serv bul -0028 rev b ai2 07 24 06 - avionicinstruments.com number 1-002-0102-2062, (boeing p/n...

ssseeerrrvvviiiccceee bbbuuulllllleeetttiiinnn

from AVIONIC INSTRUMENTS INC.

Original Release: December 10, 2004 1-002-0102-1000-24-28 Revision B Release: July 24, 2006 of 34

AVIONIC INSTRUMENTS INC. AEROSPACE FOR INDUSTRY TM 1414 Randolph Avenue, Avenel, New Jersey 07001 Tel. 732-388-3500

International Sales: REA International Limited Tel. 732-382-7100 FAX: (732) 382-4996

`` ELECTRICAL POWER-STATIC INVERTER -

BRIDGE ASSEMBLY RESISTOR R170 REPLACEMENT I PLANNING INFORMATION

A. Effectivity- The following part numbers are effected by this service bulletin:

Part Number 1-001-0102-0265, (Boeing P/N S282T004-5), Model 1C1000-1A; Part Number 1-002-0102-0265, (Boeing P/N S282T004-5), Model 1C1000-1A; Part Number 1-002-0102-0714, (Boeing P/N S282T004-7), Model 1C1000-1B; Part Number 1-110-0102-0714, (Boeing P/N S282T004-7), Model 1C1000-1B; Part Number 1-111-0102-0714, (Boeing P/N S282T004-8), Model 1C1000-1B; Part Number 1-002-0102-1000, (Boeing P/N S282T004-10), Model 1C1000-1C-1000; Part Number 1-002-0102-2059, (Boeing P/N S282T004-15), Model 1C1000-1A; Part Number 1-002-0102-2060, (Boeing P/N S282T004-17), Model 1C1000-1B; Part Number 1-002-0102-2061, (Boeing P/N S282T004-18), Model 1C1000-1B; Part Number 1-002-0102-2062, (Boeing P/N S282T004-20), Model 1C1000-1C-2062. NOTES: 1) Part Number 1-002-0102-2062, (Boeing P/N S282T004-20), Model 1C1000-1C-2062, Serial Number CJ004439 and up are compliant with this service bulletin and only need a Nameplate change to Part Number 1-002-0102-2090, (Boeing P/N S282T004-30). 2) Part Number 1-001-0102-0265 and 1-002-0102-0265 are form, fit, function equivalent. This was only a part number change per service bulletin 1-001-5601-0010.

B. Reason- Service failures of resistor R170 in the Static Inverter models listed above has required Avionic Instruments to issue this service Bulletin.

C. Description- The Service Bulletin will replace the resistor R170 with a new part number and

relocate the new resistor to the solder side of the PCB. In addition, a Nomex pad will be installed on the opposing bracket support plate to avoid contact between resistor body and support bracket.






All R170 brown Carbon Composition Resistors (AI² P/N 1-001-0618-0005 (RCR42G273JR)) or (blue body) metal film resistor R170 (AI² P/N 1- 001-0618-0005 (FP42-27K-5%)) must be removed and replaced with a new (black body) resistor R170 (AI² P/N 1-001-0607-0146(PR2D-273-JB)).

Any previously installed (black body) resistor R170 (AI² P/N 1-001-0607-0120 (PR2-FSX-273-JB) which is damaged or located on the component side of the PCB must be removed and replaced with new (black body) resistor R170 (AI² P/N 1-001-0607-0146 (PR2D-273-JB). In addition a Nomex pad will need to be installed on the opposing bracket support plate to avoid contact between resistor body and support bracket.

Customers may return the unit to Avionic Instruments Inc. (AI²) Repair Station No. V5AR787J located at 1414 Randolph Ave, Avenel, New Jersey 07001 USA for the resistor component change and follow-up Acceptance Test Procedure Testing to be performed at no charge. AI² Repair Department will notify customer of applicable freight charges.

Modification kits will consist of (1) a new resistor (AI² P/N 1-001-0607-0146

(PR2D-273-JB)), (2) a #410 Nomex Insulation pad AI² P/N 1-001-1304-0059 (2.5” x 2.5”) (6.35 cm x 6.35 cm), (3) an applicable Nameplate, and (4) two rivets for attaching nameplate. If capacitors are required, they should be requested separately. Operators must identify the part number and serial number of units they intend to modify (if they wish to order them pre-marked) in order to properly complete nameplate; otherwise blank labels will be provided.

Part Number 1-002-0102-2062, (Boeing P/N S282T004-20), Model 1C1000-1C-

2062, Serial Number CJ004439 and up only requires a Nameplate change to Part Number 1-002-0102-2090, (Boeing P/N S282T004-30). Nameplate(s) and two (2) rivets per nameplate will be provided to customers with serial number CJ004439 and up at no charge for replacement at their facility or nameplate replacement can be accomplished by Avionic Instruments Inc. upon request. Please identify serial number to allow for pre-printing of nameplate, unless operator has metal stamp capability.

