FlightSafety International

Simulation Systems

FS1000-TM-1-0000-DMS1-012

OPERATION AND MAINTENANCE MANUAL

for the
FS1000 DIGITAL MOTION SYSTEM
• SECTION 1 DIGITAL MOTION SYSTEM

• SECTION 2 MOTION BASE

• SECTION 3 MOTION CONTROL CABINET

• SECTION 4 ACCESS RAMP ASSEMBLY

• SECTION 5 EMERGENCY CONDITIONS

• SECTION 6 EXITS

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INSERT LATEST CHANGED PAGES, DESTROY SUPERSEDED PAGES.

LIST OF EFFECTIVE PAGES
A vertical line in the margin indicates a change.

Dates of issue for original and changed pages:

Original ........ 0 .......... July 2016

Revision ....... A ......... Dec 2016
Updates
Revision ....... B ......... Dec 2017
Updates

This Publication contains 302 pages.

PAGE CHANGE
NUMBER NUMBER*

Cover ........................B
A ...............................B
i thru xlix ..................B
1-1 thru 1-48 .............B
2-1 thru 2-62 .............B
3-1 thru 3-65 .............B
4-1 thru 4-38 .............B
5-1 thru 5-20 .............B
6-1 thru 6-11 .............B
G-1 thru G-4 .............B
I-1 thru I-3 ................B

* Zero in this column indicates an original page

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Table of Contents
List of Figures ........................................................................................................................................... vii

List of Tables ...............................................................................................................................................x

SECTION i. INTRODUCTION ............................................................................................................... xi

i.1. INTRODUCTION – SAFETY SUMMARY .................................................................................... xiii

i.2. INTRODUCTION – HANDLING ..................................................................................................xxxv

i.2.1. Handling – Avoiding Electrostatic Discharge .................................................................. xxxvi

i.2.2. Handling – Checklist ....................................................................................................... xxxvii
i.2.3. Handling – Unpacking .................................................................................................... xxxviii

i.3. INTRODUCTION – EMERGENCY EGRESS .................................................................................. xl

SECTION 1. DIGITAL MOTION SYSTEM .......................................................................................... 1-1

1.1. DIGITAL MOTION SYSTEM – DESCRIPTION...................................................................... 1-1

1.1.1. Description – Purpose of the DMS ....................................................................................... 1-1
1.1.2. Description – Physical Characteristics ................................................................................. 1-1
1.1.3. Description – Function of the DMS in a Simulator .............................................................. 1-2
1.1.3.1. Function – Simulator Systems ....................................................................................... 1-2
1.1.4. Description – CLM Systems ................................................................................................. 1-3
1.1.4.1. CLM System – Control System ..................................................................................... 1-4
1.1.4.2. CLM System – Digital Control Loading System .......................................................... 1-5
1.1.4.2.1. CLM DCLS – Controls I/O Patch ........................................................................... 1-5
1.1.4.2.2. CLM DCLS – CLM Cabinet ................................................................................... 1-7
1.1.4.2.2.1. CLM Cabinet – Ramp Control Module ............................................................... 1-8
1.1.4.2.2.2. CLM Cabinet – Emergency Switches ................................................................ 1-10
1.1.4.3. CLM System – Digital Motion System ....................................................................... 1-12
1.2. DMS – PRINCIPLES OF OPERATION ................................................................................... 1-16
1.2.1. DMS – Block Diagram ....................................................................................................... 1-17
1.3. DMS – PREPARATION FOR USE .......................................................................................... 1-18
1.3.1. Preparation – Environmental Requirements ....................................................................... 1-18
1.3.2. Preparation – Power and Utility Requirements .................................................................. 1-18
1.3.3. Preparation – Handling ....................................................................................................... 1-18
1.3.4. Preparation – Configuration ............................................................................................... 1-19
1.3.4.1. Configuration – Preoperational ................................................................................... 1-19
1.3.4.2. Configuration – CLM Server....................................................................................... 1-19
1.3.4.3. Configuration – Actuator Drive Control Head ............................................................ 1-20
1.3.5. Preparation – Cable Connections........................................................................................ 1-21
1.3.6. Preparation – Checkout....................................................................................................... 1-23
1.3.6.1. Check Out – Preoperational......................................................................................... 1-23
1.3.6.2. Check Out – DMS Components .................................................................................. 1-24

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1.3.6.3. Check Out – Settings ................................................................................................... 1-24

1.4. DMS – OPERATION ................................................................................................................ 1-25
1.4.1. Operation – Modes ............................................................................................................. 1-25
1.4.1.1. Operating Modes – Normal ......................................................................................... 1-25
1.4.1.1.1. Operation – Normal Engaging the DMS ............................................................... 1-26
1.4.1.2. Operating Modes – Maintenance................................................................................. 1-27
1.4.1.2.1. Operation – Return to Home Failure ..................................................................... 1-28
1.4.1.2.1.1. Return to Home Failure – Upset Recovery Procedure....................................... 1-29
1.4.2. Operation – Shut Down ...................................................................................................... 1-34
1.4.2.1. Shut Down – IOS Normal Operation .......................................................................... 1-34
1.4.2.2. Shut Down – Stopping the Control Loading and Motion Software ............................ 1-34
1.4.2.3. Shut Down – Power Down .......................................................................................... 1-35
1.4.2.4. Shut Down – Warnings and Failures ........................................................................... 1-36
1.5. DMS – MAINTENANCE.......................................................................................................... 1-37
1.5.1. DMS Maintenance – Test Equipment Required ................................................................. 1-37
1.5.2. DMS Maintenance – Materials Required ........................................................................... 1-37
1.5.3. DMS Maintenance – Tools Required ................................................................................. 1-38
1.5.4. DMS Maintenance – Cleaning and Inspections Schedule .................................................. 1-39
1.5.4.1. Cleaning – Daily .......................................................................................................... 1-40
1.5.4.2. Cleaning – Weekly ...................................................................................................... 1-41
1.5.4.3. Cleaning – Monthly ..................................................................................................... 1-41
1.5.4.4. Inspections – Daily ...................................................................................................... 1-42
1.5.4.4.1. Daily – Handles and Latches ................................................................................. 1-42
1.5.4.4.2. Daily – Obstacles/Obstructions ............................................................................. 1-42
1.5.4.5. Inspections – Weekly .................................................................................................. 1-43
1.5.4.6. Inspections – Monthly ................................................................................................. 1-43
1.5.4.7. Inspections – Annual and as Needed ........................................................................... 1-43
1.5.4.8. Inspections – DMS Operational Check ....................................................................... 1-44
1.5.5. DMS Maintenance – Troubleshooting................................................................................ 1-45
1.5.5.1. Troubleshooting – DMS .............................................................................................. 1-45
1.5.5.2. Troubleshooting – Aids ............................................................................................... 1-45
1.5.6. DMS Maintenance – Removal and Replacement ............................................................... 1-46
1.5.7. DMS Maintenance – Storage .............................................................................................. 1-47
1.6. DMS – ENGINEERING DRAWINGS ..................................................................................... 1-47
1.7. DMS – LIST OF RELATED PUBLICATIONS ....................................................................... 1-48

SECTION 2. MOTION BASE ................................................................................................................ 2-1

2.1. MOTION BASE – DESCRIPTION ............................................................................................ 2-1

2.1.1. Description – 60″ Base ......................................................................................................... 2-1
2.1.2. Description – 36″ Base ......................................................................................................... 2-3
2.1.3. Description – Accelerometer (3A10).................................................................................... 2-5
2.1.4. Description – Electric Actuators ........................................................................................... 2-6
2.1.4.1. Electric Actuators – 36-Inch Components .................................................................... 2-7
2.1.4.2. Electric Actuators – 60– Inch Components ................................................................... 2-8
2.1.4.3. Electric Actuators – Home Switch ................................................................................ 2-9
2.1.4.4. Electric Actuators – Position Encoder ......................................................................... 2-10

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2.1.4.5. Electric Actuators – Hydraulic Cushion Assembly ..................................................... 2-11

2.1.4.6. Electric Actuators – Motor Oil Fill/Drain Plug ........................................................... 2-12
2.1.4.7. Electric Actuators – Motor Thermistors ...................................................................... 2-13
2.2. MOTION BASE – PRINCIPLES OF OPERATION ................................................................ 2-14
2.3. MOTION BASE – PREPARATION FOR USE ....................................................................... 2-15
2.3.1. Inspections – Motion Base – Initial Checks ....................................................................... 2-15
2.4. MOTION BASE – OPERATION.............................................................................................. 2-15
2.4.1. Operation – Motion Base Interface..................................................................................... 2-16
2.4.2. Operation – Servo Loop...................................................................................................... 2-16
2.5. MOTION BASE – MAINTENANCE ....................................................................................... 2-17
2.5.1. Motion Base Maintenance – Cleaning ................................................................................ 2-18
2.5.1.1. Cleaning – Daily .......................................................................................................... 2-19
2.5.1.2. Cleaning – Weekly ...................................................................................................... 2-19
2.5.1.3. Cleaning – Monthly ..................................................................................................... 2-19
2.5.1.4. Cleaning – Annually/As Needed ................................................................................. 2-19
2.5.2. Motion Base Maintenance – Inspections ............................................................................ 2-20
2.5.2.1. Inspections – Daily/Weekly ........................................................................................ 2-20
2.5.2.2. Inspections – Monthly ................................................................................................. 2-20
2.5.2.2.1. Monthly Inspections – Load Path Component ...................................................... 2-21
2.5.2.2.2. Monthly Inspections – Electrical Cables Inspection ............................................. 2-22
2.5.2.2.3. Monthly Inspections – Motion Base Bearings ...................................................... 2-24
2.5.2.2.4. Monthly Inspections – Motion Base Floor Pad Mounting Bolt Torque Check .... 2-26
2.5.2.2.5. Monthly Inspections – Safety Lock Wire .............................................................. 2-28
2.5.3. Motion Base Maintenance – Troubleshooting .................................................................... 2-30
2.5.3.1. Troubleshooting – Motion Base .................................................................................. 2-30
2.5.4. Motion Base Maintenance – Removal and Replacement ................................................... 2-31
2.5.4.1. Removal and Replacement – Required Tools ............................................................. 2-31
2.5.5. Actuator – Removal ............................................................................................................ 2-33
2.5.5.1. Removal and Replacement – Clevises ........................................................................ 2-42
2.5.5.1.1. Clevises – 60" Actuator Assembly Upper Clevis .................................................. 2-43
2.5.5.1.2. Clevises – 60" Actuator Assembly Lower Clevis ................................................. 2-44
2.5.5.2. Removal and Replacement – Trunnion Bearings ........................................................ 2-45
2.5.6. Actuator – Installation ........................................................................................................ 2-51
2.5.7. Removal and Replacement – At Rest Switch ..................................................................... 2-58
2.5.8. Removal and Replacement – Secondary Thermistor Connection ...................................... 2-59
2.5.9. Motion Base – Actuator Motor Oil ..................................................................................... 2-60
2.5.10. Maintenance – Diagrams .................................................................................................... 2-62

SECTION 3. MOTION CONTROL CABINET ..................................................................................... 3-1

3.1. MOTION CONTROL CABINET – DESCRIPTION ................................................................. 3-2

3.1.1. Description – Block Diagram ............................................................................................... 3-3
3.1.2. Description – MCC Interior .................................................................................................. 3-4
3.1.3. Description – Reference Designators ................................................................................... 3-5
3.1.4. Description – Programmable Logic Control......................................................................... 3-6
3.1.5. Description – Motor Controller Drives................................................................................. 3-7
3.1.6. Description – Motor Controller Control Head...................................................................... 3-8

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3.1.7. Description – Return to Home Controls ............................................................................... 3-9

3.1.7.1. Return to Home – Controls and Indicators .................................................................. 3-11
3.1.7.2. Return to Home – +48Vdc Return to Home Batteries ................................................ 3-12
3.1.8. Description – Uninterruptible Power Supply Assembly .................................................... 3-13
3.1.8.1. UPS Assembly – Power Supply (2G1) ........................................................................ 3-14
3.1.8.2. UPS Assembly – Uninterruptible Power Supply......................................................... 3-15
3.1.8.3. UPS Assembly – Batteries........................................................................................... 3-16
3.1.9. Description – +24Vdc Cooling Fans Power Supply ........................................................... 3-17
3.1.10. Description – Step Down Control Transformer.................................................................. 3-18
3.1.11. Description – Additional MCC Components ..................................................................... 3-18
3.1.12. Description – Regeneration Resistors ................................................................................. 3-19
3.1.13. Description – Dynamic Brake Resistors ............................................................................. 3-20
3.1.14. Description – Gland Plate ................................................................................................... 3-21
3.1.15. Description – Controls and Indicators ................................................................................ 3-22
3.1.15.1. MCC – Control Loading and Motion Emergency Stop............................................... 3-23
3.1.15.2. MCC – DC Bus On Indicator ...................................................................................... 3-23
3.1.15.3. MCC – Control Loading and Motion Emergency Stop Engaged Indicator ................ 3-23
3.1.15.4. MCC – Control Loading and Motion Emergency Stop Circuit Acceptable Indicator 3-23
3.1.15.5. Controls and Indicators – Emergency Stop Switch ..................................................... 3-25
3.1.15.6. Controls and Indicators – Operation Mode Switch ..................................................... 3-26
3.1.15.7. Controls and Indicators – Main Circuit Breaker Reset Handle ................................... 3-27
3.2. MOTION CONTROL CABINET – PRINCIPLES OF OPERATION ..................................... 3-29
3.2.1. MCC Principals of Operation – AC and DC Power ........................................................... 3-30
3.2.1.1. MCC Power – Motor Drives ....................................................................................... 3-31
3.2.2. MCC Principals of Operation – Actuator Positioning ........................................................ 3-32
3.3. MOTION CONTROL CABINET – PREPARATION FOR USE ............................................ 3-33
3.3.1. Motion Control Cabinet – Initial Check Out ...................................................................... 3-34
3.4. MOTION CONTROL CABINET – OPERATION................................................................... 3-35
3.4.1.1. MCC Operation – Normal ........................................................................................... 3-35
3.4.1.2. MCC Operation – Start Up .......................................................................................... 3-36
3.4.1.2.1. Normal Start Up – Applying Power to the MCC .................................................. 3-37
3.5. MOTION CONTROL CABINET – MAINTENANCE ............................................................ 3-41
3.5.1. MCC Maintenance – Inspections........................................................................................ 3-41
3.5.1.1. Inspections – MCC Filters and Cooling Fans.............................................................. 3-41
3.5.1.2. Inspections – Electrical Cables Inspection .................................................................. 3-42
3.5.1.3. Inspections – Weekly .................................................................................................. 3-43
3.5.1.4. Inspections – Monthly ................................................................................................. 3-43
3.5.2. MCC Maintenance – Cleaning ........................................................................................... 3-44
3.5.2.1. Cleaning – Cooling Fans and Air Filters ..................................................................... 3-44
3.5.3. MCC Maintenance – Quarterly – Testing of Lead-acid Batteries and RTH Circuit .......... 3-50
3.5.3.1. Schedule – Quarterly ................................................................................................... 3-51
3.5.4. Inspections – Additional Motion Control Cabinet Components ........................................ 3-52
3.5.5. Troubleshooting – Motion Control Cabinet Faults ............................................................. 3-54
3.5.6. Troubleshooting – Timing Charts ....................................................................................... 3-54
3.5.7. MCC Maintenance – Removal and Replacement ............................................................... 3-55
3.5.7.1. Removal and Replacement – Motion Control Cabinet................................................ 3-55

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3.5.7.1.1. Motion Control Cabinet – Servo Drive Assembly Replacement .......................... 3-57
3.5.7.1.1.1. Motion Control Cabinet – Servo Drive Assembly Replacement ....................... 3-57
3.5.7.1.1.2. Motion Control Cabinet – Servo Control Head Assembly Replacement .......... 3-58
3.5.7.1.1.3. Motion Control Cabinet – Drive ID ................................................................... 3-62
3.6. MOTION CONTROL CABINET – DIAGRAMS .................................................................... 3-64
3.6.1.1. Diagrams – Return To Home ...................................................................................... 3-65

SECTION 4. ACCESS RAMP ASSEMBLY .......................................................................................... 4-1

4.1. ACCESS RAMP ASSEMBLY – FUNCTION ........................................................................... 4-1

4.2. ACCESS RAMP ASSEMBLY – DESCRIPTION ...................................................................... 4-2
4.2.1. Description – Access Ramp Assembly (4A1) ...................................................................... 4-2
4.2.2. Description – Up/Down Switches ........................................................................................ 4-4
4.2.3. Description – Floor/Ramp/Stairs Mat Switches ................................................................... 4-6
4.2.3.1. Mat Switch – Ramp/Steps ............................................................................................. 4-7
4.2.3.1.1. Description – Actuator (4A2) ................................................................................ 4-10
4.3. ACCESS RAMP ASSEMBLY – PRINCIPLES OF OPERATION ......................................... 4-11
4.3.1. Access Ramp – Ramp/Stairs Down .................................................................................... 4-12
4.3.2. Access Ramp – Ramp/Stairs Up ......................................................................................... 4-13
4.4. ACCESS RAMP ASSEMBLY – PREPARATION FOR USE ................................................. 4-14
4.4.1.1. Access Ramp Assembly – Initial Checks .................................................................... 4-14
4.5. ACCESS RAMP ASSEMBLY – OPERATION ....................................................................... 4-15
4.5.1. Access Ramp Operation – Manual ..................................................................................... 4-15
4.5.2. Description – Control Module (8A1A2)............................................................................. 4-15
4.6. ACCESS RAMP ASSEMBLY – MAINTENANCE ................................................................ 4-16
4.6.1. Access Ramp Maintenance – Troubleshooting .................................................................. 4-16
4.6.1.1. Access Ramp – System Error ...................................................................................... 4-16
4.6.1.2. Access Ramp – Ramp Will Not Come Down ............................................................. 4-16
4.6.1.3. Access Ramp – Ramp/Stairs is Stuck Somewhere in the Middle of Travel ............... 4-17
4.6.1.4. Access Ramp – What to Know about Safety Components ......................................... 4-18
4.6.1.5. Access Ramp – Ramp System Discrete Inputs to the CLM I/O System ..................... 4-20
4.6.2. Access Ramp Maintenance – Alignments and Adjustments .............................................. 4-22
4.6.2.1. Access Ramp Position and Gate Switches – Down Position Switch .......................... 4-22
4.6.2.2. Access Ramp Position and Gate Switches – Up Position and Motion Interlock ........ 4-24
4.6.3. Removal and Replacement – Access Ramp ....................................................................... 4-27
4.6.3.1. Access Ramp – Mats ................................................................................................... 4-27
4.6.3.2. Access Ramp – Switches ............................................................................................. 4-28
4.6.3.2.1. Access Ramp Switches – Down Position Switch .................................................. 4-28
4.6.3.2.2. Access Ramp Switches – Up Position/Motion Interlock switches ........................ 4-30
4.6.3.3. Access Ramp – Actuator Assembly ............................................................................ 4-32
4.6.3.3.1. Access Ramp Actuator Assembly – Actuator Encoder ......................................... 4-35
4.6.3.3.2. Access Ramp Actuator Assembly – Ramp Control (9A9A2) ............................... 4-35
4.6.3.3.3. Access Ramp Assembly – Motion Warning System ............................................. 4-36
4.6.3.3.3.1. Emergency Conditions – Emergency Power Off ............................................... 4-38
4.6.3.3.3.2. Emergency Power Off – Access Ramp Stops in Partial Travel ......................... 4-38

SECTION 5. EMERGENCY CONDITIONS ......................................................................................... 5-1

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5.1. EMERGENCY SWITCHES – DESCRIPTION .......................................................................... 5-1

5.1.1. Emergency Switches – Emergency Stop .............................................................................. 5-2
5.1.1.1. Emergency Stop – Control Loading and Motion Emergency Stop Switch ................... 5-3
5.1.1.2. Emergency Stop – CLM System On/Off....................................................................... 5-4
5.1.2. Emergency Switches – Emergency Power Off ..................................................................... 5-5
5.2. EMERGENCY SWITCHES – OPERATION ............................................................................. 5-7
5.2.1. Emergency Conditions – Control Loading and Motion Emergency Stop ............................ 5-7
5.2.1.1. Control Loading and Motion Emergency Stop – Upset Motion Recovery ................... 5-7
5.2.2. Emergency Conditions – Emergency Power Off................................................................ 5-14
5.2.2.1. Emergency Power Off – Access Ramp Stops in Partial Travel .................................. 5-14
5.2.3. Emergency Conditions – Recovery .................................................................................... 5-15
5.2.3.1. Recovery – Software Start Up Sequence..................................................................... 5-15
5.2.3.2. Recovery – Software Engaging Sequence ................................................................... 5-17
5.2.4. Emergency Conditions – Access Ramp .............................................................................. 5-19
5.3. FLIGHTSAFETY PRODUCTION SUPPORT INFORMATION ............................................ 5-20

SECTION 6. EXITS ................................................................................................................................ 6-1

6.1. EXITS – DESCRIPTION ............................................................................................................ 6-1

6.1.1. Exits – Cabin Door ............................................................................................................... 6-2
6.1.1.1. Cabin Door – Kick-out Panel ........................................................................................ 6-4
6.1.2. Exits – Egress Rope .............................................................................................................. 6-4
6.1.3. Exits – Porch ......................................................................................................................... 6-5
6.1.3.1. Porch – Kick-out Panels ................................................................................................ 6-6
6.1.4. Exits – Gate........................................................................................................................... 6-7
6.1.4.1. Gate – Locking Pin ........................................................................................................ 6-8
6.1.4.2. Gate – Switch ................................................................................................................ 6-9
6.2. EXITS – PRINCIPLES OF OPERATION ................................................................................ 6-10
6.3. EXITS – PREPARATION FOR USE ....................................................................................... 6-10
6.4. EXITS – EMERGENCY OPERATION.................................................................................... 6-10
6.5. EXITS – MAINTENANCE ....................................................................................................... 6-11
6.5.1. Maintenance – Cabin Door ................................................................................................. 6-11
6.5.2. Maintenance – Porch Floor Mat ......................................................................................... 6-11
6.5.3. Maintenance – Emergency Egress Rope ............................................................................ 6-11
6.5.4. Maintenance – Gate ............................................................................................................ 6-11

GLOSSARY AND ABBREVIATIONS................................................................................................. G-1

INDEX ..................................................................................................................................................... 6-1

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List of Figures
Figure 1-1. Component Description – 7A1 Controls Patch – Typical ..................................................... 1-6
Figure 1-2. Component Description – ClmPDU – Typical ..................................................................... 1-7
Figure 1-3. Component Description – Ramp Control Module ................................................................ 1-8
Figure 1-4. Component Description – Ramp Raise/Lower Control (9A9A3) ......................................... 1-9
Figure 1-5. Component Description – Emergency Switches ................................................................. 1-11
Figure 1-6. CLM System – Block Diagram ........................................................................................... 1-12
Figure 1-7. Component Description – DMS Components..................................................................... 1-13
Figure 1-8. DMS – Interface .................................................................................................................. 1-17
Figure 1-9. Actuator Drive Control Head Address Switches – Typical ................................................ 1-21
Figure 1-10. Upset Motion Recovery – Failed Actuator Screen ........................................................... 1-29
Figure 1-11. Upset Motion Recovery – Error Log ................................................................................ 1-30
Figure 1-12. Upset Motion Recovery – M s\cut Button ........................................................................ 1-31
Figure 1-13. Upset Motion Recovery – Motion Computation Manager Page ....................................... 1-32
Figure 2-1. Component Description – 60-inch Electric Motion Base ..................................................... 2-2
Figure 2-2. Component Description – 36-inch Electric Motion Base ..................................................... 2-4
Figure 2-3. Component Description – Accelerometer ............................................................................. 2-5
Figure 2-4. Component Description – Electric Actuator – 36″ ............................................................... 2-7
Figure 2-5. Component Description – Electric Actuator – 60″ ............................................................... 2-8
Figure 2-6. Component Description – Home Switch............................................................................... 2-9
Figure 2-7. Component Description – Position Encoder and Connection ............................................. 2-10
Figure 2-8. Component Description – Cushion/Snubber ....................................................................... 2-11
Figure 2-9. Component Description – Oil Fill/Drain Plugs ................................................................... 2-12
Figure 2-10. Component Description – Thermistors ............................................................................. 2-13
Figure 2-11. Block Diagram – Digital Motion System.......................................................................... 2-14
Figure 2-12. Block Diagram – Motion Base Servo Loop ...................................................................... 2-16
Figure 2-13. Inspections – Actuator Load Path ..................................................................................... 2-21
Figure 2-14. Inspections – Actuator Cable Inspection – Typical .......................................................... 2-23
Figure 2-15. Inspections – Upper Trunnion Bearing Locations ........................................................... 2-25
Figure 2-16. Inspections – Motion Base Anchors – Typical ................................................................. 2-27
Figure 2-17. Inspections – Upper Casting Safety Lock Wire Locations – Typical ............................... 2-29
Figure 2-18. Motion Actuator Cables – Typical .................................................................................... 2-33
Figure 2-19. Simulator Jack Cup – Typical ........................................................................................... 2-34
Figure 2-20. Aircraft Jack – Typical ...................................................................................................... 2-35
Figure 2-21. Clevis Pin Safety Wire – Typical ...................................................................................... 2-36
Figure 2-22. Actuator Balance Point – Typical ..................................................................................... 2-37
Figure 2-23. Removing Motion Actuator – Typical Lifting .................................................................. 2-38
Figure 2-24. EM Portable Actuator Drive ............................................................................................. 2-39
Figure 2-25. Placing Motion Actuator on Wood Blocks – Typical ....................................................... 2-40
Figure 2-26. Changing Actuator Clevis – Typical ................................................................................. 2-42
Figure 2-27. Trunnion Bearings – Typical ............................................................................................ 2-46
Figure 2-28. End Trunnion Bearings – Typical ..................................................................................... 2-46
Figure 2-29. Center Trunnion Bearings – Typical ................................................................................. 2-48
Figure 2-30. Trunnion to Casting Clearance – Typical ......................................................................... 2-49
Figure 2-31. Removing Lower Clevis ................................................................................................... 2-52

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Figure 2-32. Installing Upper Clevis ..................................................................................................... 2-53

Figure 2-33. Actuator and Trunnion Bearing Alignment – Typical ...................................................... 2-54
Figure 2-34. Clevis Pin and Nylon Dowel Alignment – Typical .......................................................... 2-55
Figure 2-35. Motion Base – Actuator Motor Oil Plugs ......................................................................... 2-61
Figure 3-1. Component Description – Motion Control Cabinet .............................................................. 3-2
Figure 3-2. Motion Control Cabinet – Block Diagram ............................................................................ 3-3
Figure 3-3. Motion Control Cabinet – Interior ........................................................................................ 3-4
Figure 3-4. MCC – Programmable Logic Control ................................................................................... 3-6
Figure 3-5. MCC – Motor Controller Drive (Without Control Head) ..................................................... 3-7
Figure 3-6. Controls and Indicators – Motor Controller Control Head ................................................... 3-8
Figure 3-7. MCC – Return to Home Controls ....................................................................................... 3-10
Figure 3-8. MCC – RTH Status Indicators ............................................................................................ 3-11
Figure 3-9. MCC – +48Vdc RTH Batteries ........................................................................................... 3-12
Figure 3-10. MCC – +24Vdc Uninterruptible Power Supply Assembly ............................................... 3-13
Figure 3-11. MCC – +24Vdc Power Supply ......................................................................................... 3-14
Figure 3-12. MCC – +24Vdc UPS Controls and Indicators .................................................................. 3-15
Figure 3-13. MCC – +24Vdc UPS Batteries ......................................................................................... 3-16
Figure 3-14. MCC – +24Vdc Cooling Fans Power Supply ................................................................... 3-17
Figure 3-15. MCC – Step Down Control Transformer .......................................................................... 3-18
Figure 3-16. MCC – Regeneration Resistors ......................................................................................... 3-19
Figure 3-17. MCC – Dynamic Brake Resistors ..................................................................................... 3-20
Figure 3-18. MCC – Gland Plate ........................................................................................................... 3-21
Figure 3-19. MCC – Controls and Indicators ........................................................................................ 3-22
Figure 3-20. MCC – Controls and Indicators – Cabinet Door ............................................................... 3-24
Figure 3-21. MCC – Indicator Panel Door ............................................................................................ 3-26
Figure 3-22. MCC – Main Disconnect .................................................................................................. 3-27
Figure 3-23. Digital Motion System – MCC ......................................................................................... 3-29
Figure 3-24. Block Diagram – Motion Control Cabinet ........................................................................ 3-30
Figure 3-25. Simplified Schematic Diagram – Motor Drive ................................................................. 3-31
Figure 3-26. Motor Control – IGBT Switching ..................................................................................... 3-32
Figure 3-27. MCC – Start Up ................................................................................................................ 3-37
Figure 3-28. MCC – Software Services ................................................................................................. 3-39
Figure 3-29. MCC – Train Load ............................................................................................................ 3-40
Figure 3-30. Inspection – Cooling Fan Locations – Cabinet ................................................................. 3-45
Figure 3-31. Cleaning – Air Filters ........................................................................................................ 3-46
Figure 3-32. Inspections – Cooling Fan Locations – Drives ................................................................. 3-48
Figure 3-33. Inspections – Cooling Fan Locations – Regen Resistors .................................................. 3-49
Figure 3-34. Inspections – Contactors Locations .................................................................................. 3-53
Figure 3-35. MOOG Servo Control Head.............................................................................................. 3-59
Figure 3-36. Connector Blocks Removed .............................................................................................. 3-59
Figure 3-37. Remove Ethercat Cables ................................................................................................... 3-60
Figure 3-38. Remove Screw From Underside of Servo Control Head .................................................. 3-60
Figure 3-39. Loosen Screws On Topside............................................................................................... 3-61
Figure 3-40. Remove Wire Ribbon From Servo Control Head ............................................................. 3-61
Figure 3-41. Motion Control Cabinet – Drive ID .................................................................................. 3-63
Figure 3-38. Diagram – RTH Circuit Diagram ...................................................................................... 3-65

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Figure 4-1. Component Description – Ramp Assembly .......................................................................... 4-3

Figure 4-2. Component Description – Ramp/Stairs Up/Down Switch .................................................... 4-4
Figure 4-3. Component Description – Ramp/Stairs Switches (Ref.) ....................................................... 4-5
Figure 4-4. Component Description – Floor Mat Switches ..................................................................... 4-6
Figure 4-5. Component Description – Ramp Mat Switch ....................................................................... 4-8
Figure 4-6. Component Description – Stair Mat Switches ...................................................................... 4-9
Figure 4-7. Component Description – Ramp/Stairs Actuator ................................................................ 4-10
Figure 4-8. Block Diagram – CLM Access Ramp – Typical ................................................................ 4-11
Figure 4-9. CLM Access Ramp – Down Position ................................................................................. 4-12
Figure 4-10. CLM Access Ramp – Up Position .................................................................................... 4-13
Figure 4-11. CLM Access Ramp – Up/Down Ready Switches ............................................................. 4-19
Figure 4-12. CLM Access Ramp – I/O Labels ...................................................................................... 4-20
Figure 4-13. CLM Access Ramp – Typical Ramp Mat Switches.......................................................... 4-21
Figure 4-14. Access Ramp Down Position Switch – Typical ................................................................ 4-23
Figure 4-15. Access Ramp Up Position and Motion Interlock Switches – Typical .............................. 4-25
Figure 4-16. Accesssway Ramp Down Position Switch – Typical ....................................................... 4-29
Figure 4-17. Access Ramp Up Position and Motion Interlock Switches – Typical .............................. 4-31
Figure 4-18. Access Ramp Actuator – Typical ...................................................................................... 4-34
Figure 4-19. Component Description – Strobe Light and Audible Alarm ............................................ 4-36
Figure 4-20. Component Description – Ramp/Motion Warning System Marquee ............................... 4-37
Figure 5-1. Component Description – Emergency Switches – IOS ........................................................ 5-2
Figure 5-2. Component Description – CLM Systems On/Off ................................................................. 5-4
Figure 5-3. Component Description – EPO Switch ................................................................................ 5-6
Figure 5-4. Upset Motion Recovery – Failed Actuator Screen ............................................................... 5-8
Figure 5-5. Upset Motion Recovery – Error Log .................................................................................. 5-10
Figure 5-6. Upset Motion Recovery – M s\cut Button .......................................................................... 5-11
Figure 5-7. Upset Motion Recovery – Motion Computation Manager Page ......................................... 5-12
Figure 5-8. Emergency Condition – Recovery Start .............................................................................. 5-15
Figure 5-9. Emergency Condition – Recovery ...................................................................................... 5-16
Figure 5-10. Emergency Condition – Recovery – Motion Engage ....................................................... 5-17
Figure 5-11. Emergency Condition – Recovery – Enabling Drives ...................................................... 5-18
Figure 5-12. Emergency Condition – Motion Engagement ................................................................... 5-19
Figure 6-1. Component Description – Doorway and Gate Exits ............................................................. 6-1
Figure 6-2. Component Description – Kick-out Panel ............................................................................ 6-2
Figure 6-3. Component Description – Door Kick-Out Panel Decals ...................................................... 6-3
Figure 6-4. Component Description – Emergency Egress Rope Drawer ................................................ 6-4
Figure 6-5. Component Description – Porch Area .................................................................................. 6-5
Figure 6-6. Component Description – Porch Area – Kick-out Panel ...................................................... 6-6
Figure 6-7. Component Description – Gate Switch ................................................................................. 6-7
Figure 6-8. Component Description – Gate Locking Pin ........................................................................ 6-8
Figure 6-9. Component Description – Gate Switch ................................................................................. 6-9

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List of Tables
Table 1-1. DMS Physical Characteristics (Typical) ................................................................................ 1-1
Table 1-2. Reference Designators – CLM Control System ..................................................................... 1-4
Table 1-3. Reference Designators – Controls I/O Patch .......................................................................... 1-5
Table 1-4. Reference Designators – DMS Components (Typical) ........................................................ 1-15
Table 1-5. DMS Power Requirements ................................................................................................... 1-18
Table 1-6. Actuator Drive Control Head Address Switch Settings ....................................................... 1-20
Table 1-7. Typical Motion Cable Connections ...................................................................................... 1-22
Table 1-8. Test Equipment ..................................................................................................................... 1-37
Table 1-9. Materials ............................................................................................................................... 1-37
Table 1-10. Standard and Special Tools ................................................................................................ 1-38
Table 2-1. Motion Base Cleaning Materials .......................................................................................... 2-18
Table 2-2. Motor Wiring – Typical........................................................................................................ 2-56
Table 3-1. Reference Designators – CLM MCC Cabinet ........................................................................ 3-5
Table 3-2. Drive ID ................................................................................................................................ 3-62

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SECTION i. INTRODUCTION
This manual is originally written in English. For marked products, the product complies with
applicable European Directives and Standards. See the Compliance European (CE) Declaration of
Conformity for the specific directives and standards. The CE Declaration of Conformity also lists the
authorized representative for the particular product.
This manual provides personnel with typical simulator configurations and information to operate and
maintain a typical FlightSafety International (FSI) Full Flight Simulator (FFS). It discusses operation and
maintenance of the Motion System of an FFS configuration of the model type FS1000. This manual
describes components/accessories that may/may not yet be installed on all flight simulators.
Every possible maintenance requirement cannot be discussed in this manual; this is an operations and
maintenance manual for typical simulator arrangements, not an overhaul, instructor, acceptance, or design
document. Many of the concepts discussed may also apply to Flight Training Device (FTD) and other FSI
training devices as some maintenance similarities exist.
This manual has the following front matter and sections.

• Front Matter – Title Page, List of Effective Pages (A Page), Table of Contents, Introduction, Safety
Summary, Handling, and Emergency Egress
• Section 1 – Discusses top-level definition and system overview of the Digital Motion System
(DMS) in a Full Flight Simulator (FFS)
• Section 2 – Motion Base Components
• Section 3 – Motion Control Cabinet (MCC)
• Section 4 – Access Ramp Assembly
• Section 5 – Emergency Conditions
• Section 6 – FFS Exits and means of Egress
• Glossary and Abbreviations
• Index
Each section may contain some or all of the following subsystem component information.

• Description – provides system function and purpose.

• Principles of Operation – discusses subsystem theory of operation.
• Preparation for Use – discusses information in preparing the system before use.
• Operation – discusses subsystem component operation; including startup and shutdown.
• Maintenance – system related inspection, cleaning and related diagrams.

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The List of Related Publications lists information on Commercial Off-the-Shelf (COTS) components in
this subsystem. Refer to the COTS folder on the DVD.
This subsystem manual provides typical simulator configurations; always refer to engineering drawings
and vendor documentation for specific information. Facility personnel are responsible for determining
actual simulator configuration.

NOTICE: Links to figures will display the caption at the top of the page. The Figure is located
above the Caption.

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i.1. INTRODUCTION – SAFETY SUMMARY

SAFETY SUMMARY – GENERAL
To ensure personal safety and protection of equipment, apply general safety precautions and instructions
during the operation or maintenance of this equipment. These instructions may not cover all variables,
dynamics, and aspects related to tasks associated with the machine. In order to mitigate any risk to health,
the user is required to adhere to the essential health and safety practices for the purpose of all activities
related to the machine.
FlightSafety shall not be liable for any damages to persons or properties that arise due to the failure to
follow, or willful disregard to any instructions, directions, or warnings contained herein.

WARNING: Authorized Personnel Only – only trained and qualified personnel are
authorized to operate and maintain the flight simulator.

For the purposes of this manual, a qualified person is defined as the following:

• A person who is well versed and familiar with the maintenance and operation of a Full Flight
Simulator (FFS) along with knowledge of the hazards involved with the associated tasks.
• A person who is not only trained, but is authorized to perform various tasks on the machine
while adhering to all essential health and safety practices as dictated by the company as well as
the local regulatory body.
• A person familiar with Personal Protective Equipment (PPE) and its proper use and functionality.
• A person capable of providing first aid measures or capable of summoning help.
• A person capable of reading and understanding instructions in English.

WARNING: Read and Understand Instructions before Proceeding – read and understand
all associated instructions completely before proceeding. Failure to do so could result in
serious injury or death.

The following Text Words are used in conjunction with the Pictograms.

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WARNING STATEMENTS
Warning statements appear with procedures, practices, or conditions. Warning statements apply when
related steps are repeated. Read and understand Warning statements before starting any task to ensure
personal safety.

WARNING: This warning statement describes a general hazard that if not followed could
result in serious injury or death and highlights preventative measures that need to be taken.

CAUTION STATEMENTS
Caution statements appear with procedures, practices, or conditions. Caution statements apply when
related steps are repeated. Read and understand Caution statements before starting any task to ensure
personnel protection.

CAUTION: This caution statement describes a general hazard that if not followed could
result in minor injury and highlights preventative measures that need to be taken.

DANGER STATEMENTS
Danger statements – not following these statements will result in injury or loss of life.

DANGER: This danger statement describes a dangerous hazard that if not followed will result
in serious injury or death and highlights preventative measures that need to be taken.

NOTICE STATEMENTS
Notice statements – provide helpful hints and pictographs with information to accomplish tasks safely
while minimizing chances of damaging equipment.

NOTICE: This notice statement describes general information that if not followed may or
may not result in damage to equipment.

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WARNING: Carefully observe all Caution, Warning, Danger, and Notice statements within
or preceding procedural steps in this manual.

The following Pictograms may be used in conjunction with Caution, Warning, and Danger statements.

WARNING: Electrical Hazard

WARNING: Pinch Points (moving parts) Hazard

WARNING: Hand Crush (moving parts) Hazard

WARNING: Thermal Hazard - Hot Surface

WARNING: Lifting Hazard

WARNING: Entanglement Hazard

WARNING: Toppling Danger Hazard

WARNING: Body Crush Force Hazard

WARNING: Tripping Hazard

WARNING: Radiation Hazard

WARNING: Pressure Hazard

WARNING: Toxic Gases/Asphyxiation Hazard

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MANDATORY ACTION WARNING STATEMENTS

WARNING: This Warning statement describes a mandatory action that if not followed could
result in serious injury or death and highlights preventative measures that need to be taken.

The following Pictograms may be used in conjunction with the Caution, Warning, and Danger statements.

WARNING: Read manual before proceeding

WARNING: Lockout / Electrical Power

WARNING: Use Hearing Protection

WARNING: Use Safety Glasses Protection

WARNING: Glove Protection

WARNING: Wear Face Shield

WARNING: Wear Face Mask

WARNING: Wear Respiratory Protection

WARNING: Use three (3) people to lift

WARNING: Use two (2) people to lift

WARNING: Disconnect before servicing

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PROHIBITION ACTION WARNING STATEMENTS

WARNING: This statement describes an action that is prohibited and should never take place
under any circumstances.

The following Pictograms may be used in conjunction with the Caution, Warning, and Danger statements.

WARNING: Authorized Personnel Only

WARNING: Do Not Lift

WARNING: Stay Clear

WARNING: Do Not Step

WARNING: Do Not Stand

WARNING: KEEP AWAY FROM LIVE CIRCUITS – hazardous voltages are present
within this equipment. Turn off the electrical supply before making adjustments inside the
equipment or replacing components. Capacitors can retain stored energy with power controls
in the Off position and power cables disconnected. Verify that machine power has been locked
out and tagged out as well as confirming that the machine is de-energized before proceeding
with servicing. Uninterruptible Power Supply (UPS) voltage is present when power is off.
Contact may cause electric shock or burn. Turn off and lock out UPS output power before
conducting maintenance.

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WARNING: Lock out and tag out all sources of energy to the machine before proceeding
with any repair/maintenance.

WARNING: EMERGENCY POWER OFF SWITCHES – familiarize yourself with all

the Emergency Power Off (EPO) switches located on the machine. Use EPO in the event of
an unforeseen electrical hazard.
Machine components powered by a UPS are not de-energized by the operation of the
Emergency Stop Switches.
 The Control Loading and Motion (CLM) Power Distribution Cabinet (PDU) UPS
powers the Ramp Control Module that provides power to the Emergency Lighting and
the Access Ramp for Emergency Egress. The CLM UPS output power needs to be
shut off for a full disconnect of power.
 The Off-board Equipment Cabinet’s UPS outputs power the servers. The Off-board
Equipment Cabinet Systems must be shut down correctly before the equipment
cabinets UPS output power can be shut off for a full disconnect of power. Refer to the
FS1000 Simulator Server Operation and Maintenance Manual.
 The Visual System UPS output powers the Image Generators and Visual System
Cabinet components. The Visual System must be shut down correctly before the
Visual System UPS output power can be shut off for a full disconnect of power. Refer
to the Visual System documentation.
 The Marquee UPS on the Top Cap powers the Marquee. The Marquee System needs
to be shut down correctly before the Marquee UPS output power can be shut off for a
full disconnect of power.
 The Motion Control Cabinet contains a UPS and 48Vdc batteries. Refer to the FS1000
CLM Control and the FS1000 Digital Motion System Operation and Maintenance
Manuals for instructions regarding a full disconnect of power instructions.

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WARNING: EMERGENCY STOP SWITCHES – familiarize yourself with all the

Emergency Stop Switches located on the machine. Use Emergency Stop in the event of an
unforeseen control loading or motion hazard.

WARNING: DO NOT SERVICE, OPERATE, OR ADJUST ALONE – under no

circumstances should any person reach into or enter any enclosure for the purpose of servicing
or adjusting the equipment unless another person is present who can render first aid and
perform Cardiopulmonary Resuscitation (CPR).

WARNING: DO NOT SERVICE OR ADJUST THE SIMULATOR without turning the

Control Loading and Motion Inhibit Keylock switch to Inhibit. Remove the key and carry on
your person at all times.

WARNING: HEAVY OBJECTS should not be lifted alone. When necessary ask for
assistance and use proper lifting procedures.

DANGER: SIMULATOR SAFETY – dangerous hazards exist inside and outside a

simulator. Improper use and slow or incorrect responses during an emergency might damage
the simulator or compound what might have been only minor damage. Use caution to avoid
injuries. Information in this section intends to minimize injury and damage in the event of an
emergency.

WARNING: FIRE HAZARDS – familiarize yourself with the local fire prevention plan. In
case of required Emergency Egress, refer to the Emergency Egress section. A Fire Alarm Pull
Lever located on the mezzanine or around the equipment cabinet area provides a means to
activate an audible fire alarm and visible strobe light. Smoke and heat detectors in or around
the simulator patch panels also trigger the audible fire alarm.

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WARNING: INTERLOCKS – system interlocks protect personnel. Do not depend on the

interlocks when working with the equipment. Verify that machine power has been locked out
and tagged out in addition to verifying that the machine is de-energized before proceeding
with service. Remove power from the equipment prior to opening access panels or doors. Do
not short-circuit or tamper with safety interlock switches.

WARNING: CLEANERS, CHEMICALS, AND FLUIDS – cleaners, chemicals, and

industrial fluids can adversely affect skin, eyes, and breathing. Never combine these products.
Observe manufacturer-warning labels. Unless otherwise indicated in the text, use of these
fluids should not result in any immediate health concerns. Avoid prolonged skin contact and
inhalation of mist or vapors. Wash affected areas with soap and water, and launder
contaminated clothing. Selected fluids become hot during normal system operation. Use
caution when working with fluid containing equipment and allow the system time to cool
before performing maintenance. Finally, make sure properly rated firefighting equipment is
readily available and in working order.

WARNING: JEWELRY AND LOOSE CLOTHING – remove rings, watches, other

metallic objects, and cell phones to reduce the risk of shock and to prevent snagging on
moving machinery. Do not wear loose clothing that might catch in moving machinery. Tie up
long hair or tuck it under a cap while performing installation.

WARNING: DANGEROUS PRESSURES – pressure-system precautions apply to all

ranges of pressures. Take care during testing to verify properly aligned and tightened
connections before applying pressure to any system. All system components must be
compatible with pressures applied. Compressed air propels particle(s). Direct the air stream
away from personnel. Reduce air pressure to: (less than 30 pounds per square inch (psi)
American, less than six (6) psi European). Ensure effective chip guarding is in place. Wear
Personal Protective Equipment (PPE).

WARNING: SMOKE OIL HAZARD – smoke oil is used for simulating smoke in the
simulator. Follow the first aid measures for inhalation, skin contact, ingestion, eye contact,
and pressure injection as indicated in the Smoke System vendor data.

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NOTICE: ELECTROSTATIC DISCHARGE – undetectable Electrotatic Discharge (ESD)

damages semiconductor devices and circuit card assemblies. Take care when handling and
repairing semiconductor devices and circuit card assemblies. Achieve a reasonable level of
device protection by using a grounded wrist strap when handling ESD-sensitive devices. Work
on an ESD-protected workbench and use ESD-protective packaging for shipping and storing
sensitive devices.

WARNING: BATTERIES AND THEIR DISPOSAL – handle all batteries carefully at all
times to avoid spills and any caustic or acidic reactions that would harm staff, equipment, and
property. In addition, if a battery bursts open, inflammable materials might ignite. Read and
follow manufacturer guidelines for handling a battery. Batteries at the end of their useful life
must be disposed of or recycled in accordance with local procedures.

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DANGER: Lithium batteries contain inflammable materials and may burst open and ignite if
not handled properly. Follow these precautions to prevent accidents when handling lithium
batteries.
 Do not short circuit.
 Do not disassemble, deform, or apply excessive pressure.
 Do not heat or incinerate.
 Do not subject to impact.
 Do not apply solder directly to the battery.
 Do not use different models or combine new and old batteries.
 Do not attempt to charge.
 Always check proper polarity.

DANGER: To prevent injury to personnel carefully handle all lithium batteries located in the
electronic equipment.

DANGER: When replacing lithium batteries, dispose of them in accordance with local
procedures.

NOTICE: Some stored programs in circuit cards will be lost when disconnecting the lithium
battery.

WARNING: Observe, understand, and comprehend warnings. If warnings are not heeded,
serious injury/loss of life may occur.

The Pictograms, if so equipped on the machine, are affixed to the approximate areas and machine parts as
shown on the following figures.
Reference numbers next to the Pictograms are described in the table following the figures.

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FWD 5

6 7 8

9 10 11 12

13 14 15 16 17 18 19

20 21 22 23 24 25 26 27

28 29

SIM Power Distribution Unit 30 31

CLM Power Distribution Unit

49 49
32 33 34 35 36 37 38 39

Motion System Cabinet (MSC) Equipment Cabinet

Figure i-1. FS1000 Full Flight Simulator CE Symbols – Sheet 1

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AFT
VIEW

13 13

50 49

BOTTOM
VIEW

FWD 43

40
44

41
45

42 46

Figure i-2. FS1000 Full Flight Simulator CE Symbols – Sheet 2

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TOP
VIEW

FWD

48
47

Figure i-3. FS1000 Full Flight Simulator CE Symbols – Sheet 3

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Table i-1. Compliance European Symbol Descriptions

Numbers Symbols Description

1,2,5,6,10,14,16, Hazardous Voltage inside. Disconnect and lockout power before servicing.
20,23,27,30,31, • WARNING: Stored energy may be present.
32,36,41,42,43,44, • WARNING: Follow local health and safety procedures.
45,46
Authorized Personnel only beyond this point, do not go beyond this point if not
3
authorized to do so.

4 Tripping Hazard beyond this point.

9,19,22,26,35,39 Turn off and lock out UPS output power before servicing.

UPS Voltage is present when power is off. Contact may cause electric shock or burn.
8,12,18,25,34,38
Turn off and disconnect UPS output power before servicing.
Read Operators Manual before using. Refer to the FS1000 Power Control System
28
Operation and Maintenance Manual.
Read Operators Manual before using. Refer to the FS1000 Control Loading and
29,50
Motion Control System Operation and Maintenance Manual.

40 Class 1 LED Laser product, do not stare into beam.

47 Pinch Hazard, keep hands clear.

48 Do not step on the Camera Control Equipment unit.

UPS Voltage is present when power is off. Contact may cause electric shock or burn.
7 Turn off and lock out UPS output power before servicing. Refer to the FS1000 Power
Control System Operation and Maintenance Manual.
In the specified area only: Green wires are +10Vdc and yellow wires are -10Vdc. Do
13 not confuse with green/yellow PE conductors used in AC circuits. Refer to the
FS1000 Power Control System Operation and Maintenance Manual.
In the specified area only: Green wires are +10Vdc and yellow wires are -10Vdc. Do
15 not confuse with green/yellow PE conductors used in AC circuits. Refer to the
FS1000 DMS Control System Operation and Maintenance Manual.
UPS Voltage is present when power is off. Contact may cause electric shock or burn.
11 Turn off and lock out UPS output power before servicing. Refer to the FS1000 CLM
Control System Operation and Maintenance Manual.
UPS Voltage is present when power is off. Contact may cause electric shock or burn.
17 Turn off and lock out UPS output power before servicing. Refer to the FS1000 CLM
Control System Operation and Maintenance Manual.
Read manual before servicing this high voltage device. Refer to the FS1000 Power
21
Control System Operation and Maintenance Manual.
Read manual before servicing this high voltage device. Refer to the FS1000 CLM
24
Control System Operation and Maintenance Manual.
Read manual before servicing this high voltage device. Refer to the FS1000 Power
33,37
Control System Operation and Maintenance Manual.
Thermal hazard.
49
• WARNING: Allow time for resistors to cool before servicing.

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Residual Risks

Residual risks that remain despite the inherent safety measures are listed below.

• Safety netting and temporary guard rail in place during installation or dismantling – slipping,
tripping, and falling risks
• Replacement of parts utilizing lifting devices for large parts – crushing and pinching risk
• Motion System or any component of Motion System replaced during installation or maintenance
– crushing and pinching risk
• Aircraft cockpit configuration – operations, falling, tripping, slipping during emergency
evacuation risk

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SAFETY SUMMARY – MANUAL SPECIFIC

WARNING: Only qualified personnel are to work on the Motion System. Do not allow
occupants in or near the simulator while engaging the DMS for the first time after an
installation or commissoning.

WARNING: Only qualified personnel trained on maintenance mode operation should

attempt to perform procedures in this mode.

WARNING: Ensure that no items around the system area will become loose and hit
personnel. Keep personnel out of Motion envelope at all times.

WARNING: Do not engage the DMS until all personnel are seated with seat belts securly
fastened. Do not operate the DMS with anyone standing in the simulator.

WARNING: Components overridden in the maintenance mode can create unsafe conditions
for personnel and equipment.

WARNING: In the event an actuator does not fully extend or retract, do not, under any
circumstances, put arms, legs, hands, feet, or other body parts between the Access Ramp and
simulator or in the way of any other moving parts while checking interlocks. An actuator may
move instantly when an interlock closes.

WARNING: Do not remove seat belts or stand in the simulator until the intermittent Access
Ramp warning sound stops.

WARNING: Visually ensure that the Ramp/Stairs is in the proper position and there is
indication the Simulator Access Ramp is safe to use.

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WARNING: Observe safety precautions, do not use flammable materials unless specified;
and handle with care.

WARNING: Observe all product and maintenance safety precautions.

WARNING: Ensure that all personnel are clear from the cockpit controls before pressing the
Control Loading pushbutton. The control columns move into flight-neutral position when this
button is pressed.

WARNING: Consistently close and latch the simulator door. Ensure that all personnel are
seated with seat belts fastened before engaging the DMS.

WARNING: Use only four (4) aircraft jacks approved by FSI when changing the Motion
Actuator Assembly. Employ no other substitute method for removal (i.e. maintenance jack)
unless contacting FSI first and having method approved by the simulator support department.

WARNING: The Motion Base Actuators are very heavy and have sharp edges. To avoid
injury, use proper protective clothing, lifting techniques, and equipment.

WARNING: Do not attempt this procedure unless familiar with removing and replacing
electric actuators.

WARNING: Use a meter or other appropriate testing device to ensure power removal from
equipment.

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WARNING: Wait five (5) to 10 minutes before performing maintenance on the cabinet to
allow time for the 680Vdc capacitor charge to bleed off the motor controllers and the return
to home (RTH) amplifiers.

WARNING: Disconnect the batteries prior to performing maintenance on the battery circuits
because +48Vdc will remain on them. Orange wires in the MCC are connected to batteries
and are always live.

WARNING: Wait five (5) to 10 minutes before performing maintenance on the cabinet to
allow time for the 680Vdc capacitor charge to bleed off the motor controllers.

WARNING: Some parts of the MCC retain energy after turning off the main AC power. Wait
at least 10 minutes before performing any maintenance to the actuators. Orange wires indicate
parts of the cabinet that are battery powered and live. Use lock/tag out procedures and
Personal Protective Equipment (PPE) as appropriate and necessary while performing
maintenance activities. In addition to removing facility power from the cabinet, ensure that
Motion Base movement does not occur by opening the following circuit breakers in the MCC
prior to performing maintenance: 11F1, 14F1, 17F1, 20F1, 23F1, and 26F1.

WARNING: Be alert for electrical hazards as high voltage is present in many areas; learn
where and ensure all electrical power is removed before cleaning.

WARNING: Disconnect all incoming power to the MCC prior to cleaning. After power is
disconnected, use a meter or other appropriate testing device to insure power removal from
the equipment..

WARNING: Orange wires indicate parts of the cabinet that are battery powered and live. Use
lock/tag out procedures and PPE as appropriate and necessary while performing maintenance
activities.

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WARNING: Many Motion Base components are very heavy and have sharp edges. To avoid
injury, use proper protective clothing, lifting techniques, and equipment.

WARNING: Disconnect all incoming power to the MCC prior to performing maintenance
on the Motion Base. After power is disconnected, use a meter or other appropriate testing
device to ensure power removal from the equipment.

WARNING: In addition to removing facility power from the cabinet, ensure that Motion
System movement does not occur by opening the following circuit breakers in the MCC prior
to performing maintenance: 11F1, 14F1, 17F1, 20F1, 23F1, and 26F1.

WARNING: Ensure all personnel are clear of the Motion Base and the Access Ramp prior to
de-energizing the DMS.

WARNING: Ensure that all personnel are clear of the simulator, Motion Base, and out of the
cockpit prior to operating the Motion System in the maintenance mode.

WARNING: Avoid major injury to personnel by keeping hands, fingers, elbows, and feet out
of harms way.

WARNING: The actuator assembly may move suddenly when removing the upper clevis
pin. Avoid injury by keeping hands, fingers, elbows, and feet out of harms way.

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CAUTION: Prior to proceeding, refer to and follow the instructions in the vendor
documentation assembly and installation manual (CDS38799).

CAUTION: Motor oil change should be conducted only after the Motion System has been
off for at least one (1) hour and the motor is cool to the touch.

CAUTION: Oil might be under pressure and spray as a result of the pressure. Take proper
precautions to ensure safety to personnel.

NOTICE: In normal operation the DMS is powered up and engaged, with the Motion Base
in the Neutral (or Null) position. The MCC must be running before starting training load.

NOTICE: Typically, upon reaching the neutral positions, the simulator is in the Flight Freeze
mode and the aircraft is positioned on an airport runway, ready for training.

NOTICE: Do not damage anything. Be especially careful around delicate components,

connections, and wires.

NOTICE: Use the proper cleaning materials such as a lint-free cloth wipes and non-abrasive
cleaners.

NOTICE: DO NOT use compressed air; in many cases compressed air contains moisture,
dust particles and oil, which could be harmful to the hardware, in addition, compressed air
just blows material from one area to another, not cleaning anything in the process.

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NOTICE: Both the 36" and 60" Motion Base configurations have the actuators positioned
with the motor (bottom) end of the actuators mounted to the floor pads, and the top (rod) end
of the actuators mounted to the pads mounted under the simulator frame.

NOTICE: When viewed from the top, both the 36" and 60" Motion Base configurations have
the actuators numbered in the clockwise direction, actuator #1 is located immediately to the
right of the front (fwd) end of the simulator frame.

NOTICE: If unfamiliar with running the ATG tests, contact the on-site FAA or Simulator
Certification Coordinator.

NOTICE: Trunnion bearings damage easily. Exercise care when removing or replacing the
actuator assembly.

NOTICE: Do not heat trunnions with any bearings installed.

NOTICE: When using the torque wrench with the torque adapter, the ft-lb setting on the
torque wrench must be adjusted according to the following formula:

Desired Torque Value Torque Wrench Setting

Example:

NOTICE: Due to precision tolerances, do not perform removal and replacement of trunnion
bearings in the field. Order the replacement trunnion, bearings pre-pressed, and pins from the
factory as a set.

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NOTICE: To avoid damaging the replacement trunnion bearings and to ensure a correct fit,
ensure the bearing is aligned with the hole in the trunnion when pressing the bearing into the
trunnion.

NOTICE: When installing the actuator, it is recommended to attach the lower (motor end)
actuator clevis into the trunnion prior to attaching the upper actuator clevis.

NOTICE: Avoid scoring the teflon-coated trunnion bearings. Gently move the actuator clevis
back and forth, parallel to the bearing surface, consistently as it lowers onto the side of the
bearing moving inward in such a manner that the actuator clevis does not bind.

NOTICE: It is vitally important that encoder cables not run in close proximity to motor power
cables.

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i.2. INTRODUCTION – HANDLING

Proper handling is essential to avoid damaging electronic components. Improper handling of electronic
components at any point during manufacturing, testing, shipping, unpacking, operations, or maintenance
can result in failure or latent defect that can limit or halt successful simulator operations.

NOTICE: ELECTROSTATIC DISCHARGE – undetectable Electrostatic Discharge (ESD)

damages semiconductor devices and circuit-card assemblies. Take care when handling and
repairing semiconductor devices and circuit-card assemblies. Achieve a reasonable level of
device protection by using a grounded wrist strap when handling ESD-sensitive devices. Work
on an ESD-protected workbench and use ESD-protective packaging for shipping and storing
sensitive devices.

FlightSafety simulators have many sensitive electronic components including:

• Integrated Circuits
• Diodes
• Transistors
• Solid-state Relays
• Memory Modules
• Magnetic Media
The following sections discuss basic electrostatic principles and provide a basic checklist for the proper
handling of electronic components. Though the degree of sensitivity varies, overall product reliability
depends on handling electronic components appropriately to avoid ESD.

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i.2.1. Handling – Avoiding Electrostatic Discharge

Electrostatics is the phenomena of electric charges at rest, or static (v. dynamic) electricity. An imbalance
of electrons produces an electric field on surface material and subsequently creates static electricity, or
electrostatic charge.

Electrostatic charge typically builds up when contact and then separation occurs between two (2) elements.
For example, walking across the floor generates electrostatic charge as shoes contact and then separate
from the floor. When the two (2) materials (shoes and floor) contact and then separate, negatively charged
electrons transfer from the surface of one (1) to the other. Which material loses or gains electrons is
affected by the surface areas of contact, speed of separation, relative humidity, and other factors, but one
(1) element will retain an electrostatic charge while the other becomes positively charged. The material
gaining electrons becomes negatively charged.
Similarly, sliding an electronic component in/out of a bag or across the top of a plastic toolbox generates
an electrostatic charge as the surface of the bag contacts then separates from the plastic toolbox.
Electrostatic discharge is created when a charge transfers between objects at different electrical potentials
(i.e., when the charge transfers from one material to another). Often times ESD results in failure or latent
defect.
Failure caused by ESD means the electronic component may no longer function. Therefore, ESD has
resulted in melted metal, junction breakdown, or oxide failure and possibly the destruction of the
component circuitry. If this type of failure is not identified immediately as being caused by ESD and the
component is routinely replaced without regard for the cause of the falure, the replacement component
becomes vulnerable to the same fate.
Latent defect caused by ESD exposure translates to the degradation of the electronic component. As a
result, the component might perform adequately for a time, but may ultimately experience premature
failure. A slight change in operating conditions such as power supply variation, operating frequency
alteration, or changes in operating temperature will over stress the component, resulting in occasional soft
errors and intermittent operation prior to total failure. Latent defect caused by ESD is typically more costly
due to increased troubleshooting and root–cause analysis requirements and may also create personnel
hazards in some applications.
Additionally, where an ESD event can cause obvious damage and immediate failure to a component, a
buildup of electrostatic charge without discharge options may cause electrostatic contamination resulting
in latent defect. The more static electricity present in an environment equals the greater the risk of
contamination.
The following handling checklist provides steps to minimize the damage caused by electrostatic
contamination.

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i.2.2. Handling – Checklist

Before working with Electrostatic Discharge Sensitive (ESDS) components, put on a grounding wrist strap
and connect the ground lead to chassis ground. A good rule to follow regarding the wrist strap is,

first on, last off.

NOTICE: Vinyl covered manuals are notorious static generators. Therefore, keep vinyl away from
all components and assemblies.

• Ensure 12-inch minimum space exists around the unit so that proper cooling occurs; do not
obstruct fan intakes.
• Use only fire extinguishers approved for electrical fires to prevent electric shock and minimize
damage.
• Never remove or replace any circuit board while power is on except for hot-swappable design
assemblies.
• Do not touch PC boards, internal cables, or any board components without observing
electrostatic discharge precautions.
• Do not pick up magnetic media without utilizing static discharge precautions.
• Do not place magnetic media near a source of magnetism.
• Ensure all components and assemblies are static shielded in a conductive container until ready
for installation.
Place all assemblies immediately on a grounded, nonconductive work surface. Upon project completion
remove ground lead to chassis and then remove the wrist strap.

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i.2.3. Handling – Unpacking

FlightSafety Simulation (FSS) personnel perform the initial installation, checkout, and integration of the
simulator. Upon delivery to the customer’s facility, FSS personnel reassemble and integrate the simulator
and then test the systems. Use the following checklists when preparing to use the equipment or when
replacing equipment and/or tools.

RECEIVING

• Inspect the packaging.

• After unpacking, inspect the equipment for any damage incurred during shipment.
• Document any damage found in accordance with existing procedures.

LOCATION SELECTION

• Locate in accordance with the engineering drawings.

• Accessibility must be adequate in both front and rear.
• Ensure protection from dust, heat, splash, and drip.

HANDLING

• Observe all precautions found in the shipping container(s).

WARNING: Some components are heavy. Use proper and safe methods to avoid injury. Use
two (2) persons for lifting.

NOTICE – Take measures to avoid Electrostatic Discharge (ESD).

Use proper and safe methods to avoid placing magnetic media near a source of magnetism.

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LINE CONNECTIONS

• Connect all wiring with system power off.

• Do not install or remove boards while power is supplied.
• Leave enough slack in wiring to permit partial withdrawal of units for test and installation.

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i.3. INTRODUCTION – EMERGENCY EGRESS

NORMAL EXIT FROM A MOTION EQUIPPED FLIGHT SIMULATOR

The normal method for controlling the Motion System is to bring the simulator “down” by pressing the
Motion System pushbutton located on the Tactile Monitor at the Instructor Station. This provides for
normal ramp operation and allows normal egress from the cockpit. This method is used in most cases if
there is not an immediate emergency requiring evacuation or a threat to crew safety within the simulator.

STOPPING AND EXITING THE FLIGHT SIMULATOR IN AN EMERGENCY

If a situation arises in which there is an emergency requiring immediate evacuation or a threat to crew
safety, perform the following.
1) Bring the simulator off motion by using the Emergency Power Off (EPO).
2) Get the crew and instructor out of the cockpit by following the Emergency Egress
procedures outlined in this section.
3) Exit the simulator as expeditiously as possible.
4) Evacuate the area, or proceed to a shelter if necessary.

WARNING: Emergency Egress Operation is dangerous and can cause serious injury or death if
not properly executed. In Emergency Egress situations when the EPO button is pressed, the
Access Ramp will lower automatically enabling exit from the simulator as expeditiously as
possible.

WARNING: Familiarize yourself with the local fire prevention plan. In case of required
Emergency Egress, refer to the Emergency Egress procedures in this section. A Fire Alarm Pull
Lever located on the mezzanine or around the equipment cabinet area provides a means to
activate an audible fire alarm and a visible strobe light. Smoke and heat detectors located in or
around the simulator patch panels also trigger the audible fire alarm.

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Cockpit/Instructor Area Exits

Exiting the simulator from the cockpit/instructor area requires the use of the cabin door to access the
porch/gate area, and then onto the Access Ramp. This section discusses the cabin door and porch/gate
area.
The exits consist of the following components.

• Cabin Door – entrance into the instructor area

o Kick-out Panel
• Porch – area between the cabin door and gate
o Kick-out Panel
o Egress Rope
• Gate – sliding gate to exit porch onto the Access Ramp

Swinging Cabin Ramp Control Emergency

Door Panel Egress Rope
Drawer

Sliding
Gate Porch
Area

Access
Ramp

Figure i-4. Doorway, Porch, and Gate Exits

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Emergency Egress – Simulator Door Kick-Out Panel

If an Emergency Egress becomes necessary and the simulator door will not open, the Door Kick-out Panel
is available for escape out of the cockpit/instructor area.

Door Kick-Out
Panel

Figure i-5. Emergency Egress – Door Kick-Out Panel

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One (1) of the following decals appears on the Door Kick-out Panel.

Figure i-6. Emergency Egress – Door Kick-Out Panel Decals

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Emergency Egress – Porch

The porch is the standing area between the simulator door and gate. The porch contains a pressure-
sensitive floor mat to detect the presence of objects or personnel in the area. The porch provides access to
the Sliding Gate, the Ramp Control Panel, and the Access Ramp. Use the Ramp Control Panel (only if
motion is in the fully retracted position) to lower the Access Ramp (if not already lowered) and exit by
using the Sliding Gate and the Access Ramp.
Refer to Figure i-4.

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The Emergency Egress Rope Drawer decals are above and below the Emergency Egress Pull Handle for
the rope.

Emergency
Egress Rope
Drawer Decal

Figure i-7. Emergency Egress – Rope Drawer

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Emergency Egress – Rope

The Emergency Egress Rope Drawer and Porch Kick-out Panel on the porch area are available for use in
emergency conditions when the Access Ramp is not available. The Egress Rope is stored in a compartment
on the wall near the aft side of the exit door. The rope provides a means of egress when a rapid exit is
necessary. The Emergency Egress Rope Drawer label instructs the user to pull out the vertical drawer by
the handle.

WARNING: Observe safety precautions and warnings when using the rope.

Emergency Egress – Porch Kick-Out Panel

If an Emergency Egress becomes necessary, the Porch Kick-out Panel is visible and accessible from the
porch area for use with the Emergency Egress Rope. The Porch Kick-out Panel consists of two (2) panels,
the first panel consists of aluminum honeycomb and pushes out the second panel made of fiberglass.
The Emergency Egress Porch Kick-out Panel Pictogram shows the user exiting the cockpit/instructor area
inside the simulator, kicking out the Porch Kick-out Panel, pulling out the vertical Emergency Egress
Rope Drawer by the handle, dropping the drawer and rope over the rail to deploy the knotted, nylon rope,
and egressing down the rope to a safe area below.

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Emergency
Egress Rope
Drawer

Emergency
Egress Porch
Kick Out Panel

Figure i-8. Emergency Egress – Porch Kick-Out Panel

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One (1) or both of the decals shown may be used.

Figure i-9. Emergency Egress Porch – Kick-Out Panel Decals

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Emergency Egress Operation

Emergency Egress Operation depends on many factors and variables too numerous to mention in this
document.

WARNING: The instructor is the operator of the machine and is responsible for Emergency
Egress initiation activities.

WARNING: Emergency Egress Operation is dangerous and can cause serious injury or death if
not properly executed.

Use the following procedures as general guidelines when operating the emergency exits.
1) To leave the simulator during an Emergency Egress situation:
a. Exit through the cabin door – utilize the Door Kick-out Panel as necessary.
b. Use the Ramp Control Panel (only if motion is in the fully retracted position) to
lower the Access Ramp (if not already lowered) and exit by using the Sliding
Gate and the Access Ramp.
c. If the Access Ramp does not lower or the Motion System is not in the fully
retracted position, use the Porch Kick-out Panel and the Emergency Egress Rope
as necessary.
i. Push down on the green handle located on the top end of the Kick-out
Panel and kick/push the panel out and away from the porch area.
ii. The Kick-out Panel will push the second (fiberglass) panel out and away
from the simulator frame, causing the fiberglass panel to freefall to the
nearest location below.
iii. The green-handled Kick-out Panel will drop/swing out from the hinged,
bottom end, providing an opening for personnel to exit the simulator while
holding the Emergency Egress Rope.
d. Deploy the Emergency Egress Rope by pulling out on the handle of the vertical
Rope Drawer located above the porch railing. The Rope Drawer is made of Kydex
material. Drop the Rope Drawer out of harm’s way while removing the white,
knotted, nylon rope contained within. Drop the rope over the railing.
2) Personnel must securely hold the Emergency Egress Rope while lowering to safety.

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SECTION 1. DIGITAL MOTION SYSTEM

1.1. DIGITAL MOTION SYSTEM – DESCRIPTION

This section provides general guidelines for preparing the components of the Digital Motion System
(DMS) for use. Perform assembly, testing, and acceptance according to approved methods and procedures.
Observe all warnings and cautions when handling the equipment to avoid personnel injury and equipment
damage.
Some of the instructions contained in this section may be similar to those followed during assembly and
testing. Use the instructions in this section after shut down for major maintenance or after an extended
period of non-use.

1.1.1. Description – Purpose of the DMS

The purpose of the DMS is to simulate the ground handling and in-flight movements of an actual aircraft,
based on the inputs from the simulator flight controls and host computer simulation software.

1.1.2. Description – Physical Characteristics

The Control Loading and Motion Control System Operation and Maintenance Manual lists the physical
characteristics of the Control Loading and Motion Power Distribution Unit (ClmPDU) Cabinet.
The table lists the physical characteristics of the Motion Control Cabinet, and the 36" and 60" Motion
Base.

Table 1-1. DMS Physical Characteristics (Typical)

Motion Control Cabinet 36” Motion Base 60” Motion Base

Height 67.17 in 56 in (home) 81 in (home)
107 in (maximum) 155 in (maximum)
Width 146 in 161 in 240 in
Depth 34 in 141 in 212 in
Weight 3500 lbs 7000 lbs 11000 lbs

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1.1.3. Description – Function of the DMS in a Simulator

The function of the DMS is to convert electrical power from the Motion Control Cabinet (MCC) into
physical simulator motion for the feel of an aircraft in flight. The windows-based Control Loading and
Motion (CLM) Control System manages and directs the DMS via the CLM Server according to commands
from the Host Computer.

1.1.3.1. Function – Simulator Systems

The windows-based Control Loading and Motion (CLM) Systems make up the aircraft environment
necessary to provide the students with life-like cues, conditions, and motion feedback.
A simulator is the sum of several systems and subsystems working independently and in conjunction to
facilitate a trainer capable of receiving and issuing cues in real time. Simulator systems and subsystems
include.

• Cockpit or Student Station • Sound System (SND)

• Simulation Computation Server (SCS) • Digital Control Loading and Motion (CLM)
also known as the Host Computer Control System

• Instructor Operating Station (IOS) • Digital Control Loading System (DCLS)

• File Server Computer (SFS) • Digital Motion System (DMS)

• Simulator Input/Output System (SimIO) • Communications System (COMM)

• Power Control System (PCS) • Optional Avionics Systems

• Weather Radar System (WXR) • Visual Simulation System (VSS)

These systems work in concert to provide the environment necessary to train and test the student; also
providing cues, feedback, and conditions that develop, maintain, and evaluate flight skills. The use of a
Digital Motion System on a Flight Training Device (FTD) defines the device as a Full Flight Simulator
(FFS).

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1.1.4. Description – CLM Systems

The windows-based Control Loading and Motion (CLM) Systems make up the aircraft environment
necessary to provide the students with life-like cues, conditions, and motion feedback.
Operation and control of the CLM Digital Motion System (DMS) requires the following three (3) CLM
subsystems and subsystem components:

CLM Control System – Controls the CLM systems

• CLM Server (9A2A5)

• CLM Digital Control Loading System (DCLS) – Control Loading related operation
• Input/Output (I/O) interface
• CLM Cabinet – Power Distribution Unit (PDU)
• CLM Emergency Switches

CLM DMS – Motion Base related operation

• Motion Control Cabinet (MCC) – 8A3

• Programmable Logic Controller (PLC)
• Motion Base (3A2)
• Actuators
• Access Ramp Assembly (4A1)
• Ramp Control Module
• Emergency Switches
• Emergency Stop (ESTOP)
• Emergency Power Off (EPO)
• Gate/Door Access Ramp
• Emergency Egress

The CLM Control System and the DCLS are in this manual only as they contribute to operating the DMS.
This manual covers typical operation and maintenance for the DMS on various simulator configurations.

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1.1.4.1. CLM System – Control System

The CLM Server and the Instructor Operating Station (IOS) provide the means for properly operating and
controlling the DCLS and the DMS.

• The CLM Server processes flight-model data from the Host Computer and incorporates it into the
DMS to provide realistic aircraft motion.
• The IOS area contains a means of controlling the DMS via CLM power on/off buttons and an
Emergency Stop switch enabling power to the DCLS and the DMS.

Table 1-2. Reference Designators – CLM Control System

Component Reference Designator

CLM Server 9A2 Equipment Cabinet
Server Chassis A4 or A5 (typical)
CLM Tactile Monitor IOS Area
Control Loading Switch Soft Switch
Motion System Switch Soft Switch
Reset Switch Soft Switch
Motion C/L Emergency Stop Switch ESTOP

For information on the CLM Server and other CLM Control System components, refer to the CLM Control
System Operation and Maintenance Manual.

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1.1.4.2. CLM System – Digital Control Loading System

The Digital Control Loading System (DCLS) contributes to Digital Motion System (DMS) operation using
the following components.

• Controls Input/Output (I/O) Patch – interfaces Control Loading and Motion (CLM) I/O to the CLM
Server.
• CLM Power Distribution Unit (PDU) Cabinet – CLMPDU
• Ramp Control Module – Ramp/Stairs raise/lower control
• Emergency Stop (ESTOP) and Emergency Power Off (EPO)
This manual describes the DCLS components as they relate to DMS operation.

1.1.4.2.1. CLM DCLS – Controls I/O Patch

The I/O devices for the CLM System reside in the Controls I/O Patch located in the side of the simulator
frame. The Controls I/O Patch interfaces the CLM System components to the CLM Server.

Table 1-3. Reference Designators – Controls I/O Patch

Component Reference Designator

Controls I/O Patch Assembly 7A1
CLM I/O System A1
Power Over Ethernet Switch A2
+24Vdc Switched Power Supply PS1
±10Vdc Reference Power Supply PS2
+5Vdc Power Converter PS3

Refer to the DCLS Operation and Maintenance Manual for additional DCLS component information.

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The Controls Input/Output (I/O) Patch is the interconnection and routing point for interfacing the Digital
Control Loading System (DCLS) and some Digital Motion System (DMS) components to the Control
Loading and Motion (CLM) Server; interfacing components such as interlocks, signal conditioners,
switches, and lights.

+24Vdc ±10Vdc POE

Power Reference Ethernet
Supply Generator Switch

Controls
I/O Chassis
7A1A1

Figure 1-1. Component Description – 7A1 Controls Patch – Typical

Refer to the FS1000 CLM Control Operation and Maintenance Manual for additional information on
Controls I/O Patch components.

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1.1.4.2.2. CLM DCLS – CLM Cabinet

The Control Loading and Motion (CLM) Power Distribution Unit (PDU) Cabinet, also known as the
ClmPDU Cabinet, is a result of a FlightSafety/vendor design effort in providing quality power for the
CLM DCLS.
The typical ClmPDU Cabinet may contain up to four (4) modules for DCLS operation and a Main
Transformer Assembly providing power to the ClmPDU and the Motion Control Cabinet (MCC). The
inside of the ClmPDU Cabinet door contains a sticker describing the ClmPDU Cabinet’s modules.

Figure 1-2. Component Description – ClmPDU – Typical

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1.1.4.2.2.1. CLM Cabinet – Ramp Control Module

The Ramp Control Module (8A1A2) contains the digital servo drive for driving the Ramp/Stairs actuator;
a +24Vdc power supply for ramp logic circuits, indicators, fuses, and a ramp raise/lower control switch.
The Ramp Control Module contains all functions necessary for controlling the ramp. Refer to the Digital
Control Loading System (DCLS) Operation and Maintenance Manual for ClmPDU components.
Controls and Indicators
The following paragraphs describe operation of Ramp Control Module controls.
Maintenance Mode Key Switch
The Maintenance Mode Key Switch has two (2) positions– Normal and Inhibit. In the Normal position,
the Control Loading and Motion software controls the ramp. In the Inhibit position, only the Ramp Control
Switch on the module can raise or lower the ramp. The Maintenance Mode Switch works in conjunction
with the Maintenance Key Switch located on the simulator top cap. Both switches must be in Normal
Mode to allow the CLM System to operate.

Figure 1-3. Component Description – Ramp Control Module

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Status Indicators
The Ramp Control Module has six (6) Status Indicators:

• Essential Low Voltage—illuminates when the Essential Low Voltage in the Module is present.
The Simulator Power Control System supplies the voltage required for the Ramp Control Module
to operate.
• Interlock OK – illuminates when all conditions are satisfied for raising the ramp.
• Ramp Mat – illuminates when someone or something is on the ramp mat.
• Ramp Up – illuminates when the ramp is in the fully up position.
• Ramp Down – illuminates when the ramp is in the fully down position.
Refer to Figure 1-3.

In addition to the Ramp Control Module in the ClmPDU Cabinet, a ramp raise/lower control is also
available from the Ramp Control Panel on the porch of the simulator near the entrance door. Refer to
engineering drawings for simulator-specific ramp controls.

Figure 1-4. Component Description – Ramp Raise/Lower Control (9A9A3)

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1.1.4.2.2.2. CLM Cabinet – Emergency Switches

Emergency Switches are accessible at the front of the System Control Module in the ClmPDU Cabinet;
the round, red, positive-action (push-abort-pull-on) illuminated pushbuttons activate the following
conditions according to the labels:

• Emergency Stop – activating (pushing) the Emergency Stop switch initiates a CLM System Abort
Condition that removes enabling power from the Control Loading and Motion drive amplifiers.
The Motion System returns to the At-Rest position, the Control Loading systems cease movement,
and the ramp will remain in the current up or down position. The Emergency Stop switch must be
reset (turned clockwise) in order to bring up the CLM Systems. Investigate and correct the reason
for the switch activation prior to bringing up the CLM System.
• Emergency Power Off – activating (pushing) the Emergency Power Off (EPO) positive-action
switch removes all power to the simulator except for critical systems (Emergency Lighting, Ramp,
Servers, Marque, etc.). The Motion System returns to the At-Rest position and the Ramp returns
to the down position. The Uninterruptible Power Supplies (UPS) will maintain Emergency
Lighting, Ramp circuits, CLM cabinet (8A1-8A2), equipment cabinet (9A1-9A2), and Marque
power for approximately 10 minutes, refer to simulator-specific drawings. The button must be
reset (turned clockwise) in order to bring power back to the simulator systems. Investigate and
correct the reason for the switch activation prior to bringing up simulator power.

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Prior to resetting an emergency pushbutton switch, investigate and correct the simulator conditions
initiating the switch activation.

Figure 1-5. Component Description – Emergency Switches

Refer to engineering drawings for locations of additional Emergency Switches in and around the
simulator.

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1.1.4.3. CLM System – Digital Motion System

The Digital Motion System (DMS) is present in Full Flight Simulators (FFS) and made up of the following
major DMS subsystems:

• Motion Base
• Motion Control Cabinet (MCC)
• Access Ramp Assembly and Control
• Simulator Motion Warning System
• Emergency Switches/Exits
Other components in the FFS DMS include the simulator exits (door and gate), the Motion Warning
System, and associated electrical components.
The following paragraphs describe these DMS subsystems and related components; not all components in
each subsystem exist on every simulator. These systems each contain distinct components contributing to
the operation and control of the DMS.

Figure 1-6. CLM System – Block Diagram

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This manual describes the operation and maintenance of the DMS subsystem components located
throughout the simulator area.

Simulator Balcony Mounted

Entrance/Exit Access Ramp
(4A1)

Motion Base
(3A2)

Motion System ClmPDU Cabinet

Cabinet (8A3) (8A1 and 8A2)

Figure 1-7. Component Description – DMS Components

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This section describes the components present in the major DMS subsystems:

• Motion Base (3A2)

• Accelerometer
• 36-inch / 60-inch configuration
• Actuators
• Electrical Actuator Components
• Motion Control Cabinet (MCC) – 8A3
• Programmable Logic Controller (PLC)
• Actuator Drives
• Motor Controllers
• Additional Internal Components
• Access Ramp Assembly (4A1)
• Ramp/Stairs Up/Down Switches
• Ramp/Stairs Actuator (4A2)
• Access Ramp Floor Mats
• Access Ramp Steps
• Porch
• Access Ramp Control Module (8A1A2)
• Manual Access Ramp Raise/Lower Control (9A9A3)
• Ramp/Motion Warning System
• Emergency Switches
• Emergency Stop (Formerly Motion Abort) – ESTOP and Interlock Switch
• Control Loading and Motion (CLM) System On/Off
• Emergency Power Off (EPO) Switch
• Exits
• Gate/Door
• Emergency Exits
• Kick-Out Panels
• Rope
See the table following for DMS component Reference Designators.

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Table 1-4. Reference Designators – DMS Components (Typical)

Component Reference Designator

Porch/Edge Mat Switch 4A1

Motion Warning Light Assembly 6A2A100

Motion Warning Light (Beacon) DS1

ClmPDU Cabinet 8A1

Ramp Control Module A2

Digital Servo Amplifier A1

Equipment Cabinet 9A2 – Mezzanine

CLM Server A4 or A5

Ramp Motion Warning System 9A15A4 – Marquee

Ramp Marquee
Training Marquee

Instructor Compartment Ramp Control Panel 9A9A3A1

Raise/Lower Switch (FS-1000)

4A1A2

Gate/Handrail Door 9A9A3

Ramp Control Module 8A1A2

Digital Servo Amplifier A1

+24Vdc Power Supply PS1

Emergency Lighting 9A13

Interior DS1, DS2, DS5, and DS6

Exterior DS9, DS10, and DS11
+24Vdc Power Supply PS1

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1.2. DMS – PRINCIPLES OF OPERATION

The Digital Motion System (DMS) simulates aircraft motion by converting electric energy to linear
actuator movement using a closed loop control system running on simulation software. The DMS uses the
following components from the Control Loading and Motion (CLM) subsystems; these components are
necessary to control and operate the CLM systems.

• CLM Server • Isolation Transformer

• CLM Cabinet • Access Ramp and Drive Control

• Digital Control Loading System • Motion Control Cabinet (MCC)
(DCLS) Input/Output (I/O)
• Motion Base (3A1) • Power Amps

The DMS simulates aircraft ground handling and in-flight movements, based on the inputs from the flight
controls and the simulation software resident in the CLM Server. The DMS software functions under the
Windows operating system running in the CLM Server.
The CLM Server controls the Motor Controllers and the Motion Actuators; the CLM Server interfaces to
the I/O systems of the MCC and the DCLS.
The DCLS I/O System in the Controls I/O Patch provides I/O interface to all Access Ramp and simulator
interlocks, emergency switches, and the On/Off/Clear functions at the Instructor Operating Station (IOS);
communicating status information to/from the CLM Server.
The Motion Base consists of six (6) actuators providing six (6) degrees of freedom (6DOF) directly driven
by 680-volt pulsed DC electric power from the motor controllers in the Motion Control Cabinet (MCC).
The CLM Server directly controls the motor controllers via the Ethernet interface.
The isolation transformer in the CLM Cabinet powers the Access Ramp, warning lights, Control Loading
systems, including the Secondary Motion, with power and control to the Motion Base drives/actuators via
the Motion Control Cabinet (MCC). Under control of the CLM Server, the Ramp Control Module in the
CLM Cabinet drives the Access Ramp.

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1.2.1. DMS – Block Diagram

There are two (2) types of interfaces in the Control Loading and Motion (CLM) System:

• Ethernet interface – Subsystem Servers

• EtherCAT interface – CLM Server to Actuator Drive Control Heads
Windows uses the Ethernet interface to communicate with the CLM Input/Output (I/O) System and the
other servers on the simulator Ethernet network, including the CLM Server.
For more information on the CLM Control System operation, refer to the CLM Control System Operation
and Maintenance Manual.

Figure 1-8. DMS – Interface

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1.3. DMS – PREPARATION FOR USE

Upon receiving the equipment, inspect immediately for evidence of damage during transit. If any damage
has occurred, contact FlightSafety or the respective vendor.

1.3.1. Preparation – Environmental Requirements

The environmental requirements for operating the DMS are 50 to 122°F (10 – 50°C) and 20% to 80%
relative humidity (non-condensing).

1.3.2. Preparation – Power and Utility Requirements

The Digital Motion System (DMS) receives power from the Control Loading and Motion (CLM) Power
Distribution Unit (PDU) Cabinet Isolation Transformer Module.
The table lists the power and utility requirements of the DMS.

Table 1-5. DMS Power Requirements

Component Power Requirement

Digital Motion System (DMS) Motion 480Vac, 50-60Hz, Three (3) Phase @ 160-182
Control Cabinet (MCC) Amps*
ClmPDU Cabinet 480Vac, 50-60Hz, Three (3) Phase @ 160Amps*

*The Facility Electrical Power wiring diagram, ####A00030E, lists the required simulator amperage.

1.3.3. Preparation – Handling

Refer to the Handling in the Introduction of this manual.

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1.3.4. Preparation – Configuration

This manual illustrates the configurations of various components. In all cases, use the replaced component
and engineering drawings as a guide to configuration of a replacement component.

1.3.4.1. Configuration – Preoperational

Ensure proper configurations when initially installing or relocating a simulator and prior to energizing the
DMS.

• Ensure proper configuration of all circuit boards.

• Ensure the circuit boards seat properly in their connectors.
• Check all connections for mechanical and electrical tightness.
• Close all access plates and doors.
• Ensure that the input voltage conforms to the system’s rated input voltage.
• Ensure that the input frequency conforms to the system’s rated input frequency.
• Ensure that all loads connected to the output are off.
• Ensure that all breakers and the battery disconnect are off.
• Make sure that there is no packaging, tools, or other foreign materials inside the unit.
• Ensure all cables on the DMS equipment connect correctly and supply the correct power to all
equipment and components.
• Ensure warning and safety devices are in appropriate locations and positions.
The following assemblies need initial configuration prior to installing in the system.

1.3.4.2. Configuration – CLM Server

Initial configurations of the Control Loading and Motion (CLM) Server components are in the CLM
Control System Operation and Maintenance Manual.

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1.3.4.3. Configuration – Actuator Drive Control Head

Prior to installation, verify the configuration of the Actuator Drive Control Heads. The following describes
the Control Head configuration.

• Ensure the ID1 and ID2 address switches on the front of each control head are in the proper
addressing position. The mini-rotary hex switches number 0 through F and are set according to the
location of the motor controller and control head.
Verify the Actuator Drive Control Head is set up with the correct operating parameters prior to use.
Contact FlightSafety Simulation Systems Engineering for control head setup and configuration
procedures, and refer to FSI engineering drawings.

Table 1-6. Actuator Drive Control Head Address Switch Settings

Drive ID2 ID1 Decimal Value

Location
A 2 1 33
B 2 2 34
C 2 3 35
D 2 4 36
E 2 5 37
F 2 6 38

Initial configurations of the DCLS components are in the CLM Digital Control Loading System Operation
and Maintenance Manual.
See the following figure.

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Address
Switches

Figure 1-9. Actuator Drive Control Head Address Switches – Typical

1.3.5. Preparation – Cable Connections

Typical Digital Motion System (DMS) cable connections are listed below with the origin of the cable and
its destination using Reference Designators and the name of the component where applicable. The
Reference Designators vary from simulator to simulator. Consult cable installation drawing ####ABF800
for simulator-specific cable destinations and Reference Designators.

See the table following.

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Table 1-7. Typical Motion Cable Connections

W Number From To Comments

W311 8A3P1 3A2A1P3A1 Actuator A
W312 3A2A1 B) 8A3-10X3-1 Drive A
W313 8A3-10T1P4 3A2A1P2A1 Actuator A
W314 8A3P2 3A2A2P3A1 Actuator B
W315 3A2A2 B) 8A3-13X1-1 Drive B
W316 8A3-13T1P4 3A2A2P2A1 Actuator B
W317 8A3P3 3A2A3P3A1 Actuator C
W318 3A2A3 B) 8A3-16X1-1 Drive C
W319 8A3-16T1P4 3A2A3P2A1 Actuator C
W320 8A3P4 3A2A4P3A1 Actuator D
W321 3A2A4 B) 8A3-19X2-1 Drive D
W322 8A3-19T1P4 3A2A4P2A1 Actuator D
W323 8A3P5 3A2A5P3A1 Actuator E
W324 3A2A5 B) 8A3-22X1-1 Drive E
W325 8A3-22T1P4 3A2A5P2A1 Actuator E
W326 8A3P6 3A2A6P3A1 Actuator F
W327 3A2A6 B) 8A3-25X1-1 Drive F
W328 8A3-25T1P4 3A2A6P2A1 Actuator F
W329 8A1A2P2 B) 4A1A2P1 Ramp/Stairs
W330 8A1A2P3 – Motion Inhibit
W332 8A1A2P11 4A2P1 Ramp/Stairs Actuator Drive
W333 8A1A2A2X1 4A2P2 Ramp/Stairs Actuator
Encoder
W334 9A2A5 Port 6 8A3P11 PLC EtherCAT
W335 9A2A5 Port 8 8A3P13 Drive EtherCAT
W336 9A2A2A1P2 8A1A2P6 Serial Adapter
W337 9A13A100P2 – Hatch Lockout

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1.3.6. Preparation – Checkout

The manufacturer performs initial installation, checkout, and integration of the DMS before delivery to
the customer facility. Simulator personnel will reinstall the simulator, integrate, and checkout the systems.

WARNING: Only qualified personnel are to work on the Motion System. Do not allow
occupants in or near the simulator while engaging the DMS for the first time after an installation
or commissioning.

WARNING: Ensure that no items around the system area will become loose and hit personnel.
Keep personnel out of Motion envelope at all times.

WARNING: Avoid major injury to personnel by keeping hands, fingers, elbows, and feet out of
harm’s way.

1.3.6.1. Check Out – Preoperational

Conduct these checks when initially installing or relocating the simulator. Refer to engineering drawings
and the Power Control System Operation and Maintenance Manual. Perform these check outs when
initially installing or relocating a simulator and prior to energizing the DMS.

• Ensure proper configuration of all circuit boards.

• Ensure the circuit boards seat properly in their connectors.
• Ensure the area in and around the components is clean; rid it of all extraneous material.
• Check all connections for mechanical and electrical tightness.
• Close all access plates and doors.
• Ensure that the input voltage conforms to the system’s rated input voltage.
• Ensure that the input frequency conforms to the system’s rated input frequency.
• Ensure that all loads connected to the output are off.
• Ensure that all breakers and the battery disconnect are off.
• Make sure that there is no packaging, tools, or other foreign materials inside the equipment
cabinets.
• Ensure all cables on the DMS equipment connect correctly and supply the correct power to all
equipment and components.
Refer to the CLM Control System Operation and Maintenance Manual.

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1.3.6.2. Check Out – DMS Components

Perform these check outs when initially installing or relocating a simulator and prior to energizing the
DMS.

• Handle electronic components/cards according to procedures in Handling in the Introduction of

this manual.
• Use the removal and replacement procedures in this manual, as necessary to verify that all
subsystems and components have the proper configurations.
• Install the components in the proper cabinet in accordance with the procedures in this manual.
• Ensure personnel are clear of the controls before engaging them.
Refer to engineering drawings.

1.3.6.3. Check Out – Settings

Check the following settings after completing the initial check out (pre-operational checks) and prior to
energizing the DMS.

• Ensure the Main Power circuit breakers to the equipment cabinets are in the correct/proper
position.
• Ensure all additional circuit-breaker settings are in the correct and proper positions.
• Ensure that all DMS components/cabinets settings are correct and current.
• Verify the software loads are correct and free of faults.
Refer to engineering drawings and the Control Loading and Motion (CLM) Control System Operation
and Maintenance Manual.

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1.4. DMS – OPERATION

The following paragraphs discuss the operation of the Digital Motion System (DMS).

1.4.1. Operation – Modes

Operating modes of the DMS are Normal and Maintenance. Select the mode with the Mode Key switch
on the front of the Motion Control Cabinet (MCC) or select from the Instructor Operating Station (IOS)
Debug Pages. The following paragraphs describe each mode of operation. It is important to follow all
instructions in order and to observe safety precautions at all times.

1.4.1.1. Operating Modes – Normal

The Normal mode of operation is for customer simulation and training. During the Normal mode of
operation, the DMS engages and disengages under control of the Instructor at the Instructor Operator
Station (IOS). Aircraft failure and weather-condition commands from the training instructor at the IOS
direct the DMS to react accordingly. The Control Loading and Motion (CLM) System monitors the DMS
for safe and correct operating parameters. The DMS shuts down power to the electric actuators if any part
of DMS operation exceeds safety parameters.

NOTICE: In normal operation, the DMS is powered up and engaged, with the Motion Base in
the Neutral (or Null) position. The MCC must be running before starting training load.

WARNING: Only qualified personnel are to work on the Motion System. Do not allow
occupants in or near the simulator while engaging the DMS for the first time after an installation
or commissioning.

WARNING: Ensure that no items around the system area will become loose and hit personnel.
Keep personnel out of Motion envelope at all times.

WARNING: Avoid major injury to personnel by keeping hands, fingers, elbows, and feet out of
harm’s way.

CAUTION: Prior to proceeding, refer to and follow the instructions in the vendor documentation
assembly and installation manual (CDS38799).

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Start Up/Shut Down Procedures are contained in Section 1 of the Control Loading and Motion Control
System Operation and Maintenance Manual.

1.4.1.1.1. Operation – Normal Engaging the DMS

To engage the Digital Motion System (DMS) after the Digital Control Loading System (DCLS) is engaged
and all personnel are seated with seat belts fastened.

WARNING: Do not engage the DMS until all personnel are seated with seat belts securly fastened.
Do not operate the DMS with anyone standing in the simulator.

At the Instructor Operating Station (IOS) Tactile Monitor:

1) Press the Motion System pushbutton to engage the Motion System.
2) Observe the Motion indicator flashes and that the Access Ramp Audible Alarm is heard for
15-20 seconds.
3) The motion base will move to the Neutral position after the Access Ramp is in the upright
position.
4) Observe the Motion System pushbutton illuminates steadily after the motion engage cycle is
complete.
5) The Motion System is now under control of the software load resident in the Control Loading
and Motion (CLM) Server.

NOTICE: Typically, upon reaching the neutral positions, the simulator is in the Flight Freeze
mode and the aircraft is positioned on an airport runway, ready for training.

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1.4.1.2. Operating Modes – Maintenance

The Maintenance mode of operation allows use of the Control Loading and Motion (CLM) Debug
Instructor Operating Station (IOS) pages for maintenance purposes; the maintenance technician controls
the Digital Motion System (DMS) using code sources such as a signal generator, manual inputs, or file
replay to operate the DMS manually. In the Maintenance mode, vendor simulation software and Host
commands are not active, but status feedback to the Host still operates.
In the Maintenance mode, bypassed failsafe protections create unsafe conditions for personnel and
equipment. It is important to follow instructions in order and observe safety precautions at all times. The
Software Utilities Manual (SUMAN) describes Control Loading and Motion (CLM) Debug IOS Pages
and their operation.

WARNING: Only qualified personnel trained on maintenance mode operation should attempt to
perform procedures in this mode.

WARNING: Components overridden in the maintenance mode can create unsafe conditions for
personnel and equipment.

WARNING: Ensure that all personnel are clear of the simulator, Motion Base, and out of the
cockpit prior to operating the Motion System in the maintenance mode.

WARNING: Use a meter or other appropriate testing device to ensure power removal from
equipment.

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1.4.1.2.1. Operation – Return to Home Failure

The following procedure describes Motion Upset Recovery; where a Motion Base Actuator fails to Return
to Home (RTH).

WARNING: In the event an actuator does not fully extend or retract, do not, under any
circumstances, put arms, legs, hands, feet, or other body parts between the Access Ramp and
simulator or in the way of any other moving parts while checking interlocks. An actuator may
move instantly when an interlock closes.

It is important to follow all instructions in order, observing safety precautions at all times.

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1.4.1.2.1.1. Return to Home Failure – Upset Recovery Procedure

Use this procedure to retract an actuator and recover the DMS when one or more actuator does not Return
to Home (RTH). This situation occurs when an Emergency Stop (formerly Motion Abort) occurs, and the
+12Vdc batteries in the Motion Control Cabinet (MCC) cabinet do not retain a charge. It is important to
follow all instructions in order and observe safety precautions at all times.
The following procedure describes a situation with the following conditions:

• One (1) or more Motion Actuators do not retract

• The Ramp/Stairs is up
• Control Loading and Motion (CLM) Power Distribution Unit (PDU) and MCC powered up
• CLM real-time simulation running
• The Host software running on the Simulation Control Server (SCS)

The figure illustrates an example of Actuator D (4) failing to retract:

Figure 1-10. Upset Motion Recovery – Failed Actuator Screen

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Perform the following Motion Upset Recovery procedure:

1) Press the Emergency Stop (ESTOP) button at the Motion Cabinet, wait five (5) seconds, and
reset the button to the out position.
2) Check the Motion Reset on Control Loading and Motion (CLM) Instructor Operation Station
(IOS) Debug pages. Reset if necessary:
a. Press Motion Reset button several times, until the button next to it changes to Motion
Standby (Run).
3) Press Motion Standby (Run) to engage the Motion Base.
4) Observe that the Motion Base repositions to level, and then retracts the actuators to home.
5) The Motion Reset button begins to flash; press Motion Reset several times until the Motion
Standby (Run) displays.
6) Perform a functional test on the Digital Motion System (DMS) as in Section 1.5.4.8 and
return to service when acceptable.
Evaluate the MCC cabinet and the RTH circuit to prevent a reoccurrence of a similar event. Any time a
Motion Base does not RTH during an Emergency Stop (ESTOP) or failed sequence, the RTH circuit
requires repair. Observe safety precautions at all times and Contact FlightSafety Simulation Operations
Support for assistance if this procedure does not correct the simulator condition.
7) Press the “Warns Errors” button, in the lower left corner of the CLM-IOS Page to display the
Error Log Page.

