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SpectroLink Setup and Operation Manual

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1. 68 SPECTROLAB 24 SpectroLink BOEING CO Setup and Operations Manual 033600 Revision G 1 INTRODUCTION The SpectroLink System Figures 1 3 was created to upgrade the capabilities of the SX 16 Nightsun and SX 5 Starburst Searchlights With the SpectroLink System an external system such as a camera thermal imaging system moving map or other system can be linked to the Searchlight This enables users to synchronize Searchlight movements with the movements of the linked system This manual supports white light configurations only Furthermore the SX 16 Nightsun also supports an in flight changeover IFCO function and can be referenced in the SpectroLink Setup and Operation Manual IFCO Addendum 033600 1 Features and Operations are applicable to current hardware and software revisions Contact Spectrolab Customer Service for compatibility inquiries 1 1 Description 1 1 1 FEATURES AND CAPABILITIES FOR STANDARD AND ENHANCED UNITS The Standard SpectroLink System has the following capabilities SpectroLink Features Capabilities Supports an external linked system such as a camera thermal imaging system moving map or other system Includes new motor encoders to control azimuth and elevation Supports a new Control Box analog that replaces the original SX 5 SX 16 Control Box Connectors J1 Control Box J3 Junction Box J4 encoder J5 link J8 program J9 setup J2 maintenance Supports a D
2. F Sanchez11 607 4 Source Spectrolab Inc Page 3 of 68 SPECTROLAB 24 SpectroLink BOEING CO Setup and Operations Manual 033600 Revision G Table of Contents 1 INTRODUCTION mL 6 1 1 Br tiegei me 6 1 1 1 Features and Capabilities for Standard and Enhanced Units 6 1 2 Spectrolink connectors ports sss 7 1 3 About This 7 1 4 Read Obey Keep Instructions 7 1 5 Installer 8 1 6 Quick Start Guide 8 1 7 Du E 9 1 8 Applicable 9 2 SYSTEM COMPONENTS 7i anon bant enesenn enesenn ennenen en renee 10 3 MOUNTING THE SPECTROLINK COMPONENTS eese 11 3 1 Mounting the SpectroLink Integration Box All Users 11 3 2 Mounting the Dual Motor Encoder Harness Assembly Upgrade Users Only 11 3 2 1 Description of the Dual Motor Encoder Harness 11 3 2 2 Mounting Procedure for the SX 16 00 12 3 2 3 Mounting Procedure for the SX 5 14 4 CO
3. rte eee en nnne nennen enn nne 25 5 2 Setup MENU 26 5 2 1 Mechanical Gimbal Stop Adjustment 26 5 2 2 Using the Setup 26 5 2 2 1 Computer Connection for Setup sss eem 26 5 2 2 2 HyperTerminal eee eee 27 5 2 2 3 Setup Menu Display during the Power Up Calibration 30 5 2 3 Programmable Settings and 31 6 OPERATION m 34 6 1 Safety rrr titt o eR Ie HERES 34 6 2 SpectroLink Operations eee e eee eee 35 6 3 Control Box Operationen 35 6 4 Control Box FUNCHONS eot der RR eR NERA 36 6 5 Digital Hand Controller emen 37 6 5 1 COMMANDS Switches ee eee 37 6 5 2 Faut LED S cq 39 6 6 Control Box Operational 40 6 7 Digital Hand Controller Operational SEQUENCE 4 2 41 6 8 In Flight Calibration Offset 42 6 8 1 In Flight Calibration Procedure Offset SearchiighD see eee 42 6 9 Using
4. om V L1 29 za Lr a 033589 132432 032432 1 US2436 052435 101 l ENCOOER ENCODER ans 052013 932015 101 C c mae um Li A L E L T AM R A DAN 11 11 TAM H H Zan g L Ll 033823 033588 055587 GIMEAL ASSY 030040 130 Sx 5 TO CAMERA SYSTEM Figure 32 5 5 STARBURST QUICK CONNECT SYSTEM SX 5 Interconnect Note Enhanced Control Box 030039 22 is an alternate for Standard Control Box 030039 1 68
5. Area code Phone Connect using M Figure 18 Selection 27 SPECTROLAB 21 SpectroLink Tor Setup and Operations Manual 033600 Revision G 4 Setthe following baud rate settings see Figure 19 When complete click on the Apply button to set these settings and then click on the OK button 1 Properties Port Settings Bits per second 920 oooO O v Data bits Parity v Stop bits v Elow control v Figure 19 COM Selection Settings 5 Click on File and Properties On the Properties window click on the Settings tab On the Settings tab make sure it looks like window in 20 6 On the Settings tab click on the ASCII Setup button Verify the settings match the ASCII Setup in Figure 21 HyperTerminal Properties Connect Settings Function arrow and ctl keys act as Terminal keys O Windows keys Backspace key sends Cui Gel Space Ctil H Emulation Auto detect v Telnet terminal ID ANS Backscroll buffer lines 500 Play sound when connecting or disconnecting Input Translation ASCII Setup Figure 20 Terminal Settings 28 SPECTROLAB SpectroLink Setup and Operations Manual BOEING COMPANY 033600 Revision G New Connection Properties Settings ASCII Setup ASCII Sending Send line ends with line feeds Echo typed characters locally Line delay
6. A 28 V Power Input 28 VDC 0 V open B Lamp Start Output 28 VDC Open 28 V Return Input 0 VDC Open Focus Output 28 VDC Ground E System Power Output 28 VDC Open On Off F IFCO Motor Output 28 VDC Ground G IFCO Indicator Input 28 VDC Ground H Spare wer J IFCO Motor Output 28 VDC Ground K Elevation Up Output 28 VDC Ground L Elevation Down Output 28 VDC Ground M Azimuth Left Output 28 VDC Ground N Azimuth Right Output 28 VDC Ground 51 SPECTROLAB A BOEING COMPANY SpectroLink Setup and Operations Manual 033600 Revision G 1 AZ Channel Output 0 VDC 5 V Ground to azimuth Ground encoder 2 AZ Channel index Input 5 VDC TTL positive logic pulses to SpectroLink Integration Box electronics 3 AZ Channel A Input 5 VDC TTL positive logic pulses to SpectroLink Integration Box electronics AZ Channel 5 V Output 5 VDC 5 V to azimuth encoder AZ Channel B Input 5 VDC TTL positive logic pulses to SpectroLink Integration Box electronics 7 EL Channel Output 0 VDC 5 V Ground to elevation Ground encoder 8 EL Channel index Input 5 VDC TTL positive logic pulses to SpectroLink Integration Box electronics 9 EL Channel A Input 5 VDC TTL positive logic pulses to SpectroLink Integration Box electronics 10 EL Channel 5 V Output 5 VDC 5 V to elevation encoder 11 EL Channel B Input 5 VDC TTL positive logic pulses to SpectroLink Integration Box
7. Setup 9 pin connector Maintenance 9 pin connector Linked system connector 28 volts nominal 2 volts 7 0 L x 6 0 W x 3 2 H 49 SPECTROLAB 24 SpectroLink BOEING Setup and Operations Manual 033600 Revision G 11 CONNECTOR PIN ASSIGNMENTS The tables in this section show the pin assignments for the SpectroLink Integration Box connectors including descriptions of their input output functionality Connector J1 to Control Box Input Voltage Non Pin Name Output Operational Operational A 28 V Power Output 28 VDC Open B Lamp Start Input 28 VDC Open C 28 V Return Output 0 VDC Open D Focus Input 28 VDC Ground E System On Off Input 28 VDC Open F IFCO Motor Input 28 VDC Ground G IFCO Indicator Output 28 VDC Ground H Link On Off Input 28 VDC Ground J IFCO Motor Input 28 VDC Ground K Elevation Up Input 28 VDC Ground L Elevation Down Input 28 VDC Ground M Azimuth Left Input 28 VDC Ground N Azimuth Right Input 28 VDC Ground Link Status Output 5 VDC Ground U Shield N A Note Pin B hold the Start On Off switch on the Control Box in the On position until the Lamp ignites Pin P Link Status is only available for 4 and 22 Control Boxes 50 SPECTROLAB _ 24 SpectroLink BOEING COMPANY Setup and Operations Manual 033600 Revision G
8. FLEX CABLE J1 TO BULK HEAD CABLE ASSY M CABLE ASSY gt lt SPECTROLINK FRONT SIDE amp OK NS XP 5 16 OR SX 5 EE EE J6 I O REAR TO CUSTOM END GIMBAL ASSY SHOWN FOR t REFERENCE ONLY J6 REAR TO SIDE CAR OR mna mmm 8 8 CABLE ASSY Lamp PWR Motor IR Focus REF SEARCHLIGHT 28V A N PUB TO ESET NS SX 16 OR SX 5 J BOX Aircraft REFERENCE ONLY Power INSIDE AIRCRAFT OUTSIDE AIRCRAFT CABLE ASSY INPUT FROM GIMBAL MOTOR ENCODERS CABLE ASSY BULK HEAD to DUAL MOTOR ENCODER ADAPTER HARNESS Figure 29 65 SPECTROLAB EE _ E SpectroLink BOEING COMPANY Setup and Operations Manual 033600 Revision G 15 2 Functional Block Diagram 2 BUT sige ARCRAFT AIRCRAFT AIRE AFT BULKHEAD FILTER HOOD BLY ONLY nin GH EAL Emir ice BLY dumper Come Etme El QUER Lamp PINA m ara DECO NNECT re DEARC HLIGHT JUNCTION BO SPECTROLINK SYSTEM X 16 X 16 IFCO X SEARCHLIG HTS BLOCK DIAGRAM Figure 30 System Functional Block Diagram Note Enhanced Control Box 030039 22 is an alternate for Standard Control Box 030039 1 66 SP
9. If SpectroLink fails to operate properly please contact Spectrolab Customer Service at 800 936 4888 If necessary to operate an 5 16 Nightsun amp or 5 5 Starburst Searchlight without a functioning SpectroLink Integration Box the following is the procedure for bypassing the SpectroLink Integration Box 1 Disconnect the Control Box cable 033590 from the SpectroLink Integration Box J1 connector 2 Disconnect cable 033589 from the SpectroLink Integration Box J3 connector and from the J1 Junction Box connector 3 Connect the Control Box cable 033590 directly to the J1 Junction Box connector bypassing the SpectroLink Integration Box 4 As aresult the SX 16 Nightsun or SX 5 Starburst Searchlights can be operated without the SpectroLink Box 9 CUSTOMER SERVICE For questions or require assistance with the SpectroLink System please contact Spectrolab Customer Service at 800 936 4888 48 SPECTROLAB Analog 10 SPECIFICATIONS SPECTROLINK INTEGRATION BOX 24 SpectroLink BOEING COMPANY Setup and Operations Manual 033600 Revision G Control Box IFCO Control Box Digital Digital Hand Controller Discrete I O Signals or Nightsun Sidecar connected to I O connector Control Box connector Junction Box J Box connector Encoder connector Digital Hand Controller Optional connector Optional for Sidecar use or for remote function capabilities Program 15 pin connector
10. electronics 12 Sheild N A 0 VDC Shield 13 SPARE to 15 52 SPECTROLAB 21 SpectroLink BOEING Setup and Operations Manual 033600 Revision G Connector J5 Link Connector Pin Name Input Voltage Notes Output Operational 1 N C N A 2 RS232 TX Input 12 VDC RS232 levels 3 RS232 RX Output 12 VDC RS232 levels 4 N C N A 5 Receive Link Output 5 VDC RS422 TTL levels 6 Receive Link Output 5 VDC RS422 TTL levels 7 Serial Ground 0 VDC GND to linked system 8 Transmit Link Input 2 5 VDC RS422 TTL differential 9 Transmit Link Input 2 5 VDC RS422 TTL differential 10 N C N A 11 NIC N A 12 28VDC switched aux Output 28VDC 28VoutputO0 5 13 System power on off Input OV GND on Open off 14 Start Enable Input OV GND lamp start open dont care 15 28 V Ground Output 0 VDC Ground Hold pin 14 grounded 0 volts then release when lamp is ignited Caution Serial interfaces to SpectroLink should 1 to 1 ie RX to RX TX to TX Reference Cable Assembly SpectroLink to Camera System Drawing 033591 for serial interface connection NOTE The reversal of TX to RX amp vice versa is performed internal to SpectroLink so that a straight cable no crossing of signals can be used 53 SPECTROLAB E SpectroLink BOEING COMPANY Setup and Operation
