grounding strap to the seat structure or the dedicated main harness wire to the lumbar

system ground stud when applicable.

Should the seat design architecture require a dedicated wire from the main harness to be connected to the actuator ground stud, apply protective blue varnish (NYCOTE® 7-11 / PPG coating – base material 4125/6407 & hardening material 0613/9000 - or equivalent) both on the stud & lug after connection and on the lumbar system casing 5 mm minimum around the ground stud (refer to section 3.8).

2. Lumbar system tubes shall be routed in such a way that they are not flattened or pressed between

seat parts (refer to pictures below).

3. Lumbar system tubes shall be properly engaged in their respective 90° square pneumatic

connector(s) or in their pneumatic junction connector(s) when applicable and verified for any leakage.

UNACCEPTABLE UNACCEPTABLE


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4. Every electrical harness connector’s engagement must be carefully checked after routing. Harness connector spring latch shall be correctly hooked up to the P’x’B connector latching blocks (refer to picture below).


Note : If necessary, spring latches of D-SUB connector can be secured by using clip connector.

For details regarding clips connector installation, refer to Annex 2 attached. 5. Make sure there is sufficient room around harnesses connectors to allow easy plugging and

unplugging during maintenance. 6. Ensure that there is no mechanical interference with seat parts / structure during the complete

motion. 7. The bladders shall be installed in such a way that they are not flattened or pressed between seat

moving parts but also that they are not subject to frictions inside seat cushions. Should the Customer decide not to use ZODIAC ACTUATION SYSTEMS bladders, ZODIAC ACTUATION SYSTEMS will not be responsible for Lumbar System P’x’B damage or malfunctioning caused by leakages.

3.6 ELECTRONIC CONTROL BOX (ECBA OR ECBB)

The Electronic Control Box (ECB’x’) shall be placed in such a location and / or shrouded to protect it against damage from luggages, passenger feet, or direct drink / food spillage.

In case the ECB’x’ needs to be shrouded, ZODIAC ACTUATION SYSTEMS shall be involved in the shroud design surrounding the ECB’x’ and give formal approval (the shroud should not raise the temperature air around the ECB’x’ more than 5° C Celsius in comparison to the free air operation condition).

P’x’B Connector Latching Blocks



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3.6.1 ECB’x’ Attachment to the Seat Structure

The Electronic Control Box has been qualified by using 4 screws as attachment means. Should the Customer decide not to use screws to attach the ECB’x’ to the seat structure (i.e. nylatches, etc…) ZODIAC ACTUATION SYSTEMS will not be responsible for ECB’x’ damage or malfunctioning caused by vibrations. As result ZODIAC ACTUATION SYSTEMS firmly recommends to use 4 screws to attach the ECB’x’ to the seat structure. The ECB’x’ 2 grounding straps shall be attached to the seat structure.

3.6.2 Circuit Breaker / Maintenance Connector Position

The ECB’x’ shall be installed so that the 5 Amp Circuit Breaker and Maintenance Connector remain easily accessible for maintenance purposes. Maintenance Harness extension may be used to provide a deported access to ease maintenance operations.

Note : On special ECBA”x” including “kill switch” connector, the ECBA”x” will not powered until ‘kill switch harness” (or shunt plug for test only) will be connected on J800 connector with its switch push ON.

In case of use ECBA”x” designed with “kill switch” function, ensure that “kill switch” integrated on the harness remains easily accessible for maintenance purposes.

Maintenance Connector

J600 5A Circuit Breaker

J800 connector dedicated to” kill switch” harness

ECBA363

ECBA362-1


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3.6.3 ECB’x’ Restricted Positions

The ECB’x’ connectors shall not be placed in the upward position as on the picture below. Further, every practical precaution must be taken to protect the ECB’x’ connectors against liquid contamination / spillage.

Note : ECB’x’ location should ease the access to the breaker access, to STATUS LED and to

maintenance connector J600

3.6.4 Motor Harnesses Plugging to ECB’x’ Connectors

1. Plug the motor harnesses to the ECB’x’ electrical connectors according to the ZODIAC ACTUATION SYSTEMS applicable system wiring diagram. Note : A special care shall be paid to the distribution of motor harnesses on the ECB’X’ 3

output connector

Every harness connector’s engagement shall be carefully checked after routing. Both motor

harnesses connector spring latches shall be firmly hooked up to the ECB’x’ connector latching blocks.

The installation shall ensure that the harnesses connectors spring latches cannot be

entrapped into any seat moving parts during the complete seat motion.

NOT RECOMMENDED

DOWN

UP

Upside down configuration also not

recommended

In this example, motor harness on the ECB’X’ J200 output connector

J100 J200 J300


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2. Make sure there is sufficient room around the ECB’x’ connectors to allow easy plugging and unplugging during maintenance.

