OM Manual 1TL32-6757-1 v2.0.pdf

TECHNICAL MANUAL

OPERATION AND MAINTENANCE

INSTRUCTIONS

Advanced Fuel Accessories Test System (AFATS)

1TL32-6757-1

Rev 2.0

15-June-22

8230001-0503-OC006

DISCLOSURE NOTICE: This information is furnished upon the condition that it will not be released to another nation without the authority of the Department of the United States, that will be used for military purposes only, that individual or corporate rights originating information, whether patented or not, will be respected, that the recipient will report promptly to the United States, any known or suspected compromise, and that the information will be provided substantially the same degree of security afforded it by the Department of Defense United States. Also, regardless of any other markings of the document, it will not be downgraded or declassified without written approval originating United States agency.

DISTRIBUTION STATEMENT: Distribution authorized to the Department of Defense and U.S. DoD contractors only, Critical Technology, May 2003).

WARNING: This document contains technical data whose export is restricted by the Arms Export Control Act (Title 22, U.S.C. 2751 et seq.) Executive Order 12470. Violations of these export laws are subject to severe criminal penalties. Disseminate in accordance with provisions DoD Directive 5230.25.

EMD, Inc 1411 Twin Oaks

Wichita Falls, Texas 76302

(940) 322-2206 http://www.emdinc.com

15 June 2022 1TL32-6757-1 Rev 2.0

TABLE OF CONTENTS

1 SAFETY SUMMARY

2 WARNINGS AND CAUTIONS

3 INTRODUCTION AND GENERAL INFORMATION

4 SPECIAL TOOLS AND TEST EQUIPMENT

5 PREPARATION FOR USE, STORAGE AND SHIPMENT

6 THEORY OF OPERATION

7 OPERATING INSTRUCTIONS AND TEST PROCEDURES

8 INSPECTION, CLEANING, MAINTENANCE AND LUBRICATION

9 TROUBLESHOOTING

10 CALIBRATION

11 DISASSEMBLY, REPAIR, REPLACEMENT AND ASSEMBLY

12 Appendix A – Memory Map 13 Appendix B – Accuracy Spreadsheet 14 Appendix C - Cause and Effect Chart 15 Appendix D - Checkout Package Documentation 16 Appendix E - Drawings 17 Appendix F - JPL Manual

LIST OF FIGURES

Figure Fuel Control System Components Test Station A/F46T-5 Figure Test Station Interface Diagram (Sht. 1) Figure Test Station Interface Diagram (Sht. 2) Figure - HMI Startup Screen Figure - Login Screen Figure - Lower Status Screen Figure - Main Test Selection Screen (ITA Menu) Figure - Sub Menu Selection Screen Figure - Menu Configuration Screen Figure - Test Configuration Screen Figure - Cell Configuration Screen Figure - Edit Analog Screen Figure - Edit Digital Screen Figure - Edit Assignment Macro Screen Figure - Edit Script Screen Figure - Analog Status Tag Select Screen Figure - Analog Command Tag Select Screen Figure - Digital Status Tag Select Screen Figure - Digital Command Tag Select Screen Figure - Color Selection Screen Figure - Numeric Keypad Entry Figure - Text Entry Screen

Figure - Loop Control Main Screen Figure - Historical Trending Screen Figure - Alarm History Screen Figure - First out Alarm Screen Figure - Part Information Screen Figure - Stand Control Screen Figure - Configuration Screen Figure - Shutdown Setpoints Screen 1 Figure - Shutdown Setpoints Screen 2 Figure - Shutdown Setpoints Screen 3 Figure - Shutdown Setpoints Screen 4 Figure - Shutdown Setpoints Screen 5 Figure - Shutdown Setpoints Screen 6 Figure - Transducer Height Setpoints Screen 7 Figure - UUT Setpoints Screen 8 Figure - Diagnostics Configuration Screen Page 1 Figure - Diagnostics Configuration Screen Page 2 Figure - Diagnostics Configuration Screen Page 3 Figure - Application Configuration Screen Figure - User Setup Configuration Screen Figure - Historical Data Dump Configuration Screen Figure - Backup Data Configuration Screen Figure - Restore Data Configuration Screen Figure - Easy CD Creator Example Screen Figure - CD Record Process Status Screen Figure - CD Record Process Status Screen Figure - Fluid Sample Report Figure - Vibration Calibration Screen Figure - Example Main Menu Screen (ITA Menu Button) Figure - Example Stand Control Screen Figure - Example Cart Connection Status Screen Figure - Example Calibration with Cal Cart Screen Figure - Example Connect/Disconnect Cal Cart Section Screen Figure - Example Connect/Disconnect Cal Cart Status Screen Figure - Example Calibration Summary Screen Figure - Example Calibration Selection Screen with Cal Cart Figure - Example ZT_MA1Calibration Screen with Cal Cart (Right Side) Figure - Example ZT_MA1 Calibration Summary Screen Figure - Example ET_RSLVR Calibration Summary Screen Figure - Example Transducer Height Setpoints Figure - Example PT_MPxx Calibration Selection Screen with Cal Cart Figure - Example PT_MPxx Calibration Screen with Cal Cart (Right Side) Figure - Example PT_MPxx Calibration Summary Screen Figure - Example High Pressure PT_MPxx Calibration Screen

