EFTA00277580.pdf

• e Form Approved OMB No. 2120-0020 For FAA Use Only US Department Of Transportation MAJOR REPAIR AND ALTERATION Office Identification Federal (Airframe, Powerplant, Propeller, or Appliance) Aviation Administration So- r5DO- 1 INSTRUCTIONS: Print or type all entries. See FAR 43.9, FAR 43 Appendix B, and AC43.9-1 (or subsequent revision thereof) for instructions a d disposition of this form. This report is required bylaw (49 U.S.C. 1421). Failure to report can result in a civil penalty not to exceed $1,000 for ea such violation (Section 901 Federal Aviation Act of 1958). Make Model 1. Aircraft Boeing 727-100 _ Serial No. Nationality and Registration Mark 20115 USA N908JE 2. Owner Name (As shown on registration certificate) = N om J.E.G.E, Inc. 3. For FAA Use Only .. ..• . • pties with applicable Tor, data identified here' for the above atoverthInes reqiiFements is approved described aircraft, subject ntorrnity I by a person ,uthedram 43, se 43.7. 5 (-1 --f5V 0 — i T OCT Sign of Inspector Date 4. Unit Identificati 5. Type Alteration Unit Make Model Serial No. Repair AIRFRAME (As described in Item 1 above) POWERPLANT PROPELLER Type APPLIANCE Manufacturer 6. Conformity Statement A. Agency's Name and Address B. Kind of Agency C. Certificate No. BANYAN AIR SERVICE U.S. Certificated Mechanic •VI NICS DIVISION Foreign Certificated Mechanic Radio Class 1,2,3 0 Certificated Repair Station Limited Airframe Manufacturer D. I certify that the repair and/or alteration made to the unit(s) identified in item 4 above and described on the reverse or attachments hereto have been made in accordance with the requirements of Part 43 of the U.S. Federal Aviation Regulations and that the information furnished herein is true and correct to the best of my knowledge. Date Signature of Authorized lndi .d4,31) ( 9/W_ . :,7 fr/ C?-7---46 & g_. <71, 0C)Z ' /- ,/ eeZ Steve Ouellette 7. Approval for Return to Service Pursuant to the authority given personsRecified below, the unit identified in item 4 was inspected in the manner prescribed by the Administrator of the Federal Aviation Administration and is APPROVED O REJECTED FAA Flt. Standards Manufacturer inspectfon Authorization Other (Specify) BY Inspector FAA Designee X Repair Station Person Approved by Transport Canada Airworthiness Group -b, Date of Approval or Rejection Certificate or Signatur thorized I idu d Designation No. ____ ..______ Der-0,57 _,,ao6 SD4R514M 0: Steve Ouellette l FAA Form 337 (12-88) EFTA00277580  NOTICE Weight and balance or operating limitation changes shall be entered in the appropriate aircraft record. An alteration must be compatible with all previous alterations to assure continued conformity with the applicable airworthiness requirements. 8. Description of Work Accomplished (If more space is required, attach additional sheets. Identify with aircraft nationality and registration mark and date work completed.) The purpose of this 337 is for the work performect 1•1908JE under Banyan Air Service; Avionics Division work order #71301 completed on a2s/a6 A. Installed ari AirCell Iridium ST-3100 P/N 400-10680-001 and removed a previously installed AirCell AGT.01 P/N 900001-2. Minor wiring changes were made at the mating connector IAW installation manual P/N 800-10680 Rev. B dated June 2005. B. The above installation was performed in accordance with AC43.13-1B, Chapter 7, sections 1-5, AC43.13-1B Chapterg,'Options,3-17, AC43.13-2A Chapter 1, AC43.13-2A Chapter 2, paragraphs 24 & 25 and the aircraft's maintenance manual. . 111W: C A functional test of the .ab6e/Aniprrient has been performed FAR25.1309 and FAR25 .1431 for proper operation and did not adversely affect any other aircraft systems. An electrical load analysis was conducted and it was confirmed that this installation would not exceed 80% of the generator output. D. A log book entry and equipment list was generated to reflect the above installation. The weight change is negligible. the equipment list was updated to reflect this change. E. Instructions for continued airworthiness is attached.. END ❑ Additional Sheets are Attached EFTA00277581  Instruction for Continued Airworthiness for AirCell ST 3100 Aircraft Subscriber Equipment System Installed on Boeing 727-100 N908JE S/N 20115 Revision O. Dated: 9/17/2006 EFTA00277582  •• e EFTA00277583 • APPLICATION REVISIONS . DESC. NEXT ASSY USED ON REV DESCRIPTION DATE APPROVED ST 3100 ASE SYSTEM BARON 95-B55 A BASELINE RELEASE 2002-10-16 K. FRANTZ B SEE DCN 00179 2002-10-25 K. FRANTZ • ._,.... S a • • ALL SHEETS CARRY THE SAME REVISION LETTER a UNLESS OTHERWISE SPECIFIED e a DIMENSIONING & TOLERANCING bkW ASME Y14.5M-1994 DIMENSIONS ARE IN INCHES STANDARD TOLERANCES: x = ±. .1 )(X= ± .02 )(XX= ± .010 no d ..._.7 . AirCell, Inc. 1172 Century Drive Suite 280, Building B S Louisville, CO 80027 S APPROVED DATE PREPARED BY YEAR-M O-DA K. FRANTZ 2002-10-16 MECH DESIGN YEAR-MO-DA INSTRUCTIONS FOR CONTINUED Z. HOH 2002-10-16 AIRWORTHINESS ELEC DESIGN YEAR-M O-DA B. SOUKUP 2002-10-16 TECH SUPPORT B. NIELSON YEAR-MO-DA ST 3100 ASE SYSTEM 2002-10-16 --\ SYSTEMS YEAR-MO-DA K. FRANTZ 2002-10-16 ENGINEERING YEAR-MO-DA SIZE - CAGE CODE DRAWING NUMBER REV J. POLSON 2002-10-16 A 1NO67 . 820-10680-001 B FILE FORMAT: Microsoft Word 2000 SCALE: NONE WEIGHT: NA SH 1 of 8 FILENAME: 820-10680-001-B.doc 699-10077: A-SIZE SPEC TEMPLATE.DOC EFTA00277584  • •• EFTA00277585 p. p p TABLE OF CONTENTS p 1 GENERAL INFORMATION p 3 1.1 SCOPE OF THIS DOCUMENT p 3 1.2 TECHNICAL SUPPORT CONTACT INFORMATION 3 p 1.3 • GENERAL. NOTES 3 1.4 ADVISORIES 4 2 SYSTEM DESCRIPTION 4 9 2.1 TOP LEVEL SYSTEM CONFIGURATION 1 "4 2.2 OPERATION OF THE SYSTEM p 6 OPERATIONAL TIME LIMITS AND SCHEDULED MA p INTENANCE 7 4 UNSCHEDULED MAINTENANCE p 4.1 7 TROUBLESHOOTING PROCEDURE p 7 5 AIRWORTHINESS LIMITATIONS p 7 FIGURES AND TABLES Table 2.1-1 System Component Definition 5 Figure 2.1-1 Block Diagram of ST 3100 ASE System 6 ) ) • AirCell, Inc. SIZE CAGE CODE DRAWING NUMBER REV 1172 Century Drive e A 1NQ67 820-10680-001 B Suite 280, Building B FILE FORMAT: Microsoft Word 2000 SH 2 of 8 Louisville, CO 80027 FILE NAME: 820.10680-001-B.doc 699.10077: A-SIZE SPEC TEMPLATE.DOC EFTA00277586  'I EFTA00277587  GENERAL INFORMATION 1.1 SCOPE OF THIS DOCUMENT This manual defines the instructions for continued airworthiness (ICAW Subscriber Equipment (ASE) system. Th ) for an AirCell_ 3000 Series Aircraft e manual is written to demonstra and 25.1529. Specifically, this manual te compliance with FARs 23.1529 defines the instructions for the System (ST 3100). Model 3100 Satellite Telephone This manual is subdivided into sections to support the general operation, ST 3100 system. Section 1 defines gene inspection and maintenance of the ral information for the maintenan system. Section 2 provides general ce and airworthiness of the ASE information on the configuration an Section 3 presents a discussion of d operation of AirCell ASE systems the scheduled maintenance an op . Section 4 and Appendix A provide d era tio na l tim e limits for the system. instructions for system operationa maintenance and component replac l checks, troubleshooting, unscheduled ement. Section 5 provides a brief limitations for the ST 3100 system. statement addressing airworthiness 1.2 TECHNICAL SUPPORT CONTACT INFORMATION Technical support for AirCell products is available from 08:00 to 17:00 Unite Zone GMT —7 hours) Monday through d States Mountain Time (Time Friday. The contact information for Air follows: Cell Technical Support is as From a landline: Phone (in the US): 1.888.286.9876 (toll free) Phone (outside the US): 001.303.379.0278 (toll call) From an AirCell phone: From an Air Mode/AMPS phone (in the US): 611 (toll free) From a SAT Mode (Iridium) phone (w orldwide): 2471 (toll free) Email: customerservice@aircell.com Note: The toll free numbers for AirCe ll phones will only work for AirCell pro vided phones and services. 1.3 GENERAL NOTES • All pages in this document carry the sa me revision level. Revision status is on each page of this manual. indicated by a letter printed • The material in this manual is subje ct to change. Before planning or maintenance operation, check with performing any installation or AirCell Technical Support to verify that has the latest revision. this manual is complete and • AirCell, Inc. welcomes your comm ents, suggestions, and corrections include in your correspondence the concerning this manual. Please publication number, equipment part nu and a brief description of any problem or mber, page or figure number, consideration you noted. Please se nd your comments to: AirCell, Inc. Corporate Publication Coordinato r 1172 Century Drive Suite 280, Build ing B Louisville, Colorado 80027 cpc@aircell.com AirCell, Inc. SIZE CAGE CODE DRAWING NUMBER elf 1172 Century Drive Suite 280, Building B A 1NC)67 820-10680-001 REV B FILE FORMAT: Microsoft Word 20 Louisville, CO 80027 00 I SH 3 of 8 FILE NAME: 820-10680-001-B.doc 699-10077: A-SIZE SPEC TEMPLATE. DOC EFTA00277588 i EFTA00277589  1.4 ADVISORIES WARNING Statements in this section contain critical safety info rmation. Read these statements carefully before installing this unit. WARNING Observe standard safety precautions and wear safety glasses to prevent personal injury while performing maintenance on this unit in the aircraft . WARNING Shut off power before connecting or disconnecting the ST 3100 system, as voltage transients may damage the unit or the interface wiring. WARNING Components or subassemblies found in this unit may con tain materials such as beryllium oxide, acids, lithium, radioactive material, mercury, etc. that can be hazardous to your health. If the component enclosure gal is broken , precautions must be taken against personal contact or inhalation in accordance with OSHA requirements 29CFR 1910.1000 or superseding documents. AirCell strongly discourage s the opening or disassembly of sealed components. WARRANTY AND CERTIFICATIONS Any alteration of this product voids the FAA or FCC certific ation and the AirCell warranty. 2 SYSTEM DESCRIPTION The ST 3100 ASE system provides access to a range of two way communication options from an aircraft, including voice and data applications. With the ST 3100 system these services are available when the aircraft is in the air or on the ground. The AirCell satellite mode communications link is provided using the 1600 MHz Iridium LEO (Low Earth Orbit-485 miles altit ude) satellite network, which provides coverage from the ground up over the entire surface of the earth. 2.1 TOP LEVEL SYSTEM CONFIGURATION The ST 3100 system consists of a number of primary sys tem components. The heart of the system is the ST 3100 ASE Transceiver, which includes internal elec tronics to support operation in the Iridium satellite network. Other system components include the externa lly mounted antenna, a low loss coaxial cable, and various user interfaces including multiple ASE handsets (up to 9), an RS -232 data port, and an audio panel interface. AirCell' AirCell, Inc. SIZE CAGE CODE DRAWING NUMBER REV 1172 Century Drive A 1NO67 820-10680-001 B Suite 280, Building B FILE FORMAT: Microsoft Word 2000 SH 4 of 8 Louisville, CO 80027 FILE NAME: 820-10680-001-B.doc 699-10077: A-SIZE SPEC TEMPLATE.DOC EFTA00277590  .. I EFTA00277591  AAt4r4fAco ed The primary components of an ASE system include Line Replaceable Units (LRUs) and AirCell specifi assemblies (such as coaxial cables or wiring harnesses) that are manufactured or purchased by the system installer. A list of the LRUs and specified assemblies is provided in Table 2.1-1, and a representative block diagram is provided in Figure 2.1-1 to demonstrate the interconnection of a typical ST 3100 system. For detailed information on the system components, please refer to ST 3100 ASE System installation manual (AirCell document 800-10680), or contact AirCell Technical Support for assistance. Table 2.1-1 System Component Definition System Designatio Description AirCell PN. Approved AirCell PN Component n Alternate(s) of Alternate System LRU ST 3100 Transceiver ASE Transceiver 400-10680-001 none Transceiver LRU 3/8 ATR Width 3000 Series :Mounting Tray Mounting Tray 800007-1 Mounting Rails 151-10689-001 System Wiring Specified 26 wire System NA Harness Assembly Harness ASE Handset LRU Flush Mount Standard ASE 400-10001-10X* Handset 400-10035-00X* ASE Handset Portable Coilcord ASE Handset 400-10015-00X* Custom Retractable ASE Handset 400-10019-00X* Satellite LRU 1600 MHz Satellite 1600 MHz Satellite 015-10683-001 ASE Antenna, 015-10306-001 ASE Antenna, ASE Antenna Patch Style Blade Style Satellite Channel Specified Low Loss Coaxial NA Coaxial Cable Assembly. Cable (vendor item)" "X" designates the color of the ASE handsets. ** The system coaxial cable is a required item that is not provided by AirCell. The system installer will need to purchase this item from an approved vendor as defined later in this document. AirCell, Inc. SIZE CAGE CODE DRAWING NUMBER REV (MICA: 1172 Century Drive Suite 280, Building B A 1NQ67 FILE FORMAT: Microsoft Word 2000 820-10680-001 B I SH 5 of 8 Louisville, CO 80027 FILE NAME: 820-10680-001-B.doc 699-1C077:A-SIZE SPEC TEMPLATE.DOC EFTA00277592  • . . . .. : I EFTA00277593  ASE SATELLITE \/ ANTENNA I ASE SYS HS CNCTR .44111 .\_ AIRCRAFT ASE HANDSET CHANNEL FUSELAGE ASE SYS HS CNCTR 1=1--M120 ASE HANDSET CHANNEL 0 ASE SYSTEM XCVR ASE 5Y5 HS CNCTR p Mffal ASE HANDSET CHANNEL SAT ANTENNA ID D TO AUDIO PANEL AUX CNCTR NO CONNECTION ASE SYS RS232 CNCTR I TO RS232 DATA TERMINAL SYS CNCTR TO AIRCRAFT POWER (2.8 Vdc) I I AIRCRAFT FUSELAGE I I Figure 2.1-1 Block Diagram of ST 3100 ASE System I Note: Each 'Handset Channel' listed above is capable of supporting up to 3 ASE handsets, making it possible to integrate up to 9 handsets in the ST 3100 system. I 2.2 OPERATION OF THE SYSTEM The user interface and operation of the ST 3100 system is designed to be very similar to the operation of a I terrestrial cellular or PCS phone. Some key features of the ST 3100 system are as follows: • The system will power up when the avionics master switch for the aircraft is powered on. The AirCell system is always on when the avionics master is powered on. • ' The Satellite mode network provides coverage anywhere on (or above) the surface of the earth with a I clear view of the sky in all directions. • To place a call from the system handset, the user must verify that the system is 'in service'. SAT mode calls are typically dialed as international long distance calls (00 + country code + phone number). After dialing, the user must press the " SND " key on the handset, and the phone call will proceed as a typical cellular or PCS call. At the completion of a call, the user may press the " END " key to terminate the call. • The user may receive incoming (ground to air) phone calls depending on the in service condition. The user can answer these calls by pressing the " SND " key on the handset. • Data calls can be made from Air to Ground over the ST system by connecting a Data Terminal Equipment device (such as a PC) to the RS-232 port of the system. The ST system has a built in modem function, so some user setup of the DTE will be required. ) More detailed operating instructions are provided for this system in the ST 3100 User's manual (AirCell document 810-10680). ) AirCell, Inc. SIZE CAGE CODE DRAWING NUMBER REV 6N_j.ri•Celf 1172 Century Drive Suite 280, Building B A 1NQ67 FILE FORMAT: Microsoft Word 2000 820-10680-001 B SH 6 of 8 Louisville, CO 80027 FILE NAME: 820-10680-001-B.doc 699-10077: A-SIZE SPEC TEMPLATE.D GC I EFTA00277594  I EFTA00277595  uctict)ticccfoC INTENANCE 3 OPERATIONAL TIME LIMITS AND SCHEDULED MA sys tem is des igne d and man ufac ture d to be mai nten anc e free after installation. As a result of The ST 3100 des ign, ther e are no ope ratio nal time limi ts or per iodic maintenance checks or procedures that must be this sys tem . Insp ecti ons and /or sys tem veri fica tion che cks are only required in the event of a performed for the 4 of this document. system failure (On Condition), as defined in Section the sys tem ope rato r may per form a visu al insp ecti on of the various system components at the As an option, aircraft manufacturer. or oth er per iodi c mai nten anc e inte rval as defi ned by the aircraft annual inspection, 4 UNSCHEDULED MAINTENANCE is des igne d for "On Con ditio n" mai nten anc e only . In the event of a system failure, the The ST 3100 system use r/air craf t ope rato r is adv ised to follo w the trou bles hooting procedure defined in Appendix A of this system orm ing the bas ic pro ced ure , the use r will eith er hav e returned the system to normal manual. After perf additional guidance. operation, or should contact AirCell technical support for proc ess of per form ing the trou bles hoo ting pro ced ure , auth orized field service personnel are Note that, in the ing interfaces, or (with prior to wiri ng har nes ses , RF cab le ass emb lies , mo unt permitted to perform repairs ell Tec hnic al Sup por t) to rem ove and rep lace any of the primary system Line Replaceable approval from AirC or subassembly level , und er any circ ums tanc es, auth oriz e field rep air Units (LRUs). AirCell does not on any LRU . Sea led LRU s sho uld alw ays be retu rne d to the AirCell FAA Repair Station for maintenance evaluation and repair. 4.1 TROUBLESHOOTING PROCEDURE e to iden tify sim ple pro blem s that may be iden tifie d and/or resolved with simple Appendix A provides a guid on and test pro ces ses . It is adv ised tha t the pro ced ure in this appendix should be performed field inspecti ell Tec hnic al Sup por t for add ition al inst ruct ion. No spe cialized tools or equipment are before contacting AirC required to perform this procedure. a step in this pro ced ure is not clea r, or the resu lts of a procedure are not conclusive, the In the event that t for assistance. test operator should feel free to contact Technical Suppor 5 AIRWORTHINESS LIMITATIONS ST 310 0 ASE sys tem is a non -cri tica l com mun icat ions system. In accordance with FAR The AirCell end ix G) and FAR 25.1 529 (wit h Par t 25 App end ix H) this system has no 23.1529 (with Part 23 App aircraft. Airworthiness Limitations for either Part 23 or Part 25 s limi tatio ns sec tion is FAA app rove d and spe cifie s maintenance required under Sections The airworthines eral Avia tion Reg ulat ions unle ss an alte rna tive pro gra m has been approved. 43.16 and 91.403 of the Fed DRAWING NUMBER REV AirCell, Inc. SIZE CAGE CODE A7-fr C e lf 1172 Century Drive Suite 280, Building B A 1NQ67 FILE FORMAT: Microsoft Word 2000 820-10680-001 SH 7 of 8 B Louisville, CO 80027 FILE NAME: 820-10680-001-B.doc 699-10377: A-SIZE SPEC TEMPLATE.DOC EFTA00277596  'a . . % . . . I EFTA00277597 t.d S • 0 P 9 P Appendix A ST 3100 ASE System Troubleshooting Procedure p p a a a A tirr AirCell, Inc. SIZE CAGE CODE DRAWING NUMBER F. kj ell 1172 Century Drive Suite 280, Building B A 1NQ67 820-10680-001 B FILE FORMAT: Microsoft Word 2000 I SH 8 of 8 Louisville, CO 80027 FILE NAME: 820-10680-001-B.doc 68410077,S. SPEC TEMPLATE.DOC a EFTA00277598  • EFTA00277599  EFTA00277600 TrCell' Symptom Possible Cause Discussion Verification Step(s) The handset display should always O Verify that the aircraft power system (master avionics switch) is on. Symptom 1 Power is not available to ASE be illuminated when power is O Verify that the ASE system circuit breaker is closed. System Handset Display is applied to the ASE transceiver. O Visually inspect the displays of all installed handsets in the system. If all handsets not illuminated arc off, proceed to the next bullet in this list. If most handsets are illuminated, but Because the failure of a handset display is unlikely, a `dead' display one is not, then proceed to Symptom 2. (One or more suggests that there is a problem with O If all handset displays are dead, the problem is likely in the power system wiring handsets integrated in the input power to the ASE system. before the ASE transceiver. Visually check the system connections and the wiring . system, no handset In the event that the one or more harness leads between the transceiver and the aircraft power system. Repair or displays are handset display(s) are not reconnect any obvious problems. illuminated) illuminated, the user/operator should O If needed, ring out the power lines per the system wiring diagram. Repair any verify that aircraft power is on and broken wires or rework to match the system wiring diagram. . available to the ASE transceiver. O If this procedure does not resolve the problem, contact AirCell Technical Support - for additional guidance. In a system with multiple handsets, O Some ASE systems integrate multiple handsets. If more than one handset is Symptom 2 Bad connection or faulty wiring if some handsets are operating and installed on the system, check the display on all handsets. If only one of multiple Handset Display is between handset and some arc not, then it is likely that handsets is not illuminated, then the problem is either a bad handset or in the handset not illuminated transceiver. either the handset is bad or the connection/ wiring harness between that handset cradle and the transceiver. wiring between the handset and the O Perform a visual inspection to verify that ail connections are made in accordance (ASE System has or transceiver is faulty. with the system wiring diagram. Correct any obvious problems. multiple handsets, O If all system connections are correct, then switch the `dead' handset with a known Bad handset good handset and retest the system. If the handset is still dead in the new location, and the displays of most handsets are on, then the handset is bad. Contact AirCell Technical Support for repair/replacement but one handset is not instructions. illuminated.). O If the known good handset is now dead, then the problem is in the system wiring/connections between the handset and the tra