3. Ensure that there is no mechanical interference with seat parts / structure during the complete motion.

3.6.5 ARINC harness plugging to ECB’x’ Connectors

1. The complete system, ECB’x’ and SPM (or other IFE devices when applicable), shall be switched "OFF" before any plugging of ARINC communication harness on ECB’x’ J400 connector (or ECBA363 J2 connector)

2. Plug ARINC harness to the J400 ECB’x’ electrical connector. (or ECBA363 J2 connector)

3. Both ARINC communication harness connector spring latches shall be firmly hooked up to the ECB’x’ connector latching blocks. ECBA363 J2 connector does not have spring latches. It shall be full engaged and locked.

4. Make sure there is sufficient room around the ECB’x’ connectors to allow easy plugging and unplugging during maintenance.

5. Switch ON both equipments ECB’x’ and SPM when both equipments are connected through the dedicated ARINC line.

CAUTION: ZODIAC ACTUATION SYSTEMS recommends strong ly following up usual practices during interventions on the system: the system SHALL be switched ‘OFF’ before any maintenance or installation operations on the electrical interfaces (at least through the SPM switch or preferably main cabin switch). It SHALL be avoided to perform hot unplugs and/or hot plugs.

3.6.6 ARINC communication protocol and communication harness definition

ECB’x’ ARINC communication protocol is defined in ZODIAC ACTUATION SYSTEMS ICD Document n°(see [1] page 5) according to software parameters definition date.

If ZODIAC ACTUATION SYSTEMS does not supply the ARINC 485 communication harness between the ZODIAC ACTUATION SYSTEMS ECU (ECB’x’) and the SPM (or other IFE devices when applicable), the applicable harness shall comply with the following requirements :

3.6.6.1 Shielding and connection between ECU and IFE electrical ground - ARINC communication harness shall be shielded according to ARINC485 specification.

- Shielding shall be bounded to the ground on both sides (IFE and ECU).

Note: ZODIAC ACTUATION SYSTEMS recommends that the ECU GND (ECB’x’ J400 pin

5 or ECBA363 J2 pin 6) is linked to the electrical ground of the IFE system.


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3.6.6.2 ZODIAC ACTUATION SYSTEMS ECB’x’ J400 “ARINC485” Con nector

ZODIAC ACTUATION SYSTEMS ECB’x’ J400 connector is used for the ARINC 485 communication.

J400 ECB’x’ connector reference : 788508-1 (Low density female type D-SUB 9 points). Data shall be sent through “ARINC A” (HI) and “ARINC B” (LO) ports of ECB’x’ J400 “ARINC485” connector.

ECB’x’ J400 “ARINC485” connector pin out :

Pin Description

1 Term_ARINC

2 ARINC A

3 ARINC B

4 AD0

5 GND

6 AD1

7 AD2

8 AD3

9 AD4

3.6.6.3 ZODIAC ACTUATION SYSTEMS ECB363 J2 “POWER/ARINC485” Connector

ZODIAC ACTUATION SYSTEMS ECB363 J2 connector is used for the ARINC 485 communication and POWER input. (Airbus A350 only)

J2 ECB363 connector reference : DMC-MD 24 D-K-T + DMC-M 99-01 PN (EN4165 type). Data shall be sent through “ARINC A” (HI) and “ARINC B” (LO) ports of ECB363 J2 “ARINC485” connector.

ECB363 J2 “POWER/ARINC485” connector pin out :

Pin Description

1 115VAC Phase 1

2 115VAC Phase 2

3 115VAC Phase 3

4 ARINC485 Hi

5 ARINC485 Lo

6 ARINC485 Ground

7 Tri-state voltage

8 Term_ARINC

9 Chassis Ground

10 Shield Ground

11 AC- Neutral

J400 on ECB”X”

DATA

ADDRESS

J2 on ECB363


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3.6.6.4 Hardware address definition

The hardware address shall be defined by the IFE supplier. It shall be different for each equipment communicating on the same ARINC BUS. The harness connector shall connect the ground pin to the address pins in accordance with the hardware address needed. The hardware address shall be wired within the ARINC 485 communication harness connector on ECB’x’ side (slave on the BUS line) as described below :

ARINC @ AD4 AD3 AD2 AD1 AD0 Address 0 0 0 0 0 0 Address 1 0 0 0 0 1 Address 2 0 0 0 1 0

… Address 4 0 0 1 0 0

… Address 9 0 1 0 0 1

… Address 16 1 0 0 0 0

1 : stands for connected to ground (applicable pin connected to pin 5 through a strap inside the ARINC 485 communication harness connector on ECB’x’ side).

0 : stands for not connected to ground (applicable pin connected to nothing).

Example: required hardware address = 9

1 Term_ARINC

2 ARINC A

3 ARINC B

4 AD0

5 GND

6 AD1

7 AD2

8 AD3

9 AD4

ARINC Address 9 J400

on ECB”X”


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3.6.6.5 Termination of the ARINC BUS line The ECB’x’ that closes the ARINC BUS line (i.e. the ECB’x’ which is the most distant from the IFE master on the ARINC BUS) shall provide a line termination through a termination resistor. This shall be done connecting the “Term_ARINC” pin (pin 1 of ECB’x’ J400 “ARINC485” connector) to the “ARINC B” pin (pin 3 of the same connector) through a strap in the ARINC 485 communication harness on ECB’x’ side.