Figure - Example Multi-Accuracy Pressure PT_MPxx Calibration Screen Figure - Example FT_MFxx Calibration Screen with Cal Cart (Right Side) Description Figure - Example FT_MFxx Calibration Screen with Cal Cart (Right Side) Figure - Example Calibration Selection Screen with Cal Cart Figure - Cal Cart Connect / Disconnect Screen (Right Side) Figure - Example ST_M1B Calibration Summary Screen Figure - Speed Calibration Screen Figure - Example 4 - 20mA Calibration Screen Figure - Example ITA Frequency Calibration Screen Figure - Example Pressure Calibration Screen Figure - Example Flow Calibration Screen Figure - Example Flow Verification Screen Figure - Example Temperature Calibration Screen Figure - Example TE Type Temperature Calibration Screen Figure - 3 Wire RTD Hook-up Figure - Example ZT_MLT_Hz Calibration Screen Figure - Rack 3 NI DAQ Termination Board Figure - Select Point to Calibrate Figure - Motor Winding RTD Temp Calibration Screen Figure - Motor Front Bearing Temp Calibration Screen Figure - Example TT Type Temperature Alignment Screen Figure - Example TE Type Temperature Alignment Screen Figure - Example Pressure Alignment Screen Figure - Example Flowmeter Alignment Screen Figure - Front Bearing Vibration Alignment Screen Figure - Motor Bearing Temp Alignment Screen Figure - Motor Winding RTD Temp Alignment Screen Figure – SATA IDE Figure – Graphics Media Accelerator Figure – LAN Driver Figure – PRO Network Figure – 1000 Base T Figure – Control Panel Figure – Network and Dialup Connections Figure – Local Area Connections Figure – Internet Protocol Properties Figure – Flat Panel Monitors Figure – Winzip Self-Extractor Figure – Browse for Folder Figure – Elo TouchSystems Setup Figure – Elo Auto-Detect Figure – Elo Com PortSetup Figure – Elo Setup Progress Figure – Elo TouchSystems Setup

Figure – Elo Calibration Figure – Elo Calibration Verification Figure – Computer Management Figure - Change Drive Letter Figure - Edit Drive Letter Figure - Formatting a Drive Figure – Folder Options Figure - Winzip Setup Figure - Winzip Setup Figure - Winzip Setup Figure - Winzip Setup Figure - Winzip Setup Figure - Winzip Setup Figure - Acrobat Reader Setup Figure – Network DDE DSDM Figure - Wonderware In-Touch Setup Figure - Wonderware Application Setup Figure - Wonderware Application Setup Figure – Startup And Recovery Figure – Environment Variables Figure – Edit System Variable Figure – MDAC Figure – Windows Installer Figure – Visual C++ Redristributable Figure - SIMANTIC NCM PC Config Figure - SIMANTIC NCM PC Config Figure - SIMANTIC NCM PC Config Figure – IO Server Startup Figure – PLC Cfg Figure – PLC Cfg Figure – Topic Definition Figure – Read Fast Figure – Read Slow Figure – Write Only Figure – Read Active Figure – Server Settings Figure - Alarm DB Logger Configuration Screen Figure - Alarm DB Logger Error Figure – Display Properties Figure – Purge/Archive-General Figure – Purge/Archive-Database Figure – Purge/Archive-Success Figure – Purge/Archive-Purge/Archive Figure – Run Dialog

Figure – System Configuration Editor Figure – Win INI Changes Figure – Save Changes Figure – ODBC Data Source Administrator Figure – Create New Data Source Figure – Create New SQL Data Source Figure – SQL Server Authenticity Figure – SQL Default Database Figure – SQL Server Setup Summary Figure – SQL Test Results Figure – APC Welcome Screen Figure – APC License Agreement Figure – APC Destination Figure – APC Install Complete Figure – Powerchute Configuration Figure – Powerchute Notification Figure – Powerchute Runtime Figure – Unsaved Changes Figure – Power Options Figure - Disable Hibernation

LIST OF TABLES

Table – Abbreviation Table – List of Related Table - Leading Particulars Table - Special Tools and Test Equipment Table - Interface Connector Assembly (A2A8) (ICA) Location Interface Table - Characters use to Format Numbers Table - Periodic Inspection Table - Operating Area Contaminant Limits Table - FAULT Troubleshooting Table - Test Stand Troubleshooting Table - Rotable Calibration Requirements Table - Test Method Table - Calibration Information Using Calibration Cart Table - Manual Calibration Information Table – Staubli Connector Input Pin Callout Table - Motor Winding RTD Temperature Table - Bearing Temperature

Record of Changes

Rev Page(s) Affected Revision Description Date Engr

1.7 106 Troubleshooting #12 and #13 2/29/16 T. Pham

1.7 109-113 Table-Calibration 2/29/16 T. Pham

1.8 109 Changed FT_MF6 range 6.0-200.0gpm 4/21/16 T. Pham

1.9 109 Add FT_MF15_GPM 9/27/21 T. Pham

110 Add PT_MP2 9/27/21 T. Pham

2.0 95 Add PLC Battery Replacement 6/15/22 T. Pham

111 Add PT_MP8 6/15/22 T. Pham

1 SAFETY SUMMARY

Personnel performing maintenance procedures and practices included in this manual shall be familiar with safety precautions associated with chemicals and other hazardous materials or equipment. The following are general safety precautions and instructions that shall be understood and applied during operations and maintenance to ensure personal safety and health and minimize system and equipment damage. These precautions are not inclusive.

The Material Safety Data Sheets (MSDS), the local safety office, and Air Force Occupational Safety and Health (AFOSH) standards should be consulted for specific information. WARNINGS (for personnel protection) or CAUTIONS (for equipment protection) may also precede selected procedures in this manual for additional emphasis. Disregarding either a WARNING or CAUTION or performing unauthorized maintenance can cause engine or equipment damage, serious injury, or illness.

AVOID COMPLACENCY

The computer used in this test station is a modem, state-of-the-art machine. Although it is unlikely, the possibility always exists that there could be a malfunction in this area. If this should happen, its ability to automatically detect hazards could become inoperative. For this reason, the test station operator will always remain alert and attentive to the functions being performed by the test station. Failure to do this could result in serious injury.

CLEANERS AND SOLVENTS

Many cleaning fluids and solvents are easily ignited and are irritating to skin, eyes, and respiratory system. Contact with some of these cleaners and solvents over an extended period of time can result in an accumulation of toxins in the body. Solvents used for cleaning can cause internal corrosion of engine controls if the solvents are not removed during storing or shipping the control. Keep ignition sources away, ensure adequate ventilation, wear protective clothing/equipment, store cleaners and solvents in approved containers, and read and follow all label directions.

Observe manufacturers warning labels, material safety data sheets (MSDS) instructions for proper handling, storage, and disposal, and current safety directives.