11. 2 RS232 Receive Output 12 VDC RS232 levels 3 RS232 Transmit Input 12 VDC RS232 levels 4 5 Serial Communication Input 0 VDC Ground Ground Co N 59 SPECTROLAB BOEING SpectroLink Setup and Operations Manual 033600 Revision G 12 GLOSSARY AND ACRONYMS Term Definition Cables The SpectroLink System uses cables to connect the 1 SpectroLink Integration Box to the Junction Box 2 SpectroLink Integration Box to the Gimbal encoder 3 Junction Box power to the lamp and focus motor and 4 SpectroLink Integration Box to the Control Box Calibration Mode Also called rate mode calibration mode interrupts the synchronization of Searchlight and linked system movements consequently by using the Control Box positioning control or the Hand Controller joystick the position of the Searchlight can be changed independently of the linked system enabling a user to align the position of the Searchlight more closely with the position of the linked system during an in flight calibration procedure Control Box An analog control unit SpectroLink requires an upgraded Control Box for its new functions Dual Motor Encoder An integrated unit that includes all wiring the azimuth Harness Assembly Encoder upgraded elevation motor encoders that control Searchlight movements the adapter and the connectors for the signal and power Part of t
12. Controller status LED s are not currently used 6 6 Control Box Operational Sequence To operate the Searchlight using the Control Box perform the following steps in the sequence listed Place the Start On Off switch in the middle on position to turn on power to the system SpectroLink will begin an initialization sequence Use the Up Down Left Right directional control to position the Searchlight away from the cockpit area before starting the Searchlight in flight to avoid exposing the pilot to excessive glare Toturn on the Lamp momentarily press the Start On Off switch in the up Lamp On position until the Lamp has ignited A typical start time is approximately 1 5 seconds depending on lamp life and ambient temperature Release the switch immediately after the lamp starts Holding the switch in the start position after the lamp turns on or during a prolonged series of strobes will cause premature failure of some starting circuit components and the xenon gas lamp Adjust the Up Down Left Right directional switch as desired to aim the Searchlight Note Due to the programmed soft stops clutch slip does not occur on the SpectroLink System because of the software stops Adjust the Searchlight focus by pressing the Focus button until desired beam width is obtained To enable the linked system to control the Searchlight momentarily press LINK CAL 40 SPECTROLAB 24 SpectroLink BOEING Setup
13. Figure 25 Searchlight redirected around the Keep Out Zone in Link Mode 43 SPECTROLAB SpectroLink BOEING CO Setup and Operations Manual 033600 Revision G 6 10 Keep Out Zone in Rate Mode During operator use with the Control Box or Hand Controller otherwise known as Rate Mode Not Linked the Searchlight will avoid the keep out zone by dropping out of the keep out area as shown in Figure 26 For instance when the operator is commanding or slewing the Searchlight clockwise to the right the Searchlight will drop down once it reaches the left side boundary of the keep out zone and stay below the keep out zone area while still allowing the operator to move the Gimbal in the azimuth direction as normal Once the Searchlight is out of the keep out zone boundary the Searchlight resumes normal operation in both azimuth and elevation direction Note that the Searchlight does not automatically move up in elevation once out of the keep out zone F E 555555555550 lt 525060505066 lt 9 6065 06056565 60605646526050505050505050609 KEEP OUT ZONE 00202 KNS ESI E ND START Figure 26 Searchlight Redirected around the Keep Out Zone in Rate Mode 6 11 Connector Functions J6 The functions are provided via J6 connector on the rear of the SpectroLink Box J6 is a D Subminiature female 25 contacts connector part No 207463 1 This section will list the pin number and provide
14. and Operations Manual 033600 Revision G Before landing the aircraft press the Lamp Off button to turn off the xenon gas arc lamp Note To allow for proper cooling of the Lamp do not turn off the system power for a minimum of 5 10 minutes after Lamp has been extinguished e If the aircraft has minimal ground clearance or if the Searchlight is mounted on the nose of the aircraft verify the light is raised to a horizontal position before landing the craft especially in rough terrain Turn the system off by placing the Start On Off switch to the off position 6 7 Digital Hand Controller Operational Sequence To operate the Searchlight using the digital Hand Controller perform the following steps in the sequence listed To turn on power to the SpectroLink system move the locking PWR ON OFF switch to the up position The Searchlight will begin an initialization process to find the mechanical stops for azimuth and elevation Initialization time varies depending upon the location of the stops SpectroLink motors are the high speed type with encoders that operate at 20 degrees sec If the system power was initiated on another control unit the Digital Hand Controller will also be in communication with the SpectroLink when the locking PWR ON OFF is switched to the up position Use the Force controller for directional control to point the Searchlight away from the cockpit area before starting the Searchlight in flight This avoids ex
15. bulkhead through connector e Connect one end of the control cable 033590 to the bulkhead through connector e Connect the other end of the cable to the J1 connector on the SpectroLink Integration Box 4 1 3 2 SPECTROLINK INTEGRATION BOX TO LINKED SYSTEM While you are located in the compartment where the SpectroLink Integration Box is installed Connect one end of the cable 033591 to the J5 connector on the SpectroLink Integration Box e Connect the other end of the cable to the bulkhead through connector On the other side of the bulkhead e Connect one end of the cable to the bulkhead through connector e Connect the other end of the cable to the appropriate connector on the linked system 4 1 3 3 SPECTROLINK INTEGRATION BOX TO GIMBAL MOTOR ENCODERS Connect one end of the cable 033588 to the J4 connector on SpectroLink Integration Box e Connect the other end of the cable to the bulkhead through connector On the other side of the bulkhead e Connect one end of the cable 033587 to the bulkhead through connector e Connect the other end of the cable to the connector on the Gimbal 4 1 3 4 SPECTROLINK INTEGRATION BOX TO JUNCTION BOX Connect one end of the cable 033589 to the J3 connector on the SpectroLink Integration Box e Connect the other end of the cable to the J1 connector on the Junction Box 4 1 3 5 SPECTROLINK INTEGRATION BOX TO PROGRAM UPDATE PORT The 15 pin Program port J8 is to be used for updates
16. can be mounted in the following ways The SpectroLink Integration Box can be mounted on top of the existing Junction Box If this option is chosen use the matching screw locations on the Junction Box lid to receive the attachment screws from the SpectroLink Mounting Plate 033747 then use 4 10 32 UNC screws for front and 4 10 32 UNC screws for the back to fasten the SpectroLink to the mounting plate Figure 5 Perspective View of the SpectroLink Integration Box 3 2 Mounting the Dual Motor Encoder Harness Assembly Upgrade Users Only 3 2 1 DESCRIPTION OF THE DUAL MOTOR ENCODER HARNESS ASSEMBLY To utilize the capabilities of the SpectroLink Integration Box it is necessary to replace the old Gimbal adapter and motors with the new Dual Motor Encoder Harness Assembly which is supplied with the SpectroLink Upgrade Kit The Dual Motor Encoder Harness Assembly is an integrated unit Figure 6 and includes the following components SPECTROLAB E SpectroLink BOEING Setup and Operations Manual 033600 Revision G A motor encoder that controls azimuth movements and a motor encoder that controls elevation movements All necessary wiring connecting the motor encoders to the adapter An adapter with two connectors already potted in the adapter one connector for the signal to the motor encoders and another connector to supply power to the motor encoders Motor Encoder Ea ee ELEVATION m Ad
17. in the down direction The Elevation Invert function will reverse the movement This is functional during normal use Rate Mode and will be disabled in Link Mode STOW Momentary To Stow the system momentarily press the STOW toggle switch in the up position as described in the SETUP section of this manual At this time the lamp will extinguish and the STOW status LED will illuminate and the system will not respond to joystick input commands until the operator exits Stow mode To exit the Stow mode momentarily press the STOW switch or momentarily press the CAGE toggle switch This function is disabled when the system is in link mode FOCUS FOCUS Momentary The FOCUS switch is used to focus continuously from narrow and wide beam Pressing the FOCUS switch up will cycle through the focus Bi directional focus allows the user to adjust the beam by toggling the switch up or down This feature is available on SpectroLink Boxes with supporting hardware in conjunction with enhanced Searchlights CAGE Momentary To Cage the system momentarily press the CAGE switch in the down position At this time the system will move to the Cage position and illuminate the CAGE status LED To exit the Cage mode either press the Cage switch once again or simply move the joystick to regain rate control of the Searchlight Other ways to exit the Cage mode are to command the Searchlight to Stow or Link This function is disabled when the system is in Link m
18. information about each pin s function For proper connections reference the schematic diagram in the Interface Example section of this manual Also reference the Connector J6 portion of the Connector Assignment section for logic descriptions System Power On J6 1 The System Power On pin 1 is a discrete signal that will turn on the system power to SpectroLink Box System Power On is the equivalent function as the Control Box ON OFF START Digital Hand Controller PWR On and are connected directly to the Power On logic and do not require any CPU control Note The SpectroLink System will be turned ON by any of the three System Power On ON OFF START or PWR On switches The System will be turned off only when all three switches if connected are in the OFF position J6 2 Reference document number 033600 1 for pin assignment and description J6 3 Reference document number 033600 1 for pin assignment and description 44 SPECTROLAB K SpectroLink BOEING CO Setup and Operations Manual 033600 Revision G J6 4 This pin is not used at this time Lamp OFF J6 5 Lamp Off input command will extinguish the Lamp This command has the same function as the Lamp OFF on the Control Box Lamp Off on the Hand Controller Link J6 6 Link input command will enter system in Link mode Note The system must be un stowed to enter Link mode Focus J6 7 The Focus input command is used to initiate the adjustm
19. necessary anytime the position of the mechanical hard stops that control elevation or azimuth travel limits are changed The calibration process aligns the elevation and azimuth positions to zero degrees Once the calibration is performed it will be necessary to re program Cage Stow and Keep Out zone The Nightsun amp SpectroLink system if purchased as a complete system will be calibrated in house with default mechanical hard stop positions However these mechanical hard stops may be changed to a variety of positions in both azimuth and elevation In order to calibrate the Gimbal positioning a Gimbal hard stop calibration must be performed When a manual Gimbal hard stop calibration is performed through the Setup menu selection of the axis will be required azimuth or elevation to calibrate Once prompted follow the instructions to complete the calibration process IMPORTANT It is strongly recommended to inspect settings such as HOME CAGE STOW and the KEEP OUT zone once the system has been calibrated Attention Gimbal calibration is necessary anytime mechanical hard stops have been changed Gimbal Soft Stop Gaps Once the SpectroLink has been calibrated to the Gimbal azimuth and elevation limits the software will create a soft stop gap to prevent the Gimbal from hitting the hard stop during normal operation The default value for each soft stop gap is 3 degrees Each soft stop gap for the upper and lower elevation st
20. the Linked System Mode with Programmable Keep Out Zone 43 6 10 Keep Out Zone in Rate 44 6 11 VO 6 aedi ir 44 7 2 47 8 TROUBLESHOOTING sss ess sees ese sese sese eenn ennenen de nanny ec ska soa enen 48 9 CUSTOMER 48 10 SPECIFICATIONS SPECTROLINK INTEGRATION BOX 49 11 CONNECTOR PIN 55 6 1 ereer enrere neee 50 12 GLOSSARY AND 60 13 VO INTERFACE EXAMPLE 1222 ceniza rara ca sata cn tnra aaa cna nata tn vaga tensa 62 14 CONTROL UNIT FUNCTIONALITY enrere ereenn ee 63 14 1 Command 63 14 2 Status 64 15 SYSTEM 8 2 20 04 42 aa nose cana 65 15 1 Block Diagram for SpectroLink senenn enn 65 15 2 Functional Block Diagram sci vac aras Taz an 66 15 3 SX 16 Interconnect 67 15 4 SX 5 Interconnect
21. to SpectroLink Integration Box software program updates 4 1 3 6 SPECTROLINK INTEGRATION BOX TO PROGRAMMABLE SETUP PORT The 9 pin Setup port J9 is used to program the keep out zones azimuth and elevation rates protocols Cage Stow etc 4 1 3 7 SPECTROLINK INTEGRATION BOX TO MAINTENANCE PORT The functionality of the spare 9 pin RS 232 Maintenance port has not been determined at this time SPECTROLAB 24 SpectroLink BOEING CO Setup and Operations Manual 033600 Revision G 4 1 3 8 SPECTROLINK INTEGRATION BOX TO DIGITAL HAND CONTROLLER OPTION The 13 pin Hand Controller connector J7 interfaces to a Nightsun Digital Hand Controller via two cables Integration Box to bulkhead 032639 and bulkhead to Hand Controller 032638 4 1 3 9 SPECTROLINK INTEGRATION BOX TO I O CONNECTOR OPTION The connector J6 is located in the rear of the SpectroLink Box It is a DB 25 pin connector and is used when remote capabilities are required for control of the Searchlight functions or for acquiring status of the system in real time The input and output signals of the connector are 5V TTL compatible for direct connect to computer PLC or I O card This connector can also be used as a second Control Box by using a Nightsun Sidecar 4 1 4 CONNECTIONS TO THE JUNCTION BOX 4 1 4 1 JUNCTION BOX TO INTERNAL AND EXTERNAL BULKHEAD While you are located in the compartment where the Junction Box is installed e Connect
22. two digit suffix are supplied consequently the suffix 101 indicates that the cable terminates in a 90 angle connector instead of a straight one 033588 SpectroLink Integration Box to bulkhead for Gimbal motor encoders 033587 Bulkhead from SpectroLink Integration Box to Gimbal motor encoders 032432 or 032432 101 Junction Box to bulkhead for lamp and focus motor 032435 or 032435 101 Bulkhead from Junction Box to lamp and focus motor Optional Components 032638 Digital Hand Controller cable to Bulkhead 032639 Digital HAND CONTROLLER Bulkhead to Spectrolink Box Call for Details cable to Customer Interface Figure 16 Cable Part Numbers and Connections 22 SPECTROLAB 24 SpectroLink BOEING CO Setup and Operations Manual 033600 Revision G 4 2 3 CONNECTIONS TO THE SPECTROLINK INTEGRATION BOX 4 2 3 1 SPECTROLINK INTEGRATION BOX TO CONTROL BOX e Connect one end of the Control Box cable 033582 to the Control Box e Connect the other end of the cable to the bulkhead through connector of 033590 cable Connect one end of the control cable 033590 to the internal bulkhead type connector e Connect the other end of the cable to the J1 connector the SpectroLink Integration Box 4 2 3 2 SPECTROLINK INTEGRATION BOX TO LINKED SYSTEM e Connect one end of the cable 033591 to the J5 connector on the SpectroLink Integration Box e Connect the other end of the cable to the bulkhead connector of customer ca
23. 0 milliseconds Character delay 0 milliseconds ASCII Receiving Append line feeds to incoming line ends Force incoming data to 7 bit ASCII v Wrap lines that exceed terminal width Figure 21 ASCII Setup 7 Lastly Click the OK button to close up the Settings window 29 SPECTROLAB E SpectroLink BOEING CO Setup and Operations Manual 033600 Revision G 5 2 2 3 SETUP MENU DISPLAY DURING THE POWER UP CALIBRATION SEQUENCE When the Nightsun Searchlight Gimbal starts up it performs a routine called the Power Up Sequence During this sequence the Gimbal finds a mechanical hard stop in both azimuth and elevation it then calibrates its relative position from these hard stops On the Control unit place the Power switch in the ON position to begin the system initialization process During this process the Gimbal automatically moves up and clockwise to ensure hard stops have not been altered since the last operation When the Power Up sequence is completed the Power Up intro menu will display on the computer screen Figure below and prompt instructions SPECTROLINE Software OX KAAS Version X X Build OX AM 200 Sspectrolab Inc Please wait Figure 22 Power Up Intro Menu When the Gimbal completes the Power Up Sequence the Searchlight will stop at the HOME position At this time the Setup Menu will prompt you to press the ENTER
24. 2507 Link Interface Control Document for Nightsun II Nightsun amp and SpectroLink 033712 SpectroLink Calibration Kit SPECTROLAB 2 SYSTEM COMPONENTS Please make sure that the components shown in Figure 4 except for those marked as an BOEING option are in the shipping cartons SpectroLink Setup and Operations Manual 033600 Revision G Components and Options SpectroLink Integration Box Standard Configuration shown Cables to Connect the SpectroLink Integration Box to the Junction Box Connect the Junction Box power to the lamp and focus motor Connect the SpectroLink Integration Box encoder signal to the Gimbal Connect the SpectroLink Integration Box to the Control Box Control Enhanced Dual Motor Encoder Harness Assembly Control A N 9 Optional poe u m Sidecar Digital Hand A Optional Controller geo Optional Figure 4 SpectroLink Components SPECTROLAB 24 SpectroLink BOEING CO Setup and Operations Manual 033600 Revision G 3 MOUNTING THE SPECTROLINK COMPONENTS e Users who are upgrading their existing SX 16 Nightsun or SX 5 Starburst with a SpectroLink Upgrade Kit should follow all of the instructions in this section 31 Mounting the SpectroLink Integration Box All Users The SpectroLink Integration Box Figure 5
25. ECTROLAB BOEING 15 3 SX 16 Interconnect INSIDE AIRCRAFT SpectroLink Setup and Operations Manual 033600 Revision G TO CAMERA SYSTEM SX 16 NIGHTSUN WHITE LIGHT SX 16 NIGHTSUN GOLD COLLECTOR QUICK CONNECT SYSTEM Figure 31 5 16 Interconnect 34 ANS AG im 7 20 050039 1 4 22 py x z imd imas SX 16 SPECTROLINK HS L H CONTROL BOX ASSEMBLY 171 HM AS SaaS PEN 017500 SERIES e 032400 SERIES im FE SEARCHLIGHT ASSY 1L CM AS E E AS JUNCTION BOX ASSY 0 B TT M ams 2 ANS uae RS B aag AR 26 aag gt Tera D33588 A Ed py ewe aas 20 AME 4 ae Y PE 1 LITE 1 d 033537 1 137432 032432 101 HAHH TT SPECTRDLINK BOX ASSY i AZIMUTH ELEWTON pd Lawm ENCODER ENCODER 1 CONTROLLER 1 C Lam 75 1 LL EG cam E ANG B ANG Pt ET Haimi dD 032013 022013 101 i 1 C LS i A Dae Lam LO o LSR C E LS H CL e UNAM LLC L agi e 1 1 Las C TE PNS Li r E a
26. Focus Elevation Invert Stow Cage Link BOEING SpectroLink Setup and Operations Manual 033600 Revision CONTROL UNIT FUNCTIONALITY Command Matrix CONTROL BOX HAND SIDECAR CONTROLLER PWR ON PWR ON PWR OFF PWR OFF AZ EL AZ EL N ON OFF UP DOWN LEFT RIGHT START LAMP OFF FOCUS LAMP ON LAMP ON v LAMP OFF LAMP OFF V FOGUS FOCUS vV EL INVERT S LINK ON OFF LINK ON OFF LINK CAL G 63 SPECTROLAB BOEING 14 2 Status Matrix SPECTROLINK CONTROL STATUS BOX LED LIGHT Power On n Lamp On NN Elevation Invert EE Siow Cage p Link a Fan Fault PF Gimbal Fault Po Temp Fault fF COM Fault P Keep Out Fault EE System Fault EE Gen 1 Hand Controller only HAND CONTROLLE R SYSTEM SYS L SpectroLink Setup and Operations Manual 033600 Revision G SIDECAR INK OM GE EN NEN NENNEN HE E L L L pg 64 SPECTROLAB EE _ 21 SpectroLink BOEING Setup and Operations Manual 033600 Revision G 15 SYSTEM DIAGRAMS 15 1 Block Diagram for SpectroLink System SPECTROLINK SYSTEM ENHANCED OPTIONAL DIGITAL HAND CONTROL Miu NN CONTROLLER BOX 2 CONTROL BOX REARSIDE CABLES LAMP OFF INPUT FROM OTHER LINKED SYSTEM EE EE EE J5 LINK TO CAMERA SYSTEM REAR SIDE
27. Hand Controller Functions This section provides the operations for the Digital Hand Controller with the SpectroLink system 6 5 1 COMMANDS SWITCHES Power On Off When the system turned on the power up initialization sequence will begin as described in SETUP section of this manual LAMP ON OFF To start the lamp press the LAMP ON OFF toggle switch in the up position until the lamp has ignited The LAMP ON LED will indicate that the lamp is on To extinguish the lamp press the LAMP ON OFF switch in the down position LINK Momentary To enter Link mode momentarily press the LINK toggle switch in the up position To exit Link mode momentarily press the LINK 37 SPECTROLAB K SpectroLink BOEING CO Setup and Operations Manual 033600 Revision G The LINK LED will blink until the Searchlight position and the linked system are matched synchronized at which time the LINK LED will light up solid The LINK LED will also blink when then linked system is beyond the Searchlight s range of travel invalid data is received from the linked system and when the linked system is off Note The system must be un stowed to enter link mode EL INV Momentary Elevation Invert allows the operator to reverse the elevation movement To invert the elevation movement momentarily press the EL INV switch By default the Searchlight will move up when pressing the joystick in the up direction and will move down when the joystick is pressed