Example : connection of the ECB’x’ internal termination resistor for an ECB’x’ located at the end of the ARINC BUS line

1 Term_ARINC

2 ARINC A

3 ARINC B

4 AD0

5 GND

6 AD1

7 AD2

8 AD3

9 AD4

Example: ARINC Address 4

R termination

Internal termination resistor connection

IFE ECBXXX ECBXXX ECBXXX

Term_ARINC not connected

Term_ARINC not connected

Term_ARINC connected to ARINC B

Master

ARINC Address: m ARINC Address: x ARINC Address: y ARINC Address: z

J400 on ECB”X”


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3.6.7 ECB’x’ Heat Dissipation

1. Do not fit the ECB’x’ inside a closed area. 2. Fix the ECB’x’ on metallic parts (if possible). 3. The ECB’x’ shall not be accessible by the passenger. 4. Minimum 2 inches or 50,8 mm clearance shall be maintained between the ECB’x’ surfaces where

the motor and ECB’x’ power harnesses are hooked up and a shroud in the seat (refer to schematic below).

5. Natural airflow shall be preserved around the ECU. Minimum clearances shall be maintained

between the other surfaces of the ECB’x’ and a shroud in the seat according to schematic below.

2 inches – 50,8 mm

1 inch – 25,4 mm 1 inch – 25,4 mm



1 inch – 25,4 mm under fixation plate


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3.6.8 ECB’x’ Electrical Characteristics

ECB’x’ has been designed to work properly when supplied from a 115 V / Variable Frequency (refer to current applicable airplanes manufacturers specifications) voltage. Nevertheless, ECB’x’ may operate from a 110 V / 50-60 Hz power for demo seat or marketing show only, keeping in mind that the efficiency of the seat actuation system might be reduced due to the frequency drop.

Note: During endurance tests, ECB’x’ must be supplied through 115 V / Variable Frequency (refer

to current applicable airplanes manufacturers specifications) power supply.

3.7 KEYBOARD DRIVING INTERFACE BOX (KDB), DIAGNOSTIC POWER BOX

(DPB) AND DIGITAL INTERFACE FOR ELECTROMAGNET BOX (DEB)

The KDB, the DPB and the DEB have been qualified by using 4 screws as attachment means. Should the Customer decide not to use screws to attach the KDB, the DPB and / or DEB (if any) to the seat structure (i.e. nylatches, etc…) ZODIAC ACTUATION SYSTEMS will not be responsible for KDB, DPB and / or DEB damage or malfunctioning caused by vibrations. As result ZODIAC ACTUATION SYSTEMS firmly recommends to use 4 screws to attach the KDB, the DPB and the DEB to the seat structure.

1. Attach the grounding strap to the seat structure or the dedicated main harness wire to the KDB /

DPB / DEB ground stud or even directly to the KDB / DPB / DEB casing through installation screw when applicable. Should the seat design architecture require a dedicated wire from the main harness to be connected to the KDB / DPB / DEB ground stud or directly to the KDB / DPB / DEB casing, apply protective blue varnish (NYCOTE® 7-11 / PPG coating – base material 4125/6407 & hardening material 0613/9000 - or equivalent) both on the stud / lug / installation screw after connection and on the KDB / DPB / DEB casing 5 mm minimum around the ground stud / installation screw (refer to section 3.8).

2. Plug the harnesses to the KDB, DPB and DEB (if any) electrical connectors according to the

ZODIAC ACTUATION SYSTEMS applicable system wiring diagram. 3. The harnesses connector spring latches shall be firmly hooked up to the KDB, DPB and DEB (if

any) connector latching blocks.

KDB Connector Latching Blocks


KDB Connector Latching Blocks


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Note: If necessary, spring latches of D-SUB connector can be secured by using clip connector. For more details regarding clip connector installation, refer to ZODIAC ACTUATION

SYSTEMS document n°(see [2] page 5) for straight connector and to ZODIAC ACTUATION SYSTEMS document n°(see [3] page 5) for 90° degrees connector

4. Make sure there is sufficient room around harnesses connectors to allow easy plugging and unplugging during maintenance.


motion.

Note: To ease calibration and test system operations for maintenance purposes (refer to section 5), the KDB and / or DPB (Calibration and System Test buttons, the System Status LEDs but also the DPB display when applicable) shall remain easily accessible.

3.7.1 KDB, DPB and DEB Restricted Positions

The KDB, DPB and DEB connectors shall not be placed in the upward position as on the picture below. Further, every practical precaution must be taken to protect the KDB, DPB and DEB connectors against liquid contamination / spillage.