COMPRESSED AIR

Compressed air can generate flying debris and can cause severe injury if air blast penetrates the skin or eyes. Reduce compressed air pressure for cleaning or drying to less than 30 PSIG. Do not direct air blast toward other personnel.

Use with effective chip guarding and appropriate personnel protective equipment. Use with effective chip guarding and personal protective equipment.

DANGEROUS PRESSURE

Pressure system precautions apply to all equipment using gases and fluids at all ranges of pressure. To avoid injury, stand clear of tooling and parts being pressure-tested when pressure is being applied. Proper tool installation and hose connections shall be ensured before applying pressure. All system components shall be compatible with pressures applied and the pressure medium used. Pressure shall be applied slowly. Personnel must be protected by a safety shield or at a distance sufficient to prevent injury.

DO NOT WEAR JEWELRY

Remove rings, watches, necklaces, and other metallic objects that may be snagged or cause shock or burn hazards.

FOOD AND TOBACCO

Do not smoke tobacco products or eat food before washing hands and face thoroughly. Residue of the materials used in engine and equipment maintenance can cause serious health problems if eaten or inhaled in the smoke.

HYDRAULIC HOSE CONNECTIONS

Under operational conditions, hydraulic hoses are under high pressure. When making hydraulic hose connections, always ensure that all connections are tight and secure. Failure to comply may result in serious injury.

KEEP AWAY FROM LIVE CIRCUITS

Operating personnel must think safety at all times. Do not replace components or make adjustments to equipment with the electrical supply turned on. Under certain conditions, danger may exist even when the power control is in the off position due to charges retained by capacitors. These circuits shall be properly discharged and grounded prior to servicing. Adhere to all lockout/tagout requirements.

RESUSCITATION

Personnel working with or near dangerous voltage shall be trained in current methods of resuscitation. Information and training sources may be obtained from the Director of Base Medical Services.

2 WARNINGS AND CAUTIONS

The following WARNINGS and CAUTIONS may appear throughout the manual and shall be strictly heeded:

WARNING

Whenever a condition is experienced during UUT testing which is abnormal (leaks, equipment failures, unusual noises), the test must be stopped using either the test station EMERGENCY STOP or FLUID SHUTDOWN switches. Do not attempt to halt one of these conditions by using the CANCEL TEST or SUSPEND TEST on the Operator Display Monitor (ODM). Failure to comply may result in injury to personnel or damage to equipment.

WARNING

The interactive mode of operation (if available) aids troubleshooting and engineering evaluation and development for the test equipment and the UUT. Danger exists during the use of this mode. When operating the test station in the interactive mode, the test station operator must have thorough knowledge of the test equipment and the UUT in order to avoid hazardous conditions. Failure to comply may result in serious injury or death to personnel and/or damage to equipment.

WARNING

Maintenance lockout pushbutton do not remove all electrical power. Power from 24 VDC power supply (if installed) is still available to the test station.

WARNING

Power OFF pushbutton will shutdown the PCS and disables the hydraulic control section circuits, but will not remove 24 VDC power (if installed) from the PCS. Using the power OFF pushbutton shutdown in place of main circuit breaker shutdown can result in death or injury.

WARNING

Main circuit breaker does not remove the power coming into main circuit breaker from facility.

WARNING

The Process Control Section carries lethal voltages which can cause injury or death. All enclosure doors must be closed and all door safety guards must be in place before starting the test station.

WARNING

The process control section and hydraulic control section carry lethal voltages which can cause injury or death. All enclosure doors must be closed and all door safety guards must be in place before starting the test station.

WARNING

Before cleaning, make sure electrical power to test station is off. Electricity causes shocks, burns, or death.

WARNING

Use dry cleaning solvent, P-D-680, Type III, in a well-ventilated area. Avoid excessive skin contact or prolonged inhalation of vapors. Do not use near open flames or in areas where high temperatures exist.

WARNING

Denatured alcohol is flammable and toxic. Use in a well-ventilated area. Keep away from heat and open flames.

Wear skin and eye protection. Avoid prolonged inhalation of vapors. Failure to do so may result in injury or death.

WARNING

To prevent injury to personnel, two maintenance personnel are required to lift display monitor during removal/installation.

WARNING

Soldering or de-soldering is not allowed in the test station area. Soldering is only allowed in the ITA Calibration (ITACal) room. Performing soldering in the test station area may result in injury or death.

WARNING

Use care when using a soldering iron. Soldering iron tip is extremely hot. Hot surfaces can cause skin burns or injury.

WARNING

To prevent injury to personnel, two maintenance personnel are required to lift the power meter during removal/installation.

WARNING

To prevent injury to personnel, use lift platform to lift power supply during removal/installation from equipment rack.

WARNING

Air conditioner assembly weighs in excess of 150 pounds, use lift platform for removal/installation.

WARNING

To prevent injury to personnel, two maintenance personnel are required to lift direct drive blowers during removal/installation.

WARNING

To prevent injury to personnel or damage to equipment, the facility power to the test station must be shutdown before performing removal and replacement procedures.

WARNING

CalFluid is flammable and toxic to skin, eyes, and respiratory tract. Skin eyes, and respiratory protection is required.

Avoid repeated or prolonged contact.

WARNING

Due to weight (up to 500 pounds) heat exchanger a suitable lifting device must be used to stabilize and move heat exchanger. Failure to do so may result in personal injury.

WARNING

Electrical power shall be off before connecting or disconnecting electrical connections. Electricity causes shock, burns, and death.

CAUTION

Do not rub alcohol on meter displays or plastic surfaces. Chemicals in alcohol will damage plastic surfaces.

CAUTION

To prevent damage, use only approved general purpose detergent to clean plastic or glass screens, windows, and gauges. Use of aromatic hydrocarbons and chlorinated solvents on instrumentation and electrical contacts could react chemically with plastic components and damage equipment.

CAUTION

Circuit cards may be damaged by Electrostatic Discharge (ESD) during removal and repair. Use ESD precautionary procedures in DOD-STD-1686, DOD-HNBK-263B, and T.O. 00-25-234, Section VII, for special handling procedures for ESD equipment. Failure to comply could lead to damage of equipment.

