background image

 

 

SX-16 Nightsun

®

 Searchlight System 

 

Maintenance Manual 

Document 031734-1/Revision A  

031734-1 Revision B 

 

January 27, 2014

 

  

 

  

 

3.2 

Guidelines for the Installer 

3.2.1 

General Guidelines 

Spectrolab does not install the SX-16 Nightsun

®

. It is the responsibility of system installers to ensure 

the integrity and safety of the installation, configuration, and integration with the aircraft/structure. 

 

This manual should not be your sole guide for specific installations. Assess the safety of your 
installations on a case by case basis. 

 

The SX-16 Nightsun

®

  does not require major modifications because it relies on bulkhead 

through connectors for system cabling. Consequently, the SX-16 Nightsun

®

 can be installed 

on a variety of aircraft/structures. Consult with Spectrolab for assistance in determining your 
precise installation requirements. 

3.2.2 

Technical and Safety Considerations 

When selecting a mounting location, the following technical and safety considerations are important: 

 

Consider aircraft/structure stress, fatigue, and handling characteristics before you approve an 
installation design. 

 

Locate the equipment for favorable equipment operation, and provide optimum mobility for 
aiming and focusing. 

 

On aircraft installations, consider the following elements: balance and weight distribution with 
reference to the aircraft center of gravity; aircraft operation; and optimum mobility for aiming 
and focusing in all flight patterns. 

 

Locate the equipment to facilitate adjustments, maintenance, and repairs. 

 

Route the system cables in ways that minimize their length. 

 

A stainless steel safety cable secures the Gimbal to the mounting bracket, and another 
secures the Searchlight to the Gimbal. If the Gimbal is separated from its mount (or if the 
Searchlight is separated from its Gimbal mounting), the safety cables will prevent the Gimbal 
or Searchlight from potentially falling free of the aircraft. 
 

Before installing the Searchlight, test the installation location: 

 

During operation, the Searchlight’s high-intensity  light beam can cause heat damage to 
exposed surfaces, especially if the light is aimed at a surface for long periods of time. 

o

 

Provide for heat dissipation from the Searchlight head during operation. 

o

 

Do not install the Searchlight in locations that allow the light beam to be aimed at 
nearby temperature sensitive surfaces without taking appropriate steps to mitigate 
possible damage. The light absorbed by dark colored surfaces may  cause them to 
reach combustion temperatures under some conditions. 

o

 

If the Searchlight is installed on an aircraft that is equipped with floats, the 
mechanical stops for Azimuth  and elevation may have to be adjusted. Adjust the 
stops to limit the movement of the Searchlight to prevent it from shining directly at the 
floats. The Searchlight beam may deteriorate the material in floats at close range. 

o

 

Do not expose fuel or other volatile substances to the Searchlight beam. 

o

 

Prevent the Searchlight from being aimed in ways that adversely affect the aircraft 
crew. 

o

 

Install a circuit breaker (for the SX-16 Nightsun

®

) that is accessible to the aircraft 

crew. 

o

 

Make sure that the Searchlight does not interfere with aircraft instrumentation or 
radios. 

o

 

Make sure that the Searchlight does not overload the aircraft’s electrical system 
when all other anticipated electrical systems are operating. 

3.3 

Overview of System Connections 

The SX-16 Nightsun

®

 includes a Control Box, Junction Box, Gimbal, Searchlight, and cables. Figure 2 

depicts the connections between the main components of the SX-16 Nightsun

®

. It identifies the 

 

 

 

 

 

Source:  Spectrolab, Inc. 

6

 

The document reference is online, please check the correspondence between the online documentation and the printed version.

Summary of Contents for SPECTROLAB SX-16 Nightsun

Page 1: ...separate manual provides information about operation 1 3 Read Obey and Keep Instructions To ensure the safety of people and equipment it is important to read and obey all instructions and safety warni...

Page 2: ...a voltmeter to verify that voltage in the Junction Box s large Capacitor has discharged from its 125 to 150 VDC level before touching its terminals o Similarly use a voltmeter to verify that the start...

Page 3: ...nt should be resistant to 500 F 260 C Barbecue or automotive exhaust manifold paint works well The target should be well supported by a stand that is non flammable During use it will become very hot a...

Page 4: ...install the Searchlight in locations that allow the light beam to be aimed at nearby temperature sensitive surfaces without taking appropriate steps to mitigate possible damage The light absorbed by d...

Page 5: ...dicate a hazardous situation that could result in minor or moderate injury if not avoided A caution message has the following appearance 2 3 Notice Messages Notice messages are also used in this manua...

Page 6: ...ed from its Gimbal mounting the safety cables will prevent the Gimbal or Searchlight from potentially falling free of the aircraft Before installing the Searchlight test the installation location Duri...

Page 7: ...connections Junction Box to the Control Box Junction Box to the Gimbal assembly and Searchlight Junction Box to the input power 3 5 1 Junction Box to Control Box In the compartment where the Control B...

Page 8: ...embled it serves the following functions o Mechanically supports the Searchlight and the attachment to the aircraft o Provides the electrical and communication link between the Searchlight and Junctio...

Page 9: ...cond Adjustable Elevation stop blocks are incorporated to improve ease of moving of upper and lower elevation limits in 2 increments Elevation stop block shown is for illustration purposes and may var...

Page 10: ...es on the bottom of the Gearbox It also has a fixed vertical Roll Pin mounted on top of the doubler plate In Figure 6 the main Gimbal components are illustrated Figure 6 Gimbal Assembly Older Standard...

Page 11: ...210 Enhanced Uni body 230 Enhanced Uni body with SpectroLink 022955 Series Steel 21 Standard 121 Standard High Speed 130 SpectroLink 140 IFCO SpectroLink 4 3 3 Elevation Attachment and Movement In ad...

Page 12: ...hs or 300 flight hours or 100 operation hours Use the following inspection procedures Daily o Verify that both Wing Bolts are in place and that the lanyards are connected to the angle clips on the Gim...

Page 13: ...rs or switches will have a second separate connector If not you may have to replace the standard 4 pin connector with one that has more pins 4 5 2 3 Motor Wires The condition of all motor wires is imp...

Page 14: ...archlight systems include electronically programmable stops as part of ancillary equipment such as a moving camera that has been specially installed Adjustment of these programmable stops is addressed...

Page 15: ...of the elevation stop since the replacement will be installed in the same orientation Remove the four 4 torque set flat head screws P N NAS1102E08 5P 8 32 x 5 16 LG attaching the existing Elevation st...

Page 16: ...ced in August 2004 It consists of two adjustable stop blocks Each stop block is attached to the Azimuth Adapter ring by two shoulder bolts Figure 12 The stop blocks limit movement of the Gimbal when t...

Page 17: ...o the aircraft The maximum potential movement of the Searchlight however will be compromised if the wire becomes twisted around or hampered by the Gimbal components Azimuth motion is limited by the po...

Page 18: ...arged If the hole has been enlarged in this way replace the Gimbal arm There is no repair procedure for an enlarged Roll Pin hole o If the new pin fits snug reassemble the spacer and arm on the shaft...

Page 19: ...ter from the bottom of the Gearbox There are two options One option is to rotate the adapter 90 180 or 270 so that a fresh hole is in the desired location A second option is to replace the adapter wit...

Page 20: ...bal arms pay particular attention to the area of the doubler plate and the rivets Inspect for signs of cracks corrosion or chipped or peeling paint o If any cracks or any loose or broken rivets are fo...

Page 21: ...propriate for use on 7075 aluminum alloy Follow the manufacturer s instructions Make sure to remove all residues before painting For steel Gimbals reference Gimbal Part Numbers Available by Descriptio...

Page 22: ...to be used on flight hardware should conduct the replacement The aircraft mechanic should verify that all hardware is in sound flight worthy condition upon completion of this procedure 4 10 1 Identif...

Page 23: ...imbal arm when it is reinstalled o Note the orientation of the drive motor with respect to the Gimbal arm so that it can be installed in the same position with the new Gimbal arm o Observe the routing...

Page 24: ...the Azimuth clutch to slip Drive the arms through their entire range of motion in each direction until they hit both of the stop blocks o Verify that the wires do not pull at the connector or where t...

Page 25: ...he arms through their entire range of motion in each direction until they hit both of the stop Roll Pins o Verify that the wires do not pull at the connector or where they enter the motor boots Remove...

Page 26: ...vice will then stop the motor electronically just before it hits the mechanical stops It is important to be aware of this behavior so that you can differentiate this kind of motor stopping from a clut...

Reviews: