Boeing SPECTROLAB SX-16 Nightsun User manual

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

Spectrolab, Inc. Safety and Service Bulletin # SL 0898-02 dated 09/25/98 (continued)
What you should do:
Perform the service procedure described in document # SL 0898-02A, which follows. The
procedure will guide you through the rewiring process.
What is included with this bulletin:
1. Document # SL 0898-02A– SX-16 Junction Box Searchlight Power Cable Rewiring
Instructions.
2. Mounting hardware.
If you would like to have Spectrolab perform this service for you, please call our Customer
Service Department at 1-800-936-4888 to obtain a return authorization number. Customers that
have Junction Boxes less than one year old will not be charged for this modification.
If you have any questions or comments, please contact me at any of the numbers below.
Sincerely,
Edward Ringo
Customer Service Manager
Spectrolab, Inc.
Phone: [phone]
Fax: [phone]
Bulletin # SL 0898-02 Page 2 of 2

Installation Wiring Instructions for
SX-16 Junction Boxes
Procedure 032384 Revision N/C
Date: 12/06/99
SPECTROLAB NIGHTSUN® and STARBURST® SEARCHLIGHTS
O.E.M. FACTORY DOCUMENTATION
SAVE THESE INSTRUCTIONS 1
INSTALLATION WIRING INSTRUCTIONS
FOR SX-16 JUNCTION BOXES P/N 020706
Effective for boxes
Revision V and higher,
S/N 3307 and up,
Manufactured after March 1, 1999

Installation Wiring Instructions for
SX-16 Junction Boxes
Procedure 032384 Revision N/C
Date: 12/06/99
SPECTROLAB NIGHTSUN® and STARBURST® SEARCHLIGHTS
O.E.M. FACTORY DOCUMENTATION
SAVE THESE INSTRUCTIONS 2
Table of Contents
1. SCOPE.......................................................................................................... 2
2. INTRODUCTION AND PURPOSE................................................................ 3
3. RESPONSIBILITY ........................................................................................ 3
4. DEFINITIONS (DOES NOT APPLY)............................................................ 3
5. REFERENCE DOCUMENTS........................................................................ 3
6. PROCEDURE ............................................................................................... 4
6.1. Install Control Box Cable........................................................................ 4
6.2. Install Junction Box–to-Searchlight Cable ........................................... 6
6.4. Connect Input Power (+) and (-) Cables to Junction Box .................. 11
6.5. Verification, quality assurance check and full functional tests ........ 12
7. CONTROL PLAN (DOES NOT APPLY).................................................... 18
8. APPENDIX (DOES NOT APPLY).............................................................. 18
List of Figures
Figure 1. CONTROL BOX CONNECTIONS ..................................................... 6
Figure 2. SEARCHLIGHT CABLE CONTROL WIRE CONNECTIONS............ 8
Figure 3. CLOSE UP VIEW OF E1 TERMINAL BLOCK. ................................. 9
Figure 4. CONNECTING SEARCHLIGHT POWER CABLES...................... 10
Figure 5. CONNECTIONS OF AIRCRAFT POWER (+) AND (-) CABLES INTO
JUNCTION BOX......................................................................................... 12
Figure 6. FINAL ROUTING OF WIRES IN JUNCTION BOX BEFORE CLOSING
COVER....................................................................................................... 14
INSTALLATION WIRING INSTRUCTIONS FOR SX-16 JUNCTION BOX
1. SCOPE
This document applies to the installation of all SX-16 Junction Boxes, P/N 020706, Revision V
and higher, Serial Number 3307 and up, manufactured on or after March 1, 1999.

