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Cockpit Construction Continued (Part 35) (Read 6010 times)
Jul 12th, 2007 at 11:40am

JBaymore   Offline
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Wiring Glareshield Annunciators and Caution/Warning Buttons

A lot of the pit work left is so-called "minor" work...... all the BIG jobs like creating the panel supports, enclosure, seat, and so on are done.  Yeah right!  The "minor" stuff takes a LOT of time.  Wink

On the left side of the glareshield I have had the locations for the warning type annunciators and the Master Warning and Master Caution buttons in place for a LONG time.  I bought the annunciators and switches a long time ago too (glad I did 'cause the prices for the annunciators went up $1 each since!).  I finally have gotten around to starting to wire them all up.

The annunciators are in two general groups.  On the right side there are indicator lights for localizer acquired (green), glideslope acquired (green), and decision height reached (amber).  On the left side are stall, overspeed, pull up, and terrain (all red).   In the center is the Master Caution (yellow) and Master Warn (yellow) buttons with integral indicators (Flight Deck Solutions K1 switches).


Each annunciator unit (also from Flight Deck Solutions) has two LEDs installed (in a parallel circuit) in it to give it decent brightness.  (You can also use two different color LEDs ... to cause them to display two different colors.)  The face plates legends of the annunciators are custom engraved by FDS when you order them.

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The LEDs are soldered and than glued into the small holes using clear silicone rubber glue.... in case I need to replace them later.  I use a LOT of the silicone on the backs to make the flexible silicone more "solid" as a mounting.

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Here below you can see the common ground wire soldered in place for all of the LEDs.  These warning indicators will be driven by the output from a Phidgets 8/8/8 which is part of a Phidgets Text LCD display.  I use Alan Dwyer's FS2Phidget software to run the interfacing details of picking up the appropriate data from the sim.  The white things you see are strain relief mounts for the connecting Cat5 cables I'll use to hook them up.

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Here is the face side of the un-mounted glareshield panel.  It sits directly in front of the pilot.  It is very "plain black" ... so that when something actually lights up here, you'll notice it quickly.  There are only two actuall switches/buttons up here... the Caution and Warning reset/recall buttons.

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Well....... I still have to wire up the other connections and then get it hooked to the Phidgets inputs.  Yet more time.  Sigh.  More to come later.

best,

.......................john
« Last Edit: Jul 13th, 2007 at 10:12am by JBaymore »  

... ...Intel i7 960 quad 3.2G LGA 1366, Asus P6X58D Premium, 750W Corsair, 6 gig 1600 DDR3, Spinpoint 1TB 7200 HD, Caviar 500G 7200 HD, GTX275 1280M,  Logitec Z640, Win7 Pro 64b, CH Products yoke, pedals + throttle quad, simpit
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Reply #1 - Jul 13th, 2007 at 10:44am

JBaymore   Offline
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Well....... continuing work on this part of the project after I got done trimming some freshly thrown bowls out in the studio til about 8 PM last night.....resulted in a 2AM bedtime!   Shocked  Amazing how time flys when you get involved in something.


So now below here you can see I am starting to strip the Cat 5 cables that were previously installed in the glareshield panel for this purpose.  Each cable can run 7 inputs or outputs with a common ground connection.

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Making the point here again about the importance of labeling all of the wiring in the pit.  Eventually you WILL have to fix stuff.... and it helps to find out what is what when you don't remember wiring it in the first place.  Wink

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Here below you can see the rear of the completed wiring on the glareshield annunciator and master caution and warning panel.  I changed one thing on the wiring from the first few pictures (if you look closely you should spot it  Wink ):  The common ground for the LEDs in the caution and warning switches have been moved to the second Cat 5 cable so that they are separate from the other LED's common grounds.  This keeps the caution and warning system on one cable.


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As I am working on the wiring I am jotting down notes about what wire from what cable I have hooked up to what interface, and what it's function is going to be, as you can see below.  This helps keep track of the actual wiring in the pit.  Later it gets formalized as part of the "Aircraft Maintenence Manual".

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Here is the "business end" of the Phidgets TextLCD panel.  The digital display on the front shows the level status (in %) of all of the fuel tanks.  This unit comes with 8 sensor (analog) inputs, 8 digital inputs (switches), and 8 digital outputs (LEDs).  That is what I am wiring up to here onm the back.  The outputs share a common ground, and the inputs share a common ground.  All inputs and outputs connect to simple screw terminals, while the sensors connect to three conductor Molex connectors.  Here you can see the Cat 5 Glare 1 cable getting connected to the outputs at the bottom row of connectors.  At the top are some input connections from the fuel management panel located directly below this display.


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And below is what the panel looks like when it is tucked back in place.  Just a simple digital display.  Hides all the OTHER stuff it is doing for the pit nicely, doesen't it?

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Below is a quick shot of some of the annunciators lit up using the "test" function in the FS2Phidget software.