When field upgrades are performed by operators, it is requested that they notify

AI² Repair Department, within 30 days, at [email protected] or FAX (732) 382-4996 of unit S/N and date performed within 30 days.






Any units received in-house for service bulletin upgrade will be subjected to the ATP prior to the upgrade being performed. AI² will notify the airline customer of any out-of-specification condition noted during performance of the ATP. The unit would need to be repaired prior to the upgrade being initiated.

D. Approval- This Service Bulletin has been reviewed by the Federal Aviation Administration

(FAA) and the modifications herein comply with the Federal Aviation Regulations (FAR) and are FAA approved for installation on Boeing aircraft.

E. Manpower- The estimated time required to accomplish this task is two hours. F. Material- See Section III, MATERIAL INFORMATION Cost and Availability G. Tooling- Solder Iron

H. Weight and- Net weight change ±.01 lbs.

Balance

I. Electrical- Not Affected Load Data

J. Software - Not Applicable Accomplishment Summary K. Reference- (AI2 Internal File No. 1-001-5601-0028) L. Other Revised Component Maintenance Manuals, ATA No. 24-20-13 Publications and ATA No. 24-20-27 including this Service Bulletin will be available Affected- by March 31, 2005. M. Additional Not Applicable Comments-






II ACCOMPLISHMENT INSTRUCTIONS CAUTION: DISCONNECT INPUT POWER PRIOR TO HANDLING OR REMOVAL OF THE

COVER OF THE STATIC INVERTER TO PREVENT ELECTRICAL SHOCK. Replacement of carbon composition (brown body) or metal film (blue body) resistor R170 (AI² P/N 1-001-0618-0005) requires the installer to gain access to the Bridge Control Logic PCB Assembly shown in Figure 3 for -7, -17, -8, -18, -10 and -20 inverters and Figure 8 for -5 and -15 inverters. Note: If (black body) RCD resistor R170 (AI² P/N 1-001-0607-0120 (PR2-FSX-273-JB) is installed, no resistor change is required unless resistor is damaged or is installed on the component side of the Bridge Control Logic PCB Assembly. Verify that the resistor is installed on the solder side of the PCB assembly and that a .010” thick X 2.5” x 2.5” #410 Nomex insulator pad is installed on the mounting plate directly across from the PCB where R170 is located by inspection Visually inspect the resistor R170 for signs of overheat damage. If R170 show signs of overheat then replacement of Capacitors C51 and C50 is strongly recommended. Unlike the majority of the carbon composition resistors installed, the new ceramic coated wire wound resistor R170 (AI² P/N 1-001-0607-0146) will be installed on the solder side of the Bridge Control Logic PCB. Signs of R170 overheat damage include: darkening or dulling of the resistor body, discoloration or alteration of the bright color code bands, either of which can not be restored by simple dry mechanical wiping. Other signs of overheating are: the flaking, softening or material being easily removed from the surface of the resistor when probed with sharp instrument such as awl or dental pick. If R170 is suspected as having overheated, then Capacitors C50 and C51 should be replaced due to possible undetectable heat damage. Visually inspect the parts in proximity to R170 including C50 (AI² P/N 1-001-0320-0018) and C51 (AI² P/N 1-001-0320-0002), for signs of damage due to localized heating. Signs of capacitor overheat damage include: darkening and dulling of the capacitor’s uniform surface appearance, softening or component body material being easily removed from the surface of the capacitor. If C50 and C51 are suspected as having been exposed to overheating, then C50 and C51 must be replaced. In addition, the static inverter chassis should be inspected, paying special attention to the center cooling chamber, to ensure that it is free of dust, lint, particles or other substances which may impede proper airflow or cooling of the inverter. The cleaning procedure of the Component Maintenance Manual should be followed as appropriate after all work.






INSTRUCTIONS FOR MODIFYING PART NUMBER 1-002-0102-1000 (BOEING S282T004-10) AND PART NUMBER 1-002-0102-2062 (BOEING S282T004-20) STATIC INVERTER Note: If (black body) RCD resistor R170 (AI² P/N 1-001-0607-0120 (PR2-FSX-273-JB) is installed, no resistor change is required unless resistor is damaged or is installed on the component side of the Bridge Control Logic PCB Assembly. Verify that the resistor is installed on the solder side of the PCB assembly and that a .010” thick X 2.5” x 2.5” #410 Nomex insulator pad is installed on the mounting plate directly across from the PCB where R170 is located by inspection and then apply a new nameplate. 1. Remove two (2) screws, item 10, on bottom of the rear panel, item 5 on figure 1. 2. Remove eight (8) screws secured with loctite threadlocker, item 60, securing the heatsink, item 55, to

the bridge assembly, item 260, and the flyback assembly, item 220 on figure 1. 3. Carefully remove the heatsink, item 55 on figure 1. 4. Remove eight (8) screws secured with loctite threadlocker, item 70, securing the heatsink, item 65, to

the bridge assembly, item 260, and the flyback assembly, item 220 on figure 1. 5. Carefully remove the heatsink, item 65 on figure 1. 6. Remove ten (10) screws, item 50, on the front panel, item 100 on figure 1. 7. Remove eight (8) screws, item 45 on figure 1. The inner four (4) screws are secured with locktite

threadlocker. 8. Remove fourteen (14) screws, item 35 on figure 1. 9. Remove fourteen (14) screws, item 40 on figure 1. 10. Carefully remove the top cover, item 30 on figure 1. 11. Remove one (1) screw item 185, one (1) screw item 190, one (1) screw item 195, one (1) screw item

