Airborne Instruments: Preparation for Flight and Certification Al Cooper and Al Rodi NSF Facilities Users’ Workshop Sept 2007

Preparing Instruments for Flight on Research Aircraft Procedures vary by aircraft, but all require attention to factors affecting safety, esp. in regard to:  Structural properties: Ability to withstand loads arising in flight or in emergencies  Resistance to combustion: use of appropriate wire insulation and other components to avoid flames or hazardous fumes in the cockpit.

Special Requirements for the NSF/NCAR Gulfstream-V We maintain standard transport-category certification as a civil aircraft As delivered from Gulfstream, the aircraft had a type certificate certifying compliance with the Federal Aviation Regulations. We (NSF), as owner, then obtained an airworthiness certificate – the required evidence that this particular aircraft is certified for flight. Modifications invalidate that airworthiness certificate, and we must obtain further approval to resume operations.

Some Apertures Certified on Delivery

Wing-Stores Certification:

1.First, equipment must comply with requirements for structural strength and for use of appropriate components including wiring. Cf. web sites, incl. 2.Help us meet needs for documentation, with drawings, parts lists, and analyses (by a DER). 3.Allow time for the required process, including inspections and FAA approval. What This Means for Investigators Bringing Equipment for Installation

What This Means for Investigators Bringing Equipment for Installation [2] Second, you must help us meet the requirements for whichever type of certification is required (usually, a field approval). For this, we need:  Drawings documenting the mechanical and electrical configuration of the instrument.  Accompanying parts lists including wiring, with components either selected from the list already approved or else tested as necessary. Approved parts are documented on Forms  An engineering analysis by an FAA-certified DER who approves the design. (We can often provide the DER.)‏

What This Means for Investigators Bringing Equipment for Installation [3] Third, we will perform these steps leading to certification for the G-V:  An inspection by an appropriate inspector to ensure that the equipment conforms to the drawings.  Submission of the entire package (drawings, DER analyses, Forms 8110, etc) to the FAA via Form 337. An additional conformity inspection ensures that the installation conforms to the material submitted.

The Investigator’s Handbooks Handbooks are available for both the G-V and the C-130. They include sections that describe the procedures in detail. For the G-V, see Information on mounting points, racks, load requirements, safety margins, and other design criteria are included there. The handbook also includes advice on acceptable materials for construction, acceptable fasteners, welding, weight limits for racks, overturning moments, floor loading limits, etc. There is additional information (e.g., on approved wire) at

1.Develop Design Data 2.Submit Data to DER (RAF or outside) 3.DER checks for compliance with FARs 4.Purchase Components 5.Test as Necessary 6.Build Instrument 7.Check Conformity to Data 8.Install on G-V 9.Check Conformity of Installation 10.Ready for Flight – after FAA approval CONSTRUCTING A CERTIFIED INSTRUMENT

The Data Package The G-V handbook also describes the data package needed from each investigators who brings equipment for installation. This package is typically needed about 8 wks prior to the start of flights.  Descriptive data: drawings, with dimensions, weights, materials, etc.  Substantiating data, including: Structural loads analysis Electrical loads analysis There are some sample data packages on the RAF web site ( There are also many special cases, including lasers, cryogens, toxic gases, batteries, pressure vessels, etc. The Data Package

Some Important Consequences: (a) We need drawings ahead of time so that we can do the required analyses and submit the information in time to allow approval by the FAA. (b) We are very limited in regard to what can be changed during a project. We can't change instrument configurations or make significant changes to an instrument. (c) Large complements of new instruments can be difficult to handle in the short time prior to a project, so it is desirable to install and test instruments ahead of time. Consequences for Investigators

New Recommended Policy re Testing Required instruments for a field program will need to be tested (and, for the G-V, certified) 3 mo prior to installation. Others may test first in pre-deployment testing, but failure will result in removal from the payload. Instruments previously flown are exempt if they have not been modified significantly. The status of the instrumentation will be considered appropriately in assessing the feasibility of the experiment. To assist users in testing and certifying instruments, EOL will provide periodic opportunities for installation, certification, and flight testing. New Recommended Policy Re Testing

How Does the C-130 Differ? We are moving to the same procedures, except that FAA approval is not required. We assume responsibility (but therefore must enforce similar safety requirements). As a result:  The process does not require the same lead time or formality in documentation  There is a little more flexibility in regard to what components are acceptable and what in-field procedures are possible. How Does the C-130 Differ?

Important Conclusion: Contact us early and often!  We can help guide developers through this process, often saving us all time;  Knowing about developments helps us prepare for their arrival and avoid last-minute surprises.  Important Summary:

How does the UWKA differ? Certification: FAR Part 91 restricted: A few operational restrictions that usually can be waived All modifications require FAA approval Submission of package of drawings, DER analyses, Forms 8110, etc., to the FAA via Form 337. We have our own staff of aircraft maintenance technicians, one with Inspection Authorization (IA) who can approve mods via the 337 or STC process.

UWKA certification issues Nadir port installation Radar wing Contacting us early and often - even at the 'just thinking about it' stage – is the key. UW has done some major modifications in-house. In most instances, this has involved purchasing engineering with FAA Supplemental Type Certificates (STC)  20” nadir port (AVCON)  Radar ‘wing’ (NOAA) For “minor” alterations: UW contracts with DER to do engineering. This is becoming increasingly time consuming and expensive. We cannot easily accommodate 19” rack mountable gear (especially the “standard” long racks) due to aisle (egress) requirements.  Often, special racks have to be constructed and/or equipment repackaged.

NB: Previous approval on other aircraft does not insure approval on the King Air. Our standards are not necessarily higher, but the restrictions are different. UWKA certification issues

Legacy issues: Aircraft is 30 years old, and contains much material that does not conform to current standards. However, in new installations, we will conform to use of only certified materials (i.e. appropriate wire insulation and other components to avoid flames or hazardous fumes in the cockpit). Contact us for details