CAUTION

Slide rail halves in equipment rack can be damaged if slide rail halves installed on monitor are not level.

CAUTION

Mounting rails may be seriously damaged when removing/installing ECS. The ECS rails must be accurately and carefully separated from rails on equipment rack.

CAUTION

Wires may be damaged when installing enclosure if not carefully guided through connector openings.

CAUTION

To prevent equipment damage and ensure proper operation of replacement termination panel, the signal channel strapping options must be identical to those used on replaced termination panel.

CAUTION

The capillary tube can be damaged if not properly handled during installation.

CAUTION

To prevent damage to equipment, solenoid valves should be detached from solenoid panel bracket before disconnecting inaccessible air lines at rear of faulty valve. Only disconnect air lines necessary to remove faulty valve.

CAUTION

To prevent damage to equipment, air lines should be connected to rear of replacement valve before attaching solenoid valves to solenoid panel bracket.

CAUTION

Pressure range of switch assemblies are not the same. Make sure switch assembly range is correct before installing.

Switch assembly can be damaged if incorrect pressure is applied.

CAUTION

Pressure switch assembly must be locked into receptacle before applying pressure to switch assembly. Pressure switch can be damaged if not properly secured.

CAUTION

Failure to back out adjustment stem in doser valve before installing Pressure Reducing Regulator (PRV) may damage PRV.

CAUTION

Be careful when removing/installing plate assembly to avoid damaging lines and surrounding structure.

CAUTION

Arrow on flow control valve must be pointing downstream or flow control valve will not work.

CAUTION

Arrow on pressure regulator must be pointing downstream or regulator will not work.

CAUTION

Arrow on check valve must be pointing downstream or check valve will not work.

CAUTION

Arrow on installed flowmeter must be pointing downstream or flowmeter will not work.

CAUTION

The flow transmitter is sensitive to contamination. Be careful to keep connection ports clean.

CAUTION

Increasing pressure over full scale range of pressure switch will damage the pressure switch.

CAUTION

When entering an open loop set, enter a value that will increase flow gradually to prevent damaging equipment.

3 INTRODUCTION AND GENERAL INFORMATION

INTRODUCTION

This manual provides information for the Fuel Control System Components Test Station, A/F46T-5 (Figure 1-1), here after referred to as the test station. This information is intended for use by operation and maintenance personnel. The test station is used with the one of the following Pump Modules: Low Pressure Pump Module, Part Number 8230800-0501-OC001(1TL32-6756-1); Medium Pressure Pump Module, Part Number 8232000-0501- OC001(1TL32-6777-1) or High Pressure Pump Module, Part Number 8234000-0501-OC001(1TL32-6795-1). It is also used with Mechanical Test Adapter ADU-762/E (T.O. 33D7-50-1989-2), Mechanical Test Adapter ADU-763/E (T.O. 33D7-50-1988-2) and the Secondary Reference Standards Calibration Set A/E48T-6 (T.O. 33DA92-3-1). This equipment was manufactured by AlliedSignal Inc., Aerospace Equipment Systems, 717 North Bendix Drive, South Bend, Indiana 46620-1000 and was extensively modified and updated by EMD Inc. 1411 Twin Oaks Wichita Falls, TX 76302.

PUMP MODULE

TEST STAND P/N PUMP

MODULE

VFD DISCRIPTION

8230001-0501 High None Base System + MP24 & MP25 + CP22 & CP23 + CP15 and CP6 backpressure regulators

8230001-0502 High 5HP Base System + MP24 & MP25 + CP22 & CP23 + CP15 and CP6 backpressure regulators

8230001-0503 High 5HP Base System + MP24 & MP25 + CP22 & CP23 + CP15 and CP6 backpressure regulators + TF33FC Windmill bypass Modification

Scope This manual provides maintenance information for the test station. The Illustrated Parts Breakdown (IPB) information is located in Technical Manual 1TL32-6755-4.

Purpose The test station provides all the hydraulic, pneumatic, mechanical, and electrical stimuli to the units under test (UUT) and then measures and evaluates the UUT responses to verify that they meet a predefined level of performance.

Limitations The modular design of the test station provides for an unlimited number of UUT applications. The test station is limited only by the availability of related AFATS assemblies.

Mission The test station receives calibration fluid (CalFluid), hydraulic oil, chilled water, electrical power, high pressure air, low pressure air, and vacuum from the facility. Refer to Figure Test Station Interface Diagram. These inputs are massaged and controlled by the test station and applied to the Interface Connector Adapter (ICA). In addition, the test station receives any necessary data to perform testing of UUT from the facility central computer. This is accomplished through the Local Communications Network (LCN). The test station interfaces the UUT through an Interface Test Adapter (ITA). The ITA contains a Mating Interface Connector (MIC) which connects to the ICA on the test station. Once the ITA is connected to the test station, the UUT is connected to the ITA and to the UUT connectors on the test station.

Figure Fuel Control System Components Test Station A/F46T-5

Abbreviations Abbreviations used in this manual are in accordance with MIL-STD-12, except as listed in abbreviations table.

Table – Abbreviation

Abbreviation Definition

A/D Analog-to-Digital

Table – Abbreviation

Abbreviation Definition

AC Alternating Current

AFATS Advanced Fuel Accessories Test System

AFOSH Air Force Occupational Safety and Health

CalFluid Calibration Fluid

CC Central Computer

CCA Circuit Card Assembly

CCW Counterclockwise

CKT Circuit Card

CVT Current Value Table

CW Clockwise

DC Direct Current

DMA Direct Memory Access

ECS Embedded Computer System

EP Explosion Proof

ESTOP Emergency Stop

FAC Facility Connection Point

FISO Fault Isolation

FWS Fuel-Wetted Section

HPS Hydraulic Power Supply (Hydraulic Aircraft Component Power Supply)

HPU Hydraulic Power Unit

HW Hardware

ICA Interface Connector Adapter

IS Intrinsically Safe

ITA Interface Test Adapter

ITACal Interface Test Adapter Calibration Station

LAM Look At Me

LCN Local Communication Network

LOC Location

LPPM Low Pressure Pump Module (Test Station Pump Unit)

MCM Measurement Control Module

MIC Mating Interface Connector

MSDS Material Safety Data Sheet

ODM Operator Display Monitor

Table – Abbreviation

Abbreviation Definition

OPTO Optical Coupler

PCM Power Control Module

PCS Process Control Section

PDDM Process Data Display Monitor

PM Pump Module

PMP1 Pump

PPH Pounds per Hour

PRV Pressure Reducing Valve

PSI Pounds Per Square Inch

PSIA Pounds Per Square Inch Absolute

PSID PSI Differential

PSIG Pounds Per Square Inch Gauge

RAM Random Access Memory

RTD Resistance Temperature Detector Assemblies scfm Standard Cubic Feet Per Minute

UUT Unit Under Test

VAC Volts Alternating Current

VSD Variable Speed Drive

MEC Main Electrical Enclosure

REC Remote Electrical Enclosure

RSLVR Resolver

MACC Motor Vibration

Table – List of Related

Publication Number Publication Title

DOD STD 1686A Electrostatic Discharge Control Program For Protection of Electrical and Electronic Pans, Assemblies and Equipment (Excluding Electrically Initiated Explosive Devices)

DOD-HNBK-263B Electrostatic Discharge Control Handbook For Protection of Electrical and Electronic Parts, Assemblies and Equipment (Excluding Electrically Initiated Explosive Devices)

T.O. 00-5-1 AF Technical Order System

T.O. 00-20-14 Air Force Metrology and Calibration Program

T.O. 00-25-195 AF Technical Order System Source, Maintenance, and Recoverability Coding of Air Force Weapons, Systems, and Equipments

Table – List of Related

Publication Number Publication Title

T.O. 00-25-234 General Shop Practice Requirement for Repair, Maintenance and Test of Electrical Equipment

T.O. 1-1-689 Organizational/Unit and Intermediate Maintenance, Avionics Cleaning and Corrosion Prevention/Control

T.O. 1-1-691 Aircraft Weapons Systems, Cleaning and Corrosion Control (Multiple Aircraft)

T.O. 33A2-2-71-1 Power Supply, Aircraft Component, Hydraulic

T.O. 33DA92-3-1 Operation Instructions, Secondary Reference Standards Calibration Set A/E48T-6, Part Number 8231300-0501

T.O. 33D7-50-1987-1 Operation Instructions, Advanced Fuel Accessories Test System, Intermediate Level, Interface Test Adapter Calibration Station, A/E 24t-223, Part Number 8231850-0501

T.O. 33D7-50-1988-2 Maintenance and Illustrated Parts Breakdown, Mechanical Test Adapter ADU-763/E, Part Number 8231480-0501

T.O. 33D7-50-1989-2 Maintenance and Illustrated Parts Breakdown, Mechanical Test Adapter ADU-762/E, Part Number 8231550-0501

1TL32-6755-4 Illustrated Parts Breakdown, Fuel Control Components Test Station, A/F46T-5, Part Numbers 8230001-OC Series

1TL32-6795-1 Operation and Maintenance Instructions, Advanced Fuel Accessories Test System, High Pressure Pump Module, Part Number 8234000-0501-OC001

1TL32-6777-1 Operation and Maintenance Instructions, Advanced Fuel Accessories Test System, Medium Pressure Pump Module, Part Number 8232000-0501-OC001

1TL32-6756-1 Operation and Maintenance Instructions, Advanced Fuel Accessories Test System, Low Pressure Pump Module, Part Number 8230800-0501-OC001

1TL32-112-1 Operation and Maintenance Instructions, + IPB, Advanced Fuel Accessories Test System, Variable Drive Assembly, 5HP

DESCRIPTION

Main features of the test station are as follows:

Operator Interface The operator views the test stand from the Operator Control Station. Two touch-sensitive select screens (HMI Touch Screens) are used for most command actions and provide response information to the operator. Information on the HMIs guide, informs, and instructs the operator during testing.

UUT Interface. The UUT is connected to the test station via the ITA and PTC. Measured and controlled parameters, including pressure, flow, angle, and voltage are routed through this connection. Operator adjustments are required for some parts of tests.

Facility Interface. The test station requires facility services to operate. These services include fuel, air, water, and electrical power. Additionally, the test station uses a Local Area Network (LAN) and Profibus MPI network.

Local Area Network. The test station communicates with a host PC. The network is an Ethernet network.

The network is can be connected via CAT-5 cable and the fiber optic network switch utilizing a fiber optic building infrastructure.

Profibus MPI network: The test station communicates to a PLC controlled pump module to request calibration fluid flow and to receive flow availability and fluid density data. The test station converts the copper Profibus MPI network media to a fiber optic network that links the various test stations together with the PM.

Host PC. The test station communicates to the building Host PC for archiving of calibration and UUT test data. The communication is via Ethernet on a building wide CAT-5 and fiber optic network. The Host PC is connected to various test stands and collects similar data from the different test stands. The Host PC is networked to a printer that is used to print out test data reports.

Remote Pump Module. The PM is a PLC controlled series of pumps. The PM PLC receives the test stand requests for fluid flow via the Profibus network and activates pumps to provide adequate calibration fluid flow and pressure for UUT testing. The PM will communicate back to the test stand the provided flow and pressure and if there is ample flow available for the UUT test. Refer to PM technical manual for description and operation.

Software Description. The test stand software has three components. The PLC control logic resides in the PLC CPU memory and controls basic control functions related to shutdowns, A/D conversion and machine logic. The HMI screens are utilized to present test stand data and status to the operator and for the operator to interface the PLC control logic. The UUT test environment displays within the HMI screens but it executes as a separate application on the industrial PC. The test environment allows an engineer to develop test screens for unique end items utilizing the fixed PLC and HMI configurations.

Drive Assembly. Some test stands are equipped with a speed drive assembly. Calibrations for these are in this manual. For maintenance refer to the drive listed in Table - List of Related.