245, and One (1) screw item 250 on figure 1. 12. Remove the two (2) rear screws, item 80, securing the LPS/Bridge Logic Subassembly to the bottom

panel, item 75 on figure 1. 13. Carefully tilt the LPS/Bridge Logic Subassembly back. 14. Cut cable tie, item 265, figure 1 to gain access to the rear of the Bridge Logic Subassembly.






15. Using figure 3, locate position of R170, item 180. (Note: For some previously modified units the resistor may be located on the solder side of the board)

16. Desolder carbon composition or metal film resistor R170, (AI² P/N 1-001-0618-0005), item 180, and

remove. Discard old resistor. 17. Solder in new resistor R170 (AI² P/N 1-001-0607-0146), on solder side of board as shown in figure 9

and ensure the resistor body is installed 0.007-0.012 inches off PCB to ensure that adequate clearance between chassis, item 45, (figure 2).

18 Install a #410 Nomex insulator pad, item 150 (.010” thick X 2.5” x 2.5”) to the chassis, item 45, (figure

2), directly across from the PCB where R170 is now located. The Nomex insulator should be located at the bottom left, positioned even with the middle two standoffs. (See Figure 14) The insulator should be secured with 738 Electrical Sealant/ Adhesive or equivalent adhesive.

19. Replace cable tie, item 265, figure 1. 20. Carefully reassemble the rear section of the inverter, rotating assembly upward. 21. Replace the two (2) rear screws, item 80, securing the LPS/Bridge Logic Subassembly to the bottom

panel, item 75 on figure 1. 22. Replace one (1) screw item 185, one (1) screw item 190, one (1) screw item 195, one (1) screw item

245, and one (1) screw item 250 on figure 1. 23. Carefully install the top cover, item 30 removed in step 10. 24. Replace the eight (8) screws, item 40 on figure 1. The inner four (4) screws should be secured with

locktite threadlocker or equivalent. 25. Replace the fourteen (14) screws, item 35 on figure 1. 26. Replace the fourteen (14) screws, item 45 on figure 1. 27. Replace the ten (10) screws, item 50, on the front panel, item 100 on figure 1. 28. Carefully replace the heatsink, item 65 on figure 1. 29. Replace the eight (8) screws secured with loctite threadlocker, item 70, securing the heatsink, item 65,

to the bridge assembly, item 260, and the flyback assembly, item 220 on figure 1. 30. Carefully replace the heatsink, item 55 on figure 1.






31. Replace the eight (8) screws secured with loctite threadlocker, item 60, securing the heatsink, item 55,

to the bridge assembly, item 260, and the flyback assembly, item 220 on figure 1. 32. Carefully replace the rear panel, item 5 on figure 1. 33. Replace the two (2) screws, item 10, securing the rear panel, item 5 on figure 1. 34. Identification of the Static Inverter following modification:

1- Verify that the new nameplate has the Part Number 1-002-0102-2090 (Boeing SCD No. S282T004-30). Transfer the previous MOD-level data, unit serial number, date of Mfg (Year & Month) and Code of MFG information using metal stamp. See Addendum 1 for detailed Service Bulletin/MOD Level History. (Pre-printed nameplate can be obtained from Avionic Instruments Inc. by contacting Customer Service) 2.- Using the flat-head screwdriver, or equivalent, carefully pry the old nameplate from the front panel at location of rivets. 3.- Using pliers, or equivalent, carefully grasp rivet head and pull the rivet out. Repeat for second rivet. 4.- Discard used rivets and old nameplate. 5.- Position new nameplate on front panel as shown in figure 1, item 90 and carefully secure with new rivets, item 95 by tapping rivets lightly with hammer.

35. Perform functional testing defined in Addendum 2 to verify inverter performance. 36. Return inverter to stock or installation upon successful completion of functional test. 37. Should the inverter fail the functional test, test and troubleshoot unit or return to Avionic Instruments

Inc. for repair.