3.7.2 KDB functionalities

The KDB provides the following functionalities within ZODIAC ACTUATION SYSTEMS SeatNetTM Advanced actuation system:

- interface between the Passenger Control Unit (PCU) and the system internal BUS - system diagnosis, activated by ‘System test’ button (refer to section 5) - seat calibration, which is a specific mode activated through ‘Calibration’ button (refer to

section 6 when required)

3.7.3 DPB functionalities

The DPB provides the same functionalities as the KDB within ZODIAC ACTUATION SYSTEMS SeatNetTM Advanced actuation system but allows also the following additional functionality:

- display of Event Codes and Fault Codes (EC/FC) recorded in the system memories

NOT RECOMMENDED

DOWN

UP

Upside down configuration also not recommended


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3.8 DIGITAL INTERFACE FOR ELECTROMAGNET BOX (DEB)

For the installation procedure, refer to chapter 3.7

3.8.1 DEB functionalities

The electronic functions of the DEB are defined as follows : - Electrical driving and monitoring of electromagnets - Switching ON or OFF the TTL LED (see chapter 3.3.2 for harness installation) - Reading of the switches status

3.8.2 Electromagnet installation

The electromagnet is designed to provide a mechanical locking of the seat in TTL position. This function must be ensured even when the electromagnet is not powered, therefore an additional mechanism / device must be used to maintain the pin in locked position in any circumstances. For example: In the case of vertical mounting (pin down), the gravity force applied on the pin may not be enough to ensure proper locking. A spring can be used in order to secure the pin in the right place when the seat is in TTL position It’s the customer’s responsibility to do a correct fitting in this purpose.

Electromagnet pin

maximum stroke : 10mm

Ø : 12,7mm

Force : 2,5 N min

Electromagnet device

DEB


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3.9 PASSENGER CONTROL UNIT (PCU) Should ZODIAC ACTUATION SYSTEMS not supply the PCU, ZODIAC ACTUATION SYSTEMS will not be responsible if the used PCU is defective or non compatible with ZODIAC ACTUATION SYSTEMS actuation system. In this case, ZODIAC ACTUATION SYSTEMS cannot take on the responsibility if PCU are cause of damage of ZODIAC ACTUATION SYSTEMS parts, seat or create unsafe conditions for passengers For PCU installation recommendations, refer to the corresponding Overall Dimension and interface PCU drawings (in particular for screws / nuts tightening torques and grounding requirements).

3.10 PASSENGER INTERFACE BOX (PNB) AND RS CONVERTER BOX (RCB) The PNB and the RCB have been qualified by using 2 nylatches as attachment means. Nylatches can be either installed on PNB/RCB or either on bracket.

3.10.1 PNB / RCB attachments to the seat structure

PNB and RCB equipment shall fixed to the seat structure through particular bracket. Bracket shall be machined according to the dimensions specified by ZODIAC ACTUATION SYSTEMS

Bracket dimensional criteria specifications:

(For P6 or P18 fastening)

For NYLATCH : HN3G-32-1 HN3P-32-4-1

P18 for PNB P6 for RCB


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3.10.2 PNB / RCB Restricted position:

Precaution must be taken to protect the PNB / RCB connectors against liquid contamination / spillage. RCB and PNB shall not be installed in horizontal position with STATUS LED oriented to the floor

PNB and RCB equipment can be installed in all other position in seat, nevertheless, PNB and RCB shall be installed to ease “the display” of its integrated STATUS LED (located on the top of PNB). Note: RCB, PNB equipments require bonding connected to the seat structure and to the electrical

device

3.10.3 PNB functionalities

The PNB is the interface between Passenger Control Unit and the system internal BUS. This equipment is an alternative of KDB, but PNB equipment do not include CALIBRATION and SYSTEM TEST functions Note: in case of use PNB, CALIBRATION function is launched either through PCU (by keys

combination) or either through with button located on ECB’X’ Refer to chapter “Seat Calibration” to get more detail on calibration process.

3.10.4 RCB functionalities

The RCB is the interface between ECB’x’ and additional electronic devices (ex: relaxor, captor, touch screen, etc …) RCB converts the RS 232 communication into CAN bus communication.

STATUS LED

UP

DOWN

PNB / RCB side fixed to bracket by nylatches means

P18 for PNB P6 for RCB

J17 for PNB J7 for RCB


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3.11 ROTARY L IGHT / READING L IGHT (RLB)

3.12 ELECTRICAL BONDING STRAPS

3.12.1 General bonding of system

It is Customer’s responsibility to ensure a proper electrical bonding to the general aircraft manufacturers’ specifications and directives applicable to electrical seats and cabin interiors. In case of disconnect use, the bonding strap of each LRU must be connected to the seat structure, or connected all together (by means of harness daisy chaining) and finally connected to one or more ground stud. The total resistance measurement shall not exceed the BOEING and AIRBUS specifications (see reference documents page 5).


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Electrical bonding example for an ECB’X’:

3.12.2 Equipment delivered with Bonding Straps

1. Bonding straps shall be fastened through studs installed on the seat structure, and secured.

2. Bonding straps shall not be modified (lengths) or removed. Any modifications in the bonding devices could generate unexpected EMI phenomenon.

3. Correct bonding shall be checked according to the applicable airplane manufacturer requirements.

Note: Equipment delivered with Bonding Straps by ZODIAC ACTUATION SYSTEMS will be coated with protective blue varnish (NYCOTE® 7-11 / PPG coating – base material 4125/6407 & hardening material 0613/9000 - or equivalent) both on the stud / strap lug and on the equipment casing 5 mm minimum around the ground stud.