Figure 1-11. Upset Motion Recovery – Error Log

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8) Press the “M S\cut” button at the lower right side of the CLM-IOS Page.
9) The Motion Shortcut menu displays.

Figure 1-12. Upset Motion Recovery – M s\cut Button

10) Click the Maintenance Mode is OFF button. Maintenance Mode is ON displays.

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11) Click the Hostinterface Normal button. Hostinterface Maintenance Mode displays.

12) Click the “Computation Manager” button.

13) The Motion Computation Manager (MCM) index page displays.

14) Click on the Stop button.

Figure 1-13. Upset Motion Recovery – Motion Computation Manager Page

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15) Press the Motion Reset button until Motion Standby (Run) displays.
16) Press Motion Standby (Run) to engage the Motion Base.
17) Observe that the Motion Base repositions to level and then retracts any actuators that are not
currently at home. The Ramp/Stairs lowers itself.
18) Stop the Control Loading and Motion (CLM) Real Time simulation, power cycle the Motion
Control Cabinet, and restart the CLM Real Time simulation again.
19) Perform a functional test on the Digital Motion System (DMS) as in Section 1.5.4.8 and
return to service when acceptable.

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1.4.2. Operation – Shut Down

The following instructions power down the Control Loading and Motion (CLM) and the Digital Motion
System (DMS); and stop the Control Loading and Motion (CLM) software. Follow instructions in order
and observe safety precautions at all times.

1.4.2.1. Shut Down – IOS Normal Operation

The following procedures provide instructions to shut down the DMS from the Instructor Operating
Station (IOS) via Virtual Network Connection (VNC) or remote desktop. It is important to follow
instructions in order and observe safety precautions at all times.

WARNING: Ensure all personnel are clear of the Motion Base and the Access Ramp prior to de-
energizing the DMS.

WARNING: Do not remove seat belts or stand in the simulator until the intermittent Access
Ramp warning sound stops.

WARNING: Visually ensure that the Ramp/Stairs is in the proper position and there is indication
the Simulator Access Ramp is safe to use.

At the Instructor Station:

1) Press the Motion System pushbutton at the IOS.
2) Observe as the Motion System indicator flashes and that the Access Ramp alarm remains
audible for 15 to 20 seconds.
3) Continue to observe the Motion System indicator flashing, then, illuminating solid.
4) Personnel may exit the cockpit area and egress as necessary.

1.4.2.2. Shut Down – Stopping the Control Loading and Motion Software
Start Up / Shut Down Procedures are contained in the CLM Control System Operation and Maintenance
Manual.

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1.4.2.3. Shut Down – Power Down

Start Up / Shut Down Procedures are contained in Section 1 of the FS1000 Control Loading and Motion
Control System Operation and Maintenance Manual.

WARNING: Wait five (5) to 10 minutes before performing maintenance on the cabinet to allow
time for the 680Vdc capacitor charge to bleed off the motor controllers and the return to home
(RTH) amplifiers.

WARNING: Disconnect the batteries prior to performing maintenance on the battery circuits
because +48Vdc will remain on them. Orange wires in the MCC cabinet are connected to
batteries and are always live.

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1.4.2.4. Shut Down – Warnings and Failures

View operational status, warnings, and failures of the Digital Motion System (DMS) and Control Loading
and Motion (CLM) Control System on the console Error Page. Follow instructions in order, and observe
safety precautions at all times.

WARNING: Wait five (5) to 10 minutes before performing maintenance on the cabinet to allow
time for the 680Vdc capacitor charge to bleed off the motor controllers.

WARNING: Some parts of the Motion Control Cabinet (MCC) retain energy after turning off
the main AC power. Wait at least 10 minutes before performing any maintenance to the actuators.
Orange wires indicate parts of the cabinet that are battery powered and live. Use lock/tag out
procedures and Personal Protective Equipment (PPE) as appropriate and necessary while
performing maintenance activities. In addition to removing facility power from the cabinet,
ensure that Motion Base movement does not occur by opening the following circuit breakers in
the MCC prior to performing maintenance: 11F1, 14F1, 17F1, 20F1, 23F1, and 26F1.

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1.5. DMS – MAINTENANCE

The Digital Motion System (DMS) maintenance instructions and procedures in this section use historical
records identifying areas most likely requiring attention. The emphasis in this section is on preventive
maintenance. Overhaul instructions are not included unless overhaul is specifically the responsibility of
the site technician and not the vendor or depot. Historical data has proven that a regular preventive
maintenance program diminishes catastrophic breakdowns and simulator down time. This section presents
an effective preventive maintenance program. Unless otherwise stated, the procedures herein are
applicable to all configurations of the Control Loading and Motion (CLM)-based Digital Motion Systems.

1.5.1. DMS Maintenance – Test Equipment Required

In general, the beginning of the procedures list test equipment required to complete the respective
procedure. Model numbers and manufacturers are included for reference only.

Table 1-8. Test Equipment

DESCRIPTION PART NUMBER

Digital Multimeter Fluke Model 87V or Equivalent

1.5.2. DMS Maintenance – Materials Required

The table lists recommended materials required to perform procedures contained in this section. The
materials required for each procedure are listed at the beginning of each procedure.

Table 1-9. Materials

Paper Tags
Masking Tape
Lint-Free Cloth Rags
Anti-Seize Compound
Mild Soap and Water Solution
Safety Lock Wire (.032-in., Stainless Steel)
Cushion Oil – MIL-H-5606 or 83282 or equivalent
Actuator Oil – Mobil SHC630 or equivalent (Mobil SHC 632 or Shell Omala 220)

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1.5.3. DMS Maintenance – Tools Required

The table lists standard tools and special tools required to perform the procedures in this section. Part
numbers and manufacturers are included for reference only. The beginning of the procedure lists the tools
required.

Table 1-10. Standard and Special Tools

Electronics Technician Tool Kit
Mechanic Tool Kit – SAE and Metric
Hex Socket Set – SAE and Metric
Upper Clevis Holding Toll (36-in. or 60 in.)
30-2000 in-lb Torque Wrench
10-150 ft-lb Torque Wrench
100-600 ft-lb Torque Wrench
7/8-in. Torque Adapter (1/2-in. drive) FSI Modified
15/16-in. Torque Adapter (1/2-in. drive)
24mm Hex Socket (6pt. ½-in. drive)
36mm Hex Socket (6pt. 3/4-in. drive)
1-in. Hex Socket (3/4-in. drive) and 1-in. L Wrench to mate with socket
1-in. to ¾-in. Ratchet Adapter
Wrench, Box End, 1 7/16-in. Socket to ¾-in. Drive – (Expansion Floor Anchors)
Wrench, Box End, 1 5/8-in. Socket to ¾-in. Drive – (Glue In Floor Anchors)
18: Auto (Ford) Wrench
4 each Aircraft Jacks, 10 Ton, 2 Extension – 1036-10E2-(60-in. Base)
4 each Aircraft Jacks, 10 Ton, 1 Extension – 1036-10E1 – (36-in. Base)
Small Forklift
Dead-Blow Hammer (2 lb)
Slide Hammer Assembly – FSI P/N
Bearing Removal Tool – FSI Tool – BRG 60-in. – (60-in. Base)
Bearing Removal Tool – FSI Tool – BRG 36-in. – (36-in. Base)
Bearing Press Tool – (60-in. Base)
Bearing Press Tool – (36-in. Base)
Nylon Dowel (1-in. Diameter x 8-in.)
Bronze Tapered Punch (8-in.)
Safety Lock Wire Pliers, Reversible
Nylon Web Slings (Eye and Eye, 2-in. x 32-in.)
Rubber to Wrap Web Slings
Cheater Pipe
Vacuum Cleaner
8 x 12 x 24-in. Wood Blocks
Oil Drain Pan
Small Funnel

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1.5.4. DMS Maintenance – Cleaning and Inspections Schedule

Devise a maintenance schedule that reflects the specific conditions and needs of simulator and the training
site. Developing and complying with a preventive maintenance schedule addressing the DMS is key to
identifying small problems before they become major repair issues.
Many times, preventive maintenance locates marginally-operational subassembly components, allowing
the maintenance technician the opportunity to replace the faulty component/assembly before it causes a
loss of training.
Inspect and clean the DMS on a regular basis, the more frequent the better. A good time to perform an
inspection is while cleaning. An inspection provides an opportunity to spot small problems before they
become major repairs. Conduct periodic inspections in an orderly manner. Follow circuits from beginning
to end, noting the conditions of all components as necessary. Begin at one end of a circuit/device and
proceed to the other end. Pay particular attention to components prone to failure or recently
repaired/replaced.

WARNING: Some parts of the Motion Control Cabinet (MCC) retain energy after turning off
the main AC power. Wait at least 10 minutes before performing any maintenance to the actuators.
Orange wires indicate parts of the cabinet that are battery powered and live. Use lock/tag out
procedures and Personal Protective Equipment (PPE) as appropriate and necessary while
performing maintenance activities. In addition to removing facility power from the cabinet,
ensure that Motion Base movement does not occur by opening the following circuit breakers in
the MCC prior to performing maintenance: 11F1, 14F1, 17F1, 20F1, 23F1, and 26F1.

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1.5.4.1. Cleaning – Daily

Keep components and subassemblies as clean as possible; refer to vendor documentation and engineering
drawings as necessary.

WARNING: Observe safety precautions, do not use flammable materials unless specified; and
handle with care.

WARNING: Observe all product and maintenance safety precautions.

WARNING: Be alert for electrical hazards as high voltage is present in many areas. Learn where
and ensure all electrical power is removed before cleaning.

NOTICE: Do not damage anything. Be especially careful around delicate components,

connections, and wires.

NOTICE: Use the proper cleaning materials such as a lint-free cloth wipes and non-abrasive
cleaners.

NOTICE: DO NOT use compressed air; in many cases, compressed air contains moisture, dust
particles and oil, which could be harmful to the hardware. In addition, compressed air just blows
material from one area to another, not cleaning anything in the process.

• Use a vacuum cleaner for cleaning

Clean on a regular basis and as needed, preferably while performing inspections.

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1.5.4.2. Cleaning – Weekly

Clean up spills or debris that may cause obstructions or clutter in the Digital Motion System (DMS)
operating area.

• Visually inspect all Motion Control Cabinet (MCC) air filters and cooling fans for cleanliness,
clean if necessary in accordance with the procedures in Section 3.5.2.
• Check Motion Base Actuator electrical cables for excessive wear and fraying.
Clean on a regular basis and as needed, especially before and after inspections.

1.5.4.3. Cleaning – Monthly

Perform cleaning maintenance on a regular basis, preferably while inspecting the DMS.

• Clean the MCC cooling fans and air filters in accordance with Section 3.5.2.
• Clean the MCC motor controller cooling fans according to Section 3.5.2.
Refer to component and subassembly vendor documentation as needed.

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1.5.4.4. Inspections – Daily

Perform the following pre-operational inspections/checks prior to energizing the Digital Motion System
(DMS).

• Check for signs of burning and overheating.

• Check wiring for damage or loose connections.
• Check Motion Control Cabinet (MCC) cooling fans are operational.
• Check the Motion Base motor controller cooling fans are operational.
• Check for oil leaks in and around the Motion Base.
Note the overall condition and appearance of the DMS. Look for obvious changes in condition or
developments from the previous day/shift.

1.5.4.4.1. Daily – Handles and Latches

Visually inspect and observe DMS operation from a safe distance (outside of the simulator Motion
envelope) and when the DMS is in a safe condition, such as in the Home or At-Rest position/condition.

• Ensure that equipment cabinet doors close and latch.

• Ensure the main circuit breaker handle is in the proper position.
• Ensure the Control Loading and Emergency Stop (Formerly Motion Abort) switches operate push
in / turned clockwise out.
• DC Bus On light extinguishes.
• Control Loading and Motion (CLM) Emergency Stop (ESTOP) lights operate.
• Control Loading and Emergency Stop (Formerly Motion Abort) Acceptable light illuminates on
the MCC.
Note the condition and operation of DMS components as used on a daily basis, looking for obvious or
abnormal conditions/developments.

1.5.4.4.2. Daily – Obstacles/Obstructions

Observe the placement and location of personal/outside articles brought into the simulation area.

• Check that no obstacles or obstructions exist to impair simulator motion

• Inspect for articles or obstructions accumulating in or around the simulator entrance/Ramp/Stairs
area
Clear the area around the simulator to keep outside personal items or obstructions at a safe distance.
Perform an operational check of the DMS in accordance with Section 1.5.4.8.

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1.5.4.5. Inspections – Weekly

Perform inspections on a regular basis or as needed, preferably immediately before/after cleaning.

• Inspect all Motion Control Cabinet (MCC) air filters and cooling fans for cleanliness, clean if
necessary in accordance with the procedures in Section 3.5.2.
• Check Motion Base Actuator electrical cables for excessive wear and fraying.
Refer to engineering drawings as needed.

1.5.4.6. Inspections – Monthly

Schedule to perform maintenance-related inspections and replacement of Digital Motion System (DMS)
components each month, preferably during off-peak business hours.

• Inspect all actuator cables and MCC cables in accordance with the procedures in Section 2.5.2.2.2.
• Inspect the Motion Base bearings in accordance with the procedures in the vendor documentation.
• Perform the mounting bolts (Motion Base floor pad) torque check according to vendor
documentation.
• Inspect safety lock wire for distortion and breakage in accordance with vendor documentation.
• Inspect the performance and operation of the mat and gate switches.
• Inspect the operation of the DMS system components and Emergency Stop buttons/circuits by
safely cycling the power down and then back up.
Refer to engineering drawings and vendor documentation as needed.

1.5.4.7. Inspections – Annual and as Needed

Schedule to perform annual maintenance-related inspections and replacements during off-peak business
hours.

• Inspect the condition of and check for proper operation of the emergency Egress Rope and
simulator entrance/exit related items such as wear and tear of the gate, door lock, mats, rails, etc.
• Replace oil in the actuators in accordance with vendor documentation.
• Inspect DMS-related UPS backup batteries such as Emergency Lighting batteries, Ramp/Stairs
Control Unit, MCC in accordance with vendor documentation.
Schedule required maintenance-related replacement of DMS components and sub-assemblies according
to vendor documentation.

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1.5.4.8. Inspections – DMS Operational Check

Perform the following procedure to verify proper operation of the Digital Motion System (DMS).

WARNING: Ensure that all personnel are clear from the cockpit controls before pressing the
Control Loading pushbutton. The control columns move into flight-neutral position when this
button is pressed.

1) At the IOS, sequence on the Digital Control Loading System (DCLS).

2) Verify the DCLS sequences on with no warnings or failures.

WARNING: Consistently close and latch the simulator door. Ensure that all personnel are seated
with seat belts fastened before engaging the DMS.

3) At the Instructor Operating Station (IOS), sequence on the Digital Motion System.
4) Verify the DMS sequences on with no warnings or failures.
5) Run the associated simulator Pre-Flight/Pre-Training procedures. Ensure the DMS operates
normally without any un-commanded roughness or jerks.
Upon successful completion of verifying proper DMS operation, the simulator is ready for training.

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1.5.5. DMS Maintenance – Troubleshooting

The following paragraphs provide the technicians with the available troubleshooting aids for diagnosing
problems in the Digital Motion System (DMS) and associated power components.
Refer to vendor documentation for commercial-off-the-shelf (COTS) specific troubleshooting procedures.

1.5.5.1. Troubleshooting – DMS

Once a failure has occurred, follow the following guidelines to locate the faulty assembly/component:

• Identify all Motion System components that are not working

• Identify the commonality between the Motion System components that are not working
• Verify that the applicable serial data buses are transferring data
• Check for fault indications on the motor controller drives and the PLC components
• Check the DMS error log
• Check the Control Loading and Motion (CLM) System fail log
Refer to the Control System Operation and Maintenance Manual. Refer to vendor documentation for
COTS specific troubleshooting procedures.

1.5.5.2. Troubleshooting – Aids

Troubleshooting aids exist in certain vendor-supplied DMS component documentation. Follow DMS
troubleshooting aids to the component-specific level, and then refer to vendor troubleshooting aid as
applied to the DMS.

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1.5.6. DMS Maintenance – Removal and Replacement

Removing and replacing Digital Motion System (DMS) components are discussed in the respective
subsystem section of this manual. Verify the DMS is powered down and in a safe mechanical position
before following procedures to remove and replace components of the DMS. The electric DMS assemblies
covered in this manual include the following:

Motion Base

• Electric Motion Actuator Assembly

• Motion Actuator Setup

• Clevises

• Trunnion bearings

• At-Rest (Home) Switch

• Actuator Cushion Oil Port Fill Valve

• Secondary Thermistor Connection

• Actuator Cushion Oil Filling

• Actuator Oil

• Motion Control Cabinet

o Motor Controller Control Head
o Motor Controller Driver
o Contactors

• Access Ramp
o Mats
o Ramp/Stairs Position Switches
o Down Switch
o Up Position Switch
o Actuator Ramp/Stairs Assembly
o Actuator
o Emergency Switches and Exits

Although there may exist an alternate method to perform each procedure, follow procedures in order to
provide safety to personnel and avoid damage to equipment.

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1.5.7. DMS Maintenance – Storage

The following guidelines apply to the Motion Control Cabinet (MCC), Motion Base, and any components
ordered as spares.

• Keep Motion Base components in a clean, dry area of moderate temperature.

• Cover with a suitable canvas or heavy plastic cover to prevent entrance of foreign material.
• If the equipment is stored in a cool damp area, completely cover the equipment and use heat to
prevent condensation on the equipment.
Make adequate arrangements and take precautions for any components that may require long-term storage.
Consult the training facility management for specific details.

1.6. DMS – ENGINEERING DRAWINGS

The following is a list of electrical schematics and mechanical drawings useful for troubleshooting. This
section references top-level schematics, wire lists, and mechanical drawings available and applicable to
this manual.
A complete drawing package ships with the simulator and is available on the DVD with this manual.
(Note: #### references the simulator job number.)

DRAWING NO. TITLE

####A00030 Facility Electrical Installation

####A00030E Facility Electrical Wiring Diagram
####ABF411 Electric Motion System Diagram
####ABF800 Motion Cable Installation
60003ABF050 Motion Base Assembly, 6DOF 60 In Stroke, Electric
60003ABF051 Motion Base Assembly, 6DOF 36 In Stroke, Electric
60001ABF927 Concrete Sleeve Anchor bolts (Bolt head)
60001ABF928 Concrete Epoxy Anchor Rod installations (Bolt stud with nut)

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1.7. DMS – LIST OF RELATED PUBLICATIONS

The following list of manuals reference vendor information related to Digital Motion System (DMS)
equipment. The COTS folder on the DVD includes copies of those manuals to which FlightSafety has
reproduction rights. If available, manuals without reproduction rights ship with the equipment.

COMPONENT MANUAL NAME VENDOR

Power Control System FS1000 PCS Operational and FlightSafety International

Maintenance Manual
CLM Control System FS1000 CLM Control FlightSafety International
Operational and Maintenance
Manual
Digital Control Loading System FS1000 DCLS Operational and FlightSafety International
Maintenance Manual
Digital Servo Amplifier Instruction Manual for Kollmorgen
ServoStar 300 Servo Amplifier
Electric Digital Motion System FSI Motion System User MOOG
(DMS), Manual Electric Motion Systems
Motion Control Cabinet (MCC) CDS38799 Rev C 2013
-127-338,
Actuators – 36″and 60″880-078
/ 079

Portable Electric Actuator Drive Operation Manual for EM MOOG

Actuator Portable Drive MOOG
P/N CA39178-001

Portable Electric Actuator Drive Operation Manual for EM MOOG

Actuator Portable Drive MOOG
P/N CB61301-001

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SECTION 2. MOTION BASE

This section discusses the Motion Base component of the Digital Motion System (DMS). The Motion
Base consists of six (6) electric servo-loop actuators converting electrical power into physical motion to
simulate the feel of an aircraft. The Motion Base has two (2) configurations, both configurations on
FlightSafety International (FSI) Full Flight Simulators (FFS) have the same function and purpose, the
major difference between the 36-inch and 60-inch configurations is the size, weight, and orientation of the
Motion Base Actuators.

2.1. MOTION BASE – DESCRIPTION

The DMS contains the following Motion Base components:

• Motion Base (3A2)

• Configurations: 36-inch / 60-inch
• Actuators
• Electrical Actuator Components
• Accelerometer
The following paragraphs describe the Motion Base components in the DMS.

• 36-inch Motion Base – has a 10–bolt interface at the base end and a single bolt interface at the rod
end.
• 60-inch Motion Base – has a four – (4-) bolt interface at the base end and a single bolt interface at
the rod end.
This manual focuses primarily on the operation and maintenance of the 60-inch configuration, but
identifies some differences between the configurations.

2.1.1. Description – 60″ Base

In the 60″ Motion Base Assembly, the bottom (motor end) of each actuator at the front of the simulator
(actuators one (1) and six (6)) meet and share the pad mounted on the floor. The top (rod end) of Motion
Base Actuators at the aft end of the simulator frame (actuators three (3) and four (4)) meet at the aft end
of the simulator and share the pad mounted to the bottom of the simulator frame.
See the following figure.

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Figure 2-1. Component Description – 60-inch Electric Motion Base

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2.1.2. Description – 36″ Base

In the 36" Motion Base Assembly, the top (rod end) of each actuator at the front of the simulator (actuators
one (1) and six (6)) meet and share the pad mounted to the front-bottom of the simulator frame. The bottom
(motor end) of the actuators at the aft end of the simulator frame (actuators three (3) and four (4)) meet at
the aft end of the simulator and share the pad on the floor.

NOTICE: Both the 36" and 60" Motion Base configurations have the actuators positioned with
the motor (bottom) end of the actuators mounted to the floor pads, and the top (rod) end of the
actuators mounted to the pads mounted under the simulator frame.

NOTICE: When viewed from the top, both the 36" and 60" Motion Base configurations have
the actuators numbered in the clockwise direction, actuator #1 is located immediately to the right
of the front (fwd) end of the simulator frame.

See the following figure.

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Figure 2-2. Component Description – 36-inch Electric Motion Base

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2.1.3. Description – Accelerometer (3A10)

The Motion Base uses an accelerometer for calibrated acceleration within the 6 Degrees of Freedom
(DOF) of the Motion Base The accelerometer mounts onto the underside of the Full Flight Simulator
(FFS) frame, usually directly beneath the pilot, to measure accelerations in pitch, roll, and heave. The
accelerometer signal simulates flying conditions to test/synchronize the Motion Base with visual cues in
preparation for simulator certification.

Figure 2-3. Component Description – Accelerometer

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2.1.4. Description – Electric Actuators

A Motion Base is constructed with six (6) electric actuators; each actuator has a brushless DC electric
servomotor directly driving an internal ballscrew shaft, providing linear movement at the rod end of the
actuator.
Each actuator contains the following:

• Home Switch – signals that the actuator is in the fully-retracted (home) position.
• Position Encoder – bidirectional interface encoder.
• Cushion/Snubber – protects the actuator at the retract/extend end of stroke.
• Motor Oil Fill/Drain Plug – for performing motor oil changes.
• Motor Thermistors – provides over-temperature protection for actuator motor.
The cushion/snubber protects each actuator end-of-travel, the home switch of each actuator must fully
retract (home) to activate, enabling the Access Ramp to operate. Refer to vendor documentation for
detailed information on actuator size and associated components.
See the following figures.

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2.1.4.1. Electric Actuators – 36-Inch Components

Encoder Motor Oil Home Switch

Connector Drain Plug Connection

Motor Oil Hydraulic

Encoder Ball Nut Cushion
Fill Port
Piston

Home
Switch

Figure 2-4. Component Description – Electric Actuator – 36″

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2.1.4.2. Electric Actuators – 60– Inch Components

Encoder Stator and Home

Connector Rotor Switch

Encoder

Motor Oil Motor Oil Extension

Drain Plug Fill Port Tube

Hydraulic
Cushion
Pistons

Extension
Tube

Figure 2-5. Component Description – Electric Actuator – 60″

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2.1.4.3. Electric Actuators – Home Switch

The Home Switch is a threaded proximity switch mounted on the actuator; location varies with the actuator
size:

• On a 36-inch actuator – the home switch is on the hydraulic cushion end of the actuator.
• On a 60-inch actuator – the home switch is on the motor end.
The +24Vdc home switch signals to the Programmable Logic Controller (PLC) that the actuator is in the
fully retracted (home) position.

Figure 2-6. Component Description – Home Switch

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2.1.4.4. Electric Actuators – Position Encoder

The Endat 2.2 digital Position Encoder is a digital, bidirectional, four– (4) wire encoder providing accurate
actuator position information by using a serial data interface. The serial data interface allows mode
commands to provide position, parameter, and diagnostic information with the ability to transmit/store
information and updates.

Figure 2-7. Component Description – Position Encoder and Connection

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2.1.4.5. Electric Actuators – Hydraulic Cushion Assembly

The Hydraulic Cushion, also referred to as a snubber, is oil-filled and spring loaded; located and housed
at the top (rod) end of the actuator, the cushion protects both ends of the actuator end-of-travel stroke.
The dual-acting hydraulic cushion assembly provides the following actuator protection:

• 36-inch – assembly extends to two (2)″ from end of stroke.

• 60-inch – assembly extends to three (3)″ from end of stroke.
The cushion safely dissipates kinetic energy of the simulator weight and safely limits acceleration to
Motion System occupants during worst-case failure modes. Refer to vendor documentation.

Figure 2-8. Component Description – Cushion/Snubber

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2.1.4.6. Electric Actuators – Motor Oil Fill/Drain Plug

The motor oil fill/drain plugs provide a means to replacing actuator oil according to maintenance
requirements, typically every year or 8760 hours. Refer to vendor documentation.

Figure 2-9. Component Description – Oil Fill/Drain Plugs

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2.1.4.7. Electric Actuators – Motor Thermistors

The actuator motor is protected by two (2) thermistors each measuring approximately 210KΩ – 290KΩ
(242KΩ typical) between pins seven (7) and eight (8) of the encoder connector at the bottom end of the
motor. The thermistors sense the temperature of the actuator motor in the cooling oil. One (1) active and
one (1) spare thermistor are inside the windings of the motor in the oil reservoir, sending temperature
information to the PLC and causing a fault condition shutdown if the temperature reaches +150° C or
higher.
The thermistor connections are accessible through the encoder connector at the end of the motor. Replace
the primary thermistor (black wires) with the secondary thermistor (white wires in shrink tubing)
connections using vendor-supplied insertion/removal tools if/when necessary.

Figure 2-10. Component Description – Thermistors

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2.2. MOTION BASE – PRINCIPLES OF OPERATION

The Motion Base assembly consists of six (6) actuators in a Gough/Stewart Platform (Hexapod)
configuration directly driven by the Motion Control Cabinet (MCC) to provide the following 6 Degrees
of Freedom (DOF) necessary in simulating aircraft motion:

• Roll – rotation of an aircraft about its longitudinal axis

• Pitch – rotation of an aircraft about an axis perpendicular to the longitudinal plane of symmetry,
positive nose up
• Yaw – rotation of an aircraft about the vertical body axis, positive with the nose to starboard
• Heave – up and down movement of an aircraft
• Longitude – forward and backward movement of an aircraft
• Lateral – left and right movement of an aircraft
The Motion Base simulates aircraft ground-handling and in-flight G-forces. The inputs from the flight
controls and simulation software resident in the Host Computer/Control Loading and Motion Server
command these movements. The Digital Motion System (DMS) software currently runs on a Windows
operating system.
The Motion Base consists of actuators and associated components to translate the cockpit flight-control
movements into physical movement. These combinations of the 6DOF motion simulate the aircraft within
the guidelines established by the Federal Aviation Administration (FAA) and other flight-certification
authorities.

Figure 2-11. Block Diagram – Digital Motion System

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2.3. MOTION BASE – PREPARATION FOR USE

Perform the following inspections and checks prior to applying power to the Motion Base system.

WARNING: Ensure that all personnel are clear from the Motion Base and the Access Ramp prior
to energizing the Digital Motion System (DMS).

2.3.1. Inspections – Motion Base – Initial Checks

Perform the following checks prior to using the Motion Base.

• Perform daily Motion Base inspections as applicable to the DMS maintenance schedule in Section
1.5.4.4.
• Perform additional site-specific inspections/checks as deemed necessary, such as a walk around
the simulation area to ensure safety and functional compliance.
Refer to the pre-flight checklist or related documentation as required.

2.4. MOTION BASE – OPERATION

The Motion Base operates on a closed-loop system to position each actuator with a 680Vdc, three (3)-
phase, pulsed DC electrical power signal from the respective Actuator Drive. The signal amplitude and
polarity determine the actuator direction and velocity.
As the actuator extends/retracts, the position encoder sends an actuator-position feedback signal to the
Control Loading and Motion (CLM) Server. The CLM Server uses the position feedback signal to resolve
the commanded position of the actuator and decreases actuator velocity as it approaches the commanded
position.

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2.4.1. Operation – Motion Base Interface

There are three (3) types of interfaces in the Control Loading and Motion (CLM) System:

• Ethernet interface – high speed (Gigabit/sec) data transmission

• EtherCAT interface – Ethernet-based fieldbus for Control Automation Technology (CAT)
• RS232-422 interface – serial data transmission for Ramp/Stairs actuator control
The DMS uses the Ethernet interface to communicate with the Controls Input/Output System and other
computers on the simulator Ethernet network, including the CLM Server.
The EtherCAT interface is used to send/receive signals Control Head operation/communication.
The RS232-422 interfaces the Ramp/Stairs actuator to the Ramp Control Panel.

2.4.2. Operation – Servo Loop

The servo loops controlling the Motion Base are identical, therefore, the following discussion pertains to
all six (6) servo loops. Upon receiving commands and data from the Host Computer, the CLM Server
generates a digital drive signal to the appropriate Motion drive controller of the corresponding actuator.
The digital drive signal has both a polarity (+ or -) and an amplitude; the polarity of the signal determines
which direction of the actuator movement (extend or retract), and the amplitude of the signal determines
the speed of the actuator (velocity).

Figure 2-12. Block Diagram – Motion Base Servo Loop

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2.5. MOTION BASE – MAINTENANCE

While performing maintenance, pay particular attention to components that are prone to failure or recently
repaired/replaced. Set up a scheduled maintenance program after installing or relocating a Motion Base
and prior to energizing the Digital Motion System (DMS). Clean components and subassemblies safely
and according to vendor documentation, refer to engineering drawings as needed.

WARNING: Some parts of the Motion Control Cabinet (MCC) retain energy after turning off
the main AC power. Wait at least 10 minutes before performing any maintenance to the actuators.
Orange wires indicate parts of the cabinet that are battery powered and live. Use lock/tag out
procedures and Personal Protective Equipment (PPE) as appropriate and necessary while
performing maintenance activities. In addition to removing facility power from the cabinet,
ensure that Motion System movement does not occur by opening the following circuit breakers
in the Motion Control Cabinet prior to performing maintenance: 11F1, 14F1, 17F1, 20F1, 23F1,
and 26F1.

WARNING: Disconnect all incoming power to the Motion Control Cabinet prior to cleaning.
After power is disconnected, use a meter or other appropriate testing device to ensure power
removal from the equipment.

WARNING: Wait at least 10 minutes before performing maintenance on the Motion Control
Cabinet to allow time for the 680Vdc capacitor charge to bleed off the motor controllers and the
Return to Home amplifiers.

WARNING: Orange wires indicate parts of the cabinet that are battery powered and live. Use
lock/tag out procedures and Personal Protective Equipment (PPE) as appropriate and necessary
while performing maintenance activities.

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2.5.1. Motion Base Maintenance – Cleaning

Cleaning provides an opportunity to spot small problems before they become major repairs. Inspect the
systems in an orderly manner while performing regularly scheduled cleaning; following electrical circuits
from beginning to end. Note the conditions of all components, paying particular attention to components
that are prone to failure and needing repair or replacement. Have the necessary materials available to clean
the Motion Base.

Table 2-1. Motion Base Cleaning Materials

• Isopropyl • Spray on general • Spitfire general purpose • Lint-free

alcohol purpose cleaner cleaner or equivalent wipes

Refer to vendor documentation for specific materials or substitutes.

WARNING: Disconnect all incoming power to the Motion Control Cabinet prior to cleaning.
After power is disconnected, use a meter or other appropriate testing device to insure power
removal from the equipment.

WARNING: In addition to removing facility power from the cabinet, ensure that Motion System
movement does not occur by opening the following circuit breakers in the Motion Control
Cabinet prior to performing maintenance: 11F1, 14F1, 17F1, 20F1, 23F1, and 26F1.

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2.5.1.1. Cleaning – Daily

Clean the Motion Base on a regular daily basis and prior to energizing the Digital Motion System (DMS).

• Perform the cleaning schedule in Section 1.5.4.1 as applicable to the Motion Base.
• Ensure the Access Ramp is clear of personnel and the gate is closed.
Perform site-specific cleaning as necessary to complete pre-flight requirements.

2.5.1.2. Cleaning – Weekly

Clean every week or 168 hours of operation.

• Wipe down (as necessary) indicators and switches, verifying operation of indicators.
• Clear the Motion Base area of any items or obstructions such as tools, parts, or shipping boxes that
may have accumulated or inadvertently left on or near the Motion Base.
Address discrepancies that may impair optimum Motion Base cleanliness/operation.

2.5.1.3. Cleaning – Monthly

Every month or 720 hours of operation, ensure the Motion Base cannot move or power on while cleaning.

• Wipe the hydraulic cushion area, check for weepage of oil between mating parts and actuator seals.
• Wipe the motor assembly area, check for weepage of oil between motor parts and seals.
Visibly inspect the Motion Base area for any signs of spills or contamination from other simulator systems
near or above the Motion Base.

2.5.1.4. Cleaning – Annually/As Needed

Clean every 6000 hours – 8760 hours or as needed annually when a safe opportunity presents itself.

• Clean the Motion Base area where oil may spill while changing the motor oil in accordance to
vendor documentation.
• Clean areas of the Motion Base accessible whenever performing inspections, installing new parts,
or topping off the hydraulic cushion oil supply.
Refer to vendor documentation for vendor oil-changing information.

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2.5.2. Motion Base Maintenance – Inspections

When performing scheduled maintenance, use the opportunity to perform both cleaning and inspections
simultaneously, perform site-specific cleaning/inspections as necessary to complete pre-flight
requirements.

2.5.2.1. Inspections – Daily/Weekly

Daily and weekly Motion Base inspections may overlap, depending on actual hours of operation.

• Daily and weekly inspections consist mostly of visual checks and ensuring cables are secure and
damage free.
• Inspect the Motion Base as applicable to the Digital Motion System maintenance schedule in
Section 1.5.4.
Perform inspections as the opportunity exists, while cleaning.

2.5.2.2. Inspections – Monthly

Every month or 720 hours of operation, perform the inspections in the following paragraphs. Ensure the
Motion Base cannot move while safely performing the inspections.

WARNING: Disconnect all incoming power to the Motion Control Cabinet prior to inspecting.
After power is disconnected, use a meter or other appropriate testing device to insure power
removal from the equipment.

WARNING: In addition to removing facility power from the cabinet, ensure that Motion System
movement does not occur by opening the following circuit breakers in the Motion Control
Cabinet prior to performing maintenance: 11F1, 14F1, 17F1, 20F1, 23F1, and 26F1.

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2.5.2.2.1. Monthly Inspections – Load Path Component

Every month or 720 hours, conduct a Load Path Component Safety Inspection to include load-bearing
components on the actuators and joint assemblies.
Check the following areas for signs of flaking, rust, peeling, or deformation:

• Cover Tube and Retainer • Motor and Bearing Housings

• Tie Rods and Nuts • End Plate

Cover Tube Cover Tube Tie Rod Bearing Motor

Retainer with Nut(s) Housing Housing
Screws
Tie Rod

End Plate

Figure 2-13. Inspections – Actuator Load Path

Refer to vendor documentation as necessary.

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2.5.2.2.2. Monthly Inspections – Electrical Cables Inspection

One of the most common maintenance problems with movable equipment is fraying and wearing of cables.
The design and layout of the simulator minimizes cable wear as much as possible. However, with as much
movement as the cables experience, fraying and wear of the cables still happens. Perform inspections on
a regular basis and immediately before and after cleaning.
1) Remove power to the Motion Control Cabinet (MCC) as necessary when performing cable
inspections/repair.

WARNING: Disconnect all incoming power to the Motion Control Cabinet prior to inspecting.
After power is disconnected, use a meter or other appropriate testing device to insure power
removal from the equipment.

WARNING: Orange wires indicate parts of the cabinet that are battery powered and live. Use
lock/tag out procedures and Personal Protective Equipment (PPE) as appropriate and necessary
while performing maintenance activities.

WARNING: In addition to removing facility power from the cabinet, ensure that Motion System
movement does not occur by opening the following circuit breakers in the Motion Control
Cabinet prior to performing maintenance: 11F1, 14F1, 17F1, 20F1, 23F1, and 26F1.

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2) Inspect all cables associated with the Motion System actuators, looking for frayed or worn
edges at the connectors and any sign of cables stress due to the movement of the simulator.
During the inspection, pay close attention to stretched or pinched cables. Make sure all
actuator-power cable bundles separate from the signal cable bundles by a minimum of 12".
Where the signal cable bundles must cross the power cables, make sure they cross at a 90-
degree angle to prevent signal cable noise from degrading the operation of the DMS.
3) Inspect all other Motion cables, looking for damage, frayed spots, and broken connectors.

Actuator Signal Cables Actuator Power Cables

Figure 2-14. Inspections – Actuator Cable Inspection – Typical

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2.5.2.2.3. Monthly Inspections – Motion Base Bearings

Inspect the Motion Base bearings once every month.

• The 48 Motion Base bearings are located in the upper and lower trunnions.
• Remove power to the Motion Control Cabinet as necessary when inspecting Motion bearing
inspections/repair.

WARNING: Disconnect all incoming power to the Motion Control Cabinet prior to inspecting.
After power is disconnected, use a meter or other appropriate testing device to insure power
removal from the equipment.

WARNING: Orange wires indicate parts of the cabinet that are battery powered and live. Use
lock/tag out procedures and Personal Protective Equipment (PPE) as appropriate and necessary
while performing maintenance activities.

WARNING: In addition to removing facility power from the cabinet, ensure that Motion System
movement does not occur by opening the following circuit breakers in the Motion Control
Cabinet prior to performing maintenance: 11F1, 14F1, 17F1, 20F1, 23F1, and 26F1.

The bearings are machined bushings with a Teflon coating on the weight bearing surfaces. Inspect the
areas around bearing installations for Teflon flaking or cold flow. Cold flow is a paper looking protrusion
sticking out of the bearing. Some Teflon dust (brown/tan powder) is normal and expected; however,
flaking or cold flow of the Teflon bearing surfaces indicates required replacement of the bearings.
In addition, excessively worn bearings have a backlash (excessive tolerance or space) between the
bearings and the clevis/casting pins. The backlash feels like a bump; or heard as a knock when the electric
actuator changes direction (from extending or retracting).
See the following figure.

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Upper Casting

Trunnion Trunnion
Bearings Pin

Casting
Pins

Clevis Pin

Figure 2-15. Inspections – Upper Trunnion Bearing Locations

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2.5.2.2.4. Monthly Inspections – Motion Base Floor Pad Mounting Bolt Torque Check
Perform a Motion Base floor pad mounting bolt torque once every month. The following special tools are
required to complete this procedure.

• 100– to 600-ft-lb Torque Wrench

• 36mm Hex Socket (60-inch Motion Base)

• Remove power to the Digital Motion System as necessary when inspecting the Motion Base floor
pad torques.

WARNING: Disconnect all incoming power to the Motion Control Cabinet prior to inspecting.
After power is disconnected, use a meter or other appropriate testing device to insure power
removal from the equipment.

WARNING: Orange wires indicate parts of the cabinet that are battery powered and live. Use
lock/tag out procedures and Personal Protective Equipment (PPE) as appropriate and necessary
while performing maintenance activities.

WARNING: In addition to removing facility power from the cabinet, ensure that Motion System
movement does not occur by opening the following circuit breakers in the Motion Control
Cabinet prior to performing maintenance: 11F1, 14F1, 17F1, 20F1, 23F1, and 26F1.

• Verify all floor pad anchor bolt heads, nuts, and mounting plates are marked according to the
correct drawing:

• ABF927 for Concrete Sleeve Anchor bolts (Bolt head) or

• ABF928 for Concrete Epoxy Anchor Rod installations (Bolt stud with nut)

• Keep a record of the maximum allowed cumulative rotation values listed on the above referenced
drawings.
• Using the torque wrench and a 36mm hex socket, check the service torque on each of the floor pad
anchor bolts in according to the correct drawing mentioned above.
• Verify maximum allowed cumulative rotation as listed on the referenced drawings. Replace the
bolt according to the drawings.
See the following figure.

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60-inch Motion
Base Anchor Bolts

36-inch Motion
Base Anchor Bolts

Figure 2-16. Inspections – Motion Base Anchors – Typical

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2.5.2.2.5. Monthly Inspections – Safety Lock Wire

Perform a safety-lock wire inspection of the Motion Base once every month, remove power to the Digital
Motion System as necessary when inspecting the safety lock wires.

WARNING: Disconnect all incoming power to the Motion Control Cabinet prior to inspecting.
After power is disconnected, use a meter or other appropriate testing device to insure power
removal from the equipment.

WARNING: Orange wires indicate parts of the cabinet that are battery powered and live. Use
lock/tag out procedures and Personal Protective Equipment (PPE) as appropriate and necessary
while performing maintenance activities.

WARNING: In addition to removing facility power from the cabinet, ensure that Motion System
movement does not occur by opening the following circuit breakers in the Motion Control
Cabinet prior to performing maintenance: 11F1, 14F1, 17F1, 20F1, 23F1, and 26F1.

Perform a physical inspection of the safety lock wire on all sides of the three (3) Motion Base upper
castings and all sides of the three (3) Motion Base lower castings.

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Replace any safety lock wire that is broken, missing, distorted, or excessively worn.

Safety Lock
Wire
(Not Shown)

Figure 2-17. Inspections – Upper Casting Safety Lock Wire Locations – Typical

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2.5.3. Motion Base Maintenance – Troubleshooting

The following paragraphs describe troubleshooting aids for the Motion Base.
Once a failure has occurred, follow the following guidelines to locate the faulty assembly/component:

• Identify all Motion Base components that are not working.

• Identify the commonality between the Motion Base components that are not working.
• Verify that the applicable serial data buses are transferring data.
• Check for fault indications on the motor controller drives and the PLC components.
• Check the Digital Motion System error log.
• Check the Control Loading and Motion System fail log.
Refer to vendor documentation for COTS-specific troubleshooting procedures.

2.5.3.1. Troubleshooting – Motion Base

The maintenance technician, as an aid in determining proper Motion Base operation, can perform pre-
operational tests.
The tests include the following:

• Motion Base Frequency Response Test (test #711) – The purpose of the Motion Base Frequency
Response test is to determine if the Motion Base can follow the commands from the computer
within the bandwidth necessary to provide critical cues for simulation.
• Motion Base Leg Balance Test (test #712) – The purpose of the Motion Base Leg Balance test is
to make sure that the action of any single actuator does not cause unwanted response in any other
actuator.
• Motion Base Turn-Around Check (test #713) – The purpose of the Motion Base Turn-Around
Check is to make sure that wear in the electric actuator does not cause excessive bumps during
direction changes.
Find these tests in the Acceptance Test Guide (ATG) for the simulator and run from the Instructor
Operating Station (IOS).

NOTICE: If unfamiliar with running the ATG tests, contact the on-site FAA or Simulator
Certification Coordinator.

If a failure occurs in Motion Base performance, refer to the Software Utilities Manual for using the IOS
Debug Pages in deciphering errors.

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2.5.4. Motion Base Maintenance – Removal and Replacement

Use the procedures in the following paragraphs to remove and replace components of the Motion Base.
Although there may exist an alternate method to perform each procedure, the following procedures have
been written to provide safety to personnel and to avoid damage to equipment.

WARNING: Disconnect all incoming power to the Motion Control Cabinet prior to performing
maintenance on the Motion Base. After power is disconnected, use a meter or other appropriate
testing device to ensure power removal from the equipment.

WARNING: Many Motion Base components are very heavy and have sharp edges. To avoid
injury, use proper protective clothing, lifting techniques, and equipment.

2.5.4.1. Removal and Replacement – Required Tools

Use the following procedure to remove and replace an electric Motion Actuator Assembly. Four (4) people
are required to complete this procedure. The following special tools are required to complete this
procedure. Use the aircraft jacks as recommended.
Other types of aircraft jacks may vary from the illustrations.

• Small Forklift • 1-in. Hex Socket

• 32-in. Nylon Web Slings • 1-in. diameter x 8-in. Nylon Dowel
• Rubber to Wrap Web Slings • Safety Lock Wire and Pliers
• 30-200 in-lb Torque Wrench • Paper Tags
• Multimeter • Slide Hammer
• Dead-Blow Hammer • Four (4) Aircraft Jacks, two (2)
• EM Actuator Portable Drive MOOG P/N Extensions - 60"
CB61301-001

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WARNING: Disconnect all incoming power to the Motion Control Cabinet prior to performing
maintenance on the Motion Base. After power is disconnected, use a meter or other appropriate
testing device to ensure power removal from the equipment.

WARNING: Use only four (4) aircraft jacks approved by FSI when changing the Motion
Actuator Assembly. Employ no other substitute method for removal (i.e. maintenance jack)
unless contacting FSI first and having method approved by the simulator support department.

WARNING: The Motion Base Actuators are very heavy and have sharp edges. To avoid injury,
use proper protective clothing, lifting techniques, and equipment.

WARNING: Do not attempt this procedure unless familiar with removing and replacing electric
actuators.

WARNING: The actuator assembly may move suddenly when removing the upper clevis pin.
Avoid injury by keeping hands, fingers, elbows, and feet out of harms way.

NOTICE: Trunnion bearings damage easily. Exercise care when removing or replacing the
actuator assembly.

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2.5.5. Actuator – Removal

1) Raise the Access Ramp to the upright position using the Ramp/Stairs Up switch on the
Ramp/Stairs Control Module.
2) Power down the Motion Control Cabinet in accordance with proper procedures.
3) Power down the Control Loading and Motion (CLM) control cabinet in accordance with
CLM control procedures.
4) Remove facility power to the CLM control cabinet and the MCC by turning the main power
wall switch Off. Lockout the main power switch according to local Lockout Procedures.
5) Disconnect and safely tag the electrical connections from the actuator and move the wiring
harness away from the actuator area to prevent damage during the actuator removal.

Motion Base Cables

Figure 2-18. Motion Actuator Cables – Typical

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6) Move the four (4) aircraft jacks under the simulator jacking cups on the four (4) corners of
the simulator. Extend the center jack post by screwing it out until the upper end of each jack
post is in the jacking cup on the simulator if possible. Reposition the jack as needed to meet
the jacking cup.
7) Turn the center jack post-locking nut down until it locks against the jack ram. This will
prevent the center jack post from changing position while jacking the simulator.

Center Jack
Post Simulator
Center Jack Jack Cup
Ram Post Nut

Ram Lock Ram Nut Locking

Nut Screw

Figure 2-19. Simulator Jack Cup – Typical

8) If necessary, extend the jack to position the center jackscrew in the cup by using the pump
handle. Extend the jack using the pump handle until the casters on the jack compress and the
jack feet contact the floor.
9) Note the position of the rise indicators for all four (4) jacks. They should be the same.
10) Extend all four (4) jacks at the same time using one (1) person on each jack and using equal
strokes of the pump handles. Continue extending the jacks until the actuators extend 11 to 12
inches from the original rise indicator reading.

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11) Turn the ram lock nut down until it is tight against the top of the jack cylinder. Lock it in
place by tightening the lock screw. This prevents the jacks from sinking down during the
maintenance procedure.

Center Jack Post

Center Lock Nut Ram
Jack Post Lock Nut

Rise
Indicator

Pump
Handle

Spring
Loaded
Swivel
Casters

Figure 2-20. Aircraft Jack – Typical

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12) Remove and discard the safety lock wire from the clevis pin caps located on the upper and
lower clevises of the actuator.

Clevis
Pin Cap

Clevis
Pin
Safety
Wire

Clevis Pin Cap

(Backside of Clevis)

Clevis
Pin

Safety
Wire

Figure 2-21. Clevis Pin Safety Wire – Typical

13) Secure a nylon web sling, using rubber as padding between it and the actuator, around the
actuator at the balance point of the actuator.

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WARNING: The actuator assembly may move suddenly when removing the upper clevis pin.
Avoid injury by keeping hands, fingers, elbows, and feet out of harm’s way.

14) Position the forklift, or other suitable hoist, directly above the balance point where the nylon
web sling fastens to the actuator.

Actuator Housing
Center the rubber-
padded Nylon Web
Sling on the Balance
Point of the Actuator

Figure 2-22. Actuator Balance Point – Typical

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15) After securing the loose end of the web strap(s) to the forklift, raise it slowly, until the
forklift supports the weight of the actuator. There should not be any weight on the upper
clevis.
16) Remove the clevis pin cap located on the upper clevis of the actuator.

Weight
Support

Figure 2-23. Removing Motion Actuator – Typical Lifting

NOTICE: Trunnion bearings damage easily. Exercise care when removing or replacing the
actuator assembly.

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17) Remove the upper clevis pin with the slide hammer.
18) Connect the EM Portable Actuator Drive to the actuator according to the instructions that
come with the drive. Refer to vendor documentation in the List of Related Publications.

Main Power
Switch
Encoder Cable
Connector

Actuator
Type Switch

Motion
Pendant Power
Connector Connector

Figure 2-24. EM Portable Actuator Drive

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19) Make sure to switch the drive to the correct actuator type prior to turning on the main power
switch.

• Next Generation Actuator – ENDAT 2.2 (FS1000)

20) Using the EM Portable Actuator Drive, manually guide the upper clevis free from the
trunnion by retracting the actuator rod into the actuator housing.
21) Remove the clevis pin cap located on the lower clevis of the actuator.
22) While supporting the actuator assembly, remove the lower clevis pin by gently using the
slide hammer until removable by hand.
23) Using the forklift, slowly lift the lower actuator clevis clear of the trunnion.
24) Using the forklift, move the actuator assembly clear of the Motion Base and place it on 12"
wood blocks on a sturdy, level work surface.

Figure 2-25. Placing Motion Actuator on Wood Blocks – Typical

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25) If replacing the actuator, remove the upper and lower clevises and install them on the
replacement actuator in accordance with the procedure in Section 2.5.5.1. Make sure to
install them so they are orientated the same as they were on the original actuator.

WARNING: The actuator assembly may move suddenly when removing the upper clevis pin.
Avoid injury by keeping hands, fingers, elbows, and feet out of harm’s way.

NOTICE: Trunnion bearings damage easily. Exercise care when removing or replacing the
actuator assembly.

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2.5.5.1. Removal and Replacement – Clevises

If necessary and as required, use the following procedures to remove and replace clevises of the typical
60" Motion Actuator Assemblies.

Figure 2-26. Changing Actuator Clevis – Typical

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2.5.5.1.1. Clevises – 60" Actuator Assembly Upper Clevis

Use the following special tools to complete this procedure, as required.

• 1-in. Hex Driver Socket • 250-600 ft-lb Torque Wrench

• 15/16-in. Torque Adapter (or equivalent) • Safety Lock Wire and Pliers
• Halo Tool • Typical 3/4" drive Breaker Bar
o FSI PN T-5526 - 60" actuators approximately 21" or more in length
o FSI PN T-5527 - 36" actuators

1) The use of a cheater pipe over the handles of the Halo Tool and the Breaker Bar will prove to
be advantageous during this procedure. Insert a 1" Hex Drive socket and ratchet assembly
into the cap screw in the base of the upper clevis. Position the Halo Tool on the clevis in an
opposing position to the hex drive socket and ratchet assembly.
2) Loosen the cap screw in a counterclockwise direction. Remove the cap screw and the clevis.
3) To replace the upper clevis, slide the clevis over end of the rod of the actuator assembly
ensuring the guide pin in the end of the rod correctly aligns and seats.
4) Thread the cap screw into the rod through the base of the upper clevis.
5) Insert a one (1)" hex drive socket and ratchet assembly into the cap screw. Position an 18"
auto wrench on the clevis in an opposing position to the hex drive socket and ratchet
assembly.
6) Torque the cap screw in a clockwise direction to 500 ±10 ft-lb.
7) Install the actuator assembly in accordance with the Actuator Installation Procedure in
Section 2.5.6.

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2.5.5.1.2. Clevises – 60" Actuator Assembly Lower Clevis

Use the following special tools to complete this procedure, as required.

• 50-250 ft-lb Torque Wrench • Safety Lock Wire and Pliers

1) Remove the actuator assembly in accordance with Steps 1 through 25 of the procedure in
Section 2.5.5
2) Remove the safety lock wire from the hex nuts that secure the lower clevis to the actuator
assembly.
3) Remove the lower clevis.
4) Install the replacement lower clevis onto the actuator assembly.
5) Tighten the hex nuts in a crisscross pattern in increasing torque to 170 ±5 ft-lb.

NOTICE: When using the torque wrench with the torque adapter, the ft-lb setting on the torque
wrench must be adjusted according to the following formula:

Desired Torque Value Torque Wrench Setting

Example:

6) Install safety lock wire on the hex nuts.

7) Install the actuator assembly in accordance with the Actuator Installation Procedure in
Section 2.5.6.

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2.5.5.2. Removal and Replacement – Trunnion Bearings

If necessary and as required, use the following procedures to remove and replace the Trunnion Bearings
of a typical 60" Motion Actuator Assembly.
The recommended procedure for repair of trunnions with bearings is replacement of the failed trunnion
with a trunnion that has the bearing already replaced. If this is not possible, then use the following
procedure to remove and replace the trunnion bearings in the upper or lower Motion base castings. Refer
to vendor data for actuator-specific information.

WARNING: Only qualified personnel are to work on the Motion System. Do not allow
occupants in or near the simulator while engaging the Digital Motion System (DMS) for the first
time after an installation or commissioning.

WARNING: Ensure that no items around the system area will become loose and hit personnel.
Keep personnel out of the Motion envelope at all times.

WARNING: Avoid major injury to personnel by keeping hands, fingers, elbows, and feet out of
harm’s way.

NOTICE: Due to precision tolerances, do not perform removal and replacement of trunnion
bearings in the field. Order the replacement trunnion, bearings pre-pressed, and pins from the
factory as a set.

The following special tools are required to complete this procedure.

• Safety Lock Wire Pliers • Bronze Tapered Punch

• Slide Hammer Assembly • 30-200 in-lb Torque Wrench
• Bearing Removal Tool • Safety Lock Wire
• Bearing Press Tool

1) Remove the actuator assembly in accordance with Steps 1 through 25 of the procedure in
Section 2.5.5.
2) At the Motion Base casting, remove the safety lock wire on the outboard and inboard
trunnion pin cap screws. See the figures following.
3) Remove the cap screws from the trunnion pins.

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Figure 2-27. Trunnion Bearings – Typical

Figure 2-28. End Trunnion Bearings – Typical

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4) Using the slide hammer assembly, thread it into the inboard trunnion pin and extract it.
5) While supporting the trunnion, extract the outboard trunnion pin with the slide hammer.
6) Remove the trunnion along with the thrust shim (if present) and the thrust washers.
7) To remove the bearings in the end of the trunnion, insert the bearing removal tool past the
bearing and adjust the width of the flanges outward against the inner wall of the trunnion.
Refer to Figure 2-27.
8) Tighten the cap screws to secure the flanges in position.
9) Turn the center socket-head bolt of the bearing removal tool clockwise to extract the bearing
from the trunnion.
10) To remove the center bearings of the trunnion, place the ends of the trunnion on a solid
surface. Using the tapered punch and a hammer, carefully tap the inner edge of the bearing
evenly in a crisscross or side-to-side pattern.
See the following figure.

NOTICE: Due to precision tolerances, do not perform removal and replacement of trunnion
bearings in the field. Order the replacement trunnion, bearings pre-pressed, and pins from the
factory as a set.

NOTICE: To avoid damaging the replacement trunnion bearings and to ensure a correct fit,
ensure the bearing is aligned with the hole in the trunnion when pressing the bearing into the
trunnion.

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Figure 2-29. Center Trunnion Bearings – Typical

WARNING: Only qualified personnel are to work on the Motion System. Do not allow
occupants in or near the simulator while engaging the Digital Motion System (DMS) for the first
time after an installation or commissioning.

WARNING: Ensure that no items around the system area will become loose and hit personnel.
Keep personnel out of the Motion envelope at all times.

WARNING: Avoid major injury to personnel by keeping hands, fingers, elbows, and feet out
of harm’s way.

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NOTICE: Do not heat trunnions with any bearings installed.

11) To install the replacement trunnion bearings, heat the trunnion in an oven at 150°F (66°C) for
a minimum of four (4) hours then press the bearings into the trunnion when removed from
the oven.
12) To replace the trunnion, hold the trunnion in position on the casting, insert the thrust washers,
and insert the trunnion pins.
13) Using a feeler gauge, measure the clearance between the thrust washer at the inboard end of
the trunnion and the casting. See the following figure. Check for a clearance no greater than
two-thousandths (.002") of an inch. If necessary, add one (1) or more thrust shims to the
thrust washer between the inboard end of the trunnion and the casting. Refer to Figure 2-27.

Figure 2-30. Trunnion to Casting Clearance – Typical

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14) Install and torque the cap screws that secure the trunnion pins to the casting to 84 ±10 in-lb.
15) Install safety lock wire to the trunnion pin cap screws. Refer to Figure 2-27 for the upper
trunnion.
16) Install the actuator assembly in accordance with the Actuator Installation Procedure in
Section 2.5.6.

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2.5.6. Actuator – Installation

To install the replacement actuator assembly, make sure the actuator is orientated with the correct side up,
as noted during the Actuator Removal Procedure.
1) Secure a nylon web sling, wrapped/padded with rubber where contacting the actuator, at the
balance point of the actuator.
2) Position the forklift, or other suitable hoist, directly above the point where the nylon web
sling fastens to the actuator assembly.
3) After securing the loose end of the nylon web sling to the forklift, raise it slowly, until the
forklift supports the weight of the actuator.
4) If necessary, repeat the first step to obtain the preferred center of balance.
Refer to Figure 2-23.

NOTICE: When installing the actuator, it is recommended to attach the lower (motor end)
actuator clevis into the trunnion prior to attaching the upper actuator clevis.

5) Position the forklift and actuator under the simulator so that the lower actuator clevis will
slide onto the lower trunnion bearings when lowered by the forklift.

WARNING: Avoid major injury by keeping hands, fingers, elbows, and feet out of harm’s way.

NOTICE: Avoid scoring the Teflon-coated trunnion bearings. Gently move the actuator clevis
back and forth, parallel to the bearing surface, consistently as it lowers onto the side of the
bearing moving inward in such a manner that the actuator clevis does not bind.

6) Slowly lower the actuator while carefully guiding the lower actuator clevis to the lower
trunnion; gently rock the actuator back and forth parallel to the bearing surface. When the
actuator clevis holes align with the trunnion hole, use the 1x8" nylon dowel to assist
alignment from the opposite side and carefully insert the clevis pin. Do not force the pin. If
the pin does not go in easily, remove and realign the holes.

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7) When the clevis pin has been inserted, install the clevis pin retaining screw and torque to 36
±5 in-lb.

Figure 2-31. Removing Lower Clevis

NOTICE: Avoid scoring the Teflon-coated trunnion bearings. Gently move the actuator clevis
back and forth, parallel to the bearing surface, consistently as it lowers onto the side of the bearing
moving inward in such a manner that the actuator clevis does not bind.

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8) Slowly raise the actuator with the forklift. As the actuator assembly is raised, use the portable
actuator drive to extend the actuator rod and guide the upper clevis onto the upper trunnion
bearing. See Step 15 of the Actuator Installation Procedure.
9) When the actuator clevis holes align with the trunnion hole, use the 1x8" nylon dowel to
assist alignment from the opposite side and carefully insert the clevis pin. Do not force the
pin. If the pin does not go in easily, remove and realign the holes.
10) When the clevis pin has been inserted, install the clevis pin retaining screw and torque to 36
±5 in-lb.
11) Install the clevis pin cap and retaining screw on both the lower and upper clevis pins.
See the following figures.

Figure 2-32. Installing Upper Clevis

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Figure 2-33. Actuator and Trunnion Bearing Alignment – Typical

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Figure 2-34. Clevis Pin and Nylon Dowel Alignment – Typical

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12) Lower the forklift, remove the web strap from the actuator assembly, and move the forklift
away from the Motion Base.
13) Loosen the ram-nut lock screw; turn the ram lock nut up until it contacts the top of the ram. It
may be necessary to first jack up the aircraft jack to relieve any pressure on the lock nut.
Refer to Figure 2-19.
14) Lower the aircraft jacks slowly and evenly using one (1) person on each jack and using the
pump-pressure release valves. Monitor the rise indicators to ensure all jacks lower evenly.
Continue lowering the jacks until the jacks fully retract. Refer to Figure 2-19.
15) Turn the center jack post-locking nut up until it contacts the top of the post. Screw the center
jack post all the way down into the ram. Refer to Figure 2-19.
16) Move the aircraft jacks away from the Motion Base.
17) Replace the safety lock wire on the upper and lower clevis pins and caps on the actuator
assembly. Refer to Figure 2-21.
18) Connect and tighten the electrical wiring to the actuator, see the table below. If power and
encoder cables run in parallel, maintain a minimum distance of 12 inches between them; if it
is necessary for encoder cables to cross power cables, cross at right angles. If excess cable
coils up, separate power and encoder cable coils by a minimum distance of 36 inches.

Table 2-2. Motor Wiring – Typical

Motor Terminal Block 1 2 3 Green

Wire Number 1 2 3 -
Cabinet Terminal Block 4 3 5 6
Wire Color at Cabinet RB Black White Red Green

The MCC terminal blocks are one (1), two (2), three (3), and there is a ground bus bar that runs the length
of the cabinet just behind the terminal blocks. The power wires are all black to and from the terminal
blocks.

NOTICE: It is vitally important that encoder cables not run in close proximity to motor power
cables.

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19) Remove the Lockout from the main power wall switch. Turn the main power wall switch
ON.
20) Power up the Control Loading and Motion (CLM) Power Distribution Unit (PDU) in
accordance with the procedures in the CLM Control System Operation and Maintenance
Manual.
21) Power up the Motion Control Cabinet in accordance with the procedures in SECTION 3 of
this manual.
22) Commission the actuator – Reference Moog Manual CDS38799 “FSI Motion System User
Manual” Motion axis conditioning.
23) Lower the Access Ramp to the fully down position using the Ramp/Stairs Down switch on
the Ramp Control Module.
24) Perform an operational check of the DMS.

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2.5.7. Removal and Replacement – At Rest Switch

Replace the At-Rest (Home) switch by simply unscrewing the switch from the actuator body. The location
of the switch varies with the size of the actuator. Refer to vendor data for actuator-specific information.

WARNING: Some parts of the Motion Control Cabinet retain energy after turning off the main
AC power. Wait at least 10 minutes before performing any maintenance to the actuators. Use
lock/tag out procedures and Personal Protective Equipment (PPE) as appropriate and necessary
while performing maintenance activities. In addition to removing facility power from the cabinet,
ensure that Motion System movement does not occur by opening the following circuit breakers
in the MCC prior to performing maintenance: 11F1, 14F1, 17F1, 20F1, 23F1, and 26F1.

1) Power down the MCC.

2) Remove the cable connector from the switch, Refer to Figure 2-6.
3) Remove the two (2) mounting screws.
4) Remove the faulty switch and replace it with a new switch.
5) Install the cable connector to the switch.

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2.5.8. Removal and Replacement – Secondary Thermistor Connection

Perform the following procedure to change from the primary thermistor to the secondary thermistor or to
replace the thermistor. Refer to vendor data for actuator-specific information. The following tools are
required to complete this procedure.

• Multimeter

WARNING: Disconnect all incoming power to the Motion Control Cabinet prior to performing
maintenance on the Motion Base. After power is disconnected, use a meter or other appropriate
testing device to ensure power removal from the equipment. Some parts of the Motion Control
Cabinet retain energy after turning off the main AC power. Wait at least 10 minutes before
performing any maintenance to the actuators.

WARNING: Orange wires indicate parts of the cabinet that are battery powered and live. Use
lock/tag out procedures and Personal Protective Equipment (PPE) as appropriate and necessary
while performing maintenance activities. In addition to removing facility power from the cabinet,
ensure that Motion System movement does not occur by opening the following circuit breakers
in the MCC prior to performing maintenance: 11F1, 14F1, 17F1, 20F1, 23F1, and 26F1.

1) Power down the MCC.

2) Remove the actuator oil in accordance with the procedure in Section 2.5.9.
3) Pull out the thermistor wire bundle. Refer to Figure 2-10.
4) Use a multimeter to verify the secondary thermistor lead-wire pair reads approximately
210KΩ – 290KΩ resistance at room temperature, 242KΩ typical.
5) If it reads open or shorted, replace the thermistor.
6) Cut the thermistor lead wires on the feed-through side of the crimp splices.
7) Strip the feed-through wires and crimp into the spare thermistor splices. (If replacing the
thermistor, crimp the feed-through wires into the primary thermistor lead wires.)
8) Tie wrap the lead wire bundle and insert back into the drain port.
9) Refill the oil in accordance with the following procedure.
Refer to vendor data for actuator-specific information.

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2.5.9. Motion Base – Actuator Motor Oil

Change Actuator Oil every year or approximately 8760 hours of use. Use the following procedure to
evacuate and replace the actuator oil. Refer to Section 2.1.4.6 for port locations.

WARNING: Disconnect all incoming power to the Motion Control Cabinet prior to performing
maintenance on the Motion Base. After power is disconnected, use a meter to ensure power
removal from the equipment.

The following materials and equipment are required for this procedure:

• Actuator Motor Oil

o Actuator – 2.0 Gallon (approximately)
o Mobil SHC 630 (recommended)
o Mobil SHC 632
o Shell Omala 220 – if using oil other than the recommended type, repeat the oil change
procedure after a month to flush the actuator of the old oil as recommended by oil
manufactures

• Torque Wrench 10-150 ft-lb

• 7/8-inch socket
• 5/8-inch hex bit

• Oil Drain Pan

• Funnel

CAUTION: Motor oil change should be conducted only after the Motion System has been off
for at least one (1) hour and the motor is cool to the touch.

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1) Power down the MCC.

CAUTION: Oil might be under pressure and spray as a result of the pressure. Take proper
precautions to ensure safety to personnel.

2) Vent the actuator to remove internal pressure build up by removing the Actuator Oil Fill Port
plug carefully (cover with a rag while removing) with a 7/8" socket, torque to 40 ft-lb. See
the following figure.
3) Place a drain pan capable of holding approximately seven (7) – eight (8) Liters under the
Actuator Oil Drain Port.