28. MPONENT 17 4 1 16 Teli o 17 4 1 1 17 4 12 17 4 1 3 Connections to the SpectroLink Integration 19 4 1 3 1 SpectroLink Integration Box to Control Box or Optional Control Box 19 4 1 3 2 SpectroLink Integration Box to Linked System sse 19 4 1 3 3 SpectroLink Integration Box to Gimbal Motor Encoders 19 4 1 3 4 SpectroLink Integration Box to Junction 19 4 1 3 5 SpectroLink Integration Box to Program Update 19 4 1 3 6 SpectroLink Integration Box to Programmable Setup 19 4 1 3 7 SpectroLink Integration Box to Maintenance 19 4 1 3 8 SpectroLink Integration Box to Digital Hand Controller option 20 4 1 3 9 SpectroLink Integration Box to I O Connector option 20 4 1 4 Connections to the Junction BOX triente te ed ertet ect cr rae y 20 4 1 4 1 Junction Box to Internal and External Bulkhead sees eee eee 20 4 1 4 2 Junction Box to Internal and Ext
29. N C N A 17 Link Status Output BV 5V Ground 18 Stow Status Output BV 5V Ground 55 BPE CTR UL AB BOEING COMPANY SpectroLink Setup and Operations Manual 033600 Revision G N A 19 20 System Flight Status Output 5V 5V Ground 21 Communication Flight Output 5V 5V Ground Status 22 Status Output BV 5V Ground 23 Power Status Output BV 5V Ground 24 Ref 033600 1 Output BV 5V Ground 56 BPE CTR UL AB BOEING COMPANY SpectroLink Setup and Operations Manual 033600 Revision G 1 Gimbal Receive Input RS422 Pulse 2 GimbalReceive Input RS422 Pulse 3 Gimbal Transmit Output RS422 Pulse 4 Gimbal Transmit Output RS422 Pulse 5 28V Ground 6 28VDC 7 PowerOn amp Off Input Ground 8 Lamp Start Input Ground Open 9 RS422 RTN 57 SPECTROLAB A BOEING COMPANY SpectroLink Setup and Operations Manual 033600 Revision G 1 2 RD RS232 3 TD RS232 4 DTR RS232 5 GND RS232 6 DSR RS232 7 TRS RS232 8 CTS RS232 9 10 SMODEO Input 3 3V No Connect 11 SMODE1 Input 3 3V No Connect 12 aV ppp po p 14 15 58 BPE CTR UL AB 24 SpectroLink BOEING COMPANY Setup and Operations Manual 033600 Revision G 1
30. SPECTROLAB SpectroLink BOEING CO Setup and Operations Manual 033600 Revision G SpectroLink Setup and Operation Manual Spectrolab Inc Illumination Products www Spectrolab com SEE DOCUMENT ECR FOR APPROVAL SIGNATURES Source Spectrolab Inc Page 1 of 68 SPECTROLAB K SpectroLink BOEING CO Setup and Operations Manual 033600 Revision G O 2011 Spectrolab Inc All rights reserved This document contains material including proprietary information protected by copyright No part of this document may be reproduced or transmitted in any form by any means or for any purpose without the express written consent of Spectrolab Users of this document agree not to manufacture produce sell or lease any product copied from or based on the information contained in this document without prior written consent from Spectrolab Unauthorized reproduction or distribution of copyrighted material in the United States is subject to civil and criminal remedies pursuant to Title 17 of the United States Code Spectrolab Inc 12500 Gladstone Avenue Sylmar CA 91342 USA 818 365 4611 www Spectrolab com Document 033600 Printed in the United States of America Source Spectrolab Inc Page 2 of 68 SPECTROLAB 21 SpectroLink BOEING Setup and Operations Manual 033600 Revision G CHANGE RECORD NC GP Estrada Sanchez 9 18 06 B E Quezada PerECO 22 1307 D E Quezada PerECO
31. STOW switch again Every 30Hz or 33msec an automatic self test will take place in the SpectroLink CPU to Hand Controller This is a continuous test for detecting system errors and checking the 5422 communications path Prior to landing the craft press the Lamp Off button to turn off the xenon gas arc lamp and allow the lamp to cool properly by leaving the system on for at least 5 minutes e If the aircraft has minimal ground clearance or if the Searchlight is mounted on the nose of the aircraft make sure to raise the light to a horizontal position before landing the craft especially in rough terrain or simply verify the system is in the Stow position To power down the Searchlight move the locking switch to the PWR OFF position This automatically turns the Hand Controller SpectroLink Box and Searchlight OFF 6 8 In Flight Calibration Offset The In Flight Calibration feature may be used to add a position offset to the Searchlight in order to match the Searchlight beam to the visible target on the camera To calibrate the position of the Searchlight and linked system more accurately than is possible with the on the ground calibration it is necessary to perform an in flight calibration with the Control Box or Hand Controller In Flight Calibration may be performed in two ways The first method is by using the joystick to move the Searchlight spot location to the center of the camera crosshairs while the camera stays i
32. ade Kit Refers to the components used to modify an existing SX 16 Nightsun amp or SX 5 Starburst Searchlight the SpectroLink Upgrade Kit includes the following components SpectroLink Integration Box Control Box Dual Motor Encoder Harness Assembly and cables 5 5 Starburst 500 watt short arc xenon Searchlight does not support IFCO option 5 16 Nightsun 1600 watt short arc xenon Searchlight supports IFCO option 61 SPECTROLAB E SpectroLink BOEING COMPANY Setup and Operations Manual 033600 Revision G 13 VO INTERFACE EXAMPLE OUT LINWX OUT STOW OUT FWR ST T OUT IPCO INDICATOR STAT 1 045 Ri IFCO INDICATOR R2 GAGE R3 SYSTEM FAULT Rt LINK Ld b x 19 0HN 01 190 0HN m 267 7 R5 POWER RE coum FAULT RI STOW he AN A i n2 19 0HN BL 19 0HN Db Figure 27 Connector Interface Note If interfacing to 28V lamps or logic a voltage translation will be required by using an Opto Isolator relay or transistor as shown in Figure 28 for a simple circuit using a PS2801 1 Opto Isolator to keep grounds separated To28V 16 Pins 17 24 Lampor Logc J6 Pin 14 av GND 28 GND Figure 28 Circuit Example 62 SPECTROLAB 14 14 1 SPECTROLINK COMMANDS Power On Power Off Force Controller 8 way switch controller Lamp On Lamp Off
33. apter Motor Encoder N NEED en ww E Figure 6 Dual Motor Encoder Harness Assembly 3 2 2 MOUNTING PROCEDURE FOR THE SX 16 NIGHTSUNG To mount the Dual Motor Encoder Harness Assembly Disconnect the existing cables that connect the Gimbal motors to the Junction Box retain these power cables for reuse when re connecting the unit Remove the old adapter motors and the four hole gaskets for each of the old motors Using the same mounting location and screw holes that held the old adapter to the Gimbal attach the new adapter to the Gimbal Figure 7 Using the same mounting locations and screw holes that were used for the old motors attach the new motor encoders for azimuth and elevation Figures 7 and 8 Adapter Azimuth Motor Encoder Elevation Motor Encoder 12 SPECTROLAB E SpectroLink BOEING COMPANY Setup and Operations Manual 033600 Revision G Figure 7 View of SX 16 Nightsun amp Gimbal Assembly Adapter Elevation Motor Encoder Figure 8 Side View of SX 16 Nightsun amp Gimbal Assembly SPECTROLAB 24 SpectroLink BOEING CO Setup and Operations Manual 033600 Revision G 3 2 3 MOUNTING PROCEDURE FOR THE SX 5 STARBURST To mount the Dual Motor Encoder Harness Assembly Disconnect the existing cables that connect the Gimbal motors to the Junction Box retain these power cable
34. ble from camera on the other side of the bulkhead e Connect the other end of the customer cable to the appropriate connector on the linked system 4 2 3 3 SPECTROLINK INTEGRATION BOX TO GIMBAL MOTOR ENCODERS e Connect one end of the cable 033588 to the J4 connector on the SpectroLink Integration Box e Connect the other end of the cable to the bulkhead through connector On the other side of the bulkhead e Connect one end of the cable 033587 to the bulkhead through connector e Connect the other end of the cable to the connector on the Gimbal 4 2 3 4 SPECTROLINK INTEGRATION BOX TO JUNCTION BOX e Connect one end of the cable 033589 to the J3 connector on the SpectroLink Integration Box e Connect the other end of the cable to the J1 connector on the Junction Box 4 2 3 5 SPECTROLINK INTEGRATION BOX TO PROGRAM UPDATE PORT The 15 pin Program port J8 is to be used for software updates to SpectroLink Integration Box 4 2 4 SPECTROLINK INTEGRATION BOX TO PROGRAMMABLE SETUP PORT The 9 pin Setup port J9 is used to program the keep out zones azimuth and elevation rates protocols Cage Stow etc The cable supplied with the system is a commercial DB 9 male to DB 9 female cable wired straight through not null modem 4 2 5 SPECTROLINK INTEGRATION BOX TO MAINTENANCE PORT The functionality of the spare 9 pin RS 232 Maintenance port has not been determined at this time 23 SPECTROLAB K SpectroLink BOEING CO Setup an
35. d Operations Manual 033600 Revision G 4 3 Connections to the Junction Box 4 3 1 JUNCTION BOX POWER TO SEARCHLIGHT AND GIMBAL e Connect one end of the cable 032432 or 032432 101 to the J2 connector on Junction Box e Connect the other end of this cable to the internal bulkhead connector on the other side of the bulkhead e Connect one end of the cable 032435 or 032435 101 to the bulkhead connector e Connect the other end of the cable to the connector on the Searchlight and Gimbal 4 3 2 JUNCTION BOX TO SYSTEM POWER INPUT Ensure the Start System switch of the Control Box Hand Controller Sidecar is in the Off position Then make sure that the Lamp switch also is in the Off position e Connect one end of the power cable 032013 or 032013 101 to the J3 connector on the Junction Box e Connect the other end of the power cable to the power source 24 SPECTROLAB K SpectroLink BOEING CO Setup and Operations Manual 033600 Revision G 5 SETUP 5 1 linking 5 1 1 LINK SERIAL INTERFACE The design of the SpectroLink System adds the capability to link to another Gimbaled system via a serial interface using the RS 232 or RS 422 standards This serial connection is accomplished via a D connector on the SpectroLink Integration Box J5 The default interface is RS 232 If linking to a camera that uses RS 422 interface select the RS 422 in the Setup Menu under the Link System Interface menu NOTE To achieve the best p
36. der Rotated 180 to Other Side of Gimbal SPECTROLAB K SpectroLink BOEING CO Setup and Operations Manual 033600 Revision G Azimuth Motor Encoder with Mounting Location Rotated Counterclockwise 180 Elevation Motor Encoder Figure 12 Side View of SX 5 Starburst Gimbal Assembly with Mounting Location of Azimuth Motor Encoder Rotated 180 to Other Side of Gimbal SPECTROLAB 21 SpectroLink BOEING Setup and Operations Manual 033600 Revision G 4 COMPONENT CONNECTIONS 41 SX 16 NIGHTSUNG 4 1 1 OVERVIEW Figure 13 depicts connections between SpectroLink components that are attached to an SX 16 Nightsun The figure below identifies each component and the connectors to each component and the cables attached to the connectors identified by part number 033582 033590 Control Box Linked System SpectroLink Option Integration Digital Hand Controller 032432 or 032432 101 032433 032433 101 Assembly Box 032013 or 032013 101 033590 Bulkhead Through System Connector Powver Input Figure 13 Main Components Cables and Connectors with SX 16 Nightsun amp 4 1 2 CABLING The SpectroLink System relies on various cables for power and communication The use of bulkhead through connectors makes possible a variety of installations Figure 14 depicts the cable part numbers and the connections Spectrolab cable part numbers normally appear one of t
37. ect the keep out option by typing the corresponding number on the menu To program a keep out zone the menu will prompt to use the Control Box or Hand 32 SPECTROLAB K SpectroLink BOEING CO Setup and Operations Manual 033600 Revision G Controller to position the Searchlight adjust the azimuth and elevation to a START and END position where the keep out zone should begin or end When the Searchlight is at the START position press the ENTER key to save this position In the same manner move the Searchlight to the END position and press the ENTER key to save this position The keep out zone may be deleted by entering the number 0 zero Gimbal Slew Rate The slew rate determines the speed at which the Gimbal moves for either azimuth or elevation The slew rate is determined solely according to the operator s preference A Gimbal slew rate affects the functionality of the Gimbal only during Rate Mode except Link Mode The default Gimbal slew rate is 75 of maximum rate However the Gimbal slew rate may be increased or decreased by selecting another rate Once the menu of setup options is displayed on the computer select the slew rate option by typing the corresponding number shown on the screen When prompted enter the axis azimuth or elevation to be changed and then type a slew rate percentage up to 100 Restore Factory Default System Settings This function allows the user to reset the system to the factory defa
38. ent of the Searchlight beam from narrow to wide The Focus command performs the same function as the FOCUS pushbutton the Control Box and the FOCUS toggle switch on the Hand Controller Stow J6 8 The Stow input command is used to position the Searchlight in the Stow position The Stow command performs the equivalent function as the Hand Controller STOW switch To exit the Stow mode momentarily press the STOW switch or momentarily press the CAGE toggle switch This function is disabled when the system is in Link mode Lamp Start J6 9 The Lamp Start input command is used to start the lamp The Lamp Start command performs the same function as the LAMP ON of the Hand Controller and START on the Control Box Cage J6 10 The Cage input command is used to position the Searchlight in the Cage position The Cage command performs the same function as the CAGE switch on the Hand Controller This function is disabled when the system is in Link mode System Reset J6 11 The System Reset input command performs a processor CPU reset and to be used if the system is not responding to any commands Note The System will perform a power on reset and will initiate movement of the Searchlight as is performed at power on sequence Elevation J6 12 The Elevation command is intended for a Force Controller input for Searchlight s elevation axis Azimuth J6 13 The Azimuth command is intended for a Force Controller input f
39. ernal Searchlight Gimbal Bulkhead 20 4 1 4 3 Junction Box to System Power 20 4 2 P EE 21 4 2 1 uu 21 4 2 2 e ll 22 4 2 3 Connections to the SpectroLink Integration 23 4 2 3 1 SpectroLink Integration Box to Control 23 4 2 3 2 SpectroLink Integration Box to Linked Svsienm sees eee eee eee 23 4 2 3 3 SpectroLink Integration Box to Gimbal Motor Encoders 23 4 2 34 SpectroLink Integration Box to Junction BOX sese sese eee eee 23 4 2 3 5 SpectroLink Integration Box to Program Update 23 4 2 4 SpectroLink Integration Box to Programmable Setup Port 23 4 2 5 SpectroLink Integration Box to Maintenance 23 4 3 Connections to the Junction sese eee eee ee 24 4 3 1 Junction Box Power to Searchlight and 24 4 3 2 Junction Box to System Power 24 SPECTROLAB 24 SpectroLink BOEING CO Setup and Operations Manual 033600 Revision G 5 1 IG P 25 5 1 1 Link Serial 9 25 5 1 2 Compatibility
40. he motor encoder that is attached to the Gimbal IFCO In flight changeover the IFCO function enables users to change the light filter on an SX 16 Nightsun during flight IFCO Control Box option Analog Control Box that provides IFCO functionality to the SX 16 Nightsun Junction Box Also referred to as a J Box it serves as a connection point for system components Linked Position Mode When operating in linked position mode the Searchlight and linked system move in synchronization with each other Linked System An external system such as a camera imaging system moving map or other system that can be linked to a Searchlight so that controlled movements of the external system can be synchronized with movements of the linked Searchlight Motor upgraded Part of the motor encoder that is attached to the Gimbal Rate Mode See calibration mode SpectroLink Refers to the main component of the SpectroLink System and Integration Box the SpectroLink Upgrade Kit 60 SPECTROLAB 1 SpectroLink Setup and Operations Manual 033600 Revision G BOEING Term Definition SpectroLink System Refers to an entire SpectroLink System which includes the following components SpectroLink Integration Box Searchlight Gimbal Junction Box Control Box and cables it also refers to a new SpectroLink installation which already includes these components SpectroLink Upgr
41. igital Hand Controller with full status capabilities through connector J7 Not available on Standard Configuration 033537 I O capability for full external remote control capabilities through connector J6 Not available on Standard Configuration 033537 Figure 1 Features and Capabilities SPECTROLAB 24 SpectroLink BOEING CO Setup and Operations Manual 033600 Revision G 1 2 Spectrolink connectors ports Ji ENCODER CONTROL BOX LEI RAND CONT Figure 2 Front View of the SpectroLink Integration Box 033537 1 Note Connector J7 not available on Standard Configuration 033537 6 0 3 Rear View of the SpectroLink Integration Box Note Connector J6 not available on Standard Configuration 033537 1 3 About This Manual This manual provides the following 1 information to assist in mounting mount connect set up and use the SpectroLink System and 2 information to maintain the SpectroLink System and obtain service 1 4 Read Obey and Keep Instructions To ensure the safety of personnel and equipment it is important to read and obey all warnings cautions and instructions in this document documents that accompany the Searchlight and instructions for the equipment Keep this document for reference the inf
42. ilure with the linked system If this condition occurs it may be that the SpectroLink does not detect valid data from the linked system due to incompatibility Cage Status J6 22 The Cage Status indicates when the Searchlight is in the Cage position Power Status J6 23 The Power Status indicates that the system power is on J6 24 Reference document number 033600 1 for pin assignment and description 5VDC J6 25 Provides 5VDC for external use 500 mA max 46 SPECTROLAB E SpectroLink BOEING CO Setup and Operations Manual 033600 Revision G 7 MAINTENANCE The SpectroLink System is designed for minimal maintenance Only the exterior and fan may require occasional cleaning When cleaning the SpectroLink Integration Box make sure that the SpectroLink Integration Box has no power and that the Searchlight system power is off 1 To clean the exterior surface use only a damp cloth with mild non abrasive soap Make sure that no water enters the fan inlet or vent holes 2 To clean the fan do not remove the fan screen Instead use a soft bristle brush to remove dirt Do not push dirt into the interior of the SpectroLink Integration Box To prevent loose dirt from entering the SpectroLink Integration Box through the fan opening turn the SpectroLink Integration Box upside down when cleaning the fan 47 SPECTROLAB K SpectroLink BOEING CO Setup and Operations Manual 033600 Revision G 8 TROUBLESHOOTING
43. ir enm d 26 032639 1053002 t v 8 CONTROL ASSEMELY 08 1 SIDECAR iz Tin H tt H HH H E HETT it 1 L EET 1 L L E J L ppaam L 033623 L ijse 5 033588 E E GIMBAL ASSY i 2 619059 130 230 022955150 67 SPE 15 4 CTROLAB BOEING SX 5 Interconnect Diagram SpectroLink Setup and Operations Manual 033600 Revision G Ede CONTROL BOX ASSENBLY ele le Rd 083657 1 3 032788 SPECTRDLINK J BOX ASSY IDISTL HAND AE CE T ESOS CC CONTROLLER Come 1 1 CRW Vl Cea PEO 34M H aa l Laa C CAR 11 Vl raga CET LIII Vl Pata XHSCLI C l Vl raaa ELEC 1 1 I EAAELL Od Creme Vl ose PPO 1 Ce tod aiai T T anian Z as d D32638 032633 INSIDE AIRCRAFT L 1 HE 29 S es A 024711 SERIES es o 032500 SERIES 3148 L SEARCHUGHT ASSY za ANS 6 Bia zac 22 ENS 20 BAG Ta H EEA za za 22 490 032347 5 5 H 2 um L aw JUNCTION BOX ASSY D aig Or
44. ire Searchlight system by supplying power When this switch is placed in this position the system will perform a Power Up Initialization Sequence The Searchlight will move clockwise and up until reaches both the azimuth and elevation mechanical hard stops then the Searchlight will stop once the Home position is reached At this time the system is ready for operation Power Off The lower off position turns off power to the entire system Note With the switch in the off position the fan that cools the Searchlight s internal components will also be off If turning off the system to extinguish the lamp return the switch to the On position to ensure that the lamp has had the appropriate time to cool 5 10 minutes after lamps is extinguished prior to turning the system off Lamp Off Momentary To extinguish the lamp momentarily press the LAMP OFF button This feature is only available on Enhanced SpectroLink Units with supporting hardware in conjunction with the Enhanced Searchlight configurations and operated with the Enhanced Control Box only Note If LAMP OFF is pressed for more than 2 5 seconds the system will power cycle and take up to 30 seconds to be ready for use 36 SPECTROLAB 24 SpectroLink BOEING CO Setup and Operations Manual 033600 Revision G Lamp Focus Momentary The Searchlight can be focused to wide or narrow beam by pressing the FOCUS switch on the Control Box The FOCUS button controls a mechanism
45. key in order to access the list of options At this point press the Enter key to proceed to the Setup Menu Figure 23 to begin programming system parameters by entering the number of the function that you want to access SPECTROLINK SETUP MENU MAIN MENU Software 033608 Version 1 2 Released Date 12 10 2008 1 DISPLAY CURRENT SYSTEM SETTINGS 2 PERFORM GIMBAL HARD STOP CALIBRATION 3 SET GIMBAL SOFT STOP GAPS 4 SET POWER UP HOME POSITION 5 SET CAGE POSITION 6 SET STOW POSITION 7 SET GIMBAL KEEPOUT 8 SET GIMBAL SLEW RATE 9 RESTORE FACTORY DEFAULT SYSTEM SETTINGS Enter number option gt Figure 23 Menu Options Note Figure 23 is for reference only The software version displayed may have be updated 30 SPECTROLAB 24 SpectroLink BOEING Setup and Operations Manual 033600 Revision G To access any of these options only enter the number of the function that you want to access 5 2 3 PROGRAMMABLE SETTINGS AND FUNCTIONALITY Display Current System Settings This option will display Current System Settings pertaining to the Nightsun amp SpectroLink Gimbal This option will display the Software Version Gimbal Mechanical Hard Stops and Software Stops Home Position Cage Position Stow Position Gimbal Slew Rate Gimbal Keep Out Area current Link Interface current Searchlight Gimbal position and the current Link Position Gimbal Hard Stop Calibration Gimbal Hard Stop Calibration is
46. lamp is turned on with the Control Box it can be turned off via the Digital Hand Controller or Ex If the Link is initiated via the Digital Hand Controller this command can be terminated or can be made to go to In Flight Calibration by using the Control Box or Ex 4 The direction can controlled from any control unit at any time 6 3 Control Box operation The SpectroLink Control Box resembles the Control Box originally distributed with the SX 16 Nightsun amp and SX 5 Starburst Searchlights with the addition of Lamp Off and the Link Cal buttons Figure 24 Figure 24 SpectroLink Control Box 35 SPECTROLAB K SpectroLink BOEING Setup and Operations Manual 033600 Revision G 6 4 Control Box Functions Operation of the Searchlight requires a significant amount of power from the generator The engine or an auxiliary power unit APU must supply adequate power 60 amps at 28 volts OFF ON START Switch This three position switch controls the power supply to the Searchlight system and lamp Turning on the xenon gas arc lamp requires a large amount of electrical energy Ensure the engine is up to full RPM to turn on the lamp if the aircraft is not in flight Lamp Start Momentary To start the lamp hold the START switch in the up position until it starts 3 to 5 seconds When you release the switch it automatically returns to the middle on position Power On The middle on position turns on the ent
47. le on the Digital Hand Controller and the Remote I O Box The STOW position is useful as a way to park the Searchlight in a pre set position when it is no longer required When STOW is selected the lamp will extinguish and the Searchlight will be in standby mode This inhibits the functionality of all command switches on the Hand Controller However the Gimbal assembly and Searchlight remain in communication contact with the Hand Controller and will continue to receive status information To determine an effective Stow position consider such factors as minimizing wind drag at high speeds and obtaining sufficient Searchlight ground clearance for landing the aircraft To change the Stow position select the Stow position option by typing the corresponding number on the menu Using the Control Box or the Digital Hand Controller move the Searchlight to a new position and press the ENTER key to select the position Gimbal Keep Out Zone SpectroLink can be programmed to designate a keep out zone This feature prevents an operator from inadvertently aiming the beam in undesirable directions by automatically maneuvering the Searchlight head around the keep out zone Once the Searchlight has passed the keep out zone the operator s directional controls resume normal function The keep out zone is primarily used to impede the shining of the Searchlight for an extended period of time on any area on the helicopter To change the Stow Position sel
48. n Link mode The second method is to move the camera crosshairs to the center of the Searchlight spot while the Searchlight stays fixed 6 8 1 IN FLIGHT CALIBRATION PROCEDURE OFFSET SEARCHLIGHT 1 Turn the system power on and allow for the system to complete the power up sequence 2 On the Control Box momentarily press the Link Cal switch 3 Find a common target far away to point the Linked Camera 4 Turn the lamp on and use the Control Box s joystick to re position the Searchlight such that it points to the same target as the Linked camera image This new offset position between the Searchlight and Linked System will remain saved until the Searchlight is moved to a new offset position or the camera is moved unless the Searchlight system un linked prior to turning off the system 42 SPECTROLAB E SpectroLink BOEING CO Setup and Operations Manual 033600 Revision G 6 9 Using the Linked System Mode with Programmable Keep Out Zone The 5 16 Nightsun and SX 5 Starburst Searchlights enable users to prevent the Searchlight beam from being aimed in an undesirable direction heat sensitive portions of the aircraft should be protected or mechanical stops used To prevent such occurrences the Searchlights have two methods of controlling their movement 1 Mechanical stops mounted on the Gimbal mechanism limit the elevation range and azimuth range to prevent Searchlight from entering hazardous areas 2 Programmable keep o
49. nsmit data from your computer to the SpectroLink Box Adjust the communication port settings of the terminal emulator program as shown in the figures below The Setup Menu allows the user to program the Stow position the Cage position the Home position the Keep Out Zone Slew Rate and other functions Note If your computer does not have a serial port then it may require a serial to USB converter 5 2 2 2 HYPERTERMINAL SETUP HyperTerminal is a terminal emulator that is part of most PC Windows operating systems If HyperTerminal is not available in your computer you may download any other available freeware from the internet such as TeraTerm Bray s Terminal or any other available emulator Note Figures in this section are for reference only Some settings may change The following instructions are provided to create a HyperTerminal session Please note that these instructions may not necessarily reflect the steps that you need to take depending on the operating system on your computer 1 On your computer click on Start All Programs Accessories Communications HyperTerminal 2 Following the prompts enter a session name i e HyperTerminal and click the OK button see Figure 17 Figure 17 HyperTerminal Name Selection 3 Select an available serial port on your computer and click the OK button see Figure 18 HyperT erminal Enter details for the phone number that you want to dial Country region
50. ode NOTE If using a Control Box Cage mode can also be exited by using the eight way directional switch Same holds true for the force controller used on the functions 38 SPECTROLAB K SpectroLink BOEING CO Setup and Operations Manual 033600 Revision G Joystick Force Controller AZ AZIMUTH To adjust the Searchlight angle along the azimuth axis AZ apply force to the left or right on the joystick EL ELEVATION To adjust the Searchlight angle along the elevation axis EL apply force up or down on the joystick Spare Switch A spare toggle switch has been placed for future functionality additions 6 5 2 FAULT LED S Status or Fault LED s will indicate the status of the system to the operator These LED s are either next to the command switch or in the FAULT section of the Hand Controller panel Status LED s for commands are described in the previous section Gimbal Fault The Hand Controller will display a Gimbal Fault status indicating a motion control failure This condition occurs when the motion control drivers detect an over current condition on the Gimbal which may be triggered by driving the Gimbal motors to a hard stop The GIMBAL LED when lit indicates when a malfunction has occurred within the Gimbal and or the system If this condition occurs it may be that the Gimbal hard stop calibration has not been performed correctly so the Gimbal is driven to the mechanical hard stops which could cau
51. ommands it is ready to use To change the Home Position or set other features follow the instructions in the Setup Menu SPECTROLAB K SpectroLink 1 7 BOEING CO Setup and Operations Manual 033600 Revision G Definitions SpectroLink terminology includes the following main concepts 1 8 SpectroLink System This refers to an entire SpectroLink System which includes the following components SpectroLink Integration Box Searchlight Gimbal Junction Box Control Box and cables SpectroLink Upgrade Kit This refers to the components used to modify an existing 5 16 Nightsun or 5 5 Starburst Searchlight SpectroLink Upgrade Kit includes the following components SpectroLink Integration Box Control Box Dual Motor Encoder Harness Assembly and cables SpectroLink Integration Box This is the main component of both the SpectroLink System and the SpectroLink Upgrade Kit Enhanced Configurations This refers to components such as Control Box Searchlight SpectroLink Units and Gimbals that offer additional functionality than the basic configurations The Enhanced configurations are identified by part number Applicable DOCUMENTS 033537 SpectroLink Integration Box 031734 5 16 Nightsun Searchlight Setup and Operation Manual 031718 SX 5 Starburst Searchlight User s Manual 033550 General Specifications for the SpectroLink System 033747 SpectroLink Mounting Plate 033600 1 Addendum for IFCO configuration 03
52. one end of the cable 032432 or 032432 101 to the J2 connector on Junction Box e Connect the other end of the cable to the bulkhead through connector On the other side of the bulkhead Connect one end of the cable 032433 or 032433 101 to the bulkhead through connector e Connect the other end of the cable to the connector on Searchlight and Gimbal 4 1 4 2 JUNCTION BOX TO INTERNAL AND EXTERNAL SEARCHLIGHT GIMBAL BULKHEAD While you are located in the compartment where the Junction Box is installed e Connect one end of the cable 032432 or 032432 101 to the J2 connector on Junction Box e Connect the other end of the cable to the bulkhead through connector On the other side of the bulkhead e Connect one end of the cable 032434 or 032434 101 to the bulkhead through connector e Connect the other end of the cable to the connector for the Searchlight Gimbal 4 1 4 3 JUNCTION BOX TO SYSTEM POWER INPUT Make sure that the Start System switch of the Control Box Hand Controller Sidecar is in the Off position Also verify the Lamp switch also is set to the Off position e Connect one end of the power cable 032013 or 032013 101 to the J3 connector on the Junction Box e Connect the other end of the power cable to the power source 20 SPECTROLAB K SpectroLink BOEING CO Setup and Operations Manual 033600 Revision G 42 SX 5 STARBURST 4 2 1 OVERVIEW Figure 15 depicts connections between SpectroLink components
53. op can be altered through the Setup menu as well as for the clockwise and counter clockwise azimuth stop 31 SPECTROLAB K SpectroLink BOEING CO Setup and Operations Manual 033600 Revision G Power Up HOME Position Once the Power Up Calibration Sequence is completed the Searchlight positions itself to the Home position By default the home position is in the center of travel in azimuth and elevation This position may be changed to a desired position upon prompt by using the Control Box or the digital Hand Controller move the Searchlight to a new position and pressing the ENTER key on the keyboard to select and save the new position CAGE Position Note The CAGE command is only available the Digital Hand Controller and the Remote Box The Cage position is used to point the Searchlight to a preset position It is also useful if an operator has lost track of where the Searchlight is pointing and wishes to return the Searchlight to a known pre set position This enables the operator to quickly regain a proper orientation to the position of the Searchlight The Cage position can be programmed according to the operator s preference To change the Cage position select the Cage position option by typing the corresponding number Using the Control Box or the digital Hand Controller move the Searchlight to a new position and press the ENTER key to select the position STOW Position Note The STOW command is only availab
54. or Searchlight s azimuth axis Ground J6 14 This Ground reference should be used to interface all I O inputs and outputs 45 SPECTROLAB K SpectroLink BOEING CO Setup and Operations Manual 033600 Revision G Ground J6 15 Additional ground reference This Ground reference should be used to interface all I O inputs and outputs N C J6 16 No Connection This pin is not currently used Link Status J6 17 The LINK LED will blink until the Searchlight position and the linked system are matched synchronized at which time the LINK LED will light up solid The LINK LED will also blink when the linked system is beyond the Searchlights range of travel invalid data is received from the linked system and when the linked system is off Note The system must be un stowed to enter Link mode Stow Status J6 18 Stow Status output indicates when the Searchlight is in the Stow position Remote Select J6 19 Remote Select input is used to enable all the functionality Note Lamp Start and System Power are discrete signals that do not need CPU control and therefore cannot be disabled System Status J6 20 The System Status output notifies the user when there is a fault in the system that may prevent normal operation Communication Flight Status J6 21 The Communication Flight Status output notifies the user of a failure to communicate with the camera system The COM LED will be on to indicate a communication fa
55. ormation in it is correct as of the publication date The manufacturer reserves the right to make changes to this document and associated products at any time without notice SPECTROLAB K SpectroLink BOEING CO Setup and Operations Manual 033600 Revision G 1 5 Installer Responsibility It is the responsibility of the installer to ensure the integrity and safety of the installation its configuration and its integration with the operational platform Do not depend on SpectroLink software Keep Outs for critical safety situations where the Searchlight can cause damage to aircraft Use elevation or azimuth hard stops where possible 1 6 Quick Start Guide Perform these steps to get started quickly with the default settings when upon receiving the SpectroLink system from the factory Connect the Motor Harness Assembly Hand Controller Junction Box and Link Camera to the SpectroLink Integration Box as shown in the Component Connections section of this manual Turn on the main Power to power up the system Turn the Hand Controller Power Switch to ON After a few seconds the system will start to move and perform its initial Auto Calibration which determines the range of travel This process should take approximately 15 20 seconds depending on motor speed configuration e Wait a few seconds after the Searchlight has stopped moving for values to be stored to permanent memory Once the Searchlight starts responding to Joystick c
56. osition matching in link mode it is strongly recommended that the Searchlight and the linked system be mounted on the same plane or horizontal axis i e both horizontal to the ground Otherwise the In Flight Calibration feature can offset and correct the Searchlight to point to the same target as the camera or system 5 1 2 COMPATIBILITY To successfully use a linked system such as a camera thermal imaging system or moving to the SpectroLink system for the 5 16 Nightsun and SX 5 Starburst Searchlights it is necessary to utilize the proper command message and status software protocols These protocols apply to the serial control interfaces between a linked system and the SpectroLink Integration Box The SpectroLink system identifies that a compatible system is detected When a system is connected and not detected due to incompatibility the COM LED will blink whether or not the system is in link mode In link mode the LINK LED will also blink when a connected system is not detected When a compatible system is connected the COM LED will be off whether or not the system is in link mode In link mode the LINK LED will be on steady when a connected system is detected The Nightsun interface protocol between the SpectroLink Integration Box and a linked system are shown in refer to Tables 2 and 4 Spectrolab document 032507 Link Interface Control Document for NightsunO II Nightsun amp XP and SpectroL ink Current system
57. posing the pilot to excessive glare Toturn on the lamp momentarily press the LAMP ON switch in the up Lamp On position until the lamp has ignited A typical start time is approximately 1 5 seconds depending on lamp life and ambient temperature Release the switch immediately after the lamp starts Holding the switch in the start position after the lamp turns on or during a prolonged series of strobes will cause premature failure of some starting circuit components and the xenon gas lamp Adjust the Force controller directional switch as desired to aim the Searchlight Note Due to the programmed soft stops clutch slip does not occur on the SpectroLink System because of the software stops Adjust the Searchlight focus using Focus switch by pressing the Focus button until the desired beam width is obtained 41 SPECTROLAB K SpectroLink BOEING CO Setup and Operations Manual 033600 Revision G enable the linked system to control the Searchlight momentarily press the LINK switch in the up position The solid LINK LED will indicate that the system is in Link mode and the Searchlight is matched to the linked system To Stow the Searchlight momentarily press the STOW switch When this function is performed the Searchlight will proceed to a pre selected position The STOW LED will turn on All switch functionality will be lost in this Stow mode To exit the STOW LOCK mode momentarily press the
58. rent settings Gimbal hard stop calibration Power Up home position keep out Cage position Stow position slew rate select link software interface and restore default factory settings To take advantage of these programmable settings it is necessary to 1 establish a computer connection and 2 gain access to a menu of setup options Once the computer is ready to communicate with the SpectroLink system you can gain access to the menu of setup options First make sure that the Searchlight Gimbal assembly is free to move and that there are no people or foreign objects within the Searchlight Gimbal assembly s envelope of movement Do not place fingers inside the Gimbal s area of motion when the power is on 5 2 2 1 COMPUTER CONNECTION FOR SETUP MENU Before you can gain access to the menu of setup options it is necessary to connect a computer that has a terminal emulator program such as HyperTerminal to the setup port located on the SpectroLink Box Connect a RS232 9 pin male to RS232 9 pin female straight connect cable to the 9 pin setup port on the SpectroLink Box Connect the other end of the cable to the standard 9 pin serial port to computer if your computer does not have a serial port you may require a serial to USB converter 26 SPECTROLAB K SpectroLink BOEING Setup and Operations Manual 033600 Revision G On your computer open the terminal emulator program This will enable you to tra
59. s A cement wall or metal hangar door can be good target area unless other circumstances make this practice unsafe A Caution The high intensity light beam may damage surfaces in close proximity to the Searchlight head if the light is aimed at the surface for any length of time The light beam is extremely intense and can cause eye damage Do not look directly into the light beam at distances of less than 100 feet A Caution Do not place fingers inside the Gimbal s area of motion when the power is on 34 SPECTROLAB K SpectroLink BOEING Setup and Operations Manual 033600 Revision G 6 2 SPectrolink Operations Operations of the SpectroLink Searchlight System can be accomplished with the Control Box Hand Controller Sidecar or the I O The basic functions of the SpectroLink system are 1 System On Off 2 Start 3 Beam Focus 4 Searchlight Direction 5 Link or synchronization enables another device to take control of the Searchlight positioning NOTE There are three different Searchlight control units Control Box Digital Hand Controller and Searchlight commands can be initiated with any control unit and can be terminated by using another for control units with the same function and switch Ex 1 If multiple control units are connected and any one unit is ON the system will remain on All control units must be OFF in order for the system to be off Ex 2 If the
60. s Manual 033600 Revision G SPECTROLINK BOX N A RS232 TX RS232 RX N C RS422 RX LINK RS422 RX LINK Serial Communications Ground RS422 TX LINK RS422 TX LINK 28 VDC Switched Aux Output 0 5A System Power On Off LAMP START 28V Ground 1 2 3 4 5 6 7 8 9 Link cable interface to Lin RS232 or RS422 serial interface Remote PowerOn Off Remote Lamp On note lamp off via owe Hote When connecting the SpectroLink to a linked system connect TX r On Off to TX and RX to RX Signal reversal is accomplished interal the SpectroLink System 54 SPECTROLAB A BOEING COMPANY SpectroLink Setup and Operations Manual 033600 Revision G Operational Not 1 Power System Power Input 5V Ground Open On 2 IFCO Motor Input 5 Ground Open IFCO Motor Input 5 Ground Open Calibrate ECD FLIR Input 5 Ground Open Sync Cal 5 Lamp Off Input BV Ground Open 6 Link ECD FLIR Input 5 Ground Open Slave 7 Focus Input BV Ground Open 8 Stow Input 5 Ground Open 9 Lamp Start Input BV Ground Open 10 Cage Input 5 Ground Open 11 System Reset Input BV Ground Open 12 Analog Elevation Input OV to 5V 2 5V 0 01V Control Rate 13 Analog Azimuth Input OV to 5V 2 5V 0 01V Control Rate 14 Ground N A 15 Ground N A 16
