Bruce BR3000-330-2CL User manual

101 Evans Avenue, Dayton, NV 89403
Ph: 775-246-0101 FAX: [phone]
COMPONENT MAINTENANCE
MANUAL (CMM) AND
ILLUSTRATED PARTS LIST (IPL)
FOR THE
BR3000-330-2CL, -3CL, & -2EN
MOOD LIGHTING SYSTEMS (MLS)
**PROPRIETARY NOTICE**
The content of this document was developed by and is proprietary to Bruce Aerospace. It is furnished in
strict confidence to the addressee. Being deemed as information affecting the competitive position of
Bruce Aerospace, this information is exempt from disclosure under the Freedom of Information Act or any
other law. All information contained herein is to be kept confidential by the addressee and may not be
copied, disclosed to others or used in any way adversely affecting the interest of Bruce Aerospace.
Document No. 33-21-57, Rev. A
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BR3000-330-2CL,-3CL,-2EN CMM and IPL
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TABLE OF CONTENTS
1.0 SCOPE.................................................................................................................1
1.1 Manufacturer Product Support Information.......................................................1
1.2 How to Use This Manual...................................................................................1
1.3 Warnings, Cautions, and Notes ........................................................................2
1.3.1 WARNING .................................................................................................2
1.3.2 CAUTION...................................................................................................2
1.3.3 Note...........................................................................................................2
1.4 General Safety Precautions..............................................................................2
1.4.1 Electrostatic Discharge..............................................................................2
1.4.2 Modification of Equipment..........................................................................2
1.5 Abbreviations and Unit Symbols.......................................................................3
2.0 REFERENCE DOCUMENTS ...............................................................................3
2.1 United States Government................................................................................3
2.2 Industry Documents..........................................................................................3
3.0 EQUIPMENT OVERVIEW....................................................................................4
3.1 Unit Descriptions...............................................................................................8
3.1.1 BC1-0212 MLCP........................................................................................8
3.1.2 LCM Units................................................................................................16
3.1.3 BC1-0216 CAN Bus Terminator...............................................................26
4.0 BR3000 MLS SYSTEM OPERATION ................................................................28
4.1 BR3000-330-2CL & -3CL MLS System Operation..........................................28
4.1.1 MLS System Power-Up Procedure..........................................................28
4.1.2 Power-Up Procedure ...............................................................................28
4.1.3 MLS System Reset..................................................................................31
4.1.4 SCENARIO EXECUTION........................................................................32
4.1.5 Test Function...........................................................................................33
4.2 DECOMPRESSION OVERRIDE ....................................................................34
4.3 SCENARIO RE-PROGRAMMING..................................................................34
5.0 MAINTENANCE .................................................................................................35
5.1 Vendor Codes.................................................................................................35
5.2 Outline and Mounting Information...................................................................36
5.3 BR3000 MLS Unit Identification......................................................................36
5.4 Wiring Information...........................................................................................36
5.5 Scheduled Maintenance..................................................................................38
5.5.1 Daily Check..............................................................................................38
5.5.2 Tools and Equipment, Daily Check..........................................................38
5.6 BR3000 MLS LRU Testing and Fault Isolation................................................39

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5.6.1 Tools and Equipment, Operational Test and Fault Isolation ....................39
5.6.2 Power-Up Procedure ...............................................................................39
5.6.3 Test Scenario Execution: LCM LED Check .............................................41
5.6.4 Data Cable Testing..................................................................................41
5.7 LRU REMOVAL & REPLACEMENT...............................................................43
5.7.1 BR3000-330-2CL MLS System, LRU Removal & Replacement..............43
5.8 BR3000 LRU CLEANING & INSPECTION .....................................................46
5.8.1 Cleaning Instructions ...............................................................................46
5.8.2 BR3000 MLS Inspection..........................................................................47
5.9 BR3000 MLS REPAIR AND BENCH TESTING..............................................48
5.9.1 BR3000 LRU Bench Testing....................................................................49
5.10 BR3000 MLS, LRU Storage............................................................................55
6.0 ILLUSTRATED PARTS LIST (IPL).....................................................................56
6.1 Purpose...........................................................................................................56
6.2 Guide to the Use of this IPL............................................................................56
6.3 Manufacturer Names and Addresses..............................................................56
6.4 Inclusion of LRU Part Number Information .....................................................63
7.0 APPENDIX A, OUTLINE AND MOUNTING DRAWINGS, BR3000-330-2CL MLS
64
8.0 APPENDIX B, OUTLINE AND MOUNTING DRAWINGS, BR3000-330-3CL MLS
65
9.0 APPENDIX C, OUTLINE AND MOUNTING DRAWINGS, BR3000-330-2EN MLS
66

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LIST OF TABLES
Table 1 Abbreviations and Unit Symbols........................................................................3
Table 2 BC1-0212 MLCP Connector Pin-Out...............................................................14
Table 3 BR3000-330-2CL MLS Equipment Complement.............................................17
Table 4 Vendor Codes .................................................................................................35
Table 5 Recommended Cleaning Materials .................................................................46
Table 6 Special Tools and Equipment..........................................................................49
Table 7 BR2900 LCM Input Current Test Parameters..................................................50
Table 8 MLCP Scenarios in Lab Test Mode.................................................................52
Table 9 Vendor Codes and Addresses.........................................................................56
Table 10 BC1-0212-001 MLCP Parts List....................................................................57
Table 11 BC1-0229 Series LCM Parts List...................................................................59
Table 12 BC1-0230 Series LCM Parts List...................................................................61
Table 13 BC1-0216-001 CAN Bus Terminator Parts List.............................................62

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LIST OF FIGURES
Figure 1 Basic BR3000 MLS Architecture, Business Class Zone...................................6
Figure 2 Basic BR3000 MLS Architecture, Economy Class Zone..................................7
Figure 3 BC1-0212 Mood Lighting Control Panel (MLCP)............................................12
Figure 4, MLCP Connector Pin-Out...............................................................................13
Figure 5 MLCP Block Diagram.....................................................................................15
Figure 6 BC1-0229-xxx LCM Unit, Rear View..............................................................20
Figure 7 BC1-0230-xxx LCM Unit, Rear View..............................................................21
Figure 8 BC1-0229-xxx and BC1-0230-xxx LCM Connector Pin-Out...........................22
Figure 9 LCM Unit, Basic Architecture .........................................................................23
Figure 10 LCM Unit, Input Module, Block Diagram ......................................................24
Figure 11 LCM Unit, LED Driver and LED Board, Block Diagram................................25
Figure 12 BC1-0216 CAN Bus Terminator...................................................................26
Figure 13 BC1-0216 CAN Bus Terminator Pin-Out.....................................................27
Figure 14 MLCP Power Switch Location......................................................................29
Figure 15 Lighting Control Switches on A330 Legacy Control Panel ...........................30
Figure 16 Scenario Function Buttons...........................................................................32
Figure 17 Identification Marking ...................................................................................37
Figure 18 Operational Level Troubleshooting Flowchart..............................................40
Figure 19 BR3000 Bench Test Harness.......................................................................53
Figure 20 BR3000 LRU Bench Test Configuration.......................................................54
Figure 21 BC1-0212-001 Mood Lighting Control Panel (MLCP) ...................................57
Figure 22 IPL Illustration, BC1-0229-001, -002 LCM Units ..........................................58
Figure 23 IPL Illustration, BC1-0229-003 LCM Unit .....................................................59
Figure 24 IPL Illustration, BC1-0230-001, -002 LCM Units ..........................................60
Figure 25 IPL Illustration, BC1-0230-003 LCM Unit .....................................................61
Figure 26 BC1-0216-001 CAN Bus Terminator............................................................62

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1.0 SCOPE
This document presents the Component Maintenance Manual (CMM) and Illustrated
Parts List (IPL) for the BR3000-330-2CL, -3CL, & -2EN Mood Lighting Systems (MLS)
manufactured by Bruce Aerospace. The BR3000 MLS is designed for use on the
following aircraft types:
MLS System Part Number Aircraft Type Applicability
BR3000-330-2CL Airbus A330 -200, Classic Cabin
BR3000-330-3CL Airbus A330 -300, Classic Cabin
BR3000-330-2EN Airbus A330 -200, Enhanced Cabin
1.1 Manufacturer Product Support Information
Repair and overhaul services, replacement parts, technical documentation, and other
product support services are available from the product manufacturer, Bruce
Aerospace. Please contact our sales and support department at:
Bruce Aerospace, Inc. FSCM: 17023
101 Evans Avenue
Dayton, NV 89403
USA
Tel: [phone]
Fax: [phone]
1.2 How to Use This Manual
1. Ensure that this manual is appropriate to the unit or component under
maintenance. Refer to Section 5.3 of this manual for BR3000-330-2CL, -3CL, & -
2EN Mood Lighting system and component identification information.
2. The instructions in this manual and any materials specified herein must be used
for all unit and component level maintenance.
3. Read all applicable WARNING and CAUTION notices before performing any
maintenance actions.

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1.3 Warnings, Cautions, and Notes
1.3.1 WARNING
Warning notices are used to identify materials, processes, methods, procedures, or
limits which must be followed precisely in order to avoid injury to, or death of personnel.
1.3.2 CAUTION
Caution notices are used to identify materials, processes, methods, procedures, or
limits which must be followed precisely in order to avoid damage to the aircraft or
equipment.
1.3.3 Note
Notes are used to identify beneficial optional methods or used to provide supplemental
information.
1.4 General Safety Precautions
The following general safety precautions must be observed during all phases of
operation, service, and repair of the BR3000-330-2CL, -3CL, & -2EN Mood Lighting
systems:
1.4.1 Electrostatic Discharge
The integrated circuits (ICs) and other semiconductor devices employed in the BR3000
MLS are susceptible to damage via electrostatic discharge (ESD). Careless handling
during repair can either damage or dramatically reduce the Mean Time Between Failure
(MTBF) of the unit.
1.4.2 Modification of Equipment
Never attempt unapproved modification of the BR3000 MLS. Unauthorized modification
of the BR3000 MLS can result in unsafe conditions that could cause harm to both
equipment and personnel. Furthermore, never attempt substitution of any component
within the BR3000 MLS with non-approved substitute components or materials.

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1.5 Abbreviations and Unit Symbols
Table 1 Abbreviations and Unit Symbols
Abbreviation Definition
AWG American Wire Gauge
BIT or BITE Built-in Test Equipment
CAN Controller Area Network
CMM Component Maintenance Manual
DMM Digital Multi-meter
FSCM Federal Supply Code for Manufacturers
GND Ground
IC Integrated Circuit
IPL Illustrated Parts List
kPag kilopascal – gage
LCM Lighting Control Module
LED Light Emitting Diode
MLCP Mood Lighting Control Panel
MLS Mood Lighting System
MTBF Mean Time Between Failure
OEM Original Equipment Manufacturer
P/N Part Number
RGBW Red Green Blue White
SSL Solid State Lighting
VAC Volts Alternating Current
VDC Volts Direct Current
2.0 REFERENCE DOCUMENTS
2.1 United States Government
Federal Aviation Regulations Part 25, “Airworthiness
Standards: Transport Category Airplanes”
2.2 Industry Documents
Air Transat, A330 Aircraft Wiring Manual (AWM) 33-21-11

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3.0 EQUIPMENT OVERVIEW
The BR3000 Mood Lighting System (MLS) replaces the OEM fluorescent cabin lighting
fixtures on the Airbus A330 aircraft with LED-based, multi-color capable luminaires.
The advantages of a Solid State Lighting (SSL) system include increased Mean Time
Between Failure (MTBF) for the luminaires due to the fact that lamps do not have to be
continuously replaced, and increased safety resulting from the fact that SSL lighting
does not employ high voltage power supplies.
In addition to the aforementioned benefits, the BR3000 MLS is also capable of
generating multi-colored light output utilizing a mixed array of red, blue, green, and
white LED emitters (RGBW). During flight, multi-colored lighting sequences, pre-
programmed into the MLS control system will be initiated manually from a flight
attendant lighting control panel. In the Bruce vernacular these colored lighting
sequences which change slowly over time are referred to as Scenarios.
There will be two separate BR3000 MLS systems installed in the Business Class (BC)
and Economy Class (EC) zones on the A330 aircraft. By employing two separate MLS
systems, lighting Scenarios can be selected independently for each zone which will
complement the current activities in that zone. Each MLS system will have a separate
Mood Lighting Control Panel (MLCP) which is mounted in proximity to the existing
attendant control panels.
A block diagram of the MLS configuration employed in the Business Class (BC) zone of
the A330 aircraft is provided in Figure 1. A block diagram of the MLS configuration
employed in the Economy Class (EC) zone of the A330 aircraft is provided in Figure 2.
A BR3000 MLS system consists of three primary types of units:
MLCP : Mood Lighting Control Panel, the master control unit for the MLS
system. A keypad is provided on the front of the unit for operator
interface. The MLCP communicates with the LCM units in the
system using the Controller Area Network (CAN) serial protocol.
LCM : The Lighting Control Modules are the LED-based luminaires for
the MLS.
CAN Bus : A 120 ohm terminator is attached to the terminus of each CAN
Terminator bus to prevent reflections and signal overshoot on the CAN bus.

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Note in Figure 2 which depicts the Economy Class MLS configuration, that there are two
BC1-0212-001 MLCP units employed. An additional MLCP unit is employed in the
Economy Class section in order to expand the number of LCM units which can be
controlled. The expansion MLCP unit (MLCP #3) will be hidden from view during
normal operations. Operator control of the Economy Class zone will be achieved using
the primary MLCP (MLCP #2). Using an RS-485 link between the two MLCP units, any
button actuation on MLCP #2 will be mimicked on MLCP #3.

BR3000-330-2CL,-3CL,-2EN CMM and IPL
Figure 1 Basic BR3000 MLS Architecture, Business Class Zone
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Figure 2 Basic BR3000 MLS Architecture, Economy Class Zone
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3.1 Unit Descriptions
This section will present a brief description of the basic units employed in the BR3000.
3.1.1 BC1-0212 MLCP
The Mood Lighting Control Panel (MLCP) is the heart of the MLS system and it is also
functions as the operator interface for the system. Scenario execution data is stored in
the MLCP and the unit uses this data to compute the necessary timing and intensity
values for the various Scenarios. The MLCP communicates this lighting command data
to the connected LCM units in the system using the CAN (Controller Area Network)
serial protocol. Of particular note in Figure 1 is the fact that each MLCP unit has two
separate CAN bus outputs which are used to control the ceiling and sidewall LCM units
independently. This makes it possible to design Scenario presentations that
concurrently display different colors on the sidewall and ceiling of the cabin.
The MLCP also interfaces with discrete signals from the aircraft, which in special cases,
override the operation of the MLS. An example of this would be the decompression
relay input which signals to the MLCP that a cabin depressurization event has occurred.
In this event, the MLCP would transition the cabin lighting to the full white (Default
White) condition.
A USB jack on the front of the MLCP provides real-time control of the MLS via a
connected laptop if so desired. This aids in the design of new lighting Scenarios. Once
new Scenarios are designed, they can be uploaded to the MLCP via the USB jack. The
USB jack is disabled during flight operations and is covered by a protective sliding door.
The BC1-0212 MLCP unit is depicted in Figure 3. Connector pin-out information for the
unit is provided in Figure 4 and Table 2. The same MLCP unit is used in both of the
BR3000 MLS systems employed on the A330 aircraft. Note that the operator initiates
lighting Scenario selections by simply pressing one of the pre-programmed function
buttons on the MLCP keypad. Scenario activation is signaled by an LED indicator on
each of the function buttons. Note the Day / Night special function button. This button
allows a different set of lighting Scenarios to be employed for day or night flights.
The MLCP unit operates from 28 Vdc aircraft power. A functional explanation of the
MLCP unit is included in the following sub-paragraphs. This functional description is
keyed to the numbered items in the MLCP block diagram provided in Figure 5.

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3.1.1.1 USB Input, Note 1
The BC1-0212-001 MLCP unit contains a slave-type USB port that allows a
conventional laptop computer to be connected to the MLCP. Using special application
software running on the laptop computer, three functions are provided:
Real time control of the connected mood lighting system for the purposes of
tuning and designing new lighting Scenarios.
Upload of new completed Scenario designs into the memory of the MLCP.
Upload of new operating software into the MLCP
The USB port on the BC1-0212-001 MLCP cannot operate as a master-type USB port.
That it to say, that the MLCP USB port does not allow the connection of portable
memory devices such as USB thumb drives. A special type-B USB connector is
employed to prevent the inadvertent connection of such devices. The USB port is
disabled once the aircraft is airborne, via monitoring of the Air / Ground input signal to
the MLCP. When not in use, the MLCP USB port is protected by a sliding cover.
3.1.1.2 MLCP Microcontroller, Note 2
A 32-bit microcontroller device is employed in the MLCP which is manufactured by
Microchip Corporation. The programming for this device is fixed and held in flash
memory within the device. Thus, there are no external memory devices or media
required for MLCP boot-up and operation. The MLCP microcontroller contains several
dedicated peripherals which simplify unit design, including:
USB Controller
RS-485 Serial Controller
Two CAN Bus Controllers
Analog to Digital Converters
The MLCP Microcontroller is the master processor for the MLS system. This device
calculates the timing and color amplitude values during Scenario execution. The MLCP
master processor also controls communication with the connected LCM units in the
system over the ceiling and sidewall CAN buses.
3.1.1.3 EEPROM, Note 3
A separate 1 Mbit EEPROM memory device, external to the master processor, is
utilized to store the Scenario data tables used by the master processor to calculate
Scenario transitions.
All of the four MLCP units used in the BR3000 installation are exactly the same.
However, hardwired Pin Programming inputs external to the MLCP provide a unique
address for each MLCP installation and make it possible to invoke different Scenario

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sets depending on where in the aircraft the MLCP unit is mounted. In order for the
MLCP units to be identical therefore, multiple Scenario data tables must be stored
within the EEPROM memory in each MLCP. The EEPROM memory can store up to
eight different Scenario data sets.
3.1.1.4 CPU Backup Power, Note 4
A capacitive backup circuit is used to supply the MLCP master processor with power in
the event of a momentary power interruption. The backup power circuit can provide
power to the processor for a period of up to one minute if necessary.
During a power interruption, the MLCP master processor is placed in a low-power
consumption mode. All peripherals such as keypad communication, CAN bus
communication, and the monitoring of discrete input signals, are shut down during a
power interruption. If power is returned to the MLCP within one minute, the MLCP will
simply continue Scenario execution from where it left off. However, if power to the
MLCP unit is interrupted for a period in excess of one minute, the MLCP will reset to the
default condition which commands the connected MLS system to the Full White /
Default White Scenario.
3.1.1.5 Keypad Assembly, Note 5
A membrane type keypad assembly is used in the construction of the MLCP. The
keypad assembly, which is integrated with the aluminum front panel of the unit, contains
12 pre-programmed function buttons with indicators. The function buttons are of the
snap-dome variety, providing tactile feedback to the user. Function actuation is
signaled by small amber LED indicators which are visible in the upper left hand corner
of each button. The Night / Day special function button contains two LED indicators in
order to annunciate which of the two Scenario sets is active. The keypad assembly is
backlit so that the button legends and graphics will be visible in a dimly lit environment.
Backlighting is achieved using fiber optics spread through the membrane layer, which
are illuminated by two LED emitters on the main MLCP PCB assembly.
3.1.1.6 Input Power Conversion, Note 6
The MLCP operates from aircraft 28 Vdc power. The MLCP contains a power filter
circuit which not only prevents conducted EMI emissions from the unit, but also
conversely protects the MLCP from fast rise-time transients on the input power lines.
For high efficiency, a switching Buck regulator is used to drop the 28 Vdc source
voltage down to a regulated 12 Vdc level. This conversion to a 12 Vdc level gives the
MLCP considerable immunity to abnormal high and low power variations on the 28 Vdc
line. Subsequent conversion from 12 Vdc to the 3.3 Vdc level used by the MLCP
master processor is achieved with linear regulators.