Figure 2-35. Motion Base – Actuator Motor Oil Plugs

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4) Remove the Drain Port plug using a 5/8-inch hex bit and let the oil drain for 10 to 15 minutes
into the pan. Dispose of the oil in accordance with local hazard waste procedures.
5) Install the drain port plug and torque to 100 ft-lb.
6) Using a funnel, slowly fill the actuator through the fill port with:

• Actuator Motor Oil –

o Actuator – 2.0 Gallon (approximately)
o Mobil SHC 630 (recommended)
o Mobil SHC 632
o Shell Omala 220 – if using oil other than the recommended, repeat the oil
change procedure after a month to flush the actuator of the old oil, as
recommended by oil manufactures.

• The viscosity of the oil will cause slow drainage down through the fill port. It will be
necessary to add small amounts at a time until the oil is level with the bottom of the
fill port after it has drained down into the actuator.
7) Install the fill port plug and torque to 40 ±4 ft-lb. Repeat Step six (6) daily over a three (3)
day period to allow for oil settling in the actuator. Refer to Figure 2-35.
8) Power up the MCC.
Refer to vendor data.

2.5.10. Maintenance – Diagrams

Refer to the following vendor manual for Motion Base Actuator information:

MOOG FSI Motion System User Manual

Electric Motion Systems
-127-338 Motion Control Cabinet
-880-078 / -880-079 Actuators
CDS38799 Rev C
September 2013

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SECTION 3. MOTION CONTROL CABINET

This section covers the Digital Motion System (DMS) Motion Control Cabinet (MCC) components.
The DMS MCC – 8A3 contains the following:

• Programmable Logic Control (PLC)

• Actuator Drives
• Motor Controllers
• Additional Internal Components
Refer to vendor documentation for specific MCC information and component descriptions, as well as for
MCC-specific maintenance information not covered in this manual.

WARNING: Some parts of the Motion Control Cabinet retain energy after turning off the main
AC power. Wait at least 10 minutes before performing any maintenance to the actuators. Orange
wires indicate parts of the cabinet that are battery powered and live. Use lock/tag out procedures
and Personal Protective Equipment (PPE) as appropriate and necessary while performing
maintenance activities. In addition to removing facility power from the cabinet, ensure that
Motion System movement does not occur by opening the following circuit breakers in the MCC
prior to performing maintenance: 11F1, 14F1, 17F1, 20F1, 23F1, and 26F1.

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3.1. MOTION CONTROL CABINET – DESCRIPTION

The MCC in the 8A3 area contains the components necessary to safely control and monitor the Motion
Base.

Figure 3-1. Component Description – Motion Control Cabinet

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3.1.1. Description – Block Diagram

The MCC circuitry interfaces the Motion Base to the Control Loading and Motion (CLM) Server to
provide realistic responses to student input and flight data. The following paragraphs discuss major
components of the MCC block diagram. For detailed discussion of internal MCC components, refer to
vendor documentation.

Figure 3-2. Motion Control Cabinet – Block Diagram

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3.1.2. Description – MCC Interior

The MCC contains the circuitry necessary to control the Motion Base.

MCC +24Vdc
(Left Side) UPS
Control
PLC

Gland Drive Drive Drive

Plate A B C

Amplifier
Control Heads

Battery MCC
Charger (RH Side)

Step Down
+24Vdc Power Transformer
Supply (Fans)
RTH
Amplifier
Controls Drive Drive Drive
D E F

Figure 3-3. Motion Control Cabinet – Interior

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3.1.3. Description – Reference Designators

The MCC is a major component of the DMS. It safely provides control and power to the Motion Base
Actuators using the following contents:

• Programmable Logic Controller

• Actuator Drives
• Motor Controllers
• Additional components in the MCC (8A3) include the Motion Base circuitry and components
providing electrically-powered six– (6) Degree of Freedom (6DOF) to the Full Flight Simulator
(FFS).

Table 3-1. Reference Designators – CLM MCC Cabinet

Motion Control Cabinet Device Tag Old Reference

Name
48Vdc Contactor Control 63K1 CR1
AC Contactor 1 79K1 CR2
AC Contactor 2 79K2 CR2B
240Vac Power Sense Relay 5K1 CR3
RTH Precharge 63K2 CR4
Braking Contactors A & B 6K7 CR5
Braking Contactors C & D 6K8 CR6
Braking Contactors E & F 6K9 CR7
Disconnect Battery Charger - Load Resistor Contactor Control 63K3 CR8
Main Battery Contactor Control 62K1 CR11
Drive A Contactor 6K1 CRA
Drive B Contactor 6K2 CRB
Drive C Contactor 6K3 CRC
Drive D Contactor 6K4 CRD
Drive E Contactor 6K5 CRE
Drive F Contactor 6K6 CRF
Battery Load Resistor Control 5K2 CRL

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3.1.4. Description – Programmable Logic Control

The PLC controls all logical functions within the MCC; it is responsible for controlling power-routing
devices, monitoring the status of the Motion Actuators and all cabinet components. The PLC provides
actuator-position feedback to the Control Loading and Motion Server via an Ethernet cable, and updates
the status of inhibit/enable signals such as Emergency Stop and other interlocking inhibit/enable signals.
Input/Output (I/O) modules indicate Motion Base system status and control relay outputs.

Figure 3-4. MCC – Programmable Logic Control

The three (3) power modules (30K2, 31K1, and 31K8) have gray-wired terminals and power the group of
modules (input, output, and safe-outputs modules, respectfully) to the right side of the power module.
Refer to vendor documentation.

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3.1.5. Description – Motor Controller Drives

The Motor Controller Drives convert the three– (3) phase 480Vac into a Pulse Width Modulated (PWM)
680Vdc for driving the electric Motion Actuators. The cabinet contains six (6) Motor Controller Drives
labeled Drive A through Drive F that drive Motion Actuators one (1) through six (6). Vendor
documentation may refer to these as Customizable Single Axis (CSA) drives.

Figure 3-5. MCC – Motor Controller Drive (Without Control Head)

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3.1.6. Description – Motor Controller Control Head

The Motor Controller Control Head contains the software required to generate the Pulse Width Modulated
(PWM) signal requested by actuator-position commands. The following paragraphs list their function and
indications.

• Status Display – a seven (7) segment display indicating the status of the drive and any fault or
warnings that may be present. The vendor documentation listed in this manual defines the drive
status, fault and warning displays.
• ID1 Address Switch – sets the hardware address of the control head.
• ID2 Address Switch – sets the hardware address of the control head.
The Control Head receives actuator-position signals from the CLM Server and commands the motor
controller drive to move the actuator. The actuator position signals feedback to the Actuator Drive Control
Head. The Control Head also receives actuator over-temperature signals and shuts down the actuator if
temperatures exceed 150°C or higher. Refer to the FS1000 Digital Control Loading System Operation and
Maintenance Manual for additional control head information.

ID1 Address
Switch

ID2 Address
Switch

Status
Display

Figure 3-6. Controls and Indicators – Motor Controller Control Head

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3.1.7. Description – Return to Home Controls

The six (6) Return to Home (RTH) Amplifier Controllers, in conjunction with the +48Vdc RTH batteries,
drive the Motion Base Actuators to the fully retracted (home) position when the MCC experiences a power
failure or when an emergency condition exists.
If the Motion platform faults leaving one (1) or more actuators extended or in tension, the RTH system
drives each actuator to the home position. The RTH amplifiers resident in the MCC provide sufficient
force to overcome maximum actuator tension load by operating from an independent +48Vdc battery bank
supply.

WARNING: Capacitors in the RTH controllers may retain energy after turning off the main AC
power. Wait at least 10 minutes before performing any maintenance to the RTH system. Orange
wires indicate parts of the MCC that are battery powered and live. Use lock/tag out procedures
and Personal Protective Equipment (PPE) as appropriate and necessary while performing
maintenance activities. In addition to removing facility power from the cabinet, ensure that
Motion System movement does not occur by opening the following circuit breakers in the MCC
prior to performing maintenance: 11F1, 14F1, 17F1, 20F1, 23F1, and 26F1.

See the following figure.

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Figure 3-7. MCC – Return to Home Controls

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3.1.7.1. Return to Home – Controls and Indicators

The following describes the Light Emitting Diode (LED) indicators and terminal block present on the
RTH Controller. Refer to vendor documentation.

WARNING: Wait at least 10 minutes before performing maintenance on the Motion Control
Cabinet to allow time for the 680Vdc capacitors charge to bleed off the motor controllers and
the return to home amplifiers.

Figure 3-8. MCC – RTH Status Indicators

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3.1.7.2. Return to Home – +48Vdc Return to Home Batteries

In the event of a power failure, four (4) +12Vdc series-connected, lead-acid backup batteries provide
power to the DC bus to drive the Motion Base Actuators to the fully retracted (at-rest) position.

Right
End of
Cabinet

Figure 3-9. MCC – +48Vdc RTH Batteries

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3.1.8. Description – Uninterruptible Power Supply Assembly

The Uninterruptible Power Supply (UPS) Assembly provides back-up power to the PLC and all devices
in the MCC.
The UPS Assembly contains three (3) major components:

• +24Vdc Power Supply (2G1) – Provides power for MCC circuitry under normal operating
conditions.
• UPS (2Q1) – Switches power from the power supply to batteries and vice versa.
• UPS Batteries (2C1) – Provides power for MCC circuitry under power-outage conditions, when
2G1 is disabled.
Refer to vendor documentation.

Figure 3-10. MCC – +24Vdc Uninterruptible Power Supply Assembly

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3.1.8.1. UPS Assembly – Power Supply (2G1)

The power supply in the UPS assembly is the main power source of MCC circuitry. It supplies electrical
power to all MCC components during normal operating conditions. The power supply includes an
illuminated green DC OK display and an adjustment pot as needed. Refer to vendor documentation.

Figure 3-11. MCC – +24Vdc Power Supply

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3.1.8.2. UPS Assembly – Uninterruptible Power Supply

The UPS, referenced as 2Q1, switches and controls the output of the power supply and batteries. The UPS
switches the power for MCC circuitry to batteries when a power outage disables the main +24Vdc power
supply (2G1).
The UPS monitors the system and displays the status of the battery supply, operating mode, and alarm, as
well as the communication port. Refer to vendor documentation.

Figure 3-12. MCC – +24Vdc UPS Controls and Indicators

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3.1.8.3. UPS Assembly – Batteries

The UPS batteries supply +24Vdc to the MCC when output power from the power supply is not available.
The UPS battery output consists of output wires located at the bottom side of the battery container.
Refer to the UPS controls and indicators for battery mode, power, and status.

Figure 3-13. MCC – +24Vdc UPS Batteries

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3.1.9. Description – +24Vdc Cooling Fans Power Supply

The +24Vdc Power Supply in the right-hand side cabinet only supplies power to cooling fans throughout
the MCC. The PLC monitors the output of this power supply and displays a class one (1) fault state if the
power supply fails. The UPS does not back up the fan power supply.
The cooling fan power supply has a DC OK indicator and adjustment pot for variable outputs.

Figure 3-14. MCC – +24Vdc Cooling Fans Power Supply

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3.1.10. Description – Step Down Control Transformer

The Step Down Control Transformer input of 480Vac steps down to 240Vac for powering coil contactors
and the battery chargers. The Battery Chargers keep the RTH batteries fully charged.

Figure 3-15. MCC – Step Down Control Transformer

3.1.11. Description – Additional MCC Components

Refer to vendor documentation for additional MCC control-circuit component descriptions such as
contactors, relays, circuit breakers, fuses, and battery chargers (5C1 and 5C2).

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3.1.12. Description – Regeneration Resistors

The Regeneration (Regen) Resistors are behind the two (2) center panels in the backside of the Motion
Control Cabinet and accessible from behind the cabinet by removing the back panels. The Motor
Controller Control Head commands the resistors into the DC bus circuit; maintaining the DC bus voltage
at a safe level. The two (2) resistors per actuator dissipate excess energy through heat generated during
actuator movement/retraction. The resistors each contain a temperature sensor to detect an overheat
condition and signal the PLC to shut down the Motion Base with a class 1 fault. Cooling fans reduce
resistor temperature.

WARNING: To prevent personnel burn injury, prior to servicing, verify the regeneration resistor
temperatures are cool/safe to touch.

Motion
System
Cabinet
(Rear View)

Figure 3-16. MCC – Regeneration Resistors

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3.1.13. Description – Dynamic Brake Resistors

The Dynamic Brake Resistors are adjustable resistors. These are factory set by the vendor with two (2)
parallel resistors per actuator to control the actuator retracting speed under emergency-battery operation
in the event of a power loss. The resistors are behind the two (2) outside panels in the backside of the
MCC and connect to the respective RTH controller and contactors.

Brake Resistors – Left

End Side of Cabinet
(Rear View)

Brake Resistors – Right

End Side of Cabinet

Figure 3-17. MCC – Dynamic Brake Resistors

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3.1.14. Description – Gland Plate

The Gland Plate is an Interconnection Panel located on the left end of the MCC. It provides connections
for Ethernet, Maintenance, Fire Detection, and Data Communication from/to the Programmable Logic
Computer to/from other simulator systems.

Figure 3-18. MCC – Gland Plate

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3.1.15. Description – Controls and Indicators

The far left side door of the MCC contains the controls, indicators, Mode Switch and an Emergency Stop
button.

Figure 3-19. MCC – Controls and Indicators

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3.1.15.1. MCC – Control Loading and Motion Emergency Stop

The Control Loading and Motion Emergency Stop (Formerly Motion Abort) Switch is a red, positive-
action, round push-abort-turn-on button that removes power from the Control Loading and Motion
System. When pressed, the simulator will settle to the at-rest position automatically. The Ramp/Stairs will
remain in the position it was prior to pressing the Emergency Stop.
It is NOT an Emergency Power Off function. It must be reset (turned clockwise) in order to bring up the
Control Loading and Motion Systems. Investigate and correct the reason for switch activation prior to
bringing up the Control Loading or Motion System.

3.1.15.2. MCC – DC Bus On Indicator

The DC Bus On Indicator illuminates when the +24Vdc bus powers. The bus powers when the Access
Ramp is in the full up position and the Programmable Logic Controller (PLC) sees no faults.

3.1.15.3. MCC – Control Loading and Motion Emergency Stop Engaged Indicator
The Control Loading and Motion Emergency Stop (formerly Motion Abort) Engaged Indicator illuminates
when the Control Loading and Motion Emergency Stop (Formerly Motion Abort) pushbutton is in the
latched (pushed in) position.

3.1.15.4. MCC – Control Loading and Motion Emergency Stop Circuit Acceptable Indicator
The Control Loading and Motion Emergency Stop (formerly Motion Abort) Circuit Acceptable Indicator
illuminates when the Control Loading and Motion Emergency Stop (Formerly Motion Abort) pushbutton
is in the out position and the Control Loading and Motion Emergency Stop (Formerly Motion Abort)
circuits are clear of errors.
See the following figure.

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Figure 3-20. MCC – Controls and Indicators – Cabinet Door

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3.1.15.5. Controls and Indicators – Emergency Stop Switch

The Emergency Stop (ESTOP) Switch is a round, red, positive-action pushbutton accessible at the front
of the left side cabinet.

• Emergency Stop – activating (pushing) the Emergency Stop pushbutton initiates a Control Loading
and Motion (CLM) System Abort Condition which turns off the CLM electric systems, the button
must reset (turned clockwise) in order to turn on the CLM System.
See the following figure.

WARNING: Only qualified personnel are to work on the Motion System. Do not allow
occupants in or near the simulator while engaging the DMS for the first time after an installation
or commissioning.

WARNING: Ensure that no items around the system area will become loose and hit personnel.
Keep personnel out of the Motion envelope at all times.

WARNING: Avoid major injury to personnel by keeping hands, fingers, elbows, and feet out
of harm’s way.

WARNING: Ensure that all personnel are clear of the cockpit controls before engaging the
Control Loading. The flight controls move into flight-neutral position when engaged.

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3.1.15.6. Controls and Indicators – Operation Mode Switch

The Operation Mode Switch switches the Motion System either to the Normal Mode (Host Computer)
operation or to the Maintenance Mode (Graphical User Interface (GUI) software control).

WARNING: Components overridden in the maintenance mode can create unsafe conditions
for personnel and equipment. Ensure that all personnel are clear of the simulator, Motion Base,
and out of the cockpit prior to operating the Motion System in the maintenance mode.

Mode
Switch

Emergency
Stop Switch

Figure 3-21. MCC – Indicator Panel Door

WARNING: Only qualified personnel trained on maintenance mode operation should attempt
to perform procedures in this mode.

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3.1.15.7. Controls and Indicators – Main Circuit Breaker Reset Handle

The Main Circuit Breaker on the right end of the MCC removes or restores power to the MCC and resets
the circuit breaker if it trips. Use the cabinet-door key to open the cabinet doors without powering off the
MCC.

WARNING: Only qualified persons are to work on the Motion System.

WARNING: Avoid major injury to personnel by keeping hands, fingers, elbows, and feet out of
harm’s way.

WARNING: Use a meter or other appropriate testing device to ensure power removal from
equipment.

MCC Main Power

Disconnect Switch
In Off Position

Figure 3-22. MCC – Main Disconnect

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WARNING: The MCC main disconnect switch does not prevent +48VDC battery power from
being applied to the Return to Home (RTH) amplifiers and causing actuator motion. In fact,
opening the disconnect while the actuators are not in the home position will cause the RTH
amplifiers to enable and activate. To ensure no motion occurs, in addition to removing facility
power to the MCC, open the following circuit breakers in the MCC: 11F1, 14F1, 17F1, 20F1,
23F1, and 26F1. Use a meter or other appropriate testing device to ensure power removal from
the equipment.

The Main Circuit Breaker Reset Handle is the primary power on and off switch. The Operation Mode
switch is a key switch for selecting between the Normal operation mode and the Maintenance operation
mode.

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3.2. MOTION CONTROL CABINET – PRINCIPLES OF OPERATION

The MCC distributes facility power to the motor-control drives, also known as Customizable Single Axis
(CSA) servo drives, for controlling the Motion Base Actuators within the safety limits required in normal
and failure modes. The MCC converts electrical energy to linear motion by using actuator-position
feedback to generate commands for velocity, acceleration, and current-limited Pulse Width Modulation
(PWM) torque.
The MCC contains all components necessary to transform, filter, distribute and limit electrical power from
the facility power through the motor drives, and to the Motion Base Actuators, sometimes referred to (in
vendor documentation) as Electro-Mechanical Actuators (EMA). The following paragraphs discuss MCC
principles of operation for cabinet with vendor drawing CD44117.

WARNING: Ensure all personnel are clear of the Motion Base and the Access Ramp prior to
energizing the Motion System.

Figure 3-23. Digital Motion System – MCC

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3.2.1. MCC Principals of Operation – AC and DC Power

The MCC input is 480Vac three (3)-phase through the main disconnect, an electrical filter, and then to the
series of contactors/breakers corresponding to AC and DC control circuits, including each of the six (6)
motor–controller servo drives.
AC power distribution includes 480Vac to the +24Vdc power supplies (2F1 and 2F2) and to the Control
Transformer for 240Vac distribution to the contactor coils and the +48Vdc RTH battery chargers.
One +24Vdc power supply (2F1) is dedicated to circuits for the UPS, coil contactors, the Programmable
Logic Computer (PLC), Return to Home (RTH) and home/pressure switches. The other power supply,
(2F2), outputs to circuit breakers exclusively connecting to MCC fans and motor-drive fans.

Figure 3-24. Block Diagram – Motion Control Cabinet

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3.2.1.1. MCC Power – Motor Drives

The motor drive input is 480Vac three (3)-phase. The input section of the drive is the converter.
The converter contains six (6) diodes, arranged in an electrical bridge to rectify the Alternating (AC)
waveform input resulting in a 650Vdc – 700Vdc output to the Direct Current (DC) Bus Section from a
480Vac input power waveform.
The DC Bus circuit smooth’s and conditions the rectified input waveform using an Inductor (L) and
Capacitor (C) LC filtering circuit. The DC bus outputs to the final section of the drive.
The inverter in each drive uses Insulated Gate Bipolar Transistors (IGBTs) to switch the DC bus on and
off at specific intervals. In doing so, the inverter creates a variable AC voltage and frequency output. The
output of the drive provides voltage pulses that are at a constant magnitude.
The drive controller signals the power device circuits to turn on the waveform positive half or negative
half of the power device. This alternating of positive and negative switches recreates a three (3)-phase
output to the actuator motor.

Figure 3-25. Simplified Schematic Diagram – Motor Drive

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3.2.2. MCC Principals of Operation – Actuator Positioning

The control head mounts in each motor controller, monitoring actuator parameters such as position and
temperature, while receiving/sending signals to the Programmable Logic Computer (PLC), Control
Loading and Motion (CLM), and actuators. Actuator position is determined/commanded by the use of
Hall-Effect generators resident in the actuator-motor rotor and switching the IGBTs in the appropriate
sequence.

Figure 3-26. Motor Control – IGBT Switching

The rotor position induces a pulse signal via the decoder circuit and the signal energizes the coils in the
proper sequence to achieve desired positioning.

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3.3. MOTION CONTROL CABINET – PREPARATION FOR USE

Perform the following check out and inspections prior to powering up the MCC.

WARNING: Only qualified personnel are to work on the Motion System. Do not allow
occupants in or near the simulator while engaging the DMS for the first time after an installation
or commissioning.

WARNING: Ensure that no items around the system area will become loose and hit personnel.
Keep personnel out of the Motion envelope at all times.

WARNING: Avoid major injury to personnel by keeping hands, fingers, elbows, and feet out
of harm’s way.

NOTICE: For additional information about the Motion System actuators, refer to vendor
documentation, the FSI Motion System User Manual (CDS38799).

Refer to vendor documentation.

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3.3.1. Motion Control Cabinet – Initial Check Out

Perform these check outs when initially installing or relocating a simulator and prior to energizing the
MCC for maintenance purposes or in starting up the Digital Motion System (DMS).

• Prepare the MCC as applicable, referring to Section 1.3.4.1.

• Ensure the cabinet doors close and latch.
• Ensure the main circuit breaker handle is in the proper position.
• Ensure the CLM EStop switch is reset, the DC Bus On light operates, the CLM EStop Engaged
light operates, and the CLM EStop Acceptable light illuminates.
• Ensure that the MCC components are in the correct configuration according to engineering
drawings and vendor documentation, especially the Amplifier Control Heads mentioned in Section
1.3.4.3.
• Ensure MCC cables are shielded with the shields properly terminated to ground.
• Ensure MCC warning and safety devices are in appropriate locations and positions.

WARNING: Ensure all personnel are clear of the Motion Base and the Access Ramp prior to
energizing the Motion System.

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3.4. MOTION CONTROL CABINET – OPERATION

The MCC operates and boots up as a standalone component before engaging with the DMS. Verify proper
operation of the MCC as an individual DMS component. The following paragraphs describe MCC
operation. It is important to follow all instructions in order, and to observe safety precautions at all times.

3.4.1.1. MCC Operation – Normal

The MCC mode switch is in Normal Mode to operate the DMS for customer simulation and training.
During the Normal mode of operation, the DMS engages under control of the Control Loading and Motion
(CLM) Server via Host Computer commands.
Refer to Figure 3-21.

NOTICE: During normal operation, the CLM DMS is powered up and engaged with the Motion
Base in the Neutral (or Null) position. The MCC must be running before starting training load.

WARNING: The MCC main disconnect switch does not prevent +48VDC battery power from
being applied to the RTH amplifiers and causing actuator motion. In fact, opening the disconnect
while the actuators are not in the home position will cause the RTH amplifiers to enable and
activate. To ensure no motion occurs, in addition to removing facility power to the MCC, open
the following circuit breakers in the MCC: 11F1, 14F1, 17F1, 20F1, 23F1, and 26F1. Use a meter
or other appropriate testing device to ensure power removal from the equipment.

Refer to the Section 1.4 for normal DMS operation after starting up the MCC.

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3.4.1.2. MCC Operation – Start Up

The following instructions power up the MCC. It is important to follow all instructions in order, observe
safety precautions at all times.

WARNING: Only qualified personnel are to work on the Motion System. Do not allow
occupants in or near the simulator while engaging the DMS for the first time after an installation
or commissioning.

WARNING: Ensure that no items around the system area will become loose and hit personnel.
Keep personnel out of the Motion envelope at all times.

WARNING: Avoid major injury to personnel by keeping hands, fingers, elbows, and feet out
of harm’s way.

Ensure 480Vac facility power is available to the MCC from the isolation transformer resident in the
ClmPDU Cabinet.

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3.4.1.2.1. Normal Start Up – Applying Power to the MCC

Use this procedure to turn on the MCC for DMS operation.
1) Apply power to the MCC by turning on the Main Disconnect. Allow approximately 12
seconds for the PLC to finish initializing (booting up), illuminating the AC Power On and
Backup Power Available LEDs.

• The Inhibit, Interlock, and Emergency LEDs will indicate the status of the respective
DMS components in the indicator circuits.

• The vendor software service is ready to communicate.

MCC Main Power

Disconnect Switch
in Off Position

Figure 3-27. MCC – Start Up

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WARNING: The MCC main disconnect switch does not prevent +48Vdc battery power from
being applied to the RTH amplifiers and causing actuator motion. In fact, opening the disconnect
while the actuators are not in the home position will cause the RTH amplifiers to enable and
activate. To ensure no motion occurs, in addition to removing facility power to the MCC, open
the following circuit breakers in the MCC: 11F1, 14F1, 17F1, 20F1, 23F1, and 26F1. Use a meter
or other appropriate testing device to ensure power removal from the equipment.

NOTICE: The Customizable Single Axis (CSA) servo drives will indicate faults (typically F3
and F11) until simulation software starts. A U1 will display on the drives after initial
configuration and no other faults exist.

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2) At the Keyboard Video Monitor (KVM) of the ClmPDU Cabinet, start the MCC vendor
(MOOG) Software Services using the GUI software.

Figure 3-28. MCC – Software Services

3) At the IOS or ClmPDU Cabinet KVM, start the simulation Train Load software resident in
the Simulation Control Server (SCS).

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Figure 3-29. MCC – Train Load

At this point, the MCC is operational and the EtherCAT communication between the SCS and Control
Heads is established. Software and configuration information is loaded into the heads.

NOTICE: If any Motor Controller Control Head has a problem loading configuration software,
none of the heads will display U1.

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3.5. MOTION CONTROL CABINET – MAINTENANCE

Refer to vendor documentation for complete MCC Maintenance and an Activity Matrix schedule.

3.5.1. MCC Maintenance – Inspections

Perform a visual inspection of the MCC cables, switches, and connections to ensure that items have no
damage or deterioration.

3.5.1.1. Inspections – MCC Filters and Cooling Fans

WARNING: Disconnect all incoming power to the Motion Control Cabinet prior to inspections.
After power is disconnected, use a meter or other appropriate testing device to ensure power
removal from the equipment.

WARNING: Wait at least 10 minutes before performing maintenance on the Motion Control
Cabinet to allow time for the 680Vdc capacitors charge to bleed off the motor controllers and
the return to home amplifiers.

WARNING: Disconnect the batteries prior to performing inspections on the battery circuits
because +48Vdc will remain on them.

Inspect all Motion Control Cabinet filters and cooling fans weekly and clean monthly or as needed in
accordance with the procedure in Section 3.5.2.1.

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3.5.1.2. Inspections – Electrical Cables Inspection

One of the most common maintenance problems with movable equipment is fraying and wearing of cables.
The design and layout of the simulator minimizes cable wear as much as possible. However, with as much
movement as the cables experience, fraying and wear of the cables still happens. Perform inspections on
a regular basis and immediately before and after cleaning.

WARNING: Disconnect all incoming power to the MCC prior to inspections. After power is
disconnected, use a meter or other appropriate testing device to ensure power removal from the
equipment.

WARNING: Wait at least 10 minutes before performing maintenance on the MCC to allow time
for the 680Vdc capacitors charge to bleed off the motor controllers and the return to home
amplifiers.

• Remove power to the Motion Control Cabinet by removing power to the MCC.
• Inspect all cables associated with the MCC, looking for frayed or worn edges at the connectors
and any sign of cables stress due to simulator movement. During inspection, pay close attention to
stretched or pinched cables. Make sure all actuator-power cable bundles separate from the signal
cable bundles by a minimum of 12". Where the signal cable bundles must cross the power cables,
make sure they cross at a 90-degree angle to prevent signal cable noise from degrading the
operation of the Motion Base.
• Inspect all other Motion cables, looking for damage, frayed spots, and broken connectors.

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3.5.1.3. Inspections – Weekly

Perform weekly inspections consistently and at a convenient time of the week.

• Inspect and clean simultaneously when the opportunity permits.

• Cycle the power to the MCC to ensure the cabinet starts and operates properly.

WARNING: Disconnect the batteries prior to performing inspections on the battery circuits
because +48Vdc will remain on them.

3.5.1.4. Inspections – Monthly

• Ensure that indicators and lights are operating and illuminating.
• Ensure cooling fans operate and are free of obstructions.
• Ensure switches operate and perform the designated functions as defined by vendor
documentation.

WARNING: Wait at least 10 minutes after disconnecting power before performing maintenance
on the MCC to allow time for the 680Vdc capacitors charge to bleed off the motor controllers
and the return to home amplifiers.

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3.5.2. MCC Maintenance – Cleaning

Refer to vendor documentation for complete MCC Maintenance and an Activity Matrix schedule.

3.5.2.1. Cleaning – Cooling Fans and Air Filters

Every month or 720 hours, verify that the MCC cooling fans operate with cabinet power applied; check
the following 29 fans:

• Seven (7) along the rear side of Motion Control Cabinet

• Four (4) in the back center panels below regeneration resistors
• Eighteen in the drive assemblies one (1) small and two (2) large per drive)
Use the following procedure to clean the MCC cooling fans and air filters. The following materials and
equipment are required to perform this procedure.

• Vacuum Cleaner
• Mild soap and water solution

WARNING: Disconnect all incoming power to the MCC prior to inspection/cleaning. After
power is disconnected, use a meter or other appropriate testing device to ensure power removal
from the equipment.

WARNING: Wait at least 10 minutes after disconnecting power before performing maintenance
on the Motion Control Cabinet to allow time for the 680Vdc capacitors charge to bleed off the
motor controllers and the return to home amplifiers.

The MCC air filters exist only on the cabinet doors and are hand removable from the front of the cabinet.
It is not necessary to open the MCC doors to replace the air filters.
See the following figures.

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4) Vacuum the cabinet exhaust fans on the rear side of the cabinet. Take care not to damage or
move the grills.

NOTICE: Do not operate MCC with the Air Filters removed. The Air Filters on the front side
of the MCC doors are at the only means of keeping dust out of the MCC.

MCC - Rear

Air Out - Fans

MCC - Front

Air In - Filters

Figure 3-30. Inspection – Cooling Fan Locations – Cabinet

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Figure 3-31. Cleaning – Air Filters

5) Remove the nine (9) filters and clean in warm soapy water. Rinse thoroughly and let dry.
Vacuum the filter covers and filter holders.

NOTICE: Do not operate MCC with the Air Filters removed. The Air Filters on the front side
of the MCC doors are the only means of keeping dust out of the MCC.

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6) Install the filters in the filter holders.

7) Install the filter covers by pressing firmly on the front covers until they snap in place.

NOTICE: Do not operate MCC with the Air Filters removed. The Air Filters on the front side
of the MCC doors are at the only means of keeping dust out of the MCC.

WARNING: Disconnect all incoming power to the MCC prior to inspection/cleaning. After
power is disconnected, use a meter or other appropriate testing device to ensure power removal
from the equipment.

WARNING: Wait at least 10 minutes after disconnecting power before performing maintenance
on the Motion Control Cabinet to allow time for the 680Vdc capacitors charge to bleed off the
motor controllers and the return to home amplifiers.

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8) Vacuum any dust accumulation from the three (3) cooling fans on each of the six (6) actuator
drives.
9) Vacuum the motor controller fan cooling fan grills located on the bottom of each Motor
Controller.
10) Vacuum the exterior housing and surrounding area of the motor controllers, as needed, while
performing inspections.

NOTICE: The air-flow design of the MCC keeps the interior free of dust accumulation. No air
filters are present in the MCC interior.

Figure 3-32. Inspections – Cooling Fan Locations – Drives

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11) Vacuum any dust accumulation from the four (4) regeneration resistor cooling fans, two (2)
behind each center relay panel, taking care not to damage the resistors or wiring.

WARNING: Disconnect the batteries prior to performing maintenance on the battery circuits
because +48Vdc will remain on them.

MCC - Rear

Figure 3-33. Inspections – Cooling Fan Locations – Regen Resistors

Use the MCC Start Up procedure in this Section 3.4.1.2 to power up the cabinet.

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3.5.3. MCC Maintenance – Quarterly – Testing of Lead-acid Batteries and RTH Circuit
Failed batteries prohibit the Motion System from performing the RTH function. The following procedures
prevent a Lean-Out Condition of the Electric Motion Base. Refer to vendor documentation.

WARNING: Follow required and recommended safety procedures when performing electrical
maintenance.

Test each lead-acid battery under load using a battery-load tester. Refer to engineering drawings and
vendor data as needed. Tools needed:

• Standard Technician Tools Kit

• Associated Equipment Battery Tester Model 6029, or equivalent

• Batteries Test

• Connect load tester to each battery in accordance with manufacturer specifications to

ensure proper current and voltage level.

• If only one is weak or bad, replace all batteries.

NOTICE: Batteries must be replaced every four (4) years regardless of their apparent condition.

Return to Home (RTH) Circuit Test

• Engage the Motion System to test the functionality of the RTH circuit. Wait for the
system to stabilize at the neutral position and press the Emergency Stop (ESTOP)
switch.

• Monitor LEDs on the RTH Amplifier for the following illuminations during the abort
sequence:
o Power On: Green
o Enable: Green
o Brake: Red

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If RTH amplifier LEDs do not illuminate properly or the Motion Base does not settle properly, test each
actuator RTH circuit separately. One at a time, extend each actuator 70 percent, and press the Emergency
Stop (Formerly Motion Abort) switch.

NOTICE: Batteries need time to recover from the Emergency Stop (ESTOP) event. Fully
recharge all batteries after every third Emergency Stop (ESTOP) sequence.

If LEDs still do not illuminate as noted above, further inspection of the RTH circuit is required.
Contact Flight Safety Simulation (FSS) Simulation Operations Support (SOS) Field Service engineering
as needed.

3.5.3.1. Schedule – Quarterly

Perform maintenance to components and sub-assemblies according to vendor documentation.

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3.5.4. Inspections – Additional Motion Control Cabinet Components

Perform visual inspection of the following components in the Motion Control Cabinet once every three
(3) months or more frequently if required. The following special tools are required:

• Digital Multimeter
Affected Moog Cabinet Model:

• -127-338, affecting actuators -880-078 and -079

Inspection Procedure:
1) Turn off all power to the Motion Control Cabinet.

WARNING: Prior to working on the MCC, disconnect all incoming power. After power is
disconnected, use a meter or other appropriate testing device to ensure power removal from the
equipment.

WARNING: Wait at least 10 minutes after powering down the MCC. Before performing
maintenance on the Motion Control Cabinet to allow time for the 680Vdc capacitors charge to
bleed off the motor controllers and the return to home amplifiers.

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2) Visually inspect the contactors listed immediately before or after cleaning within the
respective area:
Affected Contactor Assemblies:

• 1F1 Main Disconnect

• 62K1 and 63K1 RTH Power Contactors

• 79K1, 79K2 DC Power Bus Bar Contactors

• 6K7, 6K8 and 6K9 Dynamic Brake Resistors Contactors

3) Look for burnt, worn, or heat-damaged contactors in and around the component area, and any
evidence of burnt or worn components nearby.
Refer to vendor documentation for reference numbers and wiring diagram information if replacement or
removal of the contactors, as needed.

DC Power Bus
Contactors

Dynamic
Brake
Contactors

Figure 3-34. Inspections – Contactors Locations

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4) Inspect for signs of physical or heat damage. Ensure no damage exists on either of the
electrical contacts on the backside.
5) Measure the electrical resistance with a Digital Multi Meter (DMM). The resistance should
initially read a few Megohms and increase to infinite over about five (5) seconds. A defective
component will indicate infinite resistance for the first application of the DMM.

3.5.5. Troubleshooting – Motion Control Cabinet Faults

If experiencing problems with Motion Control Cabinet faults, refer to vendor documentation for COTS-
specific troubleshooting procedures, including corrective action trouble shooting charts and MCC faults.

3.5.6. Troubleshooting – Timing Charts

If experiencing problems with Motion Control Cabinet operation such as verifying simulation software
start up sequence, the PLC software sequence, and the DMS engagement sequence, refer to the vendor
documentation COTS-specific troubleshooting procedures, including MCC timing chart information and
Fault Code list.

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3.5.7. MCC Maintenance – Removal and Replacement

Use the following procedures for removal and replacement of typical MCC components located in the
MCC.

3.5.7.1. Removal and Replacement – Motion Control Cabinet

WARNING: Prior to working on the Motion Control Cabinet, disconnect all incoming power.
After power is disconnected, use a meter or other appropriate testing device to ensure power
removal from the equipment.

WARNING: Wait at least 10 minutes before performing maintenance on the Motion Control
Cabinet to allow time for the 680Vdc capacitors charge to bleed off the motor controllers and
the return to home amplifiers.

WARNING: Orange wires indicate parts of the cabinet that are battery powered and live. Use
lock/tag out procedures and Personal Protective Equipment (PPE) as appropriate and necessary
while performing maintenance activities.

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WARNING: In addition to removing facility power from the cabinet, ensure that Motion
System movement does not occur by opening the following circuit breakers in the MCC prior
to performing maintenance: 11F1, 14F1, 17F1, 20F1, 23F1, and 26F1.

NOTICE: To avoid damage to electrical components, observe the ESD and Handling
precautions in the introduction of this manual.

Refer to vendor documentation as necessary.

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3.5.7.1.1. Motion Control Cabinet – Servo Drive Assembly Replacement

The servo drive assembly is made up of two components: the servo drive and the servo control head. The
following section describes the removal of the servo drive assembly (the drive and the control head). The
procedure following the assembly removal describes the removal of the servo control head only.

3.5.7.1.1.1. Motion Control Cabinet – Servo Drive Assembly Replacement

1) Shut down and remove power from entire simulator before beginning, refer to Section 1.4.2.
Operation – Shut Down. Wait at least ten (10) minutes before proceeding.

WARNING: Prior to working on the Motion Control Cabinet, disconnect all incoming power.
After power is disconnected, use a meter or other appropriate testing device to ensure power
removal from the equipment.

WARNING: Wait at least ten (10) minutes before performing maintenance on the Motion
Control Cabinet to allow time for the 680Vdc capacitors charge to bleed off the motor
controllers and return to home amplifiers.

WARNING: The servo drives are very heavy and have sharp edges. To avoid injury, use
proper protective clothing, lifting techniques, and equipment.

2) Remove and label all electrical wires, connectors, and cables connected to the servo drive.

WARNING: HEAVY OBJECTS should not be lifted alone. When necessary ask for
assistance and use proper lifting procedures.

3) The drive is approximately 65 lbs. It is recommended that two (2) people lift the drive from
cabinet.
4) Loosen screws on top and bottom of drive.
5) Lift up and remove drive.

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6) Install replacement drive.

7) Replace and torque screws to 22 in lb, ± 2 in lb.
8) Reconnect all electrical wires, connectors, and cables to the new drive.
9) Adjust the Drive ID if necessary to match the Drive ID on the old drive. See Section
3.5.7.1.1.3. Motion Control Cabinet – Drive ID.
10) Power up motion cabinet as described in Section 3.4.1.2. MCC Operation – Start Up.
11) Refer to MOOG Manual: FSI Motion System User Manual Electric Motion Systems
CDS38799 Rev C 2013 to update Drive firmware.
12) Test component in maintenance mode.

3.5.7.1.1.2. Motion Control Cabinet – Servo Control Head Assembly Replacement

1) Shut down and remove power from entire simulator before beginning, refer to Section 1.4.2.
Operation – Shut Down. Wait at least ten (10) minutes before proceeding.

WARNING: Prior to working on the Motion Control Cabinet, disconnect all incoming power.
After power is disconnected, use a meter or other appropriate testing device to ensure power
removal from the equipment.

WARNING: Wait at least ten (10) minutes before performing maintenance on the Motion
Control Cabinet to allow time for the 680Vdc capacitors charge to bleed off the motor
controllers and return to home amplifiers.

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Figure 3-35. MOOG Servo Control Head

2) Remove connector blocks from the J2A and J2C ports.

Figure 3-36. Connector Blocks Removed

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3) Remove Ethercat cables from bottom of head.

Figure 3-37. Remove Ethercat Cables

4) Remove screw from underside of the servo control head.

Figure 3-38. Remove Screw from Underside of Servo Control Head

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5) Loosen the two (2) screws from the topside of the servo control head. With both screws
loose, the angle bracket will twist out of the way to allow removal of the head.

Figure 3-39. Loosen Screws On Topside

6) With the head free, remove the wire ribbon from the card inside the head.

Figure 3-40. Remove Wire Ribbon From Servo Control Head

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7) To install a new head, follow steps two (2) through six (6) in reverse order.
8) Ensure the Drive ID on the new servo control head is the same as the old one. If it is different
adjust the Drive ID, see Section 3.5.7.1.1.3. Motion Control Cabinet – Drive ID.
9) Once Drive ID is found to be correct, power up motion cabinet as described in Section
3.4.1.2. MCC Operation – Start Up.
10) Reapply home offsets with MOOG application.

3.5.7.1.1.3. Motion Control Cabinet – Drive ID

The Drive ID must be correct on the new servo control head. Ensure its ID matches the old servo control
head. The table below lists the hexadecimal values and corresponding axis and Switch IDs.

Table 3-2. Drive ID

Axis ID2 ID1 Decimal

Switch Switch Value
A 2 1 33
B 2 2 34
C 2 3 35
D 2 4 36
E 2 5 37
F 2 6 38

To adjust the servo control head, follow the procedure below.

1) Shut down and remove power from entire simulator before beginning, refer to Section 1.4.2.
Operation – Shut Down. Wait at least ten (10) minutes before proceeding.

WARNING: Prior to working on the Motion Control Cabinet, disconnect all incoming power.
After power is disconnected, use a meter or other appropriate testing device to ensure power
removal from the equipment.

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WARNING: Wait at least ten (10) minutes before performing maintenance on the Motion
Control Cabinet to allow time for the 680Vdc capacitors charge to bleed off the motor
controllers and return to home amplifiers.

2) With a small flat head screwdriver, adjust the switches on the front of the control head until
they match the old control head.

Figure 3-41. Motion Control Cabinet – Drive ID

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3.6. MOTION CONTROL CABINET – DIAGRAMS

Use the following vendor manuals for additional maintenance tasks and diagrams:

• FSI Motion System User Manual – Electric Motion Systems

• 127-388 Motion Control Cabinet
• 880-078/-880-079 Actuators

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3.6.1.1. Diagrams – Return to Home

The Return to Home (RTH) circuit activates during an emergency/fault condition. The RTH circuit
consists of Insulated Gate Bipolar Transistors (IGBT) switching to provide a series of DC pulses to the
motor and six (6) IGBTs, two (2) for each phase. The IGBTs control the frequency and voltage of the
simulated three– (3) phase Vdc to the actuators. Each IGBT has a diode in parallel but positioned to
conduct current in the opposite direction. The "anti-parallel" diodes conduct the portion of the motor
current waveform that lags the voltage.
Use the RTH circuit as necessary to troubleshoot and restart the DMS after an emergency stop condition.
Refer to vendor documentation.

Figure 3-42. Diagram – RTH Circuit Diagram

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SECTION 4. ACCESS RAMP ASSEMBLY

This manual discusses the various configurations and control of the Access Ramp Assembly as applicable
to general simulator configurations.

4.1. ACCESS RAMP ASSEMBLY – FUNCTION

The Access Ramp provides the flight students and instructors safe, normal egress to the simulator by
means of a platform or steps with guide rails.

WARNING: Stand clear of the Access Ramp Assembly while in operation. Do not touch or
impede proper motion/movement of the Access Ramp Assembly.

WARNING: Prior to working on the Access Ramp Assembly, disconnect all incoming power.
After power is disconnected, use a meter or other appropriate testing device to ensure power
removal from the equipment.

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4.2. ACCESS RAMP ASSEMBLY – DESCRIPTION

The Access Ramp consists of a platform or steps with guide rails. Typically, the Access Ramp is hinge
mounted to the facility’s balcony in such a manner as to allow convenient raising or lowering of the
Ramp/Stairs when the DMS energizes, de-energizes, or is in an emergency condition. The Access Ramp
is mounted to the floor either directly or with an intermediate platform.

4.2.1. Description – Access Ramp Assembly (4A1)

The Access Ramp Assembly (4A1) provides access to the interior of the simulator and typically includes
the following components:

• Access Ramp Floor/Ramp/Stairs Mats

• Ramp/Stairs/Steps
• Porch/Edge
• Ramp Control Module (8A1A2)
• Manual Ramp raise/lower control (9A9A2)
a. Ramp/Stairs Up/Down Switches
• Ramp/Stairs Actuator
• Ramp/Stairs/Motion Warning System
• Gate and Associated Electrical Components
See the following figure.

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Figure 4-1. Component Description – Ramp Assembly

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4.2.2. Description – Up/Down Switches

The DMS uses Access Ramp position switches for Access Ramp operation. The Motion Interlock Switch
is a safety device that prevents application of motion-actuator drive voltage when the Ramp/Stairs is not
in the fully raised position.

• Access Ramp Up Switch (4A1A2S1) – Indicates to the CLM I/O System when the Access Ramp
is in the full up position.
• Access Ramp Down Switch (4A1A2S2) – Indicates to the CLM I/O System when the Access
Ramp is in the full down position.
• Motion Interlock Switch (4A1A2S3) – Closes when the Access Ramp is in the full up position and
indicates to the DMS that the Access Ramp is out of the way and ready for Motion activation when
all other interlocks close.
• Gate Switch (9A9A3S1) – switch closes when the back porch gate is properly closed, indicating
to the Access Ramp system when the gate is out of the way of Ramp/Stairs movement.
See the following figures.

Access Ramp Down Switch

Side View
(4A1A2S2)

Front View

Side View Motion

Ready/Interlock
Switch
(4A1A2S3)

Access Ramp
Up Switch
(4A1A2S1)

Figure 4-2. Component Description – Ramp/Stairs Up/Down Switch

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Ramp Down
Condition

Ramp Up
Condition

Figure 4-3. Component Description – Ramp/Stairs Switches (Ref.)

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4.2.3. Description – Floor/Ramp/Stairs Mat Switches

The mat switches are pressure-sensitive safety devices made of flat black-rubber mats near the entrance
of the simulator and mounted on the top surface of the:

• Porch Floor/Edge
• Ramp/Steps
The CLM I/O System continuously monitors the floor-mat switch status. Applying weight to the mats
sends a signal to the CLM I/O System to inhibit the Motion-on sequence. If the Ramp/Stairs is in motion,
the ramp movement halts, then proceeds after removing the weight/pressure from the mat surface and
clearing/resetting the DMS at the IOS area.

Ramp and
Floor Mats

Figure 4-4. Component Description – Floor Mat Switches

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4.2.3.1. Mat Switch – Ramp/Steps

The Ramp/Stairs mat switch(s) is a flat black-rubber mat safety device mounted on the top surface of the
Access Ramp steps. The porch mat switch prevents Ramp/Stairs movement when activated by weight or
pressure. Removing the weight/pressure from the mat surface and clearing/resetting the DMS at the IOS
area.
The Controls I/O System monitors the Access Ramp mats. When stepped on, the mat inhibits the Motion-
on sequence, or, if the Ramp/Stairs was in motion, Ramp/Stairs movement proceeds after removing the
weight and then resetting DMS at the Instructor Operating Station (IOS).

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Ramp Floor

Figure 4-5. Component Description – Ramp Mat Switch

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A Floor mounted Access Ramp may include an intermediate platform attachment to a stairway with step
mat switches to prevent the Access Ramp from raising or lowering. Activating any one of these mats
causes the DMS (if energized) to sequence off.

Figure 4-6. Component Description – Stair Mat Switches

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4.2.3.1.1. Description – Actuator (4A2)

The Ramp/Stairs actuator contains a DC electric motor driving a screw shaft internally to provide
movement of the upper shaft of the actuator. The actuator also contains a brake, an over-temperature
sensor, and an encoder.

Actuator
(Ramp Down)

Actuator
(Ramp Up)

Actuator
Encoder

Figure 4-7. Component Description – Ramp/Stairs Actuator

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4.3. ACCESS RAMP ASSEMBLY – PRINCIPLES OF OPERATION

The Access Ramp functions in conjunction with the DMS. The following paragraphs describe the
principles of operation of the Access Ramp. The basic operation of both the balcony-mounted and the
Floor-mounted Ramp/Stairs is the same.

Ramp in Up
Position

Figure 4-8. Block Diagram – CLM Access Ramp – Typical

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4.3.1. Access Ramp – Ramp/Stairs Down

When the Motion System energizes, the CLM I/O System monitors the Ramp/Stairs to determine if the
Access Ramp is in the down position and if the gate is closed. The I/O system checks if the Access Ramp
and porch mat switches do not activate and transmits this information to the CLM Server. The CLM Server
also receives the Motion Actuator retract (home) switch inputs from all six (6) Motion Base Actuators and
verifies their home position (switches closed).

WARNING: Ensure all personnel are clear of the controls prior to energizing the Access Ramp
Assembly.

Figure 4-9. CLM Access Ramp – Down Position

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4.3.2. Access Ramp – Ramp/Stairs Up

After ensuring that the Access Ramp Assembly meets operationally safe conditions, the CLM Server
issues a ramp-up command to the Ramp Control Module. The Servo Smart Drive in the Ramp Control
Module will in turn release the brake and send output electrical power to drive up the Ramp/Stairs.
The Ramp/Stairs actuator position feeds back to the Servo Smart Drive to control the speed of the actuator
driving the Ramp/Stairs. The encoding causes the Servo Smart Drive to slow down the travel speed of the
Ramp/Stairs (to avoid position over-travel) until reaching the fully up position. The CLM I/O System
monitors to verify Access Ramp up position and The Servo Smart Drive in the Ramp Control Module
activates the brake to hold the Ramp/Stairs in place.

Figure 4-10. CLM Access Ramp – Up Position

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4.4. ACCESS RAMP ASSEMBLY – PREPARATION FOR USE

This manual discusses the various configurations and control of the Access Ramp Assembly as applicable
to general simulator configurations.

4.4.1.1. Access Ramp Assembly – Initial Checks

Perform the following checks prior to utilizing the Access Ramp Assembly.

WARNING: Disconnect all incoming power to the Access Ramp Assembly prior to inspections.
After power is disconnected, use a meter or other appropriate testing device to ensure power
removal from the equipment.

• Perform daily cleaning/inspections as applicable to the DMS maintenance schedule in Section

1.5.4.1 and Section 1.5.4.4.
• Perform additional site-specific inspections/checks as deemed necessary, such as a walkaround the
simulation area to ensure safety and functional compliance.
• Check for signs of burning and overheating.
• Check wiring for damage or loose connections.
• Check for oil leaks in and around the Access Ramp Assembly.
Note the overall condition and appearance of the Access Ramp Assembly. Look for obvious changes or
developments that may have occurred the previous day/night shift. Remove operational obstacles as
necessary.

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4.5. ACCESS RAMP ASSEMBLY – OPERATION

The Motion software controls the normal operation of the Access Ramp. The Access Ramp also operates
manually. The following paragraphs focuses on the manual operation process.

WARNING: Keep personnel away from all moving parts of the Access Ramp while it is in
operation.

4.5.1. Access Ramp Operation – Manual

Manual operation of the Access Ramp becomes necessary during emergency use when there is a system
power loss or for maintenance purposes.

WARNING: Keep arms, legs, hands, feet or other body parts away from all moving parts of the
Access Ramp while it is being raised or lowered manually.

After the Motion System is down and if the Access Ramp is in the up position when the system power is
lost, manually lower the Access Ramp by pressing the Lower Ramp Switch located on the back wall of
the Instructor Compartment. The Access Ramp also lowers by using the Ramp Control switch located on
the Ramp Control Module.

4.5.2. Description – Control Module (8A1A2)

The Ramp Control Module in the CLM Power Distribution Unit (PDU) Cabinet controls the up/down
movement of the Access Ramp Assembly and contains the following components:

• Digital Servo Drive – for driving the Ramp/Stairs actuator

• +24Vdc power supply – for ramp logic circuits
• Emergency Ramp Up and Ramp Down controls
• Voltage indicators, fuses, and related components
These components are necessary to perform all the functions to control the Ramp/Stairs. Refer to the
Digital Control Loading System Operation and Maintenance Manual.
See Section 1.1.4.2.2.1 for Ramp/Stairs Control Module information.

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4.6. ACCESS RAMP ASSEMBLY – MAINTENANCE

The following paragraphs discuss maintenance of the Access Ramp Assembly.

4.6.1. Access Ramp Maintenance – Troubleshooting

Use the procedures listed below to troubleshoot problems with Access Ramp Assembly operation. Take
corrective action to adjust/replace malfunctioning components.

4.6.1.1. Access Ramp – System Error

Check CLM IOS Debug pages for correct operation of the following safety interlock components.

• Gate/Porch Mat
• Ramp/Stairs Mat
• Emergency Stop (formerly Abort Button)
• Maintenance Mode

4.6.1.2. Access Ramp – Ramp Will Not Come Down

If failure occurs during an Emergency Power Off (EPO) situation and after the base safely settles from a
Return To Home (RTH) sequence, use the Ramp drive switches located in the instructor compartment or
at the ClmPDU Cabinet Ramp Control Module to manually drive the Ramp/Stairs down to the egress
position.
Some simulators have an optional, auto-ramp down function modification wired in case of power loss
after the six (6) Motion Base Actuators RTH. The Ramp/Stairs automatically descends in simulators with
this modification.

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4.6.1.3. Access Ramp – Ramp/Stairs is Stuck Somewhere in the Middle of Travel

Refer to System Errors using the CLM IOS Debug pages, and engineering drawings.
Could be the result of:

• Stepped On the Ramp Mat Sensor(s)

• Intermittent Ramp Mat Sensor(s)
• Intermittent/Misadjusted Gate Switch
Possible ways to remedy:

• Check if the Ramp Control Module displays a failure. Amplifier Clear Button is illuminated amber
if failure is present. Press Amplifier Clear Button. If the failure does not clear, repeat the reset up
to three (3) times. If necessary, refer to drawing ABF411.
• With no failures on the ramp cabinet, manually operate the Down Switch to move the ramp.
Recheck Ramp Control Module failures again to ensure no new failures occur.
• Once the ramp is down, go to the CLM IOS Debug pages, and press Motion Clear.

Refer to System Errors using the CLM IOS Debug pages, and refer to engineering drawings.

WARNING: Keep arms, legs, hands, feet or other body parts away from all moving parts of the
Access Ramp while it is being raised or lowered manually.

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4.6.1.4. Access Ramp – What to Know about Safety Components

Any of the following components will prevent ramp movement due to hardware interlock within the Ramp
Control System.

• The Ramp Mat Sensor is wired in series with the following components.
o Gate Switch interlock.
o Ramp Up/Down Relays inside the ramp cabinet.
o Ramp Up/Down Position Switches on the ramp.
o Ramp Actuator Brake.
Proper switch and relay settings enables ramp movement.

• The Ramp Up/Down Relays are controlled by the following.

o CLM Software through the CLM I/O System.
o Ramp Control buttons in the back of the Instructor Station.
o Ramp Control Unit in the ClmPDU Cabinet.
The Ramp Up/Down Relays are located in the module of the ClmPDU Cabinet.
See the following figure.

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To PLC

Figure 4-11. CLM Access Ramp – Up/Down Ready Switches

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4.6.1.5. Access Ramp – Ramp System Discrete Inputs to the CLM I/O System
The Motion Base will not move unless the ramp is up. The ramp-enable signal is strictly a safety hardware
interlock not controlled by software.

• Ramp/Stairs Mat
• Gate Switch/Porch Mat (same Discrete Input)
• Ramp Up Position
• Ramp Down Position
An additional switch on the ramp carries the +24Vdc enable signal to the Motion Control Cabinet (CR2).
The switch (two wires) is located next to the ramp up switch (four wires). CR2 in the Motion Control
Cabinet will NOT engage if the ramp is not up (inspect visually).
See the following figures.

Figure 4-12. CLM Access Ramp – I/O Labels

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Figure 4-13. CLM Access Ramp – Typical Ramp Mat Switches

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4.6.2. Access Ramp Maintenance – Alignments and Adjustments

Use the following procedures to perform alignments and adjustment on components of the DMS.

4.6.2.1. Access Ramp Position and Gate Switches – Down Position Switch
Use the following procedure to adjust the Access Ramp down position switch.

WARNING: Keep arms, legs, hands, feet or other body parts away from all moving parts of the
Access Ramp while it is being raised or lowered manually.

NOTICE: Two (2) people are required to complete this procedure.

3) Ensure the Access Ramp is in the fully down position.

4) With a person in the simulator, have the other person manually operate the ramp switch on
the Remote Ramp Control Panel to raise the ramp approximately 12" to gain access to the
down position switch.
5) Place a 12" wooden block between the ramp and the simulator to prevent the ramp from
being driven down.
6) Loosen the bolts that secure the down position switch just enough to move the switch up to
the top of the adjustment slots.
7) Remove the wood block.
See Figure 4-14.

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FRONT
VIEW

SIDE
VIEW

Figure 4-14. Access Ramp Down Position Switch – Typical

8) Manually operate the Ramp down switch to lower the ramp to the fully down position resting
on the stanchions.
9) Lower the switch until it actuates against the bracket on the rear porch of the simulator.
10) Tighten the bolts that secure the down position switch.
11) Perform an operational check of the Access Ramp and the DMS in accordance with the
procedure in Section 1.5.4.8.
Refer to engineering drawings as needed.

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4.6.2.2. Access Ramp Position and Gate Switches – Up Position and Motion Interlock
Use the following procedure to adjust the Access Ramp up position switch and the Motion Interlock
switch.

WARNING: Keep arms, legs, hands, feet or other body parts away from all moving parts of the
Access Ramp while it is being raised or lowered manually.

1) Loosen the setscrews that secure the cam. Position the cam on the switch roller requiring
adjustment, as shown in the following figure.
2) Tighten the hex screws that secure the cam.

NOTICE: The upright position varies with installations. Typically, it is two (2) to three (3)
degrees short of vertical.

Refer to engineering drawings as needed.

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Figure 4-15. Access Ramp Up Position and Motion Interlock Switches – Typical

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1) Loosen the switch and adjust it to the cam to actuate at the midpoint along the notch in the
cam.
2) Tighten up the screws holding the switch being careful to maintain the adjustment.
3) Manually operate the ramp down switch to lower the ramp to the fully down position.
4) Perform an operational check of the Access Ramp and DMS in accordance with the
procedure in Section 1.5.4.8.
Refer to engineering drawings and Figure 4-15 as needed.

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4.6.3. Removal and Replacement – Access Ramp

Use the following procedures to remove and replace components of the Access Ramp.
4.6.3.1. Access Ramp – Mats
Use the following procedure to remove and replace the Access Ramp and doormats. The following special
tools are required to complete this procedure.

• Multimeter • Tags

WARNING: Disconnect all incoming power to the Motion Control Cabinet prior to performing
maintenance on the Motion Base. After power is disconnected, use a meter to ensure power
removal from the equipment.

1) Power down the ClmPDU Cabinet in accordance with the procedures in the CLM Control
System Operation and Maintenance manual.
2) Disconnect the cable connector from the Access Ramp mat.
3) Remove and tag the wires from the mat connector.
4) Remove the mat moldings.
5) Remove the mat.
6) Install the replacement mat.
7) Install the connector on the replacement mat. Ensure exact installation as on the old mat.
8) Connect the replacement mat connector.
9) Install the mat moldings.
10) Power up the ClmPDU Cabinet in accordance with the procedures in the CLM Control
System Operation and Maintenance manual.
11) Place a heavy object on the mat and verify that the Access Ramp will not move up or down
using the Ramp Control switch in the simulator.
Refer to engineering drawings as needed.

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4.6.3.2. Access Ramp – Switches

Use the following procedures to remove and replace the Access Ramp position switches.
4.6.3.2.1. Access Ramp Switches – Down Position Switch
Use the following procedure to remove and replace the Access Ramp down position switch. The following
special tools are required to complete this procedure.

• Multimeter • Tags

WARNING: Disconnect all incoming power to the Motion Control Cabinet prior to performing
maintenance on the Motion Base. After power is disconnected, use a meter to ensure power
removal from the equipment.

WARNING: Two (2) people are required to complete this procedure.

1) Manually operate the Ramp Up switch on the Ramp Control Module to raise the end of the
ramp approximately one foot to gain access to the down position switch.
2) Place a 12" wood block between the ramp and the simulator to prevent the ramp from driving
down.
3) Power down the ClmPDU Cabinet in accordance with the procedures in the CLM Control
System Operation and Maintenance manual.
4) Remove and tag the wires from the down position switch.
a. Remove the switch while noting its orientation. See the following figure.
b. Install and adjust the switch in accordance with the procedure in Section 4.6.2.1
5) Connect the wires to the replacement switch in accordance with their associated tags.
6) Remove the wood block.
7) Manually operate the ramp down switch to lower the ramp to the fully down position.

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Figure 4-16. Accessway Ramp Down Position Switch – Typical

8) Verify the down position switch activates when the ramp is in the down position.
9) Power up the ClmPDU Cabinet in accordance with the procedures in the CLM Control
System Operation and Maintenance manual.
10) Perform an operational check of the DMS in accordance with the procedure in
Section 4.6.2.1.
Refer to engineering drawings as needed.

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4.6.3.2.2. Access Ramp Switches – Up Position/Motion Interlock switches

Use the following procedure to remove and replace the Access Ramp up position and Motion Interlock
switches. The following special tools are required to complete this procedure.

• Multimeter • Tags

WARNING: Disconnect all incoming power to the Motion Control Cabinet prior to performing
maintenance on the Motion Base. After power is disconnected, use a meter to ensure power
removal from the equipment.

1) Power down the ClmPDU Cabinet in accordance with the procedures in the CLM Control
System Operation and Maintenance manual.
2) Remove and tag the wires from the switch.
3) Remove the switch while noting its orientation.
4) Connect the wires to the replacement switch in accordance with their associated tags.
5) Install and adjust the switch in accordance with the procedure in Section 4.6.2.2.
6) Power up the ClmPDU Cabinet in accordance with the procedures in the CLM Control
System Operation and Maintenance manual.
7) Perform an operational check of the DMS in accordance with the procedure in
Section 1.5.4.8.
Refer to engineering drawings as needed. See the following figure.

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Figure 4-17. Access Ramp Up Position and Motion Interlock Switches – Typical

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4.6.3.3. Access Ramp – Actuator Assembly

Use the following procedure to remove and replace the Access Ramp actuator. The following special tools
are required to complete this procedure.

• Multimeter • Tags

• Masking Tape

WARNING: Disconnect all incoming power to the Motion Control Cabinet prior to performing
maintenance on the Motion Base. After power is disconnected, use a meter to ensure power
removal from the equipment.

NOTICE: Make sure to have the correct length actuator prior to beginning this procedure. The
correct actuator part number lists on the ####A00020 drawing.

WARNING: Two (2) people are required to complete this procedure.

Use the following procedure to remove and replace the Access Ramp actuator:

WARNING: Take ramp encoder readings and change the program motion tasks in the drive
graphical user interface (GUI) before returning to normal operation otherwise damage or injury
might result.

1) Take ramp encoder readings and change the program motion tasks in the drive Graphic User
Interface (GUI) before returning to normal operation or damage/injury may result. Refer to
the GUI manual for encoder set up.
2) Power down the ClmPDU Cabinet in accordance with the procedures in the CLM Control
System Operation and Maintenance manual.
3) Disconnect and tag all wiring connectors from the actuator assembly.

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4) Remove the lower clevis pin while supporting the actuator.

5) Remove the upper clevis pin while supporting the actuator.
6) Place on a flat level surface.
7) Carefully position the replacement actuator upper clevis in the bracket and install the upper
clevis pin.
8) Carefully align the lower clevis in the lower bracket and install the lower clevis pin.
9) Reconnect the wiring connectors to the actuator assembly in accordance with the tags.
10) Power up the ClmPDU Cabinet in accordance with the procedures in the CLM Control
System Operation and Maintenance manual.
11) Perform an operational check of the Access Ramp and DMS in accordance with the
procedure in Section 1.5.4.8.
See the following figure.

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Upper
Clevis

Actuator

Lower
Clevis

Figure 4-18. Access Ramp Actuator – Typical

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4.6.3.3.1. Access Ramp Actuator Assembly – Actuator Encoder

Refer to the Graphic Users Interface (GUI) Manual to set up the actuator encoder. The following special
tools are required to complete this procedure.

• Multimeter • Tags

• Masking Tape

1) Power down the ClmPDU Cabinet in accordance with the procedures in the CLM Control
System Operation and Maintenance manual.
Refer to the GUI Manual.
2) Power up the ClmPDU Cabinet in accordance with the procedures in the CLM Control
System Operation and Maintenance manual.
3) Perform an operational check of the Access Ramp and DMS in accordance with the
procedure in Section 1.5.4.8.
Refer to engineering drawings as needed.

4.6.3.3.2. Access Ramp Actuator Assembly – Ramp Control (9A9A2)

Manual control of the Ramp Assembly is available inside the cabin area near the entrance. Refer to
Section 1.1.4.2.2.1 and Figure 1-4 for ramp control information.

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4.6.3.3.3. Access Ramp Assembly – Motion Warning System

The Motion Warning System consists of:

• a flashing Motion Warning Light (6A2A15)

o Marquee display
• a flashing RAMP light
o Marquee display
• an audible alarm
The flashing Motion Warning light mounts to the underside of the simulator and indicates (strobes) when
the Motion System is active.
Located at the rear of the simulator in a panel assembly beside the entrance in a typical simulator
configuration, the audible alarm and flashing marquee indicate the Access Ramp is in motion. The
marquee also displays when training occurring, illuminating when Control Loading is turned on. The
marquee monitor also indicates ramp movement, when training is taking place, or other notable
information.
See the following figures.

WARNING: Ensure all personnel are clear of the controls prior to energizing the CLM systems.

Figure 4-19. Component Description – Strobe Light and Audible Alarm

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Marquee

Figure 4-20. Component Description – Ramp/Motion Warning System Marquee

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4.6.3.3.3.1. Emergency Conditions – Emergency Power Off

The Emergency Power Off (EPO) positive-action switch removes all power to the simulator except for
critical systems (Emergency Lighting, Ramp, Servers, Marque, etc.). The Motion System returns to the
At-Rest position and the Ramp returns to the down position. The Uninterruptible Power Supplies (UPS)
will maintain Emergency Lighting, Ramp circuits, CLM cabinet (8A1-8A2), equipment cabinet (9A1-
9A2), and Marque power for approximately 10 minutes. Refer to simulator-specific drawings. The button
must be reset (turned clockwise) in order to bring power back to the simulator systems.
Investigate and correct the reason for the activation of the Emergency Power Off switch. It is important
to observe safety precautions at all times. Reset (turn clockwise) the Emergency Power Off switch to
restore power to the simulator systems prior to applying power to the simulator.

4.6.3.3.3.2. Emergency Power Off – Access Ramp Stops in Partial Travel

WARNING: In the event that the Access Ramp does not fully extend or retract, do not, under
any circumstances, put arms, legs, hands, feet, or other body parts between the Access Ramp and
simulator or in the way of any other moving parts of the Ramp, while checking interlocks.

WARNING: Stay out of the way of Access Ramp travel while checking interlocks. The Access
Ramp may move instantly when an interlock is closed.

Check all interlocks and verify they close. Once all interlocks close, if necessary, manually raise or lower
the Access Ramp using the Ramp Control switch on the Ramp Control Module in the ClmPDU Cabinet.
If the Ramp faults, the Amplifier Clear Button is illuminated amber.
If the manual ramp control switches do not move the ramp, it may be necessary to reset the Ramp Control
Module using the Amplifier Clear pushbutton on the front of the panel.
Refer to Figure 1-4.

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SECTION 5. EMERGENCY CONDITIONS

An Emergency Condition may develop during the operation of the simulator. Emergency buttons in and
around the simulator allow the user to stop Control Loading and Motion (CLM) systems with the
Emergency Stop button.
All power is removed to the simulator systems except for critical systems powered by an Uninterruptible
Power Supply (UPS) (Emergency Lighting, Ramp, Servers, Marque, etc.) by pressing the Emergency
Power Off button.

5.1. EMERGENCY SWITCHES – DESCRIPTION

Emergency Switches are accessible in and around the simulator area varying in appearance as round, red,
positive-action (push-activate-pull-deactivate) pushbuttons or as a toggle switch. The Emergency
Switches consist primarily of the following configurations:

WARNING: Ensure all personnel are clear of the controls prior to energizing the CLM systems.

• Emergency Stop – turns off the CLM Systems

• Control Loading/Emergency Stop (Formerly Motion Abort) Switch – same function as the
Emergency Stop
• Emergency Power Off (EPO) – removes power to all simulator systems except for critical UPS
backed up systems

Prior to resetting an emergency pushbutton switch, investigate and correct the simulator conditions
initiating the switch activation. It is important to observe safety precautions at all times. Turn to release
the Emergency Switch and restore power to the simulator systems prior to applying power to the simulator.

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5.1.1. Emergency Switches – Emergency Stop

The Emergency Stop Switch is a positive action, round, push-Abort-turn clockwise-on switch that aborts
the Control Loading and Motion (CLM) systems when pressed in. Activating (pushing) the Emergency
Stop pushbutton initiates a CLM System Abort Condition, which turns off the electric CLM Systems, the
button must be reset (turned clockwise) in order to restore power back to the CLM Systems.

• The Control Loading (C/L) and Emergency Stop (Formerly Motion Abort) switch – is a round,
push-off/turn-on switch (or can be a toggle switch) found in various areas of certain simulator
configurations. The C/L and Emergency Stop switch performs the same function as the Emergency
Stop pushbutton switch, initiating a CLM System Abort Condition.
Some Emergency stop switches mount to the pedestal in the Student Station (Cockpit) area. Investigate
and correct the reason for switch activation prior to bringing up the Control Loading or Motion Systems.

Emergency
Stop

Emergency Emergency
Stop Power Off
(EPO) Switch

Figure 5-1. Component Description – Emergency Switches – IOS

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WARNING: Ensure all personnel are clear of the controls prior to energizing the CLM systems.

5.1.1.1. Emergency Stop – Control Loading and Motion Emergency Stop Switch
The Control Loading and Motion Panel in some simulator configurations contains a Control Loading and
Motion Emergency Stop (Formerly Motion Abort) switch, Control Loading (C/L) switches, as well as a
Motion System and Motion Clear switch.
Pressing the round, positive action (push-abort-turn clockwise-on) Control Loading and Motion
Emergency Stop Switch aborts the CLM Systems. Investigate and correct the reason for switch activation
prior to bringing up the Control Loading or Motion Systems.

• The illuminated C/L System and Motion System switches turn the Control Loading and Motion
Systems on/off.
• The illuminated C/L Clear and Motion Clear switches reset/clear faults in the Control Loading and
Motion Systems.
Refer to Figure 5-1.

WARNING: Ensure all personnel are clear of the controls prior to energizing the CLM systems.

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5.1.1.2. Emergency Stop – CLM System On/Off

The CLM Systems restart by using the On/Off switches appearing on the Control Loading/Motion Panel
or equivalent device such as the Tactile Monitor present in certain FFS IOS configurations.
The Control Loading and Motion System Tactile Soft Buttons turn the CLM systems on/off.

WARNING: Ensure all personnel are clear of the controls prior to energizing the CLM systems.

Figure 5-2. Component Description – CLM Systems On/Off

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WARNING: Ensure all personnel are clear of the controls prior to energizing the CLM systems.

5.1.2. Emergency Switches – Emergency Power Off

The Emergency Power Off (EPO) positive-action switch removes all power to the simulator except for
critical systems (Emergency Lighting, Ramp, Servers, Marque, etc.). The Motion System returns to the
At-Rest position and the Ramp returns to the down position. The Uninterruptible Power Supplies (UPS)
will maintain Emergency Lighting, Ramp circuits, CLM cabinet (8A1-8A2), equipment cabinet (9A1-
9A2), and Marque power for approximately 10 minutes. Refer to simulator-specific drawings. The button
must be reset (turned clockwise) in order to bring power back to the simulator systems.
Investigate and correct the reason for the activation of the EPO switch. It is important to observe safety
precautions at all times. Turn to release the Emergency Power Off switch and restore power to the
simulator systems prior to applying power to the simulator. EPO pushbutton locations vary depending on
simulator configuration.
Refer to Figure 5-1 and see the following figure.

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Emergency Power Off

(EPO) Switch

Figure 5-3. Component Description – EPO Switch

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5.2. EMERGENCY SWITCHES – OPERATION

The following paragraphs cover emergency conditions or emergency indications arising in the CLM
Systems. It is important to follow instructions in order, observe safety precautions at all times.

5.2.1. Emergency Conditions – Control Loading and Motion Emergency Stop

When pressed, the Control Loading and Motion Emergency Stop (Formerly Motion Abort) switch will
shut down the Motion and Control Loading Systems, removing power from the Control Loading and
Motion System actuators should an emergency occur. The Motion System will Return to Home (RTH)
and settle to the at-rest position. The ramp will remain in the position it was prior to pressing the
Emergency Stop.
Investigate and correct the reason for the switch activation prior to bringing up the Control Loading or
Motion System. Turn to release the Control Loading and Motion Emergency Stop (Formerly Motion
Abort) switch to bring up the Control Loading and Motion Systems.
After resetting the Motion Interlock switch, pressing the Clear switch on the Control Loading/Motion
Panel resets the abort condition. Resetting clears any minor software faults resulting from the abort action.
If the Clear switch continues to flash, the system still has a fault and requires troubleshooting. The Control
Loading and Motion Systems turn back on after addressing all failures and faults.

5.2.1.1. Control Loading and Motion Emergency Stop – Upset Motion Recovery
The following procedure describes Motion Upset Recovery.

WARNING: In the event an actuator does not fully extend or retract, do not, under any
circumstances, put arms, legs, hands, feet, or other body parts between the Access Ramp and
simulator or in the way of any other moving parts while checking interlocks. An actuator may
move instantly when an interlock closes.

Use this procedure to retract an actuator and recover the Motion System when one or more actuator does
not RTH. It is important to follow all instructions in order. Observe safety precautions at all times.

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The following procedure describes a situation with the following conditions:

• One (1) or more Motion Actuators do not retract

• The Ramp/Stairs is up
• CLM real-time simulation running
• CL and Motion cabinet powered up
• The Host software running on the Simulation Control Server (SCS)
The figure illustrates an example of Actuator D (4) failing to retract.

Figure 5-4. Upset Motion Recovery – Failed Actuator Screen

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Perform the following Motion Upset Recovery procedure:

1) Press Emergency Stop (Abort) button at the Motion Cabinet, wait five (5) seconds, and reset
the abort button.
2) Check the Motion Reset on the CLM-IOS Pages. Reset if necessary.
a) Press Motion Reset button several times, until button next to it changes to Motion
Standby (Run).
b) Press Motion Standby (Run) to engage the Motion Base.
c) Observe that the Motion Base repositions to level and then retracts the actuators not
currently at home.
d) The Motion Reset button begins to flash. Press it several times until the Motion
Standby (Run) displays.
3) Perform a functional test on the DMS as in Section 1.5.4.8 and return to service when
acceptable.
This situation may occur when the set of +12Vdc batteries located in the DMS cabinet does not retain a
charge and an Emergency Stop (Formerly Motion Abort) is executed.
Evaluate the DMS cabinet and the RTH circuit to prevent a reoccurrence of a similar event. Any time a
Motion Base does not RTH during an abort or failed sequence, the RTH circuit requires repair. Observe
safety precautions at all times. Contact FlightSafety Simulation Operations Support for assistance.

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If the procedure above does not correct the simulator condition:

4) Press the “Warns Errors” button, in the lower left corner of the CLM-IOS Page.
5) The Error log displays.

Figure 5-5. Upset Motion Recovery – Error Log

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6) Press the “M S\cut” button in the lower right side of the CLM-IOS Page.
7) The Motion Shortcut menu displays.

Figure 5-6. Upset Motion Recovery – M s\cut Button

8) Click the Maintenance Mode is OFF button. The Maintenance Mode is ON will display at the
bottom of the pop up window.

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9) Click the Hostinterface Normal button. The Hostinterface Maint Mode will display at the
same location.

10) Click the “Computation Manager” button at the top right-hand side of the window page.

The Motion Computation Manager (MCM) index page displays.

11) Click on the Stop button.

Figure 5-7. Upset Motion Recovery – Motion Computation Manager Page

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12) Press the Motion Reset button until Motion Standby (Run) displays.
13) Press Motion Standby (Run) to engage the Motion Base.
14) Observe that the Motion repositions to level then retracts any actuators not currently at
home. The Ramp/Stairs lowers itself.
15) Stop the CLM Real Time simulation. Power Cycle the Motion Control Cabinet then restart
the CLM Real Time simulation again.
16) Perform a functional test on the DMS as in Section 1.5.4.8 and return to service when
acceptable.

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5.2.2. Emergency Conditions – Emergency Power Off

The Emergency Power Off (EPO) positive-action switch removes all power to the simulator except for
critical systems (Emergency Lighting, Ramp, Servers, Marque, etc.). The Motion System returns to the
At-Rest position and the Ramp returns to the down position. The Uninterruptible Power Supplies (UPS)
will maintain Emergency Lighting, Ramp circuits, CLM cabinet (8A1-8A2), equipment cabinet (9A1-
9A2), and Marque power for approximately 10 minutes. Refer to simulator-specific drawings. The button
must be reset (turned clockwise) in order to bring power back to the simulator systems.
Investigate and correct the reason for the activation of the Emergency Power Off switch. It is important
to observe safety precautions at all times. Turn to release the Emergency Power Off switch and restore
power to the simulator systems prior to applying power to the simulator.

5.2.2.1. Emergency Power Off – Access Ramp Stops in Partial Travel

Check all interlocks and verify they close. Once all interlocks close, if necessary, manually raise or lower
the Access Ramp using the Ramp Control switch on the Ramp Control Module in the ClmPDU Cabinet.
If the ramp faults, the Amplifier Clear Button is illuminated amber.

WARNING: In the event the Access Ramp does not fully extend or retract, do not, under any
circumstances, put arms, legs, hands, feet, or other body parts between the Access Ramp and
simulator or in the way of any other moving parts of the ramp while checking interlocks. The
Access Ramp may move instantly when the interlock closes.

If the manual ramp control switches do not move the ramp, it may be necessary to reset the Ramp Control
Module using the Amplifier Clear pushbutton on the front of the panel.
Refer to Figure 1-3.

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5.2.3. Emergency Conditions – Recovery

Refer to vendor documentation for diagrams and timing sequences to reset the DMS out of emergency
conditions. The following discusses the software emergency-condition recovery sequences.

5.2.3.1. Recovery – Software Start Up Sequence

See the figure for beginning the Software Start Up Sequence when recovering from an emergency
condition. Refer to vendor documentation.

Figure 5-8. Emergency Condition – Recovery Start

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See the figure for the MCC-NG Software Start Up Sequence when recovering from an emergency
condition.

Figure 5-9. Emergency Condition – Recovery

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5.2.3.2. Recovery – Software Engaging Sequence

See the figure for the MCC-NG Software Engaging Sequence after recovering from an emergency
condition.

Figure 5-10. Emergency Condition – Recovery – Motion Engage

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See the following figure for the sequence enabling the drives after recovering from an emergency
condition.

Figure 5-11. Emergency Condition – Recovery – Enabling Drives

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See the figure for the MCC-NG Motion Engagement Sequence after recovering from an emergency
condition.

The CLM Server commands the drives to the Start Position after the Ramp reaches the
Up position.
Control Head display code changes from 0 to 1 when the EtherCat Fieldbus activates.
Motion Engage Sequence is now complete.

Figure 5-12. Emergency Condition – Motion Engagement

5.2.4. Emergency Conditions – Access Ramp

The intended purposes for the manual operation of the ramp are for personnel evacuation and maintenance
purposes. After shutting down the Motion System, press the Raise Ramp or Lower Ramp switch located
at the back wall of the Instructor Compartment or at the Ramp Control Module to manually raise or lower
the Access Ramp . Use the module for cases where an emergency condition requires manual operation of
the Access Ramp.
Refer to Figure 1-4 for Ramp Control Module information.

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5.3. FLIGHTSAFETY PRODUCTION SUPPORT INFORMATION

If assistance is required for urgent support, especially after hours, contact the FlightSafety Production
Support emergency support line:
Monday through Friday, 8am-5pm CDT – (918) 259-4200
After-hours or weekends – (918) 994-3000
Alternate after-hours, contact the
Group Leader at FlightSafety Support – (918) 407-5228
For each phone tier, if there is no answer, leave a message for quick and accurate assistance. The
appropriate alias would also be [email protected]. These contact points are the most
expeditious means to receive urgent support.

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SECTION 6. EXITS

Exiting the simulator from the cockpit, or student station, requires the use of the cabin door to access the
porch area, and then onto the Access Ramp. This section discusses the cabin door and porch/gate area.
Refer to Section 4 for Access Ramp information.

6.1. EXITS – DESCRIPTION

The exits consist of the following components:

• Cabin Door – entrance into the Instructor/Cockpit area

o Kick-out Panel
• Porch – area between the cabin door and gate
o Kick-out Panel
o Egress Rope
• Gate – sliding gate to exit simulator frame onto Access Ramp

Ramp Control Emergency

Swinging Cabin
Panel Egress Rope
Door
Drawer

Sliding Porch
Gate Area

Access
Ramp

Figure 6-1. Component Description – Doorway and Gate Exits

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6.1.1. Exits – Cabin Door

The cabin door to the Instructor Compartment is made at FlightSafety Simulation (FSS) and constructed
of honeycomb aluminum. The door contains a kick-out panel for use in rare cases where the door might
remain shut or malfunction. The door hardware includes a lock free, Commercial-Off-The-Shelf (COTS)
doorknob and hinges.

Door Kick-Out
Panel

Figure 6-2. Component Description – Kick-out Panel

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One (1) of the following decals appears on the door Kick-Out Panel.

Figure 6-3. Component Description – Door Kick-Out Panel Decals

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6.1.1.1. Cabin Door – Kick-out Panel

The Cabin Door Kick-out Panel attaches to the cabin door with silicon adhesive applied to the corner
areas. The panel is clearly labeled and instructs the user of appropriate operation in the unlikely event the
door malfunctions.
For use in emergency conditions, simply kick the panel out towards the porch. Exit through the door and
move the panel out of the way. Leave room for other occupants to exit.
Refer to Figure 6-2.

6.1.2. Exits – Egress Rope

The Emergency Egress Rope and Egress Panel near the porch area is available for use in emergency
conditions of certain simulator configurations. The door label instructs the user to pull out the vertical
drawer by the black handle to deploy the white knotted, nylon rope and egress to a safe area below. The
egress rope is stored in a compartment on the wall near the aft side of the exit door. The rope provides a
means of egress available to occupants in cases where a rapid, alternate method to exit may be required.
Observe safety precautions and warnings when using this rope.

Emergency
Egress Rope
Drawer Decals

Figure 6-4. Component Description – Emergency Egress Rope Drawer

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6.1.3. Exits – Porch

The porch is the standing area between the cabin door and gate. The porch contains a floor mat to detect
the presence of objects or personnel in the area. The porch also provides access to the Porch Kick-out
Panel, the Ramp Control Panel, and Emergency Egress Rope to use in an emergency situation.

Ramp
Control
Panel

Emergency
Egress Rope
Sliding Drawer
Gate

Figure 6-5. Component Description – Porch Area

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6.1.3.1. Porch – Kick-out Panels

If an emergency egress becomes necessary, the Porch Kick-out Panel is visible and accessible from the
porch area and is for use with the Emergency Egress Rope. The Porch Kick-out Panel consists of two (2)
panels. The first panel consists of a black aluminum honeycomb panel pushing out the second panel made
of fiberglass.

Emergency
Egress Rope
Drawer

Emergency
Egress Porch
Kick-Out Panel

Figure 6-6. Component Description – Porch Area – Kick-out Panel

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6.1.4. Exits – Gate

The gate assembly includes a switch functioning as a safety device monitored by the Control Loading and
Motion (CLM) Input/Output (I/O) System. Opening the gate activates the gate switch, placing the Digital
Motion System (DMS) (if energized) into an Emergency Stop condition.

• Gate Switch (9A9A3S1) – switch closes and deactivates when the back porch gate properly closes,
indicating to the Access Ramp Motion Warning System when the gate is clear of Ramp/Stairs
movement

Gate Switch
(9A9A3S1)
Not Shown

Figure 6-7. Component Description – Gate Switch

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6.1.4.1. Gate – Locking Pin

The gate employs a closing/opening sliding door movement and locking pin mechanism to ensure the
safety of personnel and equipment. The gate locking pin secures the gate in the closed/opened position
and enables the communication of gate and ramp positions.

Ramp Down Position

Presses Plunger to
Activate/Deactivate
Locking-Pin Mechanism

Gate Locking Pin Gate Locking Pin

(Side View Under Frame) (Front View)

Figure 6-8. Component Description – Gate Locking Pin

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6.1.4.2. Gate – Switch

The Gate Switch indicates the gate open/close position and enables/disables operation of the DMS and
Access Ramp operation.

Ramp
Control
Panel

Gate Opened/Closed
Switch
(Behind Fiberglass Panel)

Figure 6-9. Component Description – Gate Switch

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6.2. EXITS – PRINCIPLES OF OPERATION

A Full Flight Simulator (FFS) requires the use a Porch Floor Mat, Gate, and Ramp. A Flight Training
Device (FTD) or simulator without a Motion Base requires the use of a cabin door and may, depending
on training facility needs, require a porch floor mat and Access Ramp to enter/exit the simulator.

6.3. EXITS – PREPARATION FOR USE

FSI Simulators are assembled in the manufacturing facility with a cabin door, porches, and a gate.
However, certain Emergency Stop functions of these components associated with DMS operation may be
adjusted to operate in a manner designed for specific training facility needs. Refer to engineering
drawings.

6.4. EXITS – EMERGENCY OPERATION

Operation of the exits during an emergency depends on many factors and variables too numerous to
mention in this document.
Use the following procedure as a general guideline to operate the emergency exits:

WARNING: Emergency Egress Operation is dangerous and can cause serious injury or death if
not properly executed.

1) To egress from the simulator during an emergency egress situation:

a. Exit through the cabin door – utilize the door kick-out panel as necessary.
b. Use the Ramp Control Panel without standing on the porch mat (only if Motion is
in the fully retracted position) to lower the Access Ramp (if not already lowered)
and exit using the Sliding gate and the Access Ramp.
c. If the ramp does not lower or the Motion System is not in the down position, use
the Porch Kick-out Panel and the Emergency Egress Rope as necessary.

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d. Push down on the green handle located on the top end of the kick-out panel and
kick/push the panel out and away from the porch area.
i. The kick-out panel will push the second (fiberglass) panel out and away
from the simulator frame causing the fiberglass panel to freefall to the
nearest location below.
ii. The green-handled kick-out panel will drop/swing out from the hinged,
bottom end providing an area/opening for personnel to exit the simulator
while holding the Emergency Egress Rope.
e. Deploy the Emergency Egress Rope by pulling out on the handle of the vertical
rope drawer located above the porch railing. The rope drawer is made of Kydex
material Drop the rope drawer out of harm’s way while removing the white,
knotted, nylon rope contained within. Drop the rope over the railing.
2) Personnel must securely hold the Emergency Egress Rope while lowering to safety and
away from harm’s way.

6.5. EXITS – MAINTENANCE

The maintenance of simulator exits consists primarily of ensuring proper operation and condition of the
following:

6.5.1. Maintenance – Cabin Door

No electrical components or materials are present on the Cabin Door. Perform periodic functional and
visual inspections of cabin door physical/mechanical operation and conditions as needed.

6.5.2. Maintenance – Porch Floor Mat

Refer to the Access Ramp Assembly maintenance requirements for Porch Floor Mat inspections and
operation.

6.5.3. Maintenance – Emergency Egress Rope

No electrical components or materials are present on the Emergency Egress Rope and drawer. Perform
periodic functional and visual inspections of Emergency Egress Rope physical/mechanical operation and
conditions as needed.

6.5.4. Maintenance – Gate

Gate maintenance depends on specific simulator and training center requirements and applications. Refer
to engineering drawings and Access Ramp Assembly maintenance requirements.

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GLOSSARY AND ABBREVIATIONS

This section is a glossary and list of applicable abbreviations. For additional non-specific and technical
terms not contained in this glossary, consult a technical dictionary.

GLOSSARY

Access Ramp
An access way to enter/exit the simulator includes Access Stairs in providing a means to
enter/exit the simulator.
Closed Loop
A system in which some form of feedback, in a simulator position or force or both, control the
position of a device at all times. Commanded position and actual position would be the same.
Drift is not possible.
Control Loading System
A sub-system responsible for making aircraft controls feel realistic.
Encoder
A position-measuring device mounted on the end of an electric actuator and connected to the
end of the internal drive screw.

Emergency Power Off

Removes all power to the simulator except for critical systems powered by a UPS (Emergency
Lighting, Ramp, Servers, Marque, etc.). The Motion System returns to the At-Rest position,
the Control Loading systems cease movement, and the Ramp returns to the down position.

Emergency Stop
Removes enabling power from the Control Loading and Motion Systems. The Motion System
returns to the At-Rest position and the Control Loading systems cease movement. The Ramp
will remain in the Up position.
Motion System
A subsystem responsible for giving realistic aircraft motion cues to the flight crew.
Non-condensing
An environmental condition in which air-borne water molecules will not form into a liquid.
Power Controller
The device where most power to the simulator is input and distributed.

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ABBREVIATIONS

AD Analog to Digital
AC Alternating Current, not associated with a specific voltage.
ADC Analog to Digital Converter
CB Circuit Breaker
CL Control Loading
CLM Control Loading and Motion Control System
CPU Central Processing Unit
CR Carriage Return
CW Clockwise
CCW Counter clockwise
CSA Customizable Single Axis
DA Digital to Analog
DAC Digital to Analog Converter
DC Direct Current
DCLS Digital Control Loading System
DI Digital Input
DMA Direct Memory Access
DMS Digital Motion System
DO Digital Output
DRAM Dynamic Random Access Memory
EMA Electro-Mechanical Actuators
EPROM Erasable Programmable Read Only Memory
ESD Electrostatic Discharge
EtherCAT Ethernet for Control Automation Technology (EtherCAT (5, 6), RJ45
Connector)
FSI FlightSafety International

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FT LB Foot Pound, a unit of torque

GB Gigabyte
GHz Gigahertz
GND Ground
IGBT Insulated Gate Bipolar Transistors
I/O or IO Input Output
IN LB Inch Pound, a unit of torque
IOS Instructor Operating Station
I/P or IP Industry Pack
KVM Keyboard-Video-Mouse
LED Light Emitting Diode
MB Megabyte
MHz Megahertz
MCC Motion Control Cabinet (Referred to as the Motion System Cabinet in some MOOG
documentation)
MSC Motion System Cabinet
NIC Network Interface Controller
O&M Operation and Maintenance
PC Printed Circuit or Personal Computer
PCB Printed Circuit Board
PCS Power Control System
PLC Programmable Logic Computer
PPE Personal Protective Equipment
PROM Programmable Read Only Memory
PSI Pounds Per Square Inch
PWA Printed Wiring Assembly
PWM Pulse Width Modulation
PWR Power

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SOS Simulation Operations Support

SS Simulation Systems
SSR Solid State Relay
TP Test Point
UNIDIG Unidirectional Digital
Vac Alternating Current Voltage
Vdc Direct Current Voltage

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INDEX

A Removal and Replacement - 2-42

Control Head
Access Ramp Description - 3-8
Emergency Operation - 5-19 Location - 3-8
Gate and Mat Switches - 6-7 Control Loading and ESTOP Circuit Acceptable
Manual Operation - 4-15, 4-38, 5-14 Indicator
Mat Switches - 4-7 Operation - 3-23
Principles of Operation - 4-11 Control Loading and Motin ESTOP Switch
Raising - 4-12 Controls and Indicators - 3-23
Troubleshooting - 4-16 Control Loading and Motion Abort Engaged Indicator
Access Ramp Switches Operation - 3-23
Adjustments - 4-22 Control Loading and Motion ESTOP Switch
Alignments and Adjustments - 4-22 Operation - 3-23
Removal and Replacement - 4-28 Control Loading/Motion Abort - 5-7
Access Ramp Actuator Sensors Controls and Indicators
Removal and Replacement - 4-35 Control Loading and Motion ESTOP Switch - 3-23
Access Ramp Components Ramp Control Module - 1-8
Removal and Replacement - 4-27 Controls I/O Patch Assembly
Access Ramp Mats Description - 1-6
Removal and Replacement - 4-27 Location - 1-6
Actuator Oil
Removal and Replacement - 2-60 D
Adjustments - 4-22 DC Bus On Indicator
Alignments - 4-22 Operation - 3-23
At-Rest (Home) Switch DC Power
Removal and Replacement - 2-58 Return to Home (RTH) - 3-50
Audible Alarm Description
Description - 4-36 24Vdc Power Supply - 3-17
Location - 4-36 Audible Alarm - 4-36
Backup Battery Chargers - 3-18
B Control Head - 3-8
Backup Battery Chargers Controls I/O Patch Assembly - 1-6
Description - 3-18 IOS Motion Control Loading Panel - 5-3
Location - 3-18 Motion Warning Light - 4-36
Battery Failure Motor Controller Drives - 3-7
Return to Home (RTH) - 3-50 Operation Mode Key Switch - 3-26
Battery Test Porch Mat Switch - 4-7, 4-9
Return to Home (RTH) - 3-50 Ramp Actuator - 4-10
Ramp and Gate Switches - 6-7
C Ramp Control Module - 4-15
RAMP Light - 4-36
Cable Connections - 1-21 Regeneration Resistors - 3-19
Checks Retract Speed Resistors - 3-20
Pre-Operational - 1-42 Retract Switch - 2-9, 2-10, 2-11, 2-12, 2-13
Cleaning Return to Home Amplifiers - 3-9
Motion Control Cabinet Air Filters - 3-44 Simulator Systems - 1-2
MSC Cooling Fans and Filters - 3-41 Snubber - 2-11
Clevises Digital Motion System

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Power Up Checks - 1-23 Return to Home Amplifiers - 3-9

Purpose - 1-1 Snubber - 2-11
DMS
Installation - 1-23 M
E Main Circuit Breaker
Operation - 3-28
Electric Actuator Maintenance
Removal and Replacement - 2-31 General - 1-37
Electrical Cables Materials Required - 1-37
Inspection - 2-22, 3-42 Operating Modes - 1-27
Emergency Conditions Quarterly - 1-44
Return to Home (RTH) - 5-7 Tools Required - 1-38
Emergency Egress Rope Weekly - 1-41, 1-44, 3-56
Inspection - 1-44 Manual Operatin
Emergency Operation Access Ramp - 4-15
Access Ramp - 5-19 Manual Operation
Environmental Requirements - 1-18 Access Ramp - 4-38, 5-14
EPO System Mat Switches
Return to Home (RTH) - 4-16 Access Ramp - 4-7
Motion Base
I Pre-Operational Checks - 2-15, 4-14
Removal and Replacement - 2-31
Initial Configuration - 1-19 Troubleshooting - 1-46, 2-30
Inspection Motion Base Bearings
Electrical Cables - 2-22, 3-42 Inspection - 2-24
Emergency Egress Rope - 1-44 Motion Control Cabinet Air Filters
General - 1-39 Cleaning - 3-44
Motion Bearing Base - 2-24 Motion Upset Recovery
MSC Cooling Fans and Filters - 3-41 Return to Home Amplifiers - 1-29, 5-7
Installation - 1-23 Motion Warning Light
IOS Motion Control Loading Panel Description - 4-36
Description - 5-3 Location - 4-36
IOS Normal Operation Motor Controller Drives
Shut Down - 1-34 Description - 3-7
Location - 3-7
L MSC Cooling Fans and Filters
Cleaning - 3-41
List of Related Publications - 1-49, 2-62, 3-29, 3-61
Inspection - 3-41
Location
24Vdc Power Supply - 3-17
Audible Alarm - 4-36
O
Backup Battery Chargers - 3-18 Operating Modes
Control Head - 3-8 Maintenance - 1-27
Controls I/O Patch Assembly - 1-6 Operation
Motion Warning Light - 4-36 Control Loading and ESTOP Circuit Acceptable
Motor Controller Drives - 3-7 Indicator - 3-23
Operation Mode Key Switch - 3-26 Control Loading and Motion Abort Engaged Indicator
Porch Mat Switch - 4-7, 4-9 - 3-23
Ramp Actuator - 4-10 Control Loading and Motion ESTOP Switch - 3-23
Ramp and Gate Switches - 6-7 DC Bus On Indicator - 3-23
Ramp Control Module - 4-15 Main Circuit Breaker - 3-28
RAMP Light - 4-36 Operation Mode Key Switch - 3-28
Regeneration Resistors - 3-19 Operation Mode Key Switch
Retract Speed Resistors - 3-20 Description - 3-26
Retract Switch - 2-9, 2-10, 2-11, 2-12, 2-13 Location - 3-26

Copyright 2017 by FlightSafety I-2 FS1000 DMS O&M

Information Subject to Export Control Laws Rev B – December 2017
 FS1000-TM-1-0000-DMS1-012

Operation - 3-28 Access Ramp Components - 4-27

Access Ramp Mats - 4-27
P Actuator Oil - 2-60
At-Rest (Home) Switch - 2-58
Physical Characteristics
Clevises - 2-42
Motion Base - 1-1
Motion Base - 2-31
Motion Control Cabinet - 1-1
Motion Electric Actuator - 2-31
Porch Mat Switch
Thermistor - 2-59
Description - 4-7, 4-9
Retract Speed Resistors
Location - 4-7, 4-9
Description - 3-20
Power Requirments - 1-18
Location - 3-20
Power Supply - 24Vdc
Retract Switch
Description - 3-17
Description - 2-9, 2-10, 2-11, 2-12, 2-13
Location - 3-17
Location - 2-9, 2-10, 2-11, 2-12, 2-13
Power Up Checks - 1-23
Return to Home (RTH)
Pre-Operational Checks
Battery Failure - 3-50
Checks - 1-42
Emergency Conditions - 5-7
Motion Base - 2-15, 4-14
Preparation for Use - 1-1 EPO System - 4-16
Principles of Operation Return to Home Amplifiers
Access Ramp - 4-11 Description - 3-9
Production Support Location - 3-9
Information - 5-20 Motion Upset Recovery - 1-29, 5-7
Purpose
Digital Motion System - 1-1 S
Shut Down
Q IOS Normal Operation - 1-34
Quarterly Simulator Systems
Maintenance - 1-44 Description - 1-2
Snubber
R Description - 2-11
Location - 2-11
Ramp Actuator Storage - 1-48
Description - 4-10
Location - 4-10 T
Ramp and Gate Switches
Thermistor
Description - 6-7
Removal and Replacement - 2-59
Location - 6-7
Tools Required
Ramp Control Module
Maintenance - 1-38
Controls and Indicators - 1-8
Troubleshooting
Description - 4-15
Access Ramp - 4-16
Location - 4-15
Aids - 1-46, 2-30
RAMP Light
General - 1-46
Description - 4-36
Motion Base - 2-30
Location - 4-36
Regeneration Resistors
Description - 3-19 W
Location - 3-19 Warning System - 4-36
Removal and Replacement Weekly
Access Ramp Switches - 4-28 Maintenance - 1-41, 1-44, 3-56
Access Ramp Actuator Sensors - 4-35

Copyright 2017 by FlightSafety I-3 FS1000 DMS O&M

Information Subject to Export Control Laws Rev B – December 2017