INSTRUCTIONS FOR CONTINUED AIRWORTHINESS · 2017-08-16 · 365 Aerospace Ltd. ICA-0006-001 REVISION...

365 Aerospace Ltd. ICA-0006-001

REVISION B Sheet 1 of 13

Unit 9 Titmore Court, Titmore Green, Little Wymondley, Hitchin, Herts, SG4 7JT, UK. Tel: +44 (0) 1438 906666 - Web: www.365.aero

EASA DOA No. EASA.21J.575

INSTRUCTIONS FOR CONTINUED AIRWORTHINESS In accordance with EASA CS 25.1529/FAR 25.1529, Appendix H

Form No: 365-117 (ISSUE 3)

TITLE Instructions for Continued Airworthiness, Configuration 1

AIRCRAFT TYPE VARIANT REGISTRATION SERIAL No.

B737 Refer to Para 2.0 Refer to Para 2.0 Refer to Para 2.0

MASTER DATA LIST: MDL-0006

COMPILED BY: M. Hills CHECKED BY: A. Surdeanu

SIGNATURE: M. Hills SIGNATURE: A. Surdeanu

DATE: 06 Apr 16 DATE: 08 Apr 16

A. With reference to any change/repair referenced in this document, this modification is approved under the authority of EASA STC No. 10054305.

B. With reference to any Owner/Operator/Supplier change or repair, the technical content of the supplemental information associated with any listed change/repair is approved under the authority of the named Owner/Operator/Supplier of the source documents. The Owner/Operator/Supplier of the source documents has given the compiler the rights to use their information in order to produce this document.

C. The Checking process will include a verification of technical consistency with the associated change/repair and any compliance documentation which may relate to effectivity, description, effects on airworthiness and environmental protection especially when limitations are changed or affected.

D. The approval process will include ultimate verification of the Instructions for Continued Airworthiness by a 365 Aerospace Ltd Certification Verification Engineer.

CROSS-DISCIPLINE COMPLIANCE REVIEW

SPECIALISM CVE NAME SIGNATURE DATE

STRUCTURES D. Wager D. Wager 08 Apr 16

CABIN SAFETY N. Chettleburgh N. Chettleburgh 08 Apr 16

ELECTRICAL / AVIONIC SYSTEMS D. Jackson D. Jackson 08 Apr 16

FLIGHT TEST - - -

PROPRIETARY NOTICE

This document contains proprietary designs, specifications, data, information, and technical material that are the sole property of 365 Aerospace Ltd. The information contained shall be held and treated by its recipient on a confidential basis and not to be

shown or disclosed to any unauthorised organisation or persons.

http://www.365.aero/







CHANGE / REPAIR SUMMARY REPORT REVISION SHEET

Revision Classification Compiled By Checked By Revision

Approved By Date

A MINOR See Sheet 1 See Sheet 1 D. Jackson 08 Apr 16

Initial Revision.

B

MINOR 27 Jul 17

Para 4.2 – ‘Airworthiness Limitations’:

Section briefing paragraph elaborated.

Inspection type added to each limitation.

GPS Sensor statement moved to Para 4.4.

Dlink+ and Printer statements removed.

Para 4.4 – ‘Maintenance Schedule Tasks’:

Section briefing paragraph introduced.

Reference drawing added to each task.

GPS Sensor statement introduced.

Part numbers introduced for each task for clarity.








TABLE OF CONTENTS

1.0 CHANGE / REPAIR DETAILS............................................................................................................. 4

1.1. Introduction. ............................................................................................................................................. 4 1.2. Definition. ................................................................................................................................................. 4

2.0 EFFECTIVITY CROSS REFERENCE ................................................................................................. 5

2.1. Applicability. ............................................................................................................................................. 5 2.2. Configuration Definition. ........................................................................................................................... 5

3.0 COMPLIANCE WITH REQUIREMENTS ............................................................................................. 7

3.1. Required Changes to Manuals and Other Documents ............................................................................ 7 3.2. Electrical Load Analysis. .......................................................................................................................... 7 3.3. Mass and Balance. ................................................................................................................................... 8 3.4. Minimum Equipment List (MEL) Recommendations ................................................................................ 9

4.0 CONTINUED AIRWORTHINESS ........................................................................................................ 9

4.1. General .................................................................................................................................................... 9 4.2. Airworthiness Limitations ....................................................................................................................... 10 4.3. Electrical Wiring Interconnection System (EWIS) .................................................................................. 11

5.0 ASSOCIATED DOCUMENTS ........................................................................................................... 13








1.0 CHANGE / REPAIR DETAILS

1.1. Introduction.

This modification provides instructions to activate Protected Mode – Controller Pilot Data Link Communications (PM-CPDLC) on the subject aircraft.

1.2. Definition.

This modification installs an ARINC 758 Protected Mode - Controller Pilot Data Link Communications (PM-CPDLC) System on a Boeing 757 Type Aircraft.

The PM-CPDLC System installed on the subject aircraft consists of:

• A Spectralux Dlink+ w/CPDLC Line Replaceable Unit (LRU), comprising of a Communication Management Unit (CMU), Multi-Input Control Display Unit (MCDU) and VHF Data Link Radio installed in the P8 Aft Pilot Control Stand for CPDLC purposes.

• An Aircraft Personality Module (APM) installed in the P8 Panel for CPDLC purposes.

• An ARINC 740 Data Printer installed in the P8 Aft Pilot Control Stand for recording purposes.

• Blue annunciators installed on the Captain and First Officer’s instrument panels and interfaces to the Selective Calling (SELCAL) system Bell/Chime module, for ATC/ACARS message annunciation.

• Installation of a GPS Antenna on the ‘padded-up’ (skin configuration 143N3121-4/-5) crown skin at STA 690, and GPS Sensor in the EE Bay for UTC timestamp.

• Removal of the redundant VHF C Transceiver from the E4-4 Shelf and Control Panel on the P8 Panel.

• Interfaces to the existing VHF C Antenna installed at STA 1473 for transmission of ATC/ACARS messages.

• Installation of interfaces to the Iridium Satellite Communications (SATCOM) system for transmitting ACARS messages when not connected to VHF.

• Installation of wiring provisions for a Solid State Cockpit Voice Recorder (SSCVR), including a ‘DLINK REC’ fail annunciator on the P1 Panel, for provisioned recording purposes.

• Interfaces to the Flap-Slat Electronics Unit (FSEU), Air/Ground Relay, Park Brake Relay and Engine-Indicating and Crew-Alerting System (EICAS) for Out Off On In (OOOI) for ATC/ACARS message inhibition during critical phases of flight.

• Interfaces to the Flight Management Computers (FMC) and Air Traffic Control (ATC) System for various aircraft data parameters for CPDLC purposes.

The ACARS CMU and provisions are installed in conjunction with EMTEQ design data included as part of this modification. This includes installation of the Spectralux Dlink+ w/CPDLC LRU, Printer, centre VHF Antenna and associated wiring.

The Global Positioning System and provisions for CPDLC, including interfaces to OOOI, Solid State Flight Data Recorder (SSFDR) and Annunciators are installed as part of this modification.

The ACARS System interfaces the existing Iridium SATCOM system, however only ACARS messages are capable of being transmitted via SATCOM; CPDLC messages cannot be sent via SATCOM.

The PM-CPDLC System is controlled by the Spectralux Dlink+ w/CPDLC Multi-Input Control Display Unit (MCDU) installed in the Flight Deck.

The PTA-45B Data Printer is used to print the various CPDLC/ACARS screen forms. Additionally, if connected to other compatible subsystem, it will also print the screen forms for that subsystem.

Limitations of this CPDLC System have been documented within the Master Data List, MDL-0006, and Flight Manual Supplement, FMS-0006-001.

The system will be activated and fully function tested upon completion; Test Plan TP-0006-001 refers.

According the 365 Aerospace procedures, a minor change to this modification may be applied to include further effective MSNs. 365 Aerospace will be required to contact EMTEQ to obtain RTUs for the EMTEQ Documentation. Any deviations to the configuration above must be reviewed and necessary documentation produced, complied and approved in accordance with EASA Part 21 prior to embodiment accordingly.








2.0 EFFECTIVITY CROSS REFERENCE

2.1. Applicability.

Aircraft Type Variant Registration Serial No. Configuration

B757 -200

OO-TFA

25622

1

2.2. Configuration Definition.

The PM-CPDLC System installed on the subject aircraft consists of:

• A Spectralux Dlink+ w/CPDLC Line Replaceable Unit (LRU), comprising of a Communication Management Unit (CMU), Multi-Input Control Display Unit (MCDU) and VHF Data Link Radio installed in the P8 Aft Pilot Control Stand for CPDLC purposes.

• An Aircraft Personality Module (APM) installed in the P8 Panel for CPDLC purposes.

• An ARINC 740 Data Printer installed in the P8 Aft Pilot Control Stand for recording purposes.

• Blue annunciators installed on the Captain and First Officer’s instrument panels and interfaces to the Selective Calling (SELCAL) system Bell/Chime module, for ATC/ACARS message annunciation.

• Installation of a GPS Antenna on the ‘padded-up’ (skin configuration 143N3121-4/-5) crown skin at STA 690, and GPS Sensor in the EE Bay for UTC timestamp.

• Removal of the redundant VHF C Transceiver from the E4-4 Shelf and Control Panel on the P8 Panel.

• Interfaces to the existing VHF C Antenna installed at STA 1473 for transmission of ATC/ACARS messages.

• Installation of interfaces to the Iridium Satellite Communications (SATCOM) system for transmitting ACARS messages when not connected to VHF.

• Installation of wiring provisions for a Solid State Cockpit Voice Recorder (SSCVR), including a ‘DLINK REC’ fail annunciator on the P1 Panel, for provisioned recording purposes.

• Interfaces to the Flap-Slat Electronics Unit (FSEU), Air/Ground Relay, Park Brake Relay and Engine-Indicating and Crew-Alerting System (EICAS) for Out Off On In (OOOI) for ATC/ACARS message inhibition during critical phases of flight.

• Interfaces to the Flight Management Computers (FMC) and Air Traffic Control (ATC) System for various aircraft data parameters for CPDLC purposes.

The ACARS CMU and provisions are installed in conjunction with EMTEQ design data included as part of this modification. This includes installation of the Spectralux Dlink+ w/CPDLC LRU, Printer, centre VHF Antenna and associated wiring.

The Global Positioning System and provisions for CPDLC, including interfaces to OOOI, Solid State Flight Data Recorder (SSFDR) and Annunciators are installed as part of this modification.

The ACARS System interfaces the existing Iridium SATCOM system, however only ACARS messages are capable of being transmitted via SATCOM; CPDLC messages cannot be sent via SATCOM.








The PM-CPDLC System is controlled by the Spectralux Dlink+ w/CPDLC Multi-Input Control Display Unit (MCDU) installed in the Flight Deck.

The PTA-45B Data Printer is used to print the various CPDLC/ACARS screen forms. Additionally, if connected to other compatible subsystem, it will also print the screen forms for that subsystem.








3.0 COMPLIANCE WITH REQUIREMENTS

3.1. Required Changes to Manuals and Other Documents

The Airplane Flight Manual (AFM) is affected by this change (modification)/repair, refer to Paragraph 5.0 for additional information.

The Aircraft Maintenance Manual (AMM), Illustrated Parts Catalogue (IPC) and Wiring Diagram Manual (WDM) are affected by this modification.

The Maintenance Schedule is affected by embodiment of this change (modification)/repair. To ensure continued serviceability and reliability each item of installed equipment must be maintained in accordance with the appropriate vendor Component Maintenance Manual (CMM).Post installation the aircraft Operator must perform a review of the subject aircraft’s approved Maintenance Schedule and carry out any changes necessitated by embodiment of this change (modification)/repair, Paragraph 4.4 refers.

The Minimum Equipment List (MEL) is affected by this change (modification)/repair; refer to Subparagraph 3.4 for MEL Recommendations. It is the aircraft Operator's responsibility to carry out any changes necessitated by embodiment of this change (modification)/repair.

Mandatory Markings and Placards are affected by this change (modification)/repair; Master Document List MDL-0006, Subparagraph 4.2 refers.

The Operations Manual may be affected by this change (modification)/repair. Post installation the aircraft Operator must perform a review of the subject aircraft’s approved Operations Manual and carry out any changes necessitated by embodiment of this change (modification)/repair.

The aircraft Operator will be issued with a 365 Aerospace Ltd. Aircraft Manual Supplement (AMS) post installation, Paragraph 5.0 refers. It is the aircraft Operator’s responsibility to incorporate the AMS appropriately.

3.2. Electrical Load Analysis.

The electrical load demand attributable to this change (modification)/repair is detailed below:

Equipment Nominal Power

Consumption

Max Power

Consumption Electrical Bus

Removed Equipment

VHF C Transceiver 28 Watts 210 Watts 28V DC Bus, Left

VHF C Control Panel 1.6 Watts 1.6 Watts 28V DC Bus, Left

Installed Equipment

DLINK+ ACARS Unit 30 Watts 150 Watts 28V DC Bus, Right

GPS Sensor 11 Watts 13 Watts 28V DC Bus, Left

Data Printer 20 Watts 50 Watts 115V AC Bus, Left

Table 1 – Electrical Load

The electrical ratings detailed above result in:

• A decreased Power consumption in draw on the 28V DC Bus, Left of 18.6 Watts (Nominal) and 198.6 Watt (Max).

• An increased Power consumption in draw on the 28V DC Bus, Right of 30 Watts (Nominal) and 150 Watt (Max).

• An increased Power consumption in draw on the 115V AC Bus, Left of 20 Watts (Nominal) and 50 Watt (Max).

It is the aircraft operator’s responsibility to perform any documentary change necessitated by a change in electrical load introduced by this modification.








3.3. Mass and Balance.

The change to aircraft mass and balance attributed this change (modification)/repair is defined by the method identified per Table 2. According to CAT.POL.MAB.100 (b); the aircraft Operator is responsible for the accumulated effects of modifications and repairs on the mass and balance, which must be accounted for and properly documented.

Appreciable effect on Mass and Balance? (Strike through as applicable) No / Yes

Post installation aircraft weigh? (Strike through as applicable) No / Yes

Weight and Balance Supplement? (Strike through as applicable) No / Yes

Table 2

The change in mass and balance of the aircraft attributable to this change (modification)/repair is presented below:

Pre Change (modification)/Repair

Equipment Description QTY STA BA (in) Weight (lb) Moment (lb-in)

VHF C Transceiver 1 485 485.0 8.9 4316.5

VHF C Control Panel 1 245 245.0 1.9 465.5

Total 10.8 4782.0

Table 3 – Items Removed

Post Change (modification)/Repair

Equipment Description QTY STA BA (in) Weight (lb) Moment (lb-in)

Dlink+ w/CPDLC 1 245 245.0 6 1470.0

Data Printer 1 246 246.0 10.5 2583.0

GPS Antenna 1 690 690.0 0.5 345.0

GPS Sensor 1 485 485.0 2.2 1067.0

Total 19.2 5465.0

Table 4 – Items Installed

The mass and balance changes detailed above result in an additional 8.4 lb, and 683 lb-in.

It is the aircraft operator’s responsibility to perform any documentary change necessitated by a change in mass and balance introduced by this modification.








3.4. Minimum Equipment List (MEL) Recommendations

The Minimum Equipment List (MEL) has been reviewed and MEL Recommendations have been supplied below, as required:

23 - COMMUNICATIONS

(2) Rectification Interval (3) Number Installed

(1) System and Sequence Numbers

Item

(4) Number Required for Dispatch

(5) Remarks or Exceptions

23-27-1 Dlink+ w/CPDLC

C 1 0 (0) May be inoperative provided alternative procedures are established and used.

Procedures To provide alternate procedure to the crew to

manage communications, as applicable in the airspaces in which aircraft is operated.

4.0 CONTINUED AIRWORTHINESS

4.1. General

Amendments to the affected manuals detailed in Para 3.1 are produced as an Aircraft Manual Supplement (AMS), in a format that is used by the aircraft Type Certificate holder (Boeing), and recognised by the Agency. AMSs are supplied within 90 days of modification embodiment to ensure any design changes are captured.

The Aircraft Flight Manual amendment must be referred to for information on Operating Limitations, Emergency/Abnormal Operating Procedures, Normal Operating Procedures, and Performance Information.

To ensure continued serviceability and reliability of installed equipment, the aircraft Operator must maintain pertinent items in accordance with the requirements of the appropriate vendor Component Maintenance Manual (CMM). The subject aircraft’s Maintenance Schedule must include reference to this material additional to the original design.

The influence of this change (modification)/repair on Airworthiness Directive eligibility, Service Bulletin eligibility and other data must be considered and the publications monitored accordingly. The maintenance schedule for the aircraft should include reference to this material additional to the original design.

The current aircraft owner is responsible for informing 365 Aerospace Ltd. of any change in aircraft ownership and/or operator.








All placards specified by this modification must be installed. Limitations and conditions defined in the modification documentation must be observed.

The installer must verify compatibility of this modification taking into account any existing modifications installed on the subject aircraft. Where the potential for conflict exists between modifications the advice of 365 Aerospace Ltd. must be sought.

Certain operational approvals require that the aircraft and/or systems comply with specified design requirements. Where this modification records compliance with those design requirements this will not be taken as acceptance by the Agency of compliance with the relevant operational requirements, for which further justification may be required.

In addition, the following operational limitations are detailed within the Flight Manual Supplement, FMS-0006-001:

The aircraft data link system is to be used in non-critical phases of flight only; ATC/ACARS message annunciation will be inhibited during critical phases of flight. Critical phases of flight are defined by:

• Take-off run,

• Take-off flight path,

• Final approach,

• Missed approach and

• Landing.

The aircraft data link system has been demonstrated to comply with the applicable safety, performance and interoperability requirements for continental ATN B1 Data Link using VDL Mode-2. Compliance has also been demonstrated to Certification Specifications (CS) for Airborne Communications, Navigation and Surveillance (ACNS) Subpart B, Section 2.

4.2. Airworthiness Limitations

The Airworthiness Limitations section is approved and variations must also be approved.

This section identifies applicable mandatory replacement times, structural inspection intervals and related structural inspection procedures necessary for this change in accordance with CS 25.571(a)(3). Refer to section 4.4, ‘Maintenance Schedule Tasks’, for detailed instructions:

• GPS Antenna Connector, Mounting Holes and Retainer Plate attachment holes Perform a High Frequency Eddy Current (HFEC) at a threshold of 9,650 flight cycles after installation of the GPS Antenna structural provisions and at 4,200 flight cycle intervals thereafter.

• GPS Antenna Skin Area (internal & external) & Retainer Plate Perform a detailed visual inspection at a threshold of 9,650 flight cycles after installation of the GPS Antenna structural provisions and at 4,200 flight cycle intervals thereafter.








4.3. Electrical Wiring Interconnection System (EWIS)

The Electrical Wiring Interconnection System (EWIS) components must be maintained in accordance with the EWIS Instructions for Continued Airworthiness (ICA). No supplemental EWIS inspection tasks are required, therefore no additional action is required.

The following existing EWIS ICA tasks are identified as applicable:

Task Reference Task Type Task Description Inspection Interval

20-022-00 RST Restore (Clean) the Main Equipment Centre.

(EZAP)

INTERVAL NOTE: Whichever comes first.

24000 FH

72 MO

20-023-00 GVI Inspect (General Visual) all exposed wiring

and connected EWIS behind the

electrical/electronics racks of the Main

Equipment Centre, except the power feeders

and connected


24000 FH

72 MO

20-046-00 GVI Inspect (General Visual) all exposed EWIS in

the Flight Deck

Compartment. (EZAP)


ACCESS NOTE: Sidewall panels and window

liner removal required.

24000 FH

72 MO

20-047-00 RST Restore (Clean) the exposed EWIS behind

the sidewall and window liner panels in the

Flight Deck Compartment. (EZAP)


ACCESS NOTE: Sidewall panels and window

liner removal required.

24000 FH

72 MO

53-810-00 GVI INTERNAL - ZONAL (GV): Main Equipment

Centre

Perform Internal General Visual Inspection of

the zone. (EZAP)

CPC NOTE: Corrosion Prevention and

Control Basic Task required.