It is the customer responsibility to ensure that the bonding straps lug of the different seat actuation system equipment is attached on a seat structure area which is connected to the ground plane (“chassis ground”).

3.12.3 Equipment delivered without Bonding Straps (Customer request)

Should the seat design architecture require a dedicated wire from the main harness to be connected to the different equipment ground studs or directly to the equipment casing, apply protective blue varnish (NYCOTE® 7-11 / PPG coating – base material 4125/6407 & hardening material 0613/9000 - or equivalent) both on the stud / lug / installation screw after connection and on the equipment casings 5 mm minimum around the ground stud / installation screw (refer to picture above).

5mm min

Bonding straps to be connected to metallic seat structure (GROUND studs)


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Main harness bonding wire routing and installation shall comply with the following requirements:

Actuators – Straight connector

Actuators – 90° connector

Lumbar system

Length = 70 mm +/- 10 mm / 2.75" +/- 0.40"

Bonding Attachment on actuator stud.

1N.m.<Torque <1,2N.m.

Bonding Attachment on actuator stud


Length = 70 mm +/- 10 mm / 2.75" +/- 0.40"

Bonding Attachment on lumbar system stud


Length = 150 mm +/- 10 mm / 5.90" +/- 0.40"


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ECB’x’ – Main harness side

KDB / DPB / DEB – Bonding attachment with installation screw

KDB/DPB

DEB

Shall the KDB / DPB / DEB electrical bonding be designed through a grounding stud installed on the equipment, kindly proceed as per above specified. Correct bonding shall be checked according to the applicable airplane manufacturer requirements. Should the seat design architecture require a dedicated wire from the main harness to be connected to the different equipment ground studs or directly to the equipment casing, it is the customer responsibility to ensure that this dedicated wire termination lug located at the ECB’x’ level or at any intermediate disconnect levels is attached on a seat structure area which is connected to the ground plane (“chassis ground”).

Bonding Attachment on KDB/DPB through installation screw 1N.m.<Torque <1,2N.m

Bonding wire

Bonding Attachment on metallic seat

structure (GROUND)

Length = 70 mm +/- 10 mm / 2.75" +/- 0.40"


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Time (s)

START MODE BUSY MODE STABLE MODE 1,5 sec 30 sec MAX

LED light color varies over time LED light is orange

LED Operating Modes DURATION

LED color is fixed

Any equipment returned with missing parts such as bonding strap or grounding stud, when applicable, will be Customer’s liability.

4 LRU STATUS LED

4.1 GENERAL PRINCIPLES AND DEFINITIONS All LRUs have a STATUS LED. The color of the STATUS LED (green, orange and red) and its frequency over time (permanently ON, permanently OFF, flash, invert flash, blink) define the LRU status.

STATUS LED location

4.2 OPERATING MODES At each LRU power-up the LRU STATUS LED goes through 3 OPERATING MODES:

� START MODE (right after LRU power-up): It lasts approximately 1,5 seconds The STATUS LED is orange � LRU is running its self-test

� BUSY MODE:

It lasts 30 seconds MAX.

KDB

P4B/P6B/P8B

ECBA/ECBB DEB

LEB

RPB

PNB/RCB


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The STATUS LED blinks and changes color several times. The color sequence is linked to the different operations ongoing.

Note: The BUSY MODE can be different at each LRU power-up.

� STABLE MODE: This mode corresponds to the end of the LRU Initialization.

Note: During seat calibration, the STATUS LED is temporarily in “Calibration” mode (other than start, busy and stable): refer to section 6

4.3 STATUS LED TABLE

The following table summarizes the LRU STATUS that corresponds to each LED Color and its frequency over time.

STATUS LED LRU STATUS

Flash GREEN (LED is ON for 20 ms then OFF for 2 sec)

LRU is OPERATIONAL

Invert flash GREEN (LED is ON for 2 sec then OFF for 20 ms)

Maintenance mode (with special harness on

ECB’X’ J600)

Flash ORANGE (LED is ON for 20 ms then OFF for 2 sec)

TEMPORARY INOP or

PERMANENT INOP Only on KDB/DPB

Blink ORANGE

(LED is ON for 500ms then OFF for 500ms)

Only on KDB/DPB

SYSTEM TEST runs on KDB/DPB

Permanent ORANGE (LED is permanently ON)

Software download into a LRU

Invert flash RED (LED is ON for 2 sec then OFF for 20 ms) PERMANENT INOP

Blink RED (LED is ON for 500 ms then OFF for 500

ms) PERMANENT INOP

Permanent RED (LED is permanently ON) PERMANENT INOP

OFF (LED is permanently OFF) NOT CONNECTED


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5 SYSTEM TEST on KDB or DPB : SYSTEM STATUS LEDs

5.1 GENERAL PRINCIPLES All actuation system LRUs (ECB’x’, Actuators, KDB, DPB, DEB, …) monitor constantly their correct functioning. The ECB’x’ also monitors the 3 CAN BUS lines constantly. An overall actuation system test can be done through the SYSTEM TEST button on the KDB or the DPB, which is similar to the KDB with an additional display. System test displays LRUs status at the time when System Test function is activated. Note: Intermittent faults, no longer present when System Test is activated, are not displayed.

5.2 SYSTEM TEST PROCEDURE Each LRU Test Result is displayed through up to eight* orange LEDs. They are called SYSTEM STATUS LEDs and they are located on the upper surface of the KDB / DPB just above the SYSTEM TEST button (refer to the picture below). Each LED is associated to a LRU or one of the three CAN BUS lines. LED number and distribution is specific to each program (Distribution is arbitrary defined by ZODIAC ACTUATION SYSTEMS, nevertheless LED distribution can be implemented according to specific customer request).

KDB and DPB overview (for test)

KDB DPB (similar to KDB with additional display)

SYSTEM TEST button

SYSTEM STATUS LEDs : ORANGE only (# 1 to 8)

STATUS LED :

RED, GREEN or ORANGE

Display of Event Codes and Fault Codes

8

1


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Action: push the SYSTEM TEST button on the KDB / DPB. Effect: all SYSTEM STATUS LEDs light up (ORANGE color only) for approximately 3 seconds (It

corresponds to the LED auto-test). After 3 seconds, each LRU STATUS is displayed through its corresponding LED.

* only a number of LEDs equivalent to the number of LRUs installed into the seat will light in case of

system test button activation

5.3 SYSTEM TEST RESULTS ON SYSTEM STATUS LEDs

Explanations of results of SYSTEM STATUS LEDs

SYSTEM STATUS LED TEST RESULT

FLASH ORANGE (ON for 20 ms then OFF for 2 sec) LRU IS OPERATIONAL

BLINK ORANGE (ON for 500 ms then OFF for 500 ms)

TEMPORARY INOP or LRU Initialization

INVERT FLASH ORANGE (ON for 2 sec then OFF for 20 ms) PERMANENT INOP

PERMANENTLY ON ORANGE SERIOUS INOP or No LRU connected

PERMANENTLY OFF NO TEST RESULT � LED not used in TEST SYSTEM

� The SYSTEM TEST result will remain displayed through the SYSTEM STATUS LEDs

during 30 seconds *. (in case of a further SYSTEM TEST button activation, the SYSTEM STATUS LEDs are refreshed).

� After 30 seconds*, all SYSTEM STATUS LEDs turn OFF and the KDB / DPB returns to its normal operating mode.

� For more details, refer to table in Annex 1 "Trouble shooting based on LED status" Note: if an actuator is considered as an option and if is not installed in the system, the STATUS LED

associated will be ON permanently during the SYSTEM TEST (� “equipment not connected”)

* 30 seconds corresponds to the standard time out setting for System Test automatic deactivation.Specific Customer request / requirement at the time of software parameters definition may lead to a different time-out setting for dedicated programs.

Note : the display on the DPB will allow reporting the fault codes that have been stored in the system

memories. The meaning of the fault codes reported will be detailed in particular document specifically associated to the concerned programs.


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6 SEAT CALIBRATION During calibration process, the seat shall not be operated electrically by the PCU. Seat calibration may not be required according to the actuation system architecture. Note: Seat actuation system including linear actuators only (LEB / LPB / MPB) may not require any

seat calibration.

KDB and DPB overview (for calibration)

Note: procedure described below through KDB / DPB is applicable per PAX (except specific notice)

� The CALIBRATION STATUS LED, when blinking, indicates that the system is in calibration mode.

� The SYSTEM TEST button shall not be used during seat calibration procedure.

� It might be necessary to move previously some LRUs or seat parts to prevent mechanical interference during the calibration process (example: legrest to prevent interference with floor).

� Some specific programs configurations use KDB / DPB with "clone function" which means

that a KDB / DPB controls both pax. When the calibration procedure is launched in such case, both PAX enter simultaneously in calibration mode.

� If implemented in software, calibration procedure may be also launched by the PCU through

specific successive keys combinations.

� White button located close to the ECB’x’ status LED has the same function as KDB / DPB calibration button but will simultaneously launch calibration procedure for ALL PAX of the system.

DPB (similar to KDB with additional display)

KDB

CALIBRATION status LED ORANGE

CALIBRATION button

STATUS LED :

RED, GREEN or ORANGE


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Note : A plastic pin 3mm<x<4mm shall be used to press on ECBx button

Recommendations for LINEAR Actuators (LEB, LPB and MPB) The seat shall have a mechanical end stop device for each actuator before the respective actuator internal mechanical end stop. The seat mechanical stroke shall be shorter than the actuator maximum electrical stroke (the electrical stroke is specified in the actuator "Overall Dimensions" drawing).

� Seat with mechanical end stops: The linear actuators (LEB, LPB and MPB) may be calibrated as described below (Step 1 thru Step 5) so that the mechanical seat tolerances are taken into account if necessary

� Seat without mechanical end stops:

Without calibration position references (no end stop devices), the linear actuators (LEB, LPB and MPB) shall not be calibrated. - The seat will remain fully functional - The mechanical seat tolerances will not be taken into account. As result, two seats having different mechanical tolerances will behave differently in service. This is independent of the actuation system.