Table - Leading Particulars

Component/service Requirement/specification

Facility Requirements

Dimensions Height 8 feet (excluding blower and conduits) Width 11 feet 3 inches Depth 10 feet 2 inches

Weight:

Process Control Section Hydraulic Control Section Total Weight

4,200 pounds 7,300 pounds 11,500 pounds

Environmental Requirements

Operational Temperature 55-110°F

Storage Temperature 40-140°F

Humidity 20-90% noncondensing

Table - Leading Particulars

Component/service Requirement/specification

Input Requirements

Calibration Fluid Type Maximum Pressure Maximum Flow

MIL-C-7024C, Type II 1800 psig 400 gpm

Cold Water:

Maximum Temperature Maximum Flow

45°F ± 2°F 120 gpm

Low Pressure Air:

Pressure Minimum Flow

80-120 psig 20 scfm

High Pressure Air:

Pressure Minimum Flow

700-850 psig 5 scfm

Vacuum 29 InHg

Primary Electrical Power:

Voltage Power Phase Frequency

480 VAC ± 10%

0.5 KVA min. to 34 KVA max.

3 Phase AC 60Hz ± 2 Hz

Auxiliary Electrical Power:

Voltage Power Phase Frequency

208 VAC ± 10%

30 Amperes 3 Phase AC 400Hz ± 2 Hz

Output Requirements:

Calibration Fluid

400 gpm maximum flow

Water 120 gpm maximum flow

Ventilation Air 800 cfm maximum flow

Hazardous Area Rating Process Control Section Hydraulic Section

Class 1, Division 2, Group D Class 1, Division 1, Group D

PROCESS CONTROL SECTION (A1)

Video Display Terminals. Provides operator interface with the test station through use of a touch screen. Used to make selections from menus, perform operations, and display data.

Embedded Computer System. Provides functional control over the test station. Also interfaces with the pump module, and Central Computer over the fiber optic network.

Motor Starter Enclosure Assembly (A8). Provides 208 VAC to the single/dual windings as required by the UUT test requirements.

Panel 1a. Rack 2. This rack contains the Input modules for the Flowmeters, RTD's, Thermocouples, & Strain gauge.

Panel 1a. Rack 7. This rack contains the Output modules for the 3 current channels, CP22, CP23, CF18 & IEEE 488 Interface to calibration cart.

Panel 1b. Rack 3. This rack Input modules for Temperature transmitters, Pressure Transmitters, Resolver Reference Voltage, Resolver angle signal and DC current feedback.

Panel 2a. Rack 1. This rack contains the Human Machine Interface (HMI) Computer, PLC CPU, PS3& PS4 24 VDC power supply, Optical Link Module and Ethernet to FO Switch.

Panel 2b. Rack 4. This rack contains Digital Input modules and PT_MP17 & PT_MP18 analog inputs.

Panel 3. This panel contains the Intrinsically Safe Barriers.

Panel 4. Rack 5. This rack contains all the Digital Outputs including air solenoids and Dosers solenoids.

Panel 5. Rack 6. This rack contains RS232 module.

Panel 5. Rack 8. This rack contains Step Drive module.

Figure Test Station Interface Diagram (Sht. 1)

Figure Test Station Interface Diagram (Sht. 2)

Explosion Proof Light Panel Assembly (A25). The Explosion Proof (EP) light assembly contains the process control section service light Air Solenoid Panel Assembly (A32). The air solenoid panel contains 35 air solenoid valves. Each solenoid valve is electrically operated and is used to operate valves in the hydraulic control section.

Circuit Breaker (CB1). Provides isolation of the test station from the facility electrical power source. The circuit breaker is operated by a handle on the rear door of the test station.

Power Conditioner (Tl). Provides conditioned 5 KVA @ 120 VAC for all 120VAC operated components.

HYDRAULIC CONTROL SECTION (A2)

Service Panel Assembly (Al). Provides easy access to three adjustable pressure regulators, three pressure gauges, and six pressure switches. The three adjustable regulators are: pressure reducing valve (PRV16) which is adjusted to reduce the facility high pressure air down to 550 PSIG; pressure reducing valve (PRV22) which is adjusted to set the Hydraulic Power Unit (HPU) system pressure to 550 PSIG; and pressure reducing valve (PRV2) which further reduces the HPU pressure to 100 PSIG. Three gauges are used when setting the regulators; pressure gauges (GA1 and GA2) monitor the HPU and pressure gauge (GA3) monitors the high-pressure air. Six pressure switches are located on the panel. Switch (S 1) monitors CalFluid inlet supply for 260 PSIG, switch (S2) monitors facility-supplied vacuum for 12 PSIA, switch (S3) monitors Hydraulic Power Supply (HPS) for 1000 PSIG, switch (S4) monitors HPU for 500 PSIG, switch (S5) monitors the facility-supplied low-pressure air for 80 PSIG, switch (S6) monitors the facility-supplied high-pressure air for 700 PSIG. These six switches are easily removed by pressing a release button on the shaft collar.

Doser No. 1 Panel Assembly (A2). Contains 12 electrically operated valves and 5 doser valve assemblies. Two valves are required to perform a function: one valve supplies a volume of oil (dose) and the companion releases it.

Solenoid valves (SV36, SV38, SV64, SV66, SV68, and SV70) receive hydraulic pressure from the HPU. When commanded, a solenoid valve will change the volume of an actuator which will the applicable hydraulically operated valve. The companion solenoid valves (SV37, SV39, SV65, SV67, SV69, SV71), when commanded, release that volume in the line to change the hydraulic valve condition.

Doser No. 2 Panel Assembly (A3). Contains 12 electrically operated valves and 3 doser valve assemblies. Two valves are required to perform a function: one valve supplies a volume of oil (dose) and the companion releases it.

Solenoid valves (SV40, SV42, SV44, SV46, SV48, and SV50) receive hydraulic pressure from the HPU. When commanded, a valve will change the volume of an actuator which will affect the applicable hydraulically operated valve. The companion solenoid valves (SV41, SV43, SV45, SV47, SV49, SV51), when commanded, release that volume in the line to change the hydraulic valve condition.

Doser No. 3 Panel Assembly (A4). Contains 12 electrically operated valves and 5 doser valve assemblies. Two valves are required to perform a function: one valve supplies a volume of oil (dose) and the companion valve releases it. Solenoid valves (SV76, SV54, SV56, SV58, SV60, and SV62) receive hydraulic pressure from the HPU.

When commanded, a valve will change the volume of an actuator which will affect the applicable hydraulically operated valve. The companion solenoid valves (SV77, SV55, SV57, SV59, SV61, SV63), when commanded, release that volume in the line to change the hydraulic valve condition.

Air Supply Panel Assembly (A5). This panel contains manual control valves and air filters for the low and high air pressure systems. The facility low pressure air supply is isolated from the test station by manual valve (MV11). Two filters (FL17A and FL17B) trap particles and remove moisture from the incoming air. When sufficient moisture has accumulated in the glass bowl, a float will rise and the bowl will self-drain. Facility high pressure air supply is isolated from the test station by manual valve (MV13). Filter (FL18) traps particles and separates moisture from the incoming air. This filter is drained by actuator valve (AV29) deactivating and opening a line to the drain pan.

Actuator valve (AVO) closes off the air supply lines if low air pressure is lost.

Transducer Panel Assembly (A6). The transducer panel assembly contains 23 transducers and bleed valves. These transducers monitor CalFluid, air, and hydraulic oil pressures from the ICA.

Fuel Return Assembly (A7, A21, A29). This assembly receives CalFluid from the UUT through the ICA (A7: Loc 18, A21: Loc 21, A29: Loc 19). This system can measure the flow and temperature of the CalFluid passing through

it. The temperature reading can then be used for a weighted flow conversion.

Interface Connector Assembly (ICA) (A8). The ICA assembly provides the connection between the test station and the ITA carts. When an ITA cart is positioned in front of the test station with the ICA and MIC in alignment, the ICA pulling pin will extend and pull the ITA cart and its MIC assembly to the test station when selected from menu.

When this occurs, the ICA and MIC assemblies will mate. CalFluid, hydraulic oil, water, pneumatic, and vacuum are then supplied from the test station to the ITA cart through the ITA/MIC assembly interface.

Valve Panel Assembly (A9). Allows the test station to redirect pressure sources to different circuits.

Low Pressure Fuel Supply Piping Assembly (A10). This assembly receives filtered CalFluid from filter manifold No. 1 (FL1 and FL2) and filter manifold No. 2(FL3 and FL4). This system contains both a supply and return circuit.

The supply and return circuits have the ability to vary the pressures and flows going to and from the UUT through the ICA (Supply: LOC 1, Return: LOC 2). In addition to the control channels on the supply, it can measure flow through any three of its flowmeters, reference the pressure at the inlet of its flow controller and measure the temperature at the flowmeters for weighted flow conversions.

Main Fuel Supply Assembly (All). This assembly receives filtered CalFluid from filter manifold No. 2 (FL3 and FL4). This system has the ability to vary the pressures and flows going to the UUT through the ICA (LOC 5). In addition to the control channels, it can measure flow through two different flowmeters, reference the pressure at the inlet of its flow controller and measure the temperature in the circuit for weighted flow conversions.

Secondary Fuel Supply Assembly (A12).This assembly receives filtered CalFluid from filter manifold No. 2 (FL3 and FL4). This system has the ability to vary the pressures going to the UUT through the ICA (LOC 3). In addition to the control channel, it can measure flow through two different flowmeters and measure the temperature at the flowmeters for weighted flow conversions.

Return Manifold Assembly (A13). Return manifold assembly provides a central location for the collection of CalFluid that will be returning to the facility open-loop return manifold. The flow of CalFluid returning from LOC 22 is varied by flow controller DFC3 when switched in. The CalFluid leaving the manifold flows to the heat exchanger. Check valve (CV17) will permit some of the CalFluid to bypass the heat exchanger during high flowing conditions.

Hydraulic Oil Supply (A14). Provides hydraulic oil to LOC 12 of the ICA. This system has the ability to vary the pressure going to the UUT.

Water Supply Assembly (A15). Facility water is supplied to the test station. Manual valve (MVI8) provides isolation between the test station and the facility. Cooling water passes through strainer filter (FL20) and past temperature measuring device (MT14). Cooling water is supplied to test station HPU heat exchanger (HE1), CalFluid heat exchanger (HE2), VSD motors (if configured with a drive motor), the air conditioner unit, and ICA plate.

Water Return Assembly (A16). Water from the test station is returned to the facility through manual valve (MV19).

The returning water is carrying the heat picked up when passing through CalFluid heat exchanger (HE2), test station HPU heat exchanger (HE1), VSD motor (if configured with either a 5 or 150 HP motor), the air conditioner unit, and ICA plate.

Salvage Tank/Hydraulic Power Unit (A17). This assembly consists of two circuits. The first circuit is the salvage system which receives CalFluid from the ITA carts and from the non-relieving regulators. The CalFluid is stored in the tank until a float switch is activated. Upon activation of the float switch, the CalFluid is pumped back into the return manifold for reclamation. The second circuit is the hydraulic power unit, which supplies hydraulic oil to the doser solenoid valves under 550 psi of pressure. It also supplies the oil to actuate the pulling cylinder on the ICA plate.

Heat Exchanger (Al8). Cools the CalFluid that is used in the UUT testing process.

Leakage Circuit Assembly (A19). The leakage circuit is used for very small flows (CalFluid) on either the supplies or returns of the UUT.

Filter Assembly (A20, A28). Filters CalFluid that is received from the pump module and provides a visual indication when the filters are blocked.

Connector Panel Assembly (A22). The connector panel assembly is located between the ICA and the operator monitor. It provides the electrical interface between the UUT and the test station.

Fuel Return Assembly (A23). This assembly receives CalFluid from the operator UUT through the ICA (LOC 20).