INSTRUCTIONS FOR MODIFYING PART NUMBER 1-111-0102-0714 (BOEING S282T004-8), PART NUMBER 1-002-0102-2061 (BOEING S282T004-18), PART NUMBER 1-002-0102-0714, 1-110-0102-0714 (BOEING S282T004-7) AND PART NUMBER 1-002-0102-2060 (BOEING S282T004-17) STATIC INVERTERS NOTE: It is recommended that static inverters configured as part number 1-002-0102-0714, 1-110-0102-

0714 (Boeing S282T004-7) should be upgraded to Part Number 1-111-0102-0714 (Boeing SCD S282T004-8) (Ref: Service Bulletin Number 1-002-0102-0714-24-18) before performing this upgrade. As of August 9, 1993, a -7 inverter could no longer be installed on 757/767 aircraft per AD 93-13-01. The nameplates already installed had to be inspected by August 9, 1994 and any -7 inverters found had to be replaced prior to further flight. See Addendum 1 for detailed Service Bulletin History.

Note: If (black body) RCD resistor R170 (AI² P/N 1-001-0607-0120 (PR2-FSX-273-JB) is installed, no resistor change is required unless resistor is damaged or is installed on the component side of the Bridge Control Logic PCB Assembly. Verify that the resistor is installed on the solder side of the PCB assembly and that a .010” thick X 2.5” x 2.5” #410 Nomex insulator pad is installed on the mounting plate directly across from the PCB where R170 is located by inspection and then apply a new nameplate.

1. Remove four (4) screws, item 55 and 55A securing front top cover, item 50, on figure 4. 2. Remove eight (8) screws from the front and side panels securing front top cover; two (2) of item 10A

and six (6) of item 60 on figure 4. 3. Carefully pry off front top cover, item 50 on figure 4. 4. Remove four (4) screws, item 70 securing rear top cover, and item 65, on figure 4. 5. Remove six (6) screws from the rear and side panels securing rear top cover; two (2) of item 205 and

four (4) of item 75 on figure 4. 6. Carefully pry off rear top cover, item 65 on figure 4. 7. Remove seven (7) screws, item 105 securing rear bottom cover, item 95, on figure 4. 8. Remove six (6) screws from the rear and side panels securing rear bottom cover; four (4) of item 100

secured with loctite threadlocker, and two (2) of item 45 on figure 4. 9. Carefully pry off rear bottom cover, item 95 on figure 4. 10. Remove three (3) screws from wire connections; one (1) item 30, one (1) item 30A and one (1) item 155

on figure 4.






11. Remove two (2) screws from wire connections; item 115 and item 135 on figure 4. 12. Cut cable tie, item 200, securing wires on figure 4. 13. Using figure 5, locate the 12 forward screws secured with loctite threadlocker, item 15, and remove side

plate items 20 and 10; rear plate stays attached to side plates. 14. Carefully release wires and lay Bridge Control Board Assembly flat. 15. Using figure 3, locate position of resistor R170, item 180. (Note: For some previously modified units

the resistor may be located on the solder side of the board) 16. Desolder carbon composition resistor or metal film R170, (AI² P/N 1-001-0618-0005), item 180, and

remove. Discard old resistor. 17. Remove 13 screws, item 35 on figure 5; holding Bridge Control Board, item 30 on figure 5 to the

chassis item 45 on figure 5. 18. Solder in new resistor R170 (AI² P/N 1-001-0607-0146), on solder side of board as shown in figure 9


19. Install a #410 Nomex insulator pad, item 150 (.010” thick X 2.5” x 2.5”) to the chassis, item 45, (figure

5), directly across from the PCB where R170 is now located. The Nomex insulator should be located at the bottom left, positioned even with the middle two standoffs. (See Figure 14) The insulator should be secured with 738 Electrical Sealant/ Adhesive or equivalent adhesive

20. Reinstall Bridge Control Board, item 30 on figure 5 to the chassis, item 45 on figure 5. 21. Using figure 5, locate side plates, items 10 and 20, install items 10 and 20 using twelve (12) screws

secured with loctite threadlocker, item 15, six (6) on each side plate. 22. Replace two (2) screws from wire connections; item 115 and item 135 on figure 4. 23. Replace three (3) screws from wire connections; one (1) item 30, one (1) item 30A and one (1) item 155

on figure 4. 24. Carefully replace rear bottom cover, item 95, on figure 4. 25. Replace six (6) screws from the rear and side panels securing rear bottom cover; four (4) of item 100

secured with loctite threadlocker or equivalent and two (2) of item 45 on figure 4






26. Replace seven (7) screws, item 105, securing rear bottom cover, item 95, on figure 4. 27. Carefully replace rear top cover, item 65 on figure 4. 28. Replace six (6) screws from the rear and side panels securing rear top cover; two (2) of item 205 and

four (4) of item 75, on figure 4. 29. Replace four (4) screws, item 70, securing rear top cover, item 65, on figure 4. 30. Carefully replace front top cover, item 50 on figure 4 and replace eight (8) screws from the front and

side panels securing front top cover; two of item 10A and six of item 60 on figure 4. 31. Replace four (4) screws, item 55 and 55A securing front top cover, item 50, on figure 4. 32. Identification of the Static Inverter following modification:

1- Verify that the new nameplate has the Part Number 1-002-0102-2089 (Boeing SCD No. S282T004-28) for 1-002-0102-2061 (Boeing SCD No. S282T004-18) or 1-111-0102-0714 (Boeing SCD No. S282T004-8). Transfer the previous MOD-level data, unit serial number, date of Mfg (Year & Month) and Code of MFG information using metal stamp. See Addendum 1 for detailed Service Bulletin/MOD Level History. (Pre-printed nameplate can be obtained from Avionic Instruments Inc. by contacting Customer Service) Verify that the new nameplate has the Part Number 1-002-0102-2088 (Boeing SCD No. S282T004-27) for 1-002-0102-2060 (Boeing SCD No. S282T004-17) or 1-002-0102-0714, 1-110-0102-0714 (Boeing SCD No. S282T004-7). Transfer the previous MOD-level data, unit serial number, date of Mfg (Year & Month) and Code of MFG information using metal stamp. See Addendum 1 for detailed Service Bulletin/MOD Level History. (Pre-printed nameplate can be obtained from Avionic Instruments Inc. by contacting Customer Service) 2.- Using the flat-head screwdriver, or equivalent, carefully pry the old nameplate from the front panel at location of rivets. 3.- Using pliers, or equivalent, carefully grasp rivet head and pull the rivet out. Repeat for second rivet. 4.- Discard used rivets and old nameplate. 5.- Position new nameplate on front panel, item 5 as shown in figure 4 and carefully secure with new rivets by tapping rivets lightly with hammer.

33. Perform tests defined in Addendum 2 to verify inverter performance.






34. Return inverter to stock or installation upon successful completion of tests. 35. Should the inverter fail the test, test and troubleshoot unit or return to Avionic Instruments Inc. for

repair.






INSTRUCTIONS FOR MODIFYING PART NUMBER 1-001-0102-0265 AND 1-002-0102-0265 (BOEING S282T004-5) AND PART NUMBER 1-002-0102-2059 (BOEING S282T004-15) STATIC INVERTER

NOTE : The following serial number units require special instructions to perform this modification. If you have the following serial number units, please return them to Avionic Instruments Inc. Repair Department for upgrade at no cost. Serial Numbers BV000105, BV000106, BV000107, BV000108, BV000111, BV000112, and BV000114. Part Number 1-001-0102-0265 and 1-002-0102-0265 are form, fit, function equivalent. This was only a part number change per service bulletin 1-001-5601-0010. Note: If (black body) RCD resistor R170 (AI² P/N 1-001-0607-0120 (PR2-FSX-273-JB) is installed, no resistor change is required unless resistor is damaged or is installed on the component side of the Bridge Control Logic PCB Assembly. Verify that the resistor is installed on the solder side of the PCB assembly and that a .010” thick X 2.5” x 2.5” #410 Nomex insulator pad is installed on the mounting plate directly across from the PCB where R170 is located by inspection and then apply a new nameplate. . 1. Remove four (4) screws, item 40 and 40A securing top cover, item 35, on figure 6. 2. Remove eight (8) screws from the front and side panels securing top cover, two (2) of item 10A and six

of item 40 on figure 6. 3. Carefully pry off top front panel, item 35 on figure 6. 4. Remove two (2) screws item 30 on top edge of rear panel item 25 on figure 6. 5. Remove four (4) screws item 60 securing top rear panel item 50 on sides on figure 6. 6. Remove four (4) screws item 55 securing top rear panel item 50 on top on figure 6. 7. Remove top rear panel item 50 on figure 6. 8. Remove two (2) screws item 30 on bottom edge of rear panel item 25 on figure 6. 9. Remove four (4) screws item 85 on figure 6 securing bottom rear panel item 80 on sides and seven (7)

screws item 90 securing bottom rear panel item 80 on bottom. 10. Remove bottom rear panel item 80 on figure 6. 11. Using figure 7, locate the twelve (12) screws, items 15 and 25 secured with Loctite thread locker or

equivalent, securing side plates items 10 and 20 (side plates will remain attached to rear plate).






12. Remove six (6) screws item 15 and remove the side plate heatsink item 10 on figure 7. 13. Remove six (6) screws item 25 and remove the side plate heatsink item 20 on figure 7. 14. Locate six (6) screws in figure 6 (items 22, 22A, 110, 110A, 115, and 126) and remove them. Cut wire

tie at item 110 on figure 6. Fold the Bridge Control Board Assembly down flat on workbench cutting any wires preventing the assembly from lying flat.