STEP 1 Preliminary System Check

� All LRU (actuators, ECB’x’, KDB, DPB, DEB, PNB, RCB, Lumbar System) shall be installed on the seat and connected

� The ECB’x’ shall be ON: check that all LRU Status LEDs close to the connector are flashing green (refer to section 4.1 for LRU Status LEDs location)

� The SYSTEM STATUS LEDs shall be OFF

� The CALIBRATION STATUS LED shall be OFF Note: Before starting calibration procedure, move manually as necessary Legrest and/or Recline and /

or Tracking, etc… using override levers to ease access to the KDB / DPB or to ease the seat movement.

The calibration procedure may be also launched through ECB’x’ white button


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STEP 2 Potentiometer positioning procedure

Potentiometer positioning procedure is applicable to the actuation system including rotary actuator(s) only. Before entering into calibration process, it is necessary to adjust the internal position of the potentiometer with the real stroke of rotary actuator. This is done by simply realizing a complete manual stroke of the seat with respect to the rotary actuator (using declutching levers). � Move the seat part slowly and manually (using the declutching levers) to the minimum position

up to the maximum position

STEP 3 Entering the Calibration Mode

� Push and maintain the CALIBRATION button for at least 3 sec: � The CALIBRATION STATUS LED is lighted (permanently)

Note: If any of the SYSTEM STATUS LEDs is on, that means that a seat calibration was already performed and memorized by the system. By continuing the seat calibration procedure, the new parameters will be taken into account if applicable to the respective actuator.

� Once the CALIBRATION STATUS LED is blinking slowly then release the CALIBRATION button � the system is in Calibration mode*

� The CALIBRATION STATUS LED keeps blinking slowly � All SYSTEM STATUS LEDs turn OFF

*from this moment on, with no action on the actuators, the KDB / DPB remains in Calibration mode for about 4 minutes then it automatically exit the Calibration mode. In this case the calibration is not taken into account.

Note: Specific Customer request / requirement at the time of software parameters definition may lead

to a different time-out setting for dedicated programs.

IMPORTANT: - Lumbar actuators (P’x’B) as well as KDB / DPB and DEB boxes do not require

calibration

- If the seat does not have a mechanical end stop device for the Linear Actuators (LEB, LPB and MPB) then no calibration is needed (refer to “Recommendations for Linear actuators” above)

� Move manually and slowly the actuator from minimum reference position first and then to maximum reference position

� The corresponding actuator LED (within the SYSTEM STATUS LEDs) blinks during the actuator motion

Note: Calibration procedure may be slightly different on seats equipped with electromagnets. Minimum and / or maximum position(s) could be replaced by particular reference positions to ensure an accurate positioning of the seat in latches. In this case refer to the particular calibration procedure associated to the respective seat.

� If the motion of the actuator is sufficiently operated, the actuator LED (within the SYSTEM STATUS LEDs) will turn ON permanently and the value will be memorized.


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� If the calibration is NOT correctly performed, the actuator LED (within the SYSTEM STATUS LEDs) will keep blinking and the calibration values will not be memorized. In this case, it is necessary to switch OFF the ECB’x’ and start again from STEP 3.

Note: The calibration values will be rejected, during the calibration procedure, if the manual operation of an actuator, seen by the system in calibration mode, is less than 20%* of expected stroke (too little movement). In this case, the KDB / DPB System Status LED associated to the LRU doesn’t light during the movement of actuator. So it is necessary to switch OFF and switch ON ECU breaker and restart the procedure of calibration (STEP 3).

*The 20% value is a standard value, a specific Customer request / requirement at the time of software parameters definition may lead to a different setting value for dedicated programs.

� REPEAT THIS STEP FOR EACH ACTUATOR THAT REQUIRES A CALIBRATION

STEP 4 End of Seat Calibration: calibration validation � The CALIBRATION STATUS LED is blinking

� Push and maintain the CALIBRATION button on KDB / DPB or on ECU (at least 5 sec)

� The CALIBRATION STATUS LED turns firstly ON and then OFF � Release the CALIBRATION button:

� Wait at least 20 sec before activating electrically the seat. This time is needed to allow data exchange between ECB’x’ and LRUs

� Check that all LRU STATUS LEDs close to each actuator are flashing green

STEP 5 Seat Check

Command electrically the seat (through the passenger keypad) to move from TAKE-OFF to BED position: make sure that no actuator hits the seat mechanical stops.