This system has the ability to vary the flow/pressure coming from the UUT. In addition to the control channel, it can measure the flow and temperature of the CalFluid passing through it. The temperature reading can then be used for a weighted flow conversion.

Hydraulic Oil Return Assembly (A24, A30). This assembly receives hydraulic oil from the UUT through the ICA (A24: Loc 24, A30: Loc 25). This system has the ability to vary the flow/pressure coming from the UUT In addition to the control channel; it can measure the flow and temperature of the hydraulic oil passing through it. The temperature reading can then be used for a weighted flow conversion.

Medium Fuel Return Segment (A25). This assembly receives CalFluid from the UUT through the ICA (LOC 23).

This system has the ability to vary the flow/pressure coming from the UUT through the ICA (LOC 23). In addition to the control channel, it can measure the flow and temperature of the CalFluid passing through it. The temperature reading can then be used for a weighted flow conversion.

Large Fuel Return Segment (A26). This assembly receives CalFluid from the UUT through the ICA (LOC 22). This system has the ability to vary the flow/pressure coming from the UUT. In addition to the control channel, it can measure the flow and temperature of the CalFluid passing through it. The temperature reading can then be used for a weighted flow conversion.

Trolley Hoist (A31). The trolley hoist is an air-powered hoist used to assist with heavy lifting. The movable hoist is designed to lift objects up to 250 pounds in weight.

Lubrication Enclosure (A32). Controls the VSD motor lubrication system in the hydraulic control section.

Remote Cabinet (Panel 5 Rack 6) Power Meter (A6). Measures voltage, current, and power for 1 and 3 phase VAC systems and computes the power factor and phase balance.

Power Supply (A7). Provides 0-135 volts of AC power to the UUTs.

Function Generator used to provide the resolver reference voltage.

The ECS power supplies are normally controlled and programmed by the ECS via the IEEE-488 bus. The power supplies output DC voltages between 0 and 55 VDC, 0-55 amp through plug (J3) sense line pins 12 and 13, and through the positive and negative plate connectors. ECS power supply (MV1) connects to connector (J9), pins 2 and

3. ECS power supply (MV2) connects to connector (J9), pins 4 and 5, for connection to UUTs.

FUNCTIONAL DESCRIPTION

The test station provides CalFluid, hydraulics, pneumatics, electrical power, and the required stimuli to test a UUT.

It consists of two parts, the Process Control Section and the Hydraulic Control Section.

The process control section contains the operator interfaces, safety barriers, signal conditioning and interfacing, embedded computer system. The operator interfaces consist of two Touch screen video terminals. They allow the operator to enter data; request tests, view test results, and receive repair instructions. The safety barriers allow signals to be passed from a safe to a hazardous environment. The measurement control modules are a standardized electrical and mechanical instrumentation system that provides routing and signal conditioning for power, data, and control signals. The embedded computer system provides functional control over the test station through its internally stored programs. It communicates with the facility located central computer and the pump module over the LCN.

The hydraulic control section receives CalFluid, hydraulics, water, and pneumatics from the facility. It contains the pneumatic and hydraulic inlet and outlet systems, pressure and flow control systems, pressure and flow measurement devices, and an ICA. These systems are controlled by the process control section to provide the operating environment required by the UUT for testing. Once the UUT has been stimulated, the measured results are returned to the process control section for comparison with the expected results

4 SPECIAL TOOLS AND TEST EQUIPMENT

INTRODUCTION

This chapter contains special tools and test equipment required for operation, maintenance, and calibration of the test stand

SPECIAL TOOLS AND TEST EQUIPMENT

No special tools are required. Test equipment listed in table Abbreviations is required for AFATS Test Station test and troubleshooting. Equivalent equipment may be used if the recommended equipment is not available.

Table - Special Tools and Test Equipment

Tool/Equipment Number Nomenclature Use/Application

Fluke #77 Digital Multimeter (DMM) AC, DC, and resistance measurement

Tektronix 2213 Oscilloscope Provide real-time, visual display of energized circuits for voltage/frequency measurement

3M #8012 Anti-Static Kit ESD-sensitive component protection

DYNALCO F-15 Waveform Generator Produce AC waveforms at varied frequency/amplitude

Multi-Amp MS-1A Clamp-On-Ammeter Current measurements

Panasonic CF-29 Toughbook or equivalent

Laptop Computer, C1D2 Rated, Siemens Step 7 Software and Communication Cables

Troubleshooting PLC logic program.

Fisher-Rosemount Model 275 HART Communicator Troubleshoot and Configure Pressure and Temperature transmitters with HART communication capability.

5 PREPARATION FOR USE, STORAGE AND SHIPMENT

This chapter is not applicable for the Advanced Fuel Accessories Test System (AFATS) Test Station.

6 THEORY OF OPERATION

INTRODUCTION

This chapter provides a description of controls and indicators, theory of operation, safety features, and operating procedures.

THEORY OF OPERATION

The test station consists of two sections: hydraulic control and process control. The hydraulic control section provides all the hydraulic and pneumatic parameters to the unit under test (UUT) through the ICA. The process control section provides test control, monitoring, and power distribution.

AC Power Distribution Primary power for the test station is 480 VAC, 3 phase, 60 Hz. It is supplied by the facility and applied to circuit breaker (CB1) in the incoming power enclosure assembly on the test station. This input is stepped down to 240 VAC, 3 phase 60 Hz and 120 VAC, single phase, 60 Hz for use by the test station and the UUT.

Circuit breaker (CB1) is a 50-amp circuit breaker which isolates the test station from the facility. The circuit breaker handle is mounted on the rear door of the test station, but the actual circuit breaker is located behind the rear door in the incoming power enclosure assembly. When circuit breaker (CB1) is engaged, 480 VAC single-phase is applied to exhaust blower assembly , hydraulic power unit, UUT connector J11, salvage pump 2HP motor and the remote electrical cabinet Panel 5 located upstairs. The following paragraphs describe each of these circuits.

Exhaust Blower Assembly Refer to Figure AC Power Distribution Block Diagram for a block diagram or the…