Installation Wiring Instructions for
SX-16 Junction Boxes
Procedure 032384 Revision N/C
Date: 12/06/99
SPECTROLAB NIGHTSUN® and STARBURST® SEARCHLIGHTS
O.E.M. FACTORY DOCUMENTATION
SAVE THESE INSTRUCTIONS 3
If the new style E1(+)/(-) block P/N 032199 is added to update an older 020706 junction box,
installation wiring would also proceed as described below.
2. INTRODUCTION AND PURPOSE
A substantial change in the internal configuration of the SX-16 junction box was implemented
with Revision V. A new E1(+) terminal post was added as a connection point for several of the
heavy gauge wires. This change was made to make a more reliable and safer searchlight system.
Concurrently with the new hardware, changes were made in the routing and connection points
of some of the high amperage (+) wiring. This document gives detailed wiring instructions to be
followed during installation of the junction box. Mechanical installation of the Junction Box is
not addressed in this document.
3. RESPONSIBILITY
It is the responsibility of the junction box installer to follow these instructions. It is the
responsibility of Spectrolab’s Illumination Systems Engineering Department to update this
document as needed if and when changes are made to the hardware discussed in the document.
4. DEFINITIONS (does not apply)
5. REFERENCE DOCUMENTS
Electrical schematics 020720 Rev R and 030518 Rev G (IR IFCO) reflect the changes associated
with the new E1(+) terminal, as do wiring diagrams 031661 Rev E and 030519 Rev L (IR).

Installation Wiring Instructions for
SX-16 Junction Boxes
Procedure 032384 Revision N/C
Date: 12/06/99
SPECTROLAB NIGHTSUN® and STARBURST® SEARCHLIGHTS
O.E.M. FACTORY DOCUMENTATION
SAVE THESE INSTRUCTIONS 4
WARNING
!
LETHAL VOLTAGES EXIST IN COMPONENTS
Junction box components contain hazardous AC and DC voltages up to 150 volts when
powered.
To reduce risk of death or serious injury:
•Read and follow all instructions
•Junction box should never be opened nor work performed on components inside
except by properly trained personnel
•Use only properly operating test equipment rated for these voltages
•Disconnect aircraft battery and/or de-energize 28 VDC bus before opening junction
box
•If power is restored while junction box is open treat all components as live
•Do not touch live components with bare hands or conductive tools
•Never leave live open junction box unattended
6. PROCEDURE
6.1. Install Control Box Cable
6.1.1 Remove the junction box cover and remove the rubber grommet from the side
hole labeled “CONTROL.” Insert the nine-conductor intermediate control box cable p/n
018479 1into the grommet one lug at a time. If an IR IFCO system is being installed,
the cable will be a 12-conductor cable, p/n 030534 2. Pass the lugs through the hole in
1This cable has ring lugs on the junction box end and a bulkhead-style connector on the other, which is
installed in the cockpit area. It is part of the most commonly used control box wiring layout. The
commonly used retractile control box cable plugs into the bulkhead fitting. A one-piece cable which wires
directly from the junction box to the control box is available, p/n 030295.
2Similar to the white-light system discussed in note 1, this cable is an intermediate j-box to control box
cable which terminates in a bulkhead fitting in the aircraft cockpit. The retractile control box cable mates
with it. Alternately, a one-piece IFCO control cable is available, p/n 030727.

Installation Wiring Instructions for
SX-16 Junction Boxes
Procedure 032384 Revision N/C
Date: 12/06/99
SPECTROLAB NIGHTSUN® and STARBURST® SEARCHLIGHTS
O.E.M. FACTORY DOCUMENTATION
SAVE THESE INSTRUCTIONS 5
the box from which the grommet was removed. Reinstall the grommet with cable into
the hole in the box. See Figure 1.
6.1.2. Connect all the crimp lugs on the control cable’s wires to TB1 as shown in Figure 1.
They are secured under the single row of screw terminals farthest away from the main power
relay K1 and closest to the large blue capacitor C1. The wires run in almost a straight line from
the grommet-lined hole in the box to the terminal strip.
6.1.3. Connect the wire identified as “1” to the terminal strip position TB1-1, which is
identified as #1 on the marker strip. Connect the remaining numbered wires to the
matching numbered terminals of TB1. Position and adjust the wire lugs so they enter
the terminal strip neatly at a right angle and are well separated from each other.
Control box wire
connections to TB1.
Relay
K1

Installation Wiring Instructions for
SX-16 Junction Boxes
Procedure 032384 Revision N/C
Date: 12/06/99
SPECTROLAB NIGHTSUN® and STARBURST® SEARCHLIGHTS
O.E.M. FACTORY DOCUMENTATION
SAVE THESE INSTRUCTIONS 6
Figure 1. Step 1. CONTROL BOX CONNECTIONS as seen when looking inside the
junction box with the lid open and moved aside. Note numbered wires are connected to
same numbered screws on the terminal strip row opposite the power relay K1. The
cable feeds into the box through the grommet lined hole marked “CONTROL.”
6.1.4. Before final tightening of any screws, double check to make sure the correct
wires are on the correct terminal strip positions.
6.1.5. Tighten the terminal strip screws fully with a #1 Phillips or a blade screwdriver
large enough to completely span the head of the screws.
6.1.6 Press the wires down as far as possible toward the bottom of the Junction Box as
shown in Figure 1.
6.2. Install Junction Box–to-Searchlight Cable
6.2.1. Insert the junction box-to-bulkhead searchlight/gimbal cable p/n 0183053through
the cord grip in the Junction Box hole labeled “LIGHT”. If this is an older box with a
large rubber grommet instead of a cord grip, remove the grommet from the hole, feed
the cable into it one lug at a time, run the lugs and wires into the hole and replace
grommet.
6.2.2. Connect the nine AWG 20 wires with numbered lugs to the like numbered
terminals of terminal strip TB1 in the row opposite the one to which the wires from the
control box are connected. If an IR IFCO system is being installed 4, there will be
twelve AWG 20 wires instead of nine. See Figure 2.
6.2.3. Remove the 1/4-20 hex nut and outer washers from the negative (lower) E1
terminal. Install the ring lug of the negative AWG 6 searchlight power cable marked
E1(-) on to this E1(-) terminal of the terminal block. Loosely install the flat washer, lock
3This is the most commonly used intermediate cable used in a white light installation. It terminates in a
bulkhead connector at the skin of the aircraft into which the flexible external cable P/N 018306 is
connected. Alternately, a one-piece j-box to searchlight cable is available, p/n 017617.
4Just like the white-light system discussed in note 3, this IFCO cable, p/n 030512 is an intermediate j-box
to searchlight/gimbal/IFCO cable which terminates in a bulkhead fitting penetrating the skin of the aircraft.
External cable p/n 030511 mates with it. Alternatively, a one-piece j-box to searchlight/gimbal/IFCO
cable, p/n 030511 may be used.

Installation Wiring Instructions for
SX-16 Junction Boxes
Procedure 032384 Revision N/C
Date: 12/06/99
SPECTROLAB NIGHTSUN® and STARBURST® SEARCHLIGHTS
O.E.M. FACTORY DOCUMENTATION
SAVE THESE INSTRUCTIONS 7
washer and the nut to temporarily hold the cable in place. (Another wire will be stacked
onto this one in Paragraph 3.4.) See Figure 3 for E1 Terminal Block details.
6.2.4. Remove the #10-32 hex nut and outer washers from the positive (upper)
terminal of the E1 power block. Connect the positive AWG 6 searchlight power cable
marked E1(+) (or C1(+) on older units) to the E1(+) terminal of the terminal block.
Install the flat washer, lock washer and nut, in this order on top of the lug. Fully tighten
the connection.
6.2.5. After completing the electrical connections of the searchlight power cable in the
junction box, verify that all the wires in the box are routed and dressed neatly. Tighten
the cord grip or reinstall the rubber grommet onto the searchlight
power cable where it exits the junction box. This completes the wiring of the
searchlight-to-junction box cable. See details in Figure 4.

Installation Wiring Instructions for
SX-16 Junction Boxes
Procedure 032384 Revision N/C
Date: 12/06/99
SPECTROLAB NIGHTSUN® and STARBURST® SEARCHLIGHTS
O.E.M. FACTORY DOCUMENTATION
SAVE THESE INSTRUCTIONS 8
Searchlight
cable wires
Booster
transformer
(on j/b lid)
Figure 2 Step 2. SEARCHLIGHT CABLE CONTROL WIRE CONNECTIONS to
terminal strip TB1. Numbered AWG 20 wires are connected to the row of screws
across from control cable wire connections. Wire numbers correspond to those on
control cable wires. (booster transformer in foreground)
6.3. Install Gimbal Cable p/n 017482 (If a separate gimbal cable is used)5
6.3.1. Remove the small rubber grommet from the hole marked “GIMBAL”.
5This is an infrequently used alternate configuration. The most common wiring layout uses a single
cable, which combines the searchlight and gimbal conductors under one jacket into a single cable, as
discussed in the preceding section.