Note: To ensure the complete check of the Seat Actuation System, test every single command of the

Passenger Control Unit and verify correct operation of the system accordingly - Caution: some motions might be restricted according to the safety areas defined in the

system to prevent interferences with the floor or the backshell of the seat in front


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7 LRU REPLACEMENT

CASE 1 = ECB’x’ Replacement - switch the ECB’x’ OFF through the circuit breaker - If SPM (or another IFE device) is connected on ECB’x’, switch OFF SPM (or the

another IFE device connected) - unplug all harnesses - remove the ECB’x’ - replace the ECB’x’ and hook up the harnesses - switch ON the SPM (or the another IFE device to be connected) - switch the ECB’x’ ON through the circuit breaker - wait at least 10 sec and then check that the LRU Status LED is flashing green

(refer to the section 4.1 for LRU Status LED location) - command electrically the seat (through the passenger keypad) to move from TAKE-

OFF to BED position: make sure that no actuator hits the seat mechanical stops

CASE 2 = Linear Actuator Replacement (LEB, LPB and MPB) - switch the ECB’x’ OFF through the circuit breaker - unplug the harness - remove the actuator - wait at least 5 sec - replace the actuator and hook up the harness - switch the ECB’x’ ON through the circuit breaker - wait at least 10 sec and then check that LRU Status LED is flashing green (refer to the

section 4.1 for LRU Status LED location) - command electrically the seat (through the passenger keypad) to move from TAKE-


CASE 3 = Rotary Actuator Replacement (RPB) - switch the ECB’x’ OFF through the circuit breaker - unplug the harness - remove the rotary actuator - wait at least 5 sec - replace the rotary actuator and hook up the harness - switch the ECB’x’ ON through the circuit breaker - wait at least 10 sec and then check that LRU Status LED is flashing green (refer to the

section 4.1 for LRU Status LED location) - Carry out the actuator calibration (steps 2 thru 5 of section 6)* * relevant rotary actuator calibration ONLY. There is no need to calibrate all actuators - command electrically the seat (through the passenger keypad) to move from TAKE-



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CASE 4 = KDB or DPB or DEB or P’x’B or PNB or RCB Replacement - switch the ECB’x’ OFF through the circuit breaker - unplug the harnesses - remove the LRU - wait at least 5 sec - replace the LRU and hook up the harness - switch the ECB’x’ ON through the circuit breaker - wait at least 10 sec and then check that LRU Status LED is flashing green (refer to section

4.1 for LRU Status LED location) - command electrically the seat (through the passenger keypad) to move from TAKE-OFF to

BED position: make sure that no actuator hits the seat mechanical stops Note: DEB and / or KDB can be configured into "clone mode" as part of some specific programs. In

such case, 1 DEB and / or 1 KDB only control(s) the operation respectively for solenoids and / or keypads of both PAX. This particular function allows minimizing the number of LRUs used in double PAX seat configuration. In this case, after DEB or KDB replacement, it is required to carry out a double "power up" to keep actuators calibration without need for recalibration of the complete seat (Switch ON the ECB’x’ wait 20s, Switch OFF, wait 3s and then Switch ON the ECB’x’).

CASE 5 = Multiple LRUs Replacement (LEB, LPB, MPB, RPB, P’x’B, KDB, DPB, DEB, ECB’x’, PNB, RCB)

Note:

� The LRUs shall be replaced one at the time

� The ECB’x’ shall always be the first LRU to be replaced - switch the ECB’x’ OFF through the circuit breaker - unplug the harness(es) - remove first LRU - wait at least 5 sec - replace the LRU and hook up the harness - switch the ECB’x’ ON through the circuit breaker - wait at least 10 sec and then check that LRU Status LED is flashing green (refer to the

section 4.1 for LRU Status LED location) - repeat these steps for each LRU - command electrically the seat (through the passenger keypad) to move from TAKE-OFF to

BED position: make sure that no actuator hits the seat mechanical stops Note : DEB and / or KDB can be configured into "clone mode" as part of some specific programs. In

such case, 1 DEB and / or 1 KDB only control(s) the operation respectively for solenoids and / or keypad of both PAX. This particular function allows minimizing the number of LRUs used in double PAX seat configuration. In this case, after DEB or KDB replacement, it is required to carry out a double "power up" to keep actuators calibration without need for recalibration of the complete seat (Switch ON the ECB’x’ wait 20s, Switch OFF, wait 3s and then Switch ON the ECB’x’).

CAUTION: in case of difficulties, carry out a seat calibration (steps 1 thru 5 of section 6)


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8 CONFIGURATION MANAGEMENT AND RESPONSIBILITY SHARING

Any modification made to ZODIAC ACTUATION SYSTEMS equipments after delivery shall lead to a total responsibility transfer from ZODIAC ACTUATION SYSTEMS to the seat manufacturer. According to Airplanes Manufacturers requirements, requests for modification and service bulletins are necessary to apply any modification to ZODIAC ACTUATION SYSTEMS equipments. According to the EASA PART 21G regulation, the approval of the equipment modification is mandatory to allow ZODIAC ACTUATION SYSTEMS the release of an EASA Form 1. Should the Customer not be able to approve the modification, ZODIAC ACTUATION SYSTEMS will be in the obligation to submit the Request For Modification to the European Aviation Safety Agency (EASA). This may result in significant lead-time (several weeks) to obtain the EASA regulatory visa.


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ANNEX 1: "Trouble shooting based on status LED"


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ANNEX 2: "Clip connector installation"

Straight D-SUB connector: use clip connector reference 4170090540


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90° degrees D-SUB connector: use clip connector reference 4170090600

4516351100 revaa_instructions for seatnet advanced installationx draft v1

Documents

rev aa

system addition

deb details relative

project instructions

clip connector installation

ride system

pasquer system

boeing airplanes instructions