61. s for reuse when reconnecting the unit Remove the old adapter motors and the four gaskets for each of the old motors e Using the same mounting location and screw holes that held the old adapter to the Gimbal attach the new adapter to the Gimbal Figure 9 e Using the same mounting locations and screw holes that were used for the old motors attach the new motor encoders for azimuth and elevation Figures 9 and 10 e On SX 5 Starburst installations you have a choice of two options to permit free movement of the Gimbal 1 Rotate the elevation motor encoder counterclockwise 90 using the mounting location described above and as shown in Figures 9 and 10 2 Rotate the mounting location of the azimuth motor encoder 180 to the other side of the Gimbal as shown in Figures 11 and 12 Elevation Motor Encoder Rotated Counterclockwise 90 Figure 9 View of SX 5 Starburst Gimbal Assembly with Elevation Motor Encoder Rotated 90 14 SPECTROLAB 24 SpectroLink BOEING CO Setup and Operations Manual 033600 Revision G Elevation Motor Encoder Rotated Counterclockwise 90 Adapter Figure 10 Side View of SX 5 Starburst Gimbal Assembly with Elevation Motor Encoder Rotated 90 Azimuth Motor Encoder with Mounting Location Rotated Counterclockwise 180 Figure 11 View of SX 5 Starburst Gimbal Assembly with Mounting Location of Azimuth Motor Enco
62. s that SpectroLink is compatible with are e FLIR including Star Safire WESCAM including MX 15 PolyTech LEO AXSYS POP ARGOS 25 SPECTROLAB 24 SpectroLink BOEING Setup and Operations Manual 033600 Revision G 5 2 Setup Menu Connect serial cable to Setup port in rear of the SpectroLink Box and other end to a computer serial port For instructions reference SpectroLink Menu Options and Functionality section of this manual 5 2 1 MECHANICAL GIMBAL STOP ADJUSTMENT PROCEDURE The Gimbal hard stop calibration must be performed whenever hard stops AZ and or EL are moved to a different location e Gimbal hard stop calibration must be performed before any other setup e Gimbal hard stop calibration is performed via the Setup Menu e Once Hard Stops have been configured as required for aircraft a Gimbal hard stop calibration must be performed before any other setup via the setup menu is performed The Gimbal hard stop calibration is performed to identify the hard stop locations for azimuth and elevation axes These values are then stored in memory so that the CPU always knows where all the hard stops are located Please refer to the applicable maintenance manual instructions to change the location of hard stops Instructions to setup new hard stop locations are in the Gimbal Hard Stop section of this manual 5 2 2 USING THE SETUP MENU The setup menu allows the user to customize the following programmable settings view cur
63. se the gears to lock up Perform a power cycle to reset the system by turning the power off and then back on If the issue persists contact Spectrolab Customer Service for further instructions COM Fault Communication The COM LED will be on to indicate a communication failure with the linked system If this condition occurs it may be that the SpectroLink does not detect valid data from the linked system due to incompatibility Keep Out Zone Fault The digital Hand Controller will display a Keep Out Fault status indicating the Searchlight Gimbal is positioned at a Keep Out zone A Keep Out Zone violation does not impede the functionality of the Searchlight or the Gimbal A Keep Out Zone violation may be displayed if the Stow position is programmed inside a Keep Out Zone The KEEP OUT LED when lit alerts the operator when the Searchlight is positioned in these zones This zone can be programmed or re programmed using the Setup Menu 39 SPECTROLAB 24 SpectroLink BOEING Setup and Operations Manual 033600 Revision G TEMP Temperature Fault The Temperature TEMP Fault status displayed on the digital Hand Controller is currently not used Fan Fault The Fan Fault status displayed on the digital Hand Controller is currently not defined SYS SYSTEM Fault The SYS System Fault status displayed on the Hand Controller is currently not used Digital Hand Controller Undefined Inactive Status Signals Un labeled Hand
64. that adjusts the Searchlight beam in only one adjustment sequence If you press this button and hold it down the beam continuously cycles from a wide focus to a tight focus back to a wide focus and so on Bi Directional Focus Momentary Bi directional focus allows the user to adjust the beam by pressing the button up or down Note This feature is only available on Enhanced SpectroLink Units with supporting hardware in conjunction with the Enhanced Searchlight configurations and operated with the Enhanced Control Box only 8 way Directional Switch Up Down Left Right The 8 way directional switch controls the elevation and azimuth position of the Searchlight The Searchlight moves in that direction It can move up and down left and right diagonally to the upper right lower left diagonally to the upper left and lower right The switch will return to the central no movement position once released LINK Momentary To enter Link mode momentarily press the LINK button on the Control Box The LINK LED will indicate the link status To exit Link mode momentarily press the LINK pushbutton again The LINK LED will blink until the Searchlight position and the linked system are matched synchronized at which time the LINK LED will light up solid The LINK LED will also blink when the linked system is beyond the Searchlight s range of travel invalid data is received from the linked system and when the linked system is off 6 5 Digital
65. that are attached to an SX 5 Starburst 033582 033590 J9 5 Control Box n Linked System SpectroLink Option 032639 Integration Box Digital Hand Controller Ena Searchlight and 032435 or Gimbal 032435 101 Assembly 032432 or 032432 101 Junction Sidecar Box 033002 032013 or 032013 101 Bulkhead custom cable Through System Connector Power Input Figure 15 Main Components Cables and Connectors with SX 5 Starburst 21 SPECTROLAB 24 SpectroLink BOEING Setup and Operations Manual 033600 Revision G 4 2 2 CABLING The SpectroLink System relies on various cables for power and communication The use of bulkhead through connectors makes possible a variety of installations Figure 16 depicts the cable part numbers and the connections that they make Regarding Spectrolab cable part numbers Part numbers normally appear in one of two ways 1 or 2 xxxxxx 101 xx 3 For an example such as the first six digits indicate the part number and the last two digits indicate the length of the cable in inches 4 an example such as 101 the first six digits indicate the part number the 101 indicates that the cable terminates in a 90 angle connector instead of a straight one and the last two digits indicate the length of the cable in inches e Inthe Figure however no cable lengths the
66. ult settings However if the system settings are restored the system will recalibrate when a power cycle is completed turn power off then on At this time the Gimbal will move to locate the hard stop locations for azimuth and elevation Once the hard stops are located the system will stop moving for approximately 20 seconds while the system is saving parameters All parameters such as Stow Cage Home and Keep Out zone will be reset and can be reprogrammed 33 SPECTROLAB 21 SpectroLink BOEING Setup and Operations Manual 033600 Revision G 6 OPERATION 6 1 Safety Guidelines e The orientation of the craft structure partly determines where the Searchlight is pointing but a Searchlight operator can control the Searchlight and coordinate its movements skillfully to illuminate any point e A Searchlight operator who also is piloting a craft may risk devoting too much attention to the Searchlight target instead of avoiding navigational hazards such as power lines and antennas e Avoid operating the Searchlight below 25 feet above ground level AGL because it can ignite flammable material or dry vegetation at focal point The focal point varies and can be as close as one meter from the light e When landing the aircraft the lamp should be turned off e When operating the lamp while the aircraft is in a hangar direct the beam away from nearby flammable objects Make sure to select a suitable target area for testing purpose
67. ut zones are established by using the Setup menu with the use of a personal computer Programmable Keep Out zones are to be used in less hazardous areas that do not pose a risk to aircraft When a Searchlight is being operated in Link mode the programmable keep out zones function in the following manner 1 When the linked system such as a camera or thermal imaging system attempts to aim the Searchlight in a direction that is within a keep out zone the Searchlight will follow the perimeter of the keep out zone 2 As long as the linked system attempts to aim the Searchlight within a keep out zone the Searchlight will refuse to move there and it will continue to monitor the directional signals from the linked system 3 As soon as the linked system attempts to aim the Searchlight in a direction that is not within a keep out zone the Searchlight will move to the indicated position In Link Mode the Searchlight is moving in the same position in both azimuth and elevation as that of the linked system However when the linked system and the Searchlight come into a keep out zone the Searchlight will drop out of the keep out zone as shown in Figure 25 while maintaining the same horizontal position in azimuth as that of the linked system Once the linked system is out of the keep out zone the Searchlight will then resume normal link operation by moving to the same position in both azimuth and elevation as that of the linked system
68. wo ways 1 or 2 XXxxxx 101 xx 1 For an example such as the first six digits indicate the part number and the last two digits indicate the length of the cable in inches 2 Foran example such as xxxxxx 101 xx the first six digits indicate the part number the 101 indicates that the cable terminates in a 90 angle connector instead of a straight one and the last two digits indicate the length of the cable in inches 17 SPECTROLAB 24 SpectroLink BOEING CO Setup and Operations Manual 033600 Revision G e In Figure 13 however cable lengths the two digit suffix are not supplied consequently the suffix 101 indicates that the cable terminates in a 90 angle connector instead of a straight one e For IFCO configuration refer to 033600 1 IFCO SpectroLink Setup and Operations Manual 033588 SpectroLink Integration Box to bulkhead for Gimbal motor encoders 033587 Bulkhead from SpectroLink Integration Box to Gimbal motor encoders Bulkhead from Junction Box to lamp and focus motor Figure 14 Cable Part Numbers and Connections 18 SPECTROLAB 24 SpectroLink BOEING CO Setup and Operations Manual 033600 Revision G 4 1 3 CONNECTIONS TO THE SPECTROLINK INTEGRATION BOX 4 1 3 1 SPECTROLINK INTEGRATION BOX TO CONTROL BOX OR OPTIONAL IFCO CONTROL BOX e Connect one end of the Control Box cable 033582 to the Control Box e Connect the other end of the cable to the

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