15. Remove thirteen (13) screws, item 35 on figure 7 holding the Bridge Control board, item 30 on figure 7

to the chassis, item 45 on figure 7. 16. Using figure 8, locate position of resistor R170, item 180. (Note: For some previously modified units

the resistor may be located on the solder side of the board) 17. Desolder carbon composition or metal film resistor R170, (AI² P/N 1-001-0618-0005) item 180, and

remove. Discard old resistor. 18. Solder in new resistor R170 (AI² P/N 1-001-0607-0146), on solder side of board as shown in figure 10


19. Install a #410 Nomex insulator pad, item 150 (.010” thick X 2.5” x 2.5”) to the chassis, item 45, (figure

7), directly across from the PCB where R170 is now located. The Nomex insulator should be located at the bottom left, positioned even with the middle two standoffs. (See Figure 14) The insulator should be secured with 738 Electrical Sealant/ Adhesive or equivalent adhesive

20. Reassemble Bridge Control Assembly reversing steps 14 and 15. Replace any wires cut in disassembly. 21. Using figure 7, locate side plate item 20. Install item 20 using the six (6) screws secured with locktite

threadlocker or equivalent. 22. Using figure 7, locate side plate item 10. Install item 10 using the six (6) screws secured with locktite

threadlocker or equivalent. 23. Position bottom rear panel item 80. 24. Install four (4) screws item 85 on figure 6 securing bottom rear panel item 80 on sides and seven (7)

screws item 90 securing bottom rear panel item 80 on bottom. 25. Install two (2) screws item 30 on figure 6 on bottom edge of rear panel item 25. 26. Position top rear panel item 50 on figure 6.






27. Install four (4) screws item 55 on figure 6 securing top rear panel item 50 on top. 28. Install four (4) screws item 60 on figure 6 securing top rear panel item 50 on sides. 29. Install two (2) screws item 30 on figure 6 on top edge of rear panel item 25. 30. Carefully position top front panel, item 35 on figure 6. 31. Install eight (8) screws from the front and side panels securing top cover, two (2) of item 10A and six

(6) of item 40 on figure 6. 32. Install four (4) screws, items 40 and 40A securing top cover, item 35, on figure 6. 33. Identification of the Static Inverter following modification:

1- Verify that the new nameplate has the Part Number 1-002-0102-2087 (Boeing SCD No. S282T004-25). Transfer the previous MOD-level data, unit serial number, date of Mfg (Year & Month) and Code of MFG information using metal stamp. See Addendum 1 for detailed Service Bulletin/MOD Level History. (Pre-printed nameplate can be obtained from Avionic Instruments Inc. by contacting Customer Service)

2.- Using the flat-head screwdriver, or equivalent, carefully pry the old nameplate from the front panel at location of rivets. 3.- Using pliers, or equivalent, carefully grasp rivet head and pull the rivet out. Repeat for second rivet. 4.- Discard used rivets and old nameplate. 5.- Position new nameplate on front panel, item 5 as shown in figure 6 and carefully secure with new rivets by tapping rivets lightly with hammer.

34. Perform tests defined in Addendum 2 to verify inverter performance. 35. Return inverter to stock or installation upon successful completion of tests. 36. Should the inverter fail the tests, test and troubleshoot unit or return to Avionic Instruments Inc. for

repair.






III MATERIAL INFORMATION The following items will be required to complete this service bulletin. Parts may be ordered individually or as a kit.

Description Part Number Qty Resistor , 27k, 5%, 2W, Flameproof, Non-inductive, Opt. S, max component body diameter 0.305”

AI² P/N 1-001-0607-0146 # (RCD Components Inc. P/N PR2D-273-JB)

1

Capacitor, Metallized-Polypropylene Film (if required) ( C50 )&

AI² P/N 1-001-0320-0018 A/R

Capacitor, Metallized-Polypropylene Film (if required) ( C51 )&

AI² P/N 1-001-0320-0002 A/R

#410 NomexTM Insulation pad, 0.010 Thick x 2.5” x 2.5” AI² P/N 1-001-1304-0059 1

Dow Corning 738 General-purpose Acetoxy RTV Electrical Sealant/ Adhesive (or equivalent non-conductive flexible Electrical Sealant adhesive)

AI² P/N 1-001-2302-0026 (Mfg. P/N 738 Electrical Sealant) A/R

Solder Sn60/40 Type Sn60/40 A/R The following items will be required to complete service bulletin marking, as applicable.

Description Qty 1-001-2501-0184 *Nameplate for P/N 1-002-0102-2087 (S282T004-25) 1 1-001-2501-0185 *Nameplate for P/N 1-002-0102-2088 (S282T004-27) 1 1-001-2501-0186 *Nameplate for P/N 1-002-0102-2089 (S282T004-28) 1 1-001-2501-0187 *Nameplate for P/N 1-002-0102-2090 (S282T004-30) 1 1-001-3001-0043 Rivet, Stud, Grooved 2 Loctite Thread locker #242 Thread-Locking Compound (or equivalent) A/R

NOTES:

* Only one (1) nameplate of the listed is required depending on unit being modified. Nameplates may be obtained from Avionic Instruments Inc. by contacting Repair Department by Telephone (732) 388-3500, FAX (732) 382-4996 or Email [email protected]. Please provide the information from the existing nameplate including (1) Serial Number, (2) Mod Level, (3) Code/Date of MFG, and (4) YR/MONTH, if possible. Facilities performing modification with capability of imprinting on a metal nameplate may request the blank nameplates.






