C-17IGV_TestInstruction.pdf.pdf

T.O. 2G-GTCP331-3-4

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INLET GUIDE VANE ACTUATOR

P/N 3886167-3, 3886167-4

(TRIUMPH AIR REPAIR)

1 GENERAL INFORMATION

The inlet guide vane actuator positions the load compressor inlet guide vanes in order to regulate airflow through the load compressor. The actuator consists of a hydraulic piston, an electro-hydraulic servo-valve, and an integral LVDT type position sensor. Under normal operation, electrical current applied to the electro-hydraulic servo-valve causes a differential pressure to develop across the hydraulic piston, causing it to move. Position feedback is provided via the integral LVDT position sensor.

The differential area across the hydraulic piston causes the actuator to fail in the fully extended position in the event of a jammed rod, rod failure, or electrical failure. Inlet guide vane actuator specifications are listed in Table 1-1. Figure 1-1 shows the actuator’s drain port, View A shows both the return and pressure ports. A functional schematic is provided in Figure 1-2 and Figure 1-3; Figure 1-4 shows the actuators contact pins.

Table 1-1. Inlet Guide Vane Actuator Specifications

Parameter Specification

Working Fluid Jet Fuel: JP-4, JP-5, JP-8, Jet A or Jet B

Operating Pressure

Supply Port 150 to 275 psig

Return Port 10 to 100 psig

Operating Temperature -65 to 260°F

Dry Weight 3 lbs (1.36 kg)

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Figure 1-1. Inlet Guide Vane Actuator

Drain Port

See View A

Pressure Port

Return Port

VIEW A

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PRESSURE PORTRETURN PORT

DRAIN PORT

ELECTRO HYDRAULIC SERVO VALVE

LINEAR VARIABLE

DIFFERENTIAL

TRANSDUCER

Figure 1-2. Hydraulic Schematic

PRIMARY COIL

CONNECTOR

S E C

RED

WHITE

BLUE

YELLOW

RED

BLACK

ORANGE

EHSV

LVDT

RET

EXT

Figure 1-3. Electrical Schematic

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Figure 1-4. Actuator Contact Pins

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3 TESTING AND FAULT ISOLATION

3.1. Refer to Table 3-1 for a list of test equipment and materials.

Table 3-1. Test Materials and Equipment

Material/Equipment Manufacturer Information

Equivalent substitutes may be used.

Beaker, Graduated Commercially Available

1000 mL

281600-7-1 Fuel Accessory Test Stand Honeywell

3210135-1 Actuator Test Console, Engine, Systems, and Services

Electronic Aerospace Support Equipment

290375LTF Test Fixture 717 North Bendix Drive

South Bend, IN 46628

DAB7249G300-001 Actuator Test Console, Northrup B-2 Division

Hydraulic

TE3310523-1 Hook-up Kit

TE3310527-1 Test Adapter Triumph Air Repair

TE3310526-1 Wiring Harness 50 S 56 th

St

TE3310806-1 Wiring Harness Chandler, AZ 85226

Phone: (480) 824-2700

URL: www.triumphgroup.com

Multimeter Fluke Electronics

Model 87 III 6920 Seaway Blvd, Everett, WA, USA 98203

P.O. Box 9090, Everett, WA USA 98206

Phone: (425) 347-6100

Insulation Resistance Tester Megger

Model BMM80 4271 Bronze Way

Dallas, TX 75237

Phone: (610) 676-8579

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3.2. Perform electrical tests as follows:

3.2.1. Perform insulation resistance test as follows:

WARNING

High voltage is present during insulation resistance test. Keeps hands away from unit under test while voltage is applied.

3.2.1.1. Connect TE3310806-1 Test Cable as follows:

3.2.1.1.1. Connect cable labeled “UNIT” to unit under test.

3.2.1.1.2. Connect remaining cables as instructed below.

3.2.1.2. Using a 500VDC insulation resistance tester, measure the resistance across pin 1 (positive) and pin 7

(negative). Insulation resistance shall be 40 megohms minimum.

3.2.1.3. Using a 500VDC insulation resistance tester, measure the resistance across pin 3 (positive) and pin 7

(negative). Insulation resistance shall be 40 megohms minimum.

3.2.1.4. Using a 500VDC insulation resistance tester, measure the resistance across pin 5 (positive) and pin 7

(negative). Insulation resistance shall be 40 megohms minimum.

3.2.1.5. Record results on test data sheet (see Figure 3-1).

3.2.2. Perform component resistance test as follows:

3.2.2.1. Using a multimeter, measure case ground resistance across pin 7 and case. Case ground resistance shall not exceed 1.0 ohms.

3.2.2.2. Using a multimeter, measure EHSV resistance across pins 1 and 2. EHSV resistance shall be 28.6 to

34.7 ohms.

3.2.2.3. Using a multimeter, measure LVDT input resistance across pins 5 and 6. LVDT input resistance shall be 94 to 126 ohms.

3.2.2.4. Using a multimeter, measure LVDT output resistance across pins 3 and 4. LVDT Output resistance shall be 84 to 114 ohms.

3.2.2.5. Record results on test data sheet (see Figure 3-1).

MIL-C-7024 Type II Calibration Fluid – Reference Number: 1

3.3. Prepare for functional tests as follows:

3.3.1. Install IGV actuator onto 290375LTF Test Fixture, extend LVDT to strike plate.

NOTE

Ensure packings on TE3310527-1 Manifold Adapter are acceptable for use; replace if damaged. To ease installation of Manifold Adapter onto IGV Actuator, apply petrolatum to packings prior to installing adapter.

3.3.2. Install TE3310527-1 Manifold Adapter onto IGV actuator.

3.3.3. Connect cable between test stand and electrical connector of IGV actuator. Connect cable between test stand and electrical connector on LVDT of 290375LTF Test Fixture. See Figure 1-3 for wiring schematic.

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3.3.4. Connect a hose from fuel stand Supply to INLET on the IGV and a hose from fuel stand return to OUTLET on the IGV.

3.3.5. Excite LVDT primary coil with 3551 (±71) Hz at 7.070 (±0.035) Vrms.

Perform polarity test as follows:

3.3.6. Apply 305 (±15) psig inlet pressure. Restrict outlet line to 30 (±10) psig of back pressure.

3.3.7. Apply 0 to +5 mA of current to EHSV. Verify IGV actuator is in the fully extended position.

3.3.8. Apply +59 to +64 mA of current to EHSV. Verify actuator moves to the fully retracted position.

3.4. Perform proof pressure test as follows:

3.4.1. Apply 0 to +5 mA of current to EHSV and verify actuator moves to the fully extended position.

3.4.2. Apply 750 (±25) psig inlet pressure and 180 (±5) psig of back pressure on the outlet. Maintain for 2 minutes minimum.

3.4.3. Observe external surfaces for leakage. None permitted.

3.4.4. Decrease inlet pressure to 305 (±50) psig and back pressure on the outlet to 30 (±10) psig.

3.4.5. Increase current applied to EHSV to +59 to +64 mA and verify actuator moves to the fully retracted position.

3.4.6. Increase inlet pressure to 750 (±25) psig and back pressure on outlet line to 180 (±5) psig. Maintain for 2 minutes minimum.

3.4.7. Observe external surfaces for leakage. None permitted.

3.4.8. Decrease inlet pressure to 305 (±15) psig and back pressure on outlet line to 30 (±10) psig.

3.4.9. Record results on test data sheet (see Figure 3-1).

3.5. Perform stroke test as follows:

3.5.1. Decrease current applied to EHSV to -5 to 0 mA and verify actuator moves to the fully extended position.

3.5.2. Zero position indicator on 290375LTF Test Fixture.

3.5.3. Increase current applied to EHSV to +64 to +69 mA and verify actuator moves to the fully retracted position.

3.5.4. Measure stroke length using indicator on 290375LTF Test Fixture. Stroke length shall be 0.99 to 1.01 inches.

3.5.5. Record results on test data sheet (see Figure 3-1).

3.6. Perform LVDT null position test as follows:

3.6.1. Decrease current applied to EHSV to -5 to 0 mA and verify actuator moves to fully extended position.

3.6.2. Zero position indicator on 290375LTF Test Fixture.

3.6.3. Slowly increase input current until actuator moves 0.500 (±0.002) inches as indicated on 290375LTF Test

Fixture.

3.6.4. Verify secondary coil voltage is 0±15 mVrms.

3.6.5. Apply -5 to 0 mA input current to EHSV and verify actuator moves to fully extended position.

3.6.6. Record results on test data sheet (see Figure 3-1).

3.7. Perform shaft seal leakage test as follows:

3.7.1. Apply 385 (±15) psig inlet pressure. Restrict outlet line to 30 (±10) psig of back pressure.

3.7.2. Zero position indicator on 290375LTF Test Fixture.

3.7.3. Slowly increase input current until actuator moves 0.500 (±0.002) inches as indicated on 290375LTF Test

Fixture.

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3.7.4. With current signal still applied to EHSV, vary the frequency of the signal to a 0.25 to 0.50 Hz sine wave.

Slowly increase the amplitude of the wave until the actuator cycles between mechanical stops. Lower the amplitude just below this amount so the mechanical stops are no longer hit on each cycle.

3.7.5. Cycle the actuator 100 to 150 cycles.

3.7.6. Leakage from drain must be less than 3 drops per minute. A slight wetting of the piston assembly is allowed, but no formed drops are permitted.

3.7.7. While actuator is cycling, observe leakage from shaft seal. Seal leakage shall not exceed 3 drops per minute.

3.7.8. Record results on test data sheet (see Figure 3-1).

3.8. Perform internal leakage test as follows:

3.8.1. Apply 305 (±15) psig inlet pressure. Restrict outlet line to 30 (±10) psig of back pressure.

3.8.2. Apply 64 to 69 mA input current to EHSV and verify actuator moves to fully retracted position.

3.8.3. Flow rate from return port (interal leakage) shall be less than 665 cc/min.

3.8.4. Slowly increase input current until actuator moves 0.500 (±0.01) inches as indicated on 290375LTF Test

Fixture.

3.8.5. Flow rate from return port (interal leakage) shall be less than 665 cc/min.

3.8.6. Apply -5 to 0 mA input current to EHSV and verify actuator moves to fully extended position.

3.8.7. Flow rate from return port (interal leakage) shall be less than 665 cc/min.

3.8.8. Apply 275 (±15) psig inlet pressure. Open outlet line for minimal back pressure.

3.8.9. Apply a 0.5 Hz square wave input current alternating from 0 (±1) mA to +64 (±2) mA. Verify actuator extends and retracts continuously.

3.8.10. Measure time for actuator to fully extend.

3.8.11. Calculate extend rate as follows:

Extend Rate (in/sec) = 1 .

Extend Time (sec)

3.8.12. Extend rate shall be 4.0 in/sec minimum. Record results on test data sheet (see Figure 3-1).

3.8.13. Measure time for actuator to fully retract.

3.8.14. Calculate retract rate as follows:

Retract Rate (in/sec) = 1 .

Retract Time (sec)

3.8.15. Retract rate shall be 4.0 in/sec minimum. Record results on test data sheet (see Figure 3-1).

3.9. Perform shaft seal verification test as follows:

3.9.1. Connect hydraulic line with a ¼ inch AN type fitting to the overboard drain port.

3.9.2. Apply 25 (±5) psig pressure to the overboard drain for a minimum of 1 minute. Leakage observed from interface of piston assembly and DC excluder shall be no more than 1 cc/minute (5 drops/min).

3.9.3. Decrease pressure to zero.

3.10. Remove unit from test set-up.

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Test Data Sheet

Inlet Guide Vane Actuator

Test Date: Part Number:

Test

Operator: Serial Number:

Test Step Description Units Limits Actual Pass/Fail

3.2.1 Insulation Resistance Test

3.2.1.2 1 to 7 Megohms 40 min

3.2.1.3 3 to 7 Megohms 40 min

3.2.1.4 5 to 7 Megohms 40 min

3.2.2 Component Resistance Test

3.2.2.1 Case Ