Return to Light - Engineers notes

Project return to light – Maintenance File for aircraft AXDN at DAS Duxford

TO BE STORED IN AIRCRAFT MAINTANENCE FOLDER

21/03/2013

In attendance Graham Cahill, John Dunlevy, Ian Mosdell, Gaute Lund

10am Meeting with David Garside and Chris Giles to discuss work in the cockpit to return the instrument lighting to working order

11.30am John Dunlevy and Ian Mosdell began the detailed and comprehensive inspection of the circuitry and contactors associated with the main aircraft batteries DC supply, specifically Bus Bars, 1PP, 2PP, 3PP and 4PP, together with the Essential Main Split Components.
Individual connectors on the instrument panels were removed to check for corrosion and overall condition. Wiring, pins and connectors found to be in excellent condition.
John Dunlevy applies power to the 28volt circuits upon completion of the inspection with all breakers out. Individual breakers are pressed to close and results monitored as progress is made.

28 volt systems are found to be in excellent condition with just a few filaments out, John replaces some lamps and they light. More spares required for next visit

A full survey of the aircraft instruments is completed and we find the following.

Both Machmeters are missing, both ASI units are missing, both sideslips are missing, both VSI’s are missing, the ADI on the co pilots side is not pre production and is possibly from another aircraft, the clock is missing from the pilots side.
Engineers panel is largely intact however the Discharge vent guage is missing and the Cabin diff pressure is missing.

Job Status -  28Volt applied require 10 replacement filaments  happy with condition for us to continue. Museum happy with progress

Discuss with team how to progress in illuminating the instrument lights

Heritage Concorde orders  3 x 5volt PSU’s for donation to the museum

08/05/2013

Meeting 10am in attendance Graham Cahill, John Dunlevy, Gaute Lund, and David Garside.
Discuss if DAS happy to progress – Answer is Yes. 
Discussion about replacing lighting transformers for 5v PSU and museum is happy to continue as long as it is done safely and with H&S in mind and with the preservation of original components in mind.

10.45 John Graham and Gaute attend the aircraft and John removes the engineers document stowage panel to gain access to the lighting transformers. With difficulty he gains access and removes them to inspect. He removes much of the engineers panel and inspects the connectors to most of the instruments, cleaning the connectors with electrical spray. The 5 volt power supply is connected to the first transformer output connectors and the instrument lights to the right hand side of the engineers panel illuminate, the upper centre console also illuminates.
John removes the power supply and stores the original transformers for re fitting next visit.

Job Status - 
28Volt applied  Job Complete

require 10 replacement 28v filaments

5 volt working ok to RHS engineers panel and overhead panel final connection required

Re fitting of original transformers required

 

 

04/06/2013

Meeting 10am in attendance Graham Cahill, John Dunlevy and David Garside

DAS is happy for us to continue

10.30 John and Graham attend the aircraft and John makes a suitable wiring loom for the lights on the entire engineers panel, John replaces the original transformers removed on our last visit and connects the 115v cables so if in future power is applied no problems occur. John tests the engineers panel individually all circuits are working and the instruments illuminate

John asks Graham to try and locate the transformers for the centre console these are located and the side panels are removed and temporarily replaced for our next visit

John disconnects the 5v power supply and removes it from site we are ready to permanently connect the 5volt at our next visit.

 

Job Status - 
28Volt applied  Job Complete

Re fitting of original transformers Job complete

require 10 replacement 28v filaments

5 volt working ok to entire engineers panel and overhead panel final connection to PSU required

Centre console transformers require connection to PSU

 

 

 

 

03/07/2013

10am meeting in attendance Graham Cahill, John Dunlevy David Garside, Discussion and update on progress we request that a bracket be made to hold PSU’s in place David says they will construct one  DAS is happy for us to continue work

10:30 Work resumes John completes the wiring for the engineers panel and routes the wires neatly, Graham under Johns supervision removes the output wires from the two transformers within the centre console that power the LH and RH pilots instrument panels and prepares them for John to connect to transformer

John confirms the engineers panel is safe and connects the PSU to the instruments and GND on the aircraft, the bracket for the PSU’s is fitted and one PSU is in place ready for use.

The automonitor is not illuminating and the rate of climb instument has failed, John investigates the ROC and finds the filament has failed, we will investigate the Automonitor next visit.

Job Status - 
28Volt applied  Job Complete

Re fitting of original transformers Job complete

Require 10 replacement 28v filaments

5 volt working ok to entire engineers panel and overhead panel final connection to PSU Job complete

Pilot and Co pilot transformer connections require connection to PSU

Investigate Automonitor

Replace ROC filament

 

 

30/07/2013

10am meeting in attendance Graham Cahill, John Dunlevy Phil Cairns, David Garside
DAS is happy for us to continue work we request that DAS install permanent sockets in the cockpit to enable DAS to simply switch on the lights when required, DAS say they will arrange it.

10:45 We attend the aircraft John continues to work in the cockpit and connects the pilot and co pilot instruments to the second power supply, we find that many of the instruments do not light, John investigates further and finds most of the instruments are unplugged so he spends the rest of the day cleaning and plugging them back in where possible. We remove the Autopilot controller (autopilot) to find the last transformer and locate it on the RHS of the AFCS rack, the Autopilot controller is replaced ready for next time . We take inventory of missing instruments and add them to the list.

Job Status - 
28Volt applied  Job Complete

Re fitting of original transformers Job complete

Require 10 replacement 28v filaments

5 volt working ok to entire engineers panel and overhead panel final connection to PSU Job complete

Pilot and Co pilot transformer connections require final connection to PSU

Investigate Automonitor

Replace ROC filament

Centre console transformer connections requires connection to PSU

Sockets required to be fitted by DAS

Mach meter x 2 missing

ASI x2 Missing

VSI x 2 Missing

Icovol incorrect for aircraft

Sideslip x 2 missing

Co pilots ADI incorrect for aircraft

Pilots clock missing

Pressurisation controller gauge on engineers panel is missing

Discharge vent gauge missing on engineers panel

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

13/8/2013

Meeting in attendance John Dunlevy, Ian Mosdell, David Garside
Graham Cahill joins later due to traffic congestion. DAS is happy to continue, installing the permanent sockets for the lighting is more compliucated than anticipated however it will be done as soon as possible

John investigates the automonitor and finds it is unplugged and the connectors are hanging behind the bracket, upon further investigation the automonitor is found to be incorrect for the aircraft so we will need to adapt it or replace it further investigation is required.

The Autopilot controller and ADI are removed to gain access to the last transformer John manages to disconnect the wires and makes a wiring loom for all three transformers to go back to the engineers panel where the PSU’s will be situated. The lights are tested and most are working. John removes the nose selector switch and cleans both the pins and connectors then replaces it.

Job Status - 
28Volt applied  Job Complete

Re fitting of original transformers Job complete

Require 10 replacement 28v filaments

5 volt working ok to entire engineers panel and overhead panel final connection to PSU Job complete

Pilot and Co pilot transformer connections require final connection to PSU Job Complete

Investigate Automonitor

Replace ROC filament

Centre console transformer connections requires connection to PSU Job Complete

Sockets required to be fitted by DAS

Mach meter x 2 missing

ASI x2 Missing

VSI x 2 Missing

Icovol incorrect for aircraft

Sideslip x 2 missing

Co pilots ADI incorrect for aircraft

Pilots clock missing

Pressurisation controller gauge on engineers panel is missing

Discharge vent gauge missing on engineers panel

 

 

 

 

 

 

 

 

 

 

 

 

 

20/8/2013

Meeting in attendance Graham Cahill, John Dunlevy, Gaute Lund, David Garside. DAS are happy to continue and we discuss how to proceed.

John fits the following instruments to the aircraft, these are obtained from the monitor  station in the rear of the aircraft, 1x Machmeter to Pilots side. 1 x VSI to pilots side, 1 x side slip to pilots side. 1x side slip to co pilots side. all are checked prior to fitting to ensure part numbers a re correct. The icovol is swapped for the one in the monitor station as it is correct for the cockpit and the ROC instrument is swapped and fitted to the engineers panel. We tested the automonitor using a wiring loom and found it to be faulty so this was still outstanding. We found the ground connection to the new PSU’s was inadequate so we disabled the PSU’s and added it to our jobs to do list

Job Status - 
28Volt applied  Job Complete

Re fitting of original transformers Job complete

Require 10 replacement 28v filaments

5 volt working ok to entire engineers panel and overhead panel final connection to PSU Job complete

Pilot and Co pilot transformer connections require final connection to PSU Job Complete

Investigate Automonitor

Replace ROC filament Job complete

Centre console transformer connections requires connection to PSU Job Complete

Sockets required to be fitted by DAS

Mach meter x 1 missing  Dummy required

Mach meter x 1 replaced Job complete

ASI x2 Missing Dummy’s required

VSI x 1 Missing Dummy required

VSI Replaced Job complete

Icovol incorrect for aircraft Job complete

Sideslip x 2 missing Job complete

Co pilots ADI incorrect for aircraft

Side slip x 2 dummies required for monitor station

Pilots clock missing

Pressurisation controller gauge on engineers panel is missing

Discharge vent gauge missing on engineers panel

Gnd Connection inadequate

 

 

 

 

 

 

 

 

 

 

 

27/8/2013

Meeting 10am In attendance Graham Cahill, John Dunlevy, Chris Giles. DAS are happy to continue

John Dunlevy connects extra ground connections to the aircraft and makes sure it is adequate for the ampage drawn. We run the lighting for 5 continuous hours and check wiring loom for hot spots, there are none. We continue by replacing panels and screws which we removed for access to the various areas. We remove the stick on labels which say “in op” off the instruments which improves the display again. (The intake control system had been made non-operational for the flight into Duxford and Inoperative stickers (INOP) covered the relative Ramp and Spill Door indicators/captions.)

We apply the 28 volt power to the aircraft for the last hour to ensure no problems occur.

Job Status - 
28Volt applied  Job Complete

Re fitting of original transformers Job complete

Require 10 replacement 28v filaments

5 volt working ok to entire engineers panel and overhead panel final connection to PSU Job complete

Pilot and Co pilot transformer connections require final connection to PSU Job Complete

Investigate Automonitor

Replace ROC filament Job complete

Centre console transformer connections requires connection to PSU Job Complete

Sockets required to be fitted by DAS

Mach meter x 1 missing  Dummy required

Mach meter x 1 replaced Job complete

ASI x2 Missing Dummy’s required

VSI x 1 Missing Dummy required

VSI Replaced Job complete

Icovol incorrect for aircraft Job complete

Sideslip x 2 missing Job complete

Co pilots ADI incorrect for aircraft

Side slip x 2 dummies required for monitor station

Pilots clock missing

Pressurisation controller gauge on engineers panel is missing

Discharge vent gauge missing on engineers panel

Gnd Connection inadequate Job complete

 

 

 

 

 

 

 

 

 

 

1/10/2013

Meeting 10am in attendance Graham Cahill, John Dunlevy, Ian Mosdell, David Garside, Chris Giles. DAS are happy to continue and we discuss the status of the jobs

10.45 We attend the aircraft.
We have obtained through donation from one of our engineers an original Production Concorde ASI and the correct automonitor for this aircraft among other spares.

John fits the ASI to the Pilots side of the aircraft and constructs a wiring loom to accommodate it, it works fine. He then removes the brackets for the automonitor and asks Chris Giles (DAS) to remove the side brackets which adapt it for the incorrect one. Chris returns with the bracket correctly changed and the bracket and automonitor are fitted, it works fine.

We spend the rest of the day fitting as many screws to the aircraft as possible to make the cockpit complete. The Co Pilots ADI is removed and taken away so we can return the next day with it prepared for power.

 

 

 

 

 

 

 

 

 

 

2/10/2013

No meeting this morning we go straight to the aircraft to work.

We fit the ADI which is now ready for the Co pilots side and it works. John Applies 28 volt power to the aircraft and replaces 10 to 15 filaments in the captions, some do not illuminate we think this is a bulb holder issue however most are fine. John spends the rest of the day neatening up the wiring looms and preparing the aircraft for display.

Job Status - 
28Volt applied  Job Complete

Re fitting of original transformers Job complete

Require 10 replacement 28v filaments  Job complete

5 volt working ok to entire engineers panel and overhead panel final connection to PSU Job complete

Pilot and Co pilot transformer connections require final connection to PSU Job Complete

Investigate Automonitor Job complete

Replace ROC filament Job complete

Centre console transformer connections requires connection to PSU Job Complete

Sockets required to be fitted by DAS

Mach meter x 1 missing  Dummy required

Mach meter x 1 replaced Job complete

ASI x1 Missing Dummy’s required

Original ASI requires fitting Job complete

VSI x 1 Missing Dummy required

VSI Replaced Job complete

Icovol incorrect for aircraft Job complete

Sideslip x 2 missing Job complete

Co pilots ADI incorrect for aircraft (wired to illuminate) Job complete

Side slip x 2 dummies required for monitor station

Pilots clock missing

Pressurisation controller gauge on engineers panel is missing

Discharge vent gauge missing on engineers panel

Gnd Connection inadequate Job complete

 

Graham constructs the dummies required for replacement of instruments removed from monitor station and put in cockpit as follows

Sideslip x 2

Machmeter x 1

Graham Constructs illuminating models of the following instruments for the Co pilots side to replace the pictures as follows

Mach Meter x 1

VSI x 1

Graham orders ASI from the USA which looks like the ASI in Concorde, the ASI is marked “NOT A CONCORDE INSTRUMENT” so in the future it will not be confused as original.

 

 

 

 

22/11/13

We arrive at 10am we meet with David Garside and he is happy for us to continue.

John Dunlevy and Graham Cahill attend the aircraft

Graham removes the two Perspex panels on the monitor station and fits three dummies which we have constructed during our absence, we do not have enough screws to fill all the holes in the dummies but two in each will do until more can be found.

John fits a Discharge vent gauge and a pressurisation controller gauge to the engineer’s panel which we have obtained on loan from Brooklands

John then fits the ASI using a special wiring loom.

All the instruments light fine

The dummy illuminating Mach Meter and the Dummy illuminating VSI are fitted to the aircraft using a specially constructed wiring loom.

They work fine

John extends the power supply leads so DAS can make a cover for the footwell of the engineers position

The Icovol does not illuminate, this has been an ongoing problem and we add it to the job list for next visit

Job Status - 
28Volt applied  Job Complete

Re fitting of original transformers Job complete

Require 10 replacement 28v filaments  Job complete

5 volt working ok to entire engineers panel and overhead panel final connection to PSU Job complete

Pilot and Co pilot transformer connections require final connection to PSU Job Complete

Investigate Automonitor Job complete

Replace ROC filament Job complete

Centre console transformer connections requires connection to PSU Job Complete

Sockets required to be fitted by DAS  Job complete

Mach meter x 1 missing  Dummy required   Job complete

Mach meter x 1 replaced Job complete

ASI x1 Missing Dummy’s required Job complete

Original ASI requires fitting Job complete

VSI x 1 Missing Dummy required Job complete

VSI Replaced Job complete

Icovol incorrect for aircraft Job complete

Sideslip x 2 missing Job complete

Co pilots ADI incorrect for aircraft (wired to illuminate) Job complete

Side slip x 2 dummies required for monitor station  Job complete

Pilots clock missing No spares available

Pressurisation controller gauge on engineers panel is missing Job complete

Discharge vent gauge missing on engineers panel Job complete

Gnd Connection inadequate Job complete

Icovol not illuminating

 

We have now completed the entire job except for the Icovol which we will return to fix next time we are down

 

Interim work visit

DAS supply a new power supply which will protect the aircraft by cutting out if there is a problem the spec is 28v, 1Kw Protected Power supply similar to the 5 v one fitted earlier in the project.
The power supply is tested (PAT) and fitted in place of the transformer. It works fine and will allow safe operation of the 28v supply.

27/03/2014

John Dunlevy removes the Icovol from the cockpit and swaps it back with the one in the monitor station, he then designs a wiring loom so the Icovol in the cockpit can be illuminated. it is fitted and it works fine.

John investigated the AWS and MWS and finds it is still operable he commissions the system and it works fine.

Job Status - 
28Volt applied  Job Complete

Re fitting of original transformers Job complete

Require 10 replacement 28v filaments  Job complete

5 volt working ok to entire engineers panel and overhead panel final connection to PSU Job complete

Pilot and Co pilot transformer connections require final connection to PSU Job Complete

Investigate Automonitor Job complete

Replace ROC filament Job complete

Centre console transformer connections requires connection to PSU Job Complete

Sockets required to be fitted by DAS  Job complete

Mach meter x 1 missing  Dummy required   Job complete

Mach meter x 1 replaced Job complete

ASI x1 Missing Dummy’s required Job complete

Original ASI requires fitting Job complete

VSI x 1 Missing Dummy required Job complete

VSI Replaced Job complete

Icovol incorrect for aircraft Job complete

Sideslip x 2 missing Job complete

Co pilots ADI incorrect for aircraft (wired to illuminate) Job complete

Side slip x 2 dummies required for monitor station  Job complete

Pilots clock missing No spares available

Pressurisation controller gauge on engineers panel is missing Job complete

Discharge vent gauge missing on engineers panel Job complete

Gnd Connection inadequate Job complete

Icovol not illuminating      Job complete

AWS MWS working           Job complete

 

 

 

 

 

 

 

 

 

Follow up visits

John Dunlevy tests the AWS and closes the breaker, the AWS system now operates

John Dunlevy removes the automonitor previously supplied by Heritage Concorde and refits the original Automonitor that was in the aircraft which DAS have now found, it illuminates correctly

John Dunlevy makes a red caption for the overhead panel and fits it to the aircraft, it is not quite the same as the rest but visually it looks better than the open bulb holder that it covers.

John Dunlevy replaces various other blown filaments and covers with spare he has in stock.

The ground call system is tested and a replacement lamp is put on the unit on the front landing gear, the system works as expected

End of Project

Condition of wiring found to be excellent we recommend periodic inspection.

We will send a separate definitive list of breakers that should be checked when non authorised personnel are allowed access to the cockpit. It is important that only these breakers are closed or stray voltage will be allowed to areas of the aircraft we do not recommend such as fuel valves.

 

Additional work will be communicated on a separate report

 

This is a FILE COPY FOR AIRCRAFT maintenance records