AC POWER - A CHALLENGE ?? @ WAEA - TC Seattle, June 2000 SKY power

AC POWER - A CHALLENGE ??

@ WAEA - TC Seattle, June 2000

SKY power

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KID-Systeme GmbH - June2000 - All Rights Reserved

In-seat power for notebook computers, handheld video players and other PED’ s

SKY power

POWER TO THE PEOPLE

Power management for electrical seat equipment

15 VDC system certified and in-service since October 1998

110 VAC system certified in July 1999

110 VAC system in-service since April 2000

Corresponds to the latest safety and certification standards

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US Airways A319/A320/A330 (line fit) EIS 1998 / ongoing

LTU B767, A330 (retrofit ) EIS 1998 / completed

Gulf Air A330 (line fit) EIS 1999 / completed

British Airways B747/B777 EIS 1999 / ongoing

Lan Chile A319/A320/A340 (line fit) EIS 2000 / RFC - 110VAC

Airline Aircraft Type Program Status

110VAC approx. 4.000 Seats In-Service

15VDC approx. 10.000 Seats In-Service

Lufthansa B747, A340 (retrofit) EIS 04.2000 / ongoing

Grupo Taca A319/A320 (line fit) EIS 09.2000 / ongoing

Lan Chile A319/A320/A340 (line fit) EIS 2001

D.C. Aviation A319 Corporate Jet EIS 2000 / completed

China Airlines A340 (line fit) EIS 2001

15 VDC 110 VAC&SKY power CUSTOMER

TECHNICAL ISSUE&

INSTALLATION

AC POWER

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SKY power SYSTEM LAYOUT 15VDC & 110VAC

Seat Group

LEDMCU

Other Systems

CrewPanel

BITE

A/CPowerSupply

A/C PowerManagement

(future)

PM

Column Right (1)

Outlet

Outlet

ISPC

FDB

furtherseat

systems

Note: LED = “outlet used” Indication, FDB = Floor Disconnect Box, ISPC = In-Seat Power Converter PM = Programming Module, MCU = Master Control Unit

Power lineControl line

Column Centre Right (3)

Column Centre Left (3)

Column Left (4)

FDB

ISPC ISPC ISPC ISPC ISPC ISPCISPC

Portable Electronic Device (PED)

Future Applications (5)

Outlet

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15 independent configurable power lines (5 columns, 3 phases each)

Comprehensive power management of all connected seat equipment

System performances individually configurable via Programming Module

BITE performed after „power on“, reset and continuously during operation

SKY power - MASTER CONTROL UNIT

Programmable overload protection for each power line

Ground Fault Interrupt for each column

POWER MANAGEMENT & SAFETY

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KID-Systeme GmbH - June2000 - All Rights ReservedIN-SEAT POWER SUPPLY 110 VAC

Electrical load sensor

Power supply 110 VAC @ 60 HZ

75 W per outlet - 150 W total

Available for 2-seat / 3-seat assemblies

EMI filtering

Electrical Ground Fault Protection (GFI)

Over-voltage and over-current protection

Outlet sensor management

SKY power millennium

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KID-Systeme GmbH - June2000 - All Rights ReservedOUTLET UNIT 110 VAC

Receptacle for US 2 / 3 pin plug and European standard

Plug pin sensors

LED Indication Plug chassis sensor

Mechanical children protection to prevent manipulation

3 sensors and a micro-controller release power only if a plug is engaged

LED system status information

SKY power millennium

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Seat Integration Example of the In-Seat Power Converter

front view side view top view

ISPC cover removed

Electrical bonding & conductive cooling via seat chassis

SKY power INSTALLATION

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Economy Class SeatsPremium Class Seats

Seat Integration Example of the 110 VAC Outlet Unit

SKY power INSTALLATION

BENCHMARK 15VDC 110VAC

AC POWER

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KID-Systeme GmbH - June2000 - All Rights ReservedHOW MANY PASSENGER WILL USE IT ?

Some power is available

15 VOLT - MARKETING ASPECTS

The Hypertronic outlet is small, discreet and easy to integrate

Neither the 15 VDC power output nor the receptacle respond to computer industry

standards (there may be some exceptions)

Additional DC-DC laptop power transformer are required (approx. 60 different types

on the market, priced US$ 80 - 100)

Providing adapters to passengers is a serious cost and logistic challenge for the

airline

Not to provide the adapters means not to respond to the passengers’ expectations

SKY power 15 VDC VS. 110VAC

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15 VOLT - TECHNICAL AND SAFETY ASPECTS

15 VDC voltage is not considered critical

A third manufacturer’s adapter breaks the chain of OEM equipment

(ISPSS -- notebook)

The power outlet is small and easy to integrate into the seat

Existing 15 VDC - 110 VAC transformer (some manufacturers offer such products)

are of potential danger when operated by passengers without any system safety

protection

Not all third party adapters correspond to airworthiness qualification standards

(DO 160) and the notebook manufacturers’ specifications

Potential risks: Grey market, EMI problems, unregulated battery charging


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KID-Systeme GmbH - June2000 - All Rights ReservedMEET THE PASSENGER’S EXPECTATIONS

110 VOLT - MARKETING ASPECTS

The passengers can operate their laptop computers like at home

No additional voltage transformer is required

(Non-US notebook computers operate in the range of 110 - 240 VAC @ 50/60 Hz)

No additional cost and logistic issues for the airlines

Instant access meets the passengers expectations

Crew / passenger instructions are required in order to advise passengers


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110 VOLT - TECHNICAL AND SAFETY ASPECTS

The notebook OEM transformer meets the individual specifications of the notebooks

This supports a continuous chain of OEM equipment

The load limit of 75 W does not allow operation of hair dryers or other critical

equipment

Additional passenger safety features in the seat end

GFI, mechanical locks, over-voltage / over-current protection, load sensor, plug sensors

The size of the outlet unit may require more seat engineering skills


AC POWER

CERTIFICATIONASPECTS

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Following items are relevant to AC-Systems:

JAA policy harmonised with the FAA, based on previous FAA Memo

“No conventional duplex outlet, special adapter required”

Objective: to control access of the in-seat power system

Compliance: the outlet accommodates normal Euro/US duplex connectors, but the built-in safety features provide a safety equivalent to a special adapter.

“Indication of power outlets in use”

Objective: to allow easy monitoring of in-seat power use by the cabin crew, in particular in a dark cabin on long range flight

Compliance: final ISPSS standard has an indication light on the aisle side of each seat group

ISPSS APPROVAL CONDITIONS

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ALL TESTS PASSED SUCCESSFULLY

Additional Aircraft Inspection and Ground Test on In-Service Aircraft

Aircraft installation inspection

Safety features (overload, short circuit outlet, short circuit phases, ground fault, over-heat conditions, mishandling)

Aircraft Inspection at the Assembly Line and Lab Tests at KID-Systeme

Aircraft installation inspection

Safety features (short circuit MCU)

Spilling liquid

Smoke / fire containment of seat box (ISPC)

Flammability

REVIEW OF FAA TEST AND INSPECTION

Standard Qualification for Airborne Equipment

Qualification Report (Do 160); Load & Safety Analysis; EMI & Functional Ground Test...

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Mishandling of the 110 VAC Outlet Unit

Attempt to overcome the mechanical and electronic safety protections

Deliberate mishandling by introducing loose pins and similar objects into the outlet

The safety features prevented activation under all tested circumstances

Did not succeed to release power on the outlet

REVIEW OF FAA TEST AND INSPECTION

TEST PASSED SUCCESSFULLY

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A damaged PED power cord under load is trapped under the flap of the folding table in the seat armrest.

After the cord is cut through a short circuit or a ground fault switches off outlet power immediately.

Mishandling of PED Power Cord under Load


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LED

AC power not released but available (LED green)

Outlet submergedPower no longer available

(LED off)

conductive liquid (salt water)

110 VAC OUTLET UNIT LIQUID INGRESS TEST


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Power interrupted by differential current protection after ingress of liquid

Spilling conductive liquid on the AC Outlet used by light bulb testload

110 VAC OUTLET UNIT LIQUID INGRESS TEST


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KID-Systeme GmbH - June2000 - All Rights ReservedNO SMOKE - NO FIRE - NO FUMES

Deliberate Heating with 400°C Air Blower

Connectors started to melt down

No damages at PCB and components

Unit switched off at temperature limit

HEAT TEST OF ISPC UNIT ON LAB TEST RIG

THANK YOU !

Documents

AC POWER - A CHALLENGE ?? @ WAEA - TC Seattle, June 2000 SKY power