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3.1.1.7 Isolated Interface, Note 7
The two CAN bus ports, the discrete control inputs from the Cabin Management System
(ACESS), and an auxiliary RS-485 port that can be used to tie the functions of two
MLCP units together, are all isolated from MLCP master processor in order to protect
the MLCP processing circuitry from transients and ground loops. For the CAN bus and
RS-485 ports, a magnetic isolation device called an i-coupler is utilized. These three
ports are bi-directional. The discrete, one-way, inputs from the ACESS system are
isolated from the MLCP processing circuitry by means of a photo-coupler. All four of the
isolation circuits are individually powered from their own isolated power source. A self-
contained 12 volt to 12 volt DC conversion module is used to create the necessary
isolation power. These small DC to DC conversion devices are contained on 4-pin SIP
(single in-line package) modules.

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Figure 3 BC1-0212 Mood Lighting Control Panel (MLCP)
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Figure 4, MLCP Connector Pin-Out
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Table 2 BC1-0212 MLCP Connector Pin-Out
J1 pin number Signal Name Comments
1 n.c.
2 n.c.
3 n.c.
4 Chassis Ground 1 (New Signal)
5 (Hi)Ceiling CAN Trunk #1, CAN High
6 (Hi) Sidewall CAN Trunk #2, CAN High
7 n.c.
8 Night In, IN Unused
9 Decompression + 28 Vdc internal pull-up, Active Low
10 Ceiling In, RTN ACESS control override input, Ground
11 Ceiling In, Sig 1 ACESS control override input, ON/OFF,
isolated pull-up, 12 to 28 Vdc
12 Sidewall In, Sig 2 ACESS control override input, BRT/DIM,
isolated pull-up, 12 to 28 Vdc
13 n.c.
14 Pin Programming, Bit 2 Used to invoke alternate Scenario sets
based on MLCP installed location
15 Pin Programming, Bit 0
16 n.c.
17 Alternate MLCP, (A) RS-485 (A), Optional connection to inter-
operable MLCP unit.
18 Chassis Ground 2 (New Signal)
19 + 28 Vdc Power Input
20 n.c.
21 n.c.
22 Ceiling Bus, Shield Ground CAN Trunk #1, Shield Ground (New
Signal)
23 (Lo) Ceiling CAN Trunk #1, CAN Low
24 (Lo) Sidewall CAN Trunk #2, CAN Low
25 Sidewall Bus, Shield Ground CAN Trunk #2, Shield Ground (New
Signal)
26 Night In, RTN Unused
27 n.c.
28 Air / Ground + 28 Vdc internal pull-up, Active Low
(Aircraft on ground)
29 Ceiling In, Sig 2 ACESS control override input, BRT/DIM,
isolated pull-up, 12 to 28 Vdc
30 Sidewall In, RTN ACESS control override input
31 Sidewall In, Sig 1 ACESS control override input, ON/OFF,
isolated pull-up, 12 to 28 Vdc
32 Pin Programming, RTN
33 Pin Programming, Bit 1
34 n.c.
35 Alternate MLCP, (B) RS-485 (B), Optional connection to inter-
operable MLCP unit.
36 Alternate MLCP, Shield Ground Shield ground for RS-485
37 Power Return