The EZAP Zonal GVI requirement with

interval 24000 FH / 72 MO is satisfied by this

zonal inspection.

6000 FH

18 MO

53-856-00 GVI INTERNAL - ZONAL (GV): Control Cabin

Perform Internal General Visual Inspection of

the zones. (EZAP)


The EZAP Zonal GVI requirement with

interval 24000 FH / 72 MO is satisfied by this

zonal inspection.

6000 FH

18 MO








4.4. Maintenance Schedule Tasks

In relation to section 4.2, ‘Airworthiness Limitations’, Maintenance Schedule Tasks to be added to the aircraft operator’s appropriate aircraft maintenance program are listed below. Any defects, such as cracks or corrosion, discovered during these inspections, must be reported to 365 Aerospace immediately for support and documenting purposes. Repair guidance can also be provided from the Type Certificate holder (Boeing), or another suitably qualified Part 21J Design Office.

GPS Antenna Connector, Mounting Holes & Retainer Plate (P/N: 365-23-0003-101) attachment holes

With reference to 365 Aerospace drawing 365-23-0003, remove the GPS Antenna and Retaining Plate. In accordance with Non-Destructive Testing (NDT) manual Part 6, ATA 53-30-14; perform a High Frequency Eddy Current (HFEC) surface scan and bolt hole scan inspection of the antenna connector, mounting holes and Retainer Plate attachment rivet holes. The inspector should look for cracks and corrosion on the surfaces of the fuselage skin around the antenna connector and all mounting/attachment holes.

GPS Antenna Skin Area (internal & external) & Retainer Plate

With reference to 365 Aerospace drawing 365-23-0003, remove the GPS Antenna and Retaining Plate. Perform a detailed visual inspection around the rivet holes, the Retainer plate itself and also the general aircraft skin and surrounding structure. The inspector should look for cracks and corrosion on the surfaces of the fuselage skin, Retaining Plate, and around the rivet holes. The inspector should also look for cracks in and around the radius of the milled pad-up area on which the Retainer Plate is installed.

Additional, non-structural tasks to be added to the aircraft operator’s appropriate aircraft maintenance program, are listed below:

GPS Sensor (P/N: 84327-50-200B)

Maintenance Manual information for the 1203 GWSS (system description, removal, installation, testing, etc.) is contained in FreeFlight Systems Installation Manual, 84345.

Scheduled Maintenance Program tasks to be added to the aircraft operator’s appropriate airplane maintenance program are as follows:

a. Recommended Periodic Scheduled Servicing Tasks None Required

b. Recommended Periodic Scheduled Preventative Maintenance Tests/ Checks

to Determine System Condition and/or Latent Failures

None Required

c. Recommended Periodic Inspections None Required

d. Recommended Periodic Structural Inspections None Required

Spectralux Dlink+ w/CPDLC Unit (P/N: 14114-1-02)

Perform a BITE test every A check.

Note: The Spectralux Dlink+ w/CPDLC Unit automatically performs a BITE check on boot. Power up the Unit and ensure no errors are displayed.

Perform an ACARS System Test every C check, in accordance with AMM Supplement 23-22-00, page block 501.

For required test and repair instructions specific to the Dlink+ w/CPDLC, reference Spectralux Component Maintenance Manual 23-20-02. The instructions and procedures defined in the CMM are necessary to ensure the product operates satisfactorily over its service lifetime. Shop level repair is limited to replacement of Circuit Boards.

Honeywell Multi-Input Cockpit Data Printer (P/N: 805515-4503)

Perform a System Test every A check in accordance with AMM Supplement 31-33-00, page block 501.








5.0 ASSOCIATED DOCUMENTS

Further Continued Airworthiness information is contained in the following documents:

Document Number Document Description Document Supplier

AMS-757-25622 Aircraft Manual Supplement 365 Aerospace

FMS-0006-001 Flight Manual Supplement 365 Aerospace


INSTRUCTIONS FOR CONTINUED AIRWORTHINESS · 2017-08-16 · 365 Aerospace Ltd. ICA-0006-001 REVISION...

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