# Resistors may be obtained from Avionic Instruments Inc. at no cost or direct from the resistor manufacturer RCD Components Inc, Manchester, NH (603)669-0054 or www.rcdcomponents.com. Requests should be sent to Avionic Instruments Inc. Customer Service Department and reference service bulletin number.

&

Capacitors may be obtained from Avionic Instruments Inc. Requests should be sent to Avionic Instruments Inc. Customer Service Department and reference service bulletin number.

As an option, operators may request Kits for their unit which includes: (1) resistor (AI² P/N 1-001-0607-0146(PR2D-273-JB)) (1) #410 Nomex Insulation pad (2.5” x 2.5”) (6.35 cm x 6.35 cm) (AI² P/N 1-001-1304-0059) (1) applicable Nameplate (2) Rivet, Stud, Grooved (AI² P/N 1-001-3001-0043)

Inverter Part/Model Number Kit Number Part Number 1-001-0102-0265 and 1-002-0102-0265 (Boeing P/N S282T004-5), and Part Number 1-002-0102-2059, (Boeing P/N S282T004-15), Model 1C1000-1A.

AI² P/N 1-001-6301-0016

Part Number 1-002-0102-0714, 1-110-0102-0714 (Boeing P/N S282T004-7), and Part Number 1-002-0102-2060, (Boeing P/N S282T004-17), Model 1C1000-1B.

AI² P/N 1-001-6301-0017

Part Number 1-111-0102-0714, (Boeing P/N S282T004-8), and Part Number 1 002-0102-2061, (Boeing P/N S282T004- 18) Model 1C1000-1B.

AI² P/N 1-001-6301-0018

Part Number 1-002-0102-1000, (Boeing P/N S282T004-10), Part Number 1-002-0102-2062, (Boeing P/N S282T004-20), Model 1C1000-1C.

AI² P/N 1-001-6301-0019

Send Kit request to Avionic Instruments Inc. Customer Service Department by Telephone (732) 388-3500, FAX (732) 382-4996 or Email [email protected]. Operators should include number of kits required, the part number and serial number of units they intend to modify in order to properly complete nameplate. Kit requirement is one per inverter.






FIGURE 1

FINAL ASSEMBLY MODEL 1C1000-1C (S282T004-10 and -20) STATIC INVERTER






FIGURE 2 EXPLODED VIEW OF BRIDGE ASSEMBLY OF S282T004-10 & -20

150






FIGURE 3 BRIDGE CONTROL LOGIC PCB ASSEMBLY

(S282T004-7, S282T004-8, S282T004-10 and S282T004-20) STATIC INVERTER






FIGURE 4 FINAL ASSEMBLY MODEL 1C1000-1B (S282T004-7&-17 AND S282T004-8&-18)

STATIC INVERTER






FIGURE 5 EXPLODED VIEW OF BRIDGE ASSEMBLY OF S282T004-7&-17 AND S282T004-8&-18

150






FIGURE 6 FINAL ASSEMBLY MODEL 1C1000-1A (S282T004-5&-15) STATIC INVERTER






FIGURE 7

EXPLODED VIEW OF BRIDGE ASSEMBLY OF S282T004-5&-15

150







(S282T004-5&-15) STATIC INVERTER







(S282T004-7&17, S282T004-8&18 AND S282T004-10&20) PLACEMENT OF R170

0.020”- 0.030” for -5/-7/-8/-15/-17/-18 0.007”- 0.012” for -10/-20






FIGURE 10 BRIDGE CONTROL LOGIC PCB ASSEMBLY (S282T004-5 and -15)

PLACEMENT OF R170

0.020”- 0.030” for -5/-7/-8/-15/-17/-18 0.007”- 0.012” for -10/-20






FIGURE 11 NAMEPLATE (p/n 1-001-2501-0185) MARKING INFORMATION FOR

MODEL 1C1000-1C (S282T004-30) STATIC INVERTER

FIGURE 12 NAMEPLATE (p/n 1-001-2501-0185) forS282T004-27 and

NAMEPLATE (p/n 1-001-2501-0186) for S282T004-28 MARKING INFORMATION






FIGURE 13 NAMEPLATE (p/n 1-001-2501-0184) MARKING INFORMATION FOR

(S282T004-25) STATIC INVERTER






TOP

R170NOMEX

0.30" (0.762 cm)

1.0"( 2.54 cm)

3.0” ( 7.62cm)

4.5" (11.43cm)

NOTE: RTV to be applied to Nomex pad prior to placement on bracket support plate

FIGURE 14

NOMEX PLACEMENT ON BRIDGE CONTROL LOGIC BRACKET SUPPORT PLATE






ADDENDUM 1 PART/MODEL NUMBER SERVICE BULLETIN HISTORY






ADDENDUM 2 FUNCTIONAL TEST REQUIREMENTS

1. GENERAL

This section contains instructions for testing the part number 1-002-0102-2059, 1-002-0102-2060, 1-002-0102-2061, 1-002-0102-2062, 1-001-0102-0265, 1-002-0102-0265, 1-002-0102-0714, 1-110-0102-0714, 1-111-0102-0714, 1-002-0102-1000, 1-002-0102-2087, 1-002-0102-2088, 1-002-0102-2089, and 1-002-0102-2090 Static Inverters. Acceptance testing will be successfully performed according to the procedure outlined in this section before reintroducing the inverter into service. The purpose of this test is to verify that the static inverter meets all critical parameters and operates within the specified limits.

2. TEST EQUIPMENT

A. Required Test Equipment

Table 1 specifies the test equipment that is required for this test procedure. Alternate test equipment may be substituted provided its accuracy and performance are suitable for obtaining data consistent with the requirements of this procedure.

3. TEST SET-UP

WARNING: DISCONNECT ALL POWER FROM THE STATIC INVERTER BEFORE MAKING CONNECTIONS OR PERFORMING ASSEMBLY OR DISASSEMBLY OPERATIONS.

A. Test Setup (See Figure 15)

(1) Connect dc power supply, dc ammeter (with shunt, if required), and dc voltmeter to input of

unit-under-test (UUT) -- TB1 on front panel. (Large diameter stud is positive (+); small diameter stud is negative (-).

(2) Connect ac ammeter, ac voltmeter, and no load to pins 1 and 3 of J1 on the front panel of the

inverter.

NOTE: For regulation, power and efficiency measurements to be valid the AC voltage measurement must be made at P1/J1 and the DC voltage measurement must be made directly at TB1.






The equipment listed in Table 1 below is required to perform acceptance testing. The equipment listed is only intended as a guide to the application of such equipment. Alternate equipment may be substituted provided that, their accuracy and performance meet the requirements of the test. Actual test equipment used may vary depending on availability at test locations.

TABLE 1: TEST EQUIPMENT

EQUIPMENT MFG MODEL RATING DC Power Supply Sorenson DCR40-125A 0-40 V, 0-125 A DC Voltmeter Weston 931 0-50 V ±2% DC Ammeter Weston 931 0-100 A ±0.5% Shunt, if required AC True RMS Voltmeter Weston 433 0-150 V ±2% AC Ammeter Weston 904 0-50 A ±2% SPST Switch Any Any 0.5A min. 1000W Linear Load Any Any 1000W, 1.0 pf

NOTES: 1) AC ammeter may require external shunt 2) DC ammeter may require external shunt or current transformer or may be self contained. or be self contained.

FIGURE 15

ELECTRICAL TEST CONNECTIONS






4. TEST PROCEDURE

This procedure establishes the operating conditions for the unit. Perform steps of test procedure in listed order. Figure 16 specifies limits for each measured value. Testing must be stopped if any reading is out of tolerance and should be continued only after all faults have been corrected.

(1) No-Load Test

(a) Verify that there is No Load connected to the output of the inverter at pins of J1-1 and J1-3.

(b) Adjust input dc power supply to 24 -2/+4 Vdc. (c) Measure and record input current, output voltage. Record measured values and compare to

limits in Figure 16.

(2) Full-Load Test

(a) Connect a 1000 W, nominal linear load to J1-1 and J1-3 of inverter. (b) Adjust input dc power supply to 24 -2/+4 Vdc. (c) Measure and record input current and voltage, and output current and voltage.

Record measured values and compare to limits in Figure16. (d) Calculate the efficiency at 1000 W load and at input voltages of 22 V or greater using the

following equation:

η = WattsV I

out

in in**100

The calculated efficiency at full-rated load must be at least 82% at input voltages

of 22 V or greater.






(3) Remote On/Off Test

(a) Adjust dc power supply to 24 -2/+4Vdc. (b) Close remote on/off switch for 5 seconds. This grounds Pin J1-4. (c) The inverter output should be zero. (d) Open remote on/off switch. Verify that output returns to normal limits. (e) Turn off dc power supply and disconnect load.

5. TEST LIMITS, MEASURED VALUES

Check all readings against values specified in Figure 16. Repairs are required if input current, output voltage, or efficiency is not within tolerance.

Input Output

Voltage (Vdc)

Current (Adc)

Voltage (Vrms)

Current (A)

Nominal Load (W)

22-28 3.5 (1) 110-120 0 0

22-28 70 (1) 110-120 8.7 (2) 1000

NOTES: (1) Worst case input current limit for 22 V input, 1000 W load. (2) Nominal output current, load dependent. 1000 W current equal to output voltage divided by load

resistance (typically 13.2 ohms at 1000 W).

FIGURE 16

LIMITS FOR MEASURED VALUES

serv bul -0028 rev b ai2 07 24 06 - avionicinstruments.com number 1-002-0102-2062, (boeing p/n...

Documents