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And last but not least, all of the wiring documentation is cleaned up and put into the "Aircraft Maintenence Manual" for any needed later reference.  Each sheet is dated so that I know if it is current.  It is saved in a file in my computer, and in a black threee ring binder.  As I add functions / wiring, I update the sheets

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Now I am working on programming the logic in the FS2Phidget software.  Soon all those annuncitaors and switches will work as intended.



So....... more as it develops.

best,

............................john
 

... ...Intel i7 960 quad 3.2G LGA 1366, Asus P6X58D Premium, 750W Corsair, 6 gig 1600 DDR3, Spinpoint 1TB 7200 HD, Caviar 500G 7200 HD, GTX275 1280M,  Logitec Z640, Win7 Pro 64b, CH Products yoke, pedals + throttle quad, simpit
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Reply #2 - Jul 14th, 2007 at 11:33pm

JBaymore   Offline
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Well.... configured the FS2Phidget software initialization file... and now the overspeed, stall, glideslope acquired and localizer acquired annuncitor lights come on at the correct times.  

Did three circuits at KBOS tonight online ...and it works SO nicely when flying the ILS!  Those little lights are just sitting right there in your lower (or upper...depending on where you are looking.....windscreen or instruments) peripheral field of view and are very obvious when they come on.

As are the RED ones just off the the left.

Now I have to get a relay on the overspeed line so that I can install a stick shaker on the column.  Yet ANOTHER "little" project.

I also have to get the rest of the annunciators programmed.  Those are a little more difficult.  Particualrly the GPWS ones.

The key to home cockpit building....... one step at a time.  Wink

best,

....................john
 

... ...Intel i7 960 quad 3.2G LGA 1366, Asus P6X58D Premium, 750W Corsair, 6 gig 1600 DDR3, Spinpoint 1TB 7200 HD, Caviar 500G 7200 HD, GTX275 1280M,  Logitec Z640, Win7 Pro 64b, CH Products yoke, pedals + throttle quad, simpit
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Reply #3 - Jul 15th, 2007 at 2:20pm

JBaymore   Offline
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New Power Supply

Today's work on the "pit" was actually work on my main FS machine.

I went from an Antec 400 W single rail power supply to a Rosewill 600W dual rail power supply....... in anticipation of a new honking video card (and more fans).

All is completed.

best,

.....................john
 

... ...Intel i7 960 quad 3.2G LGA 1366, Asus P6X58D Premium, 750W Corsair, 6 gig 1600 DDR3, Spinpoint 1TB 7200 HD, Caviar 500G 7200 HD, GTX275 1280M,  Logitec Z640, Win7 Pro 64b, CH Products yoke, pedals + throttle quad, simpit
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Reply #4 - Jul 15th, 2007 at 3:22pm

Akula.   Offline
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Nice work! I've taken some time to read through every step of this construction, and I'm absolutely gobsmacked. How far do you think you have to go before this pit is finished? And, more importantly, what are you going to do with your hours upon hours of free time once you have finished it  Grin
 

- Akula
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Reply #5 - Jul 15th, 2007 at 4:15pm

JBaymore   Offline
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Thanks!   Smiley

Akula. wrote on Jul 15th, 2007 at 3:22pm:
How far do you think you have to go before this pit is finished?


My guess is that there is at least another year's work left before I get to a "tentative done" point.  Still lots to do yet.  Mainly, I am not made of money....and this is NOT a cheap hobby.  Spread out over time.... it is doable... but not all at once. 

Likely there will always be refinements going on as computer techniology progresses and I get new ideas.


Akula. wrote on Jul 15th, 2007 at 3:22pm:
And, more importantly, what are you going to do with your hours upon hours of free time once you have finished it  Grin


Fly, my friend........
FLY!
  Wink

best,

........................john
 

... ...Intel i7 960 quad 3.2G LGA 1366, Asus P6X58D Premium, 750W Corsair, 6 gig 1600 DDR3, Spinpoint 1TB 7200 HD, Caviar 500G 7200 HD, GTX275 1280M,  Logitec Z640, Win7 Pro 64b, CH Products yoke, pedals + throttle quad, simpit
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Reply #6 - Jul 20th, 2007 at 12:05am

JBaymore   Offline
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Reply #7 - Jul 20th, 2007 at 11:34pm

Professor_Fate   Offline
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Looking great, John!  You are absolutely right about labeling wiring.  That will save many headaches later on if you need to repair something.

Fate
 
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Reply #8 - Aug 6th, 2007 at 3:33pm

beaky   Offline
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Professor_Fate wrote on Jul 20th, 2007 at 11:34pm:
Looking great, John!  You are absolutely right about labeling wiring.  That will save many headaches later on if you need to repair something.

Fate


It's an absolute must, especially if you don't even have circuit diagrams.

You are making drawings, aren't you, J....?    Grin
 

...
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