LEACH Solutions for Power Switching and Control - Esterline

LEACH ® Solutionsfor Power Switching and ControlLEACH ® Solutions for Power Switching and Control

Esterline Power Systems – Leading the Way in Aerospace and Defense EngineeringAs one of the core capabilities of Esterline Technologies Corporation, Esterline Power Systems (EPS)draws upon the rich aerospace and military heritage of LEACH ® in the field of power switching andcontrol. For nearly 100 years, LEACH has advanced military aerospace and power switching designand technology. LEACH introduced the first “break-in” relay in 1919 and further developed state-ofthe-artswitching power throughout the 20 th century —including Balanced Armature and BalancedForce relays, and rotary and solenoid contactors.While LEACH relay and contactor breakthroughs have set the industry standard for traditionalcomponent design, the past two decades have brought even further advancement in powerdistribution equipment utilizing solid state power controllers, smart contactors, and safety-criticalGround Fault Interrupter (GFI) products. As a result, Esterline Power Systems provides components andequipment for thousands of aerospace, military, rail and high-end industrial applications worldwide.Global OperationsEsterline Power Systems has manufacturing facilities in North America, Europe and Asia. Each facility offers unique engineering,manufacturing, sales and service capabilities, and each functions as an integral part of the Esterline Power Systems team. Withthe industry’s finest electrical testing laboratories, combined with state-of-the-art manufacturing and assembly lines, EsterlinePower Systems is able to provide world-class service and an ever-expanding product line to you, our global customers.The AmericasTwo manufacturing facilities(encompassing nearly 200,000 squarefeet) – one in Buena Park, Calif., andone in Tijuana, Mexico, – provideEsterline Power Systems with extensivedesign, assembly, manufacturing andtesting capabilities. Both plants providecomponent and subassembly operationsand have MIL-STD-790 certification,ISO 9001:2008, AS9100:2004, as wellas numerous customer approvals. TheBuena Park facility features hybrid andmicrocircuit manufacturing in a Class100,000 clean room environment.Subminiature and hybrid relays receivefinal assembly and adjusting in Class100 Laminar Flow stations.Cover Photos: Copyright SAAB AB - Gripen, Katsuhiko Kokunaga photographer; Northrop Grumman – Global Hawk; NASA – International Space Station;Bombardier Aerospace – Lear Jet; The Boeing Company – 777; Airbus Military – A400M; Bombardier Transportation – High Speed Train; GeneralDynamics Land Systems – M1A2 Abrams Main Battle Tank. All Rights Reserved.

EuropeEsterline Power Systems Europeanoperations have two production facilities,totaling nearly 100,000 square feet,located in Sarralbe(57) and Niort(79),France. Each of these operations hasachieved ISO 9001:2008, AS 9100revision B:2004, and MIL-STD-790certification. In addition, the Niortfacility includes ESA Qualification,reflecting its capabilities in spaceapplication work. The CustomerSupport organization, centralizedin Niort, provides an accessible,customer-focused maintenancecenter dedicated to supporting its civil,aerospace and railway customer base.The maintenance center is dedicatedto delivering repairs, spares, technicalpublications and support, as well astraining and integrated logistics support.Initially established for LEACH products,the center also can maintain productsproduced by other manufacturers.Industries and ApplicationsServedEsterline Power Systems supplies themilitary and commercial aerospaceindustries with a wide variety ofproducts. LEACH components andequipment assemblies can be foundaboard the majority of commercialaircraft flying today, as well as on manyhelicopters, military aircraft and groundvehicles.Moreover, LEACH relays are used inmajor space programs such as theInternational Space Station, launchvehicles and satellites.Many of the world’s finest railtransportation systems use LEACHcustom equipment and componentsincluding: TGV in France and Korea,BART in San Francisco, NYCTA inNew York, Metro in Paris, AVE inSpain, Underground in London, STIB inBelgium, and Eurostar.LEACH products are also used innuclear power plants and other high-endindustrial applications where safety andreliability are critical concerns.Esterline Power Systems is a significantcontributor of Esterline TechnologiesCorporation’s key capabilities in avionicssystems, control systems, interfacetechnologies, communications systems,advanced sensors, engineered materialsand defense technologies.AsiaBased in Hong Kong, Asian operationsoversee the designing, manufacturingand marketing of a broad line ofproducts for the Asia-Pacific region,as well as for strategic offerings to theEuropean and American markets. In1999, Esterline Power Systems formeda joint-venture, 20,000 square-footmanufacturing facility – the GuizhouLeach-Tianyi Aviation ElectricalCompany in Zunyi City, China. Asianfacilities maintain ISO 9001:2008certification and other USA andEuropean customer approvals.

Primary Distribution Assemblies for AerospaceEsterline Power Systems offers a variety of power distribution configurations — from a simple set of discrete components to fullyintegrated primary distribution assemblies featuring control logic and protection. LEACH completely equipped software teamshave the capability to carry out full systems integration in cooperation with its customers. Designed with industry leading LEACHcomponents, these primary distribution assemblies satisfy all specific customer program conditions and requirements.Key features anddesign strategies:• Highly integrated designs forsignificant weight and volume savings• Relay and contactor power switchingdevices, featuring numerousmounting styles, ratings and voltageswitching capabilities, for either AC orDC power distributionPrimary electrical power distributionassembly for a jet trainerDC primary power distribution assembly forfighter aircraft• AC and DC current sensing devicesfor all types of required protection(such as over-current, under- andover-voltage, reverse polarity, etc.)• Contactor and current sensing deviceassemblies designed as LineReplaceable Units (LRU) foreasy-change installation• Modular concepts for easyreconfiguration of future requirements• Distributed or integrated architecturefor optimization of aircraft specificitiesAC primary power distributionassembly for commercial helicopter• Plug-in module or articulatedjunctions to associate secondarydistribution assemblies with primarydistribution assemblies for enhancedtroubleshooting and maintenanceoperationsPrimary electricalpower distributioncenter for a largemilitary transportaircraft

Advanced electronic featuresinclude, upon request:• “Design-to-safety” electronics i.e.,optimized architecture to achievethe safety objectives of the equipmentspecifications• BITE features such as Fully AutomaticPower On Built-in-Test (PBIT) andContinuous Built-in-Test (CBIT)DC power distributionassembly and circuit breakerpanel for a military helicopter• Under- and over-voltage protection• internal or external automaticreconfiguration in case offailure• Source paralleling protection forAC distributionMilitaryand civil helicopterpower distribution assembly• Various communication buses(ARINC 429, CAN, RS422/485,MIL-STD-1553, Ethernet buses, etc.)for internal use and for communicationwith man/machine interface, aircraftcentral computer, and other aircraftequipment• Load reporting and management• Fully reprogrammable control logic• Over-current, short circuit, reversecurrent protection; under-currentindication• TRU and battery over-temperatureprotectionAC primary powerdistribution assembly for anunmanned aerial vehicle

Secondary Power Distribution Assemblies for Command/ControlEsterline Power Systems offers a variety of secondary electrical distribution configurations — including relay panels foraerospace and railway markets, as well as fully integrated solid state secondary power distribution units featuring control logic,specified protection(s), power supplies and data bus communication. LEACH completely equipped software teams have thecapability to carry out full systems integration.Key features and designstrategies:• Highly integrated designs forsignificant weight and volume savings• AC and DC secondary distributionutilizing electromechanical and/or solidstate power switching devices• High integration of current sensingfunctions• Assemblies and subassembliesdesigned as LRUs for ease ofreplacementMilitaryhelicopter relayboard• Modular concepts for flexibility,reduced cost, easy reconfigurationand future requirements• Distributed or integrated architectureto optimize electrical power systemperformance, safety and reliability• Strategically integrated connections toassociate secondary distributionassemblies with primary distributionassemblies• Choice of technical solutions basedon standard circuit breakers or solidstate power controllersRelay rack for alight rail vehicleMilitary helicopterrelay boardAdvanced features for relaypanels include:• Full integration of hermetically sealedrelays onto a PCB• 2A-, 5A-, 10A- and 25A-ratings; lowlevel to 110VDC network voltage• 1-, 2-, 3-, 4- or 6-pole relays• Sockets available for easy relayremoval• Use of separated transientsuppression devices (PCB mountingor plug-in sockets) and otherelectronic components (e.g. diodes)• Time delay relay integration (PCBmounting or plug-in socket)• Flexible technical approach allowsfor easy change ormodification of schematics• Relay panels designed as LRUs forease of replacementSolid-stateload management unit for acommercial aircraftAdditional features for circuitbreaker panels include:• Fully integrated circuit breakers onpanels for space and weight savings• Panel plug-in concept to the primarydistribution or separated panels forcockpit installation• PCB plug-in circuit breakers for costreduction and easy maintenance• Circuit breaker status reporting usingcommunication buses such as CAN,ARINC, or othersRelay panel for acommercial power plantAdvanced electronic features forSSPCs include:• “Design-to-safety” electronicsi.e., optimized architecture to achievethe safety objectives of the equipmentspecifications• BITE features such as Fully AutomaticPower On Built-in-Test (PBIT),Continuous Built-in-Test (CBIT) andInitiated Built-in-Test (IBIT)

• Accurate I²t over-current and shortcircuit protection with thermal memoryand fully compliant (or better than)thermal circuit breaker trip curve• Reprogrammable trip curvesRelay panel for intercity trainElectrical relay box for a business jet• Various communication buses(ARINC 429, CAN, RS422/485, MIL-STD-1553, Ethernet buses, etc.) forinternal use, and for communicationwith man/machine interface, aircraftcentral computer, and otheraircraft equipment• Load reporting and management suchas load shedding, soft start for specificloads (light), and current measurement• Zero voltage turn-on and turn-off(AC device)• Synchronization between 3 phases forAC SSPCs (any phase trip will tripall phases)• Current threshold and delay foractuator overload protection• Programmable time delay on operateor release• Fail-safe functions• Optional arc fault detection• Very low heat dissipation using solidstate technologyModular railrelay rack withindividual relaymodulesSecondary powerdistribution assembly featuringnext generation solid-statepower controllers

Other Switching Assemblies and Relay PanelsEsterline Power Systems has integrated its extensive line of LEACH relays into a wide range of power switching assemblies andpanels for a variety of industries. Used on fighter aircraft, helicopters, regional jets and high-speed rail platforms worldwide, theseassemblies combine the quality and dependability of LEACH components with solutions that showcase the engineering andmanufacturing expertise of Esterline Power Systems’ solutions philosophy.Key features and designconcepts:By maximizing the best componentselection, mounting, wiring options andadvanced technology, Esterline PowerSystems can optimize customers’specific functional requirements.Examples of Esterline Power Systems’expertise include: central warningpanels, anti-ice controllers, thrustreverser control assemblies, integratedwiring assemblies, overhead controlpanels and related products. Our designchoices are governed by maintenanceconditions (e.g., LRU at the assembly,subassembly or component level) aswell as mechanical, environmental,thermal and climatic conditions.Powerdistributionassembly for ahelicopter applicationSolutions for maintenanceconditions• Plugging relays into sockets ormounting directly onto a PC board• Soldering relays on multi-layeredflex-rigid PVC or on modular PCB’splugged into an assemblySolutions for environmental,thermal and climatic conditions• Adding metallic covers over entireassemblies• Implementing waterproof designsutilizing compatible conductivegaskets with metal-cast housings• Electrical hardening of pyrotechnicalcircuits using filtering and lightningprotection• Adding spare relays to provide futureflexibilityMilitary helicopter anti-ice controllerSolid-statepower module for a space applicationBusinessjet thrust reversercontrol unitLightbusinessjet windshielddeicing control unit

Man Machine InterfaceAnother specialty of Esterline Power Systems is the design and manufacture of customized, compact keyboard panels specific toboth military and civil aircraft, and mobile ground systems.Key features and design concepts• Aluminum or Plexiglas front plates(available with back-lighted legends)• Totally sealed panels as required• Plastic, aluminum or silicon key topmaterial• Plastic, glass or EMI shielded glass fordisplay window material• All standard switching componentsand potentiometers, including toggle,rotary switch, etc.Emergencyengine controls for amilitary helicopterDisplay solutions• Alphanumeric, DOT matrix or LCD• Sunlight-readable DOT matrix displaysup to 2500 FI may be specified (fullyNVIS Green B compatible)CDU front panelfor a business jetPanel-integrated electronics• Standard and specific display drivers• Dimming electronics• FPGA panel control filteringOverhead panel for a regional jetOptical solutions• All NVIS- and non-NVIS-compatiblecolors available for backlights andindicators• Standard indicator luminance with fullsunlight readability• NVIS properties customizable forcustomer requirements (NVIS ClassA and B, as well as specific radiancelevels, are available – such as NVISradiance down to 10E-12)Speedwarning displayfor a rail applicationData acquisition panel fora military jet

Power Distribution Components for Aerospace, Rail and IndustryRelays and SocketsLEACH military-qualified miniature,subminiature and half-crystal canrelays for dry-circuit switching rangefrom low level to 75 amps and comein DC and AC versions. LEACHsubminiature relays are hermeticallysealed against contaminants, pollutants,and the temperature extremes of harshenvironments. Many components canwithstand vibration and shock up to200G. A variety of sockets complementthe miniature and subminiature relaylines. The Company’s Balanced-Force ®and balanced armature relaysare available in various ratings,configurations and mounting styles.LEACH relays for rail applications arespecifically designed for critical, fail-safeoperation and can be combined withhigh technology circuit boards to offereconomical solutions to the constraintsof rolling stock. Custom-packagedequipment and LRU racks featuringLEACH relays are ideal for use inPositive Train Separation (PTS) andAutomated Train Control Systems (ATS)as well as in communications-basedcontrol and grade crossing systems.Control DevicesLEACH control devices, combiningmany proven features of standardrelays with highly reliable hybridmicroelectronic circuits, include fixedand adjustable AC/DC time delay, solidstatetime delay and programmable timedelay devices, and RCCBs. In addition,a variety of power monitors and sensorsare available for timing, sensing, andprotection of current, voltage, frequencyand phase.ContactorsLEACH high power contactors offermain contacts ranging from 25 to 1000amps and are available hermetically orenvironmentally sealed in DC and ACversions. A variety of configurations,power terminations and packaging stylesare available. Options include LRUversions, which feature a plug-in plungerinterface for quick change installation,and lightweight busbar-mountconfigurations for modern electricalpower distribution systems.

Smart DevicesLEACH smart relays and contactorsare hybrid devices combining standardproduction relays with an electronicmodule and electrical sensors thatinterface with on-board computers.Smart relays control the flow of powerto the equipment without the use of aconventional circuit breaker panel. TheLEACH Ground Fault Interrupter (GFI)relay is one example of a smart devicethat provides ground fault protection andgives added protection to wiring andequipment. This GFI circuitry can beincorporated into the majority of LEACHswitching products.Solid State PowerControllers (SSPCs)Ideal for today’s modern computercontrolledsystems, LEACH SSPCsutilize FET output stages and areconstructed using thick-film, surfacemounttechnology in hermetically sealedmetal or ceramic packages. In responseto customer needs, Esterline PowerSystems has incorporated Built-in-Testcapabilities, data bus compatibility andother features into its Next GenerationLEACH SSPCs and Secondary PowerDistribution Units (SPDUs). Our SSPCsprovide enabling technology for futureadvanced electrical power systems– including data bus capability whererequired.Switches and KeypadsLighted pushbutton switches anddisplay indicators are designed andmanufactured to exacting specificationsfor aerospace and rail applications.LEACH customized, compact keypadsfeature backlighting and a choice ofdisplay styles. Additional options includea variety of manufacturing materials andswitching technologies.

Our Commitment to Performance, Quality and ValueThe Esterline Power Systems AdvantageAs a single-source provider of power distribution and switching solutions for vehicles of all type, we offer:• Expertise to meet the most demanding customer needs including building to print, customizing existingproducts, designing replacement products, designing to specifications, and specifying, evaluating anddesigning for particular requirements.• Environmental or hermetically sealed components and assemblies featuring optimized structural integrity,with size and weight economies.• Strategically located customer support teams committed to the through-life of our products, ensuringyour logistical and technical maintenance requirements.• Exceptional value as a lean enterprise.Esterline Power Systems andLEACH ® products —Meeting the demands of today...anticipating the needs of tomorrowFeaturing LEACH ® Pow er and Control Solutionsw w w. e s t e r l i n e . c o mAmericas6900 Orangethorpe Ave.P.O. Box 5032Buena Park, CA 90622 USATel: (1) 714-736-7599Fax: (1) 714-670-1145Europe2, Rue GoetheF-57430 SarralbeFranceTel: (33) 3 87 97 98 97Fax: (33) 3 87 97 96 86AsiaUnits 602-603 6/F Lakeside 1No.8 Science Park West AvenuePhase Two, Hong Kong Science ParkPak Shek Kok, Tai Po, N.T.Hong KongTel: (852) 2-191-3830Fax: (852) 2-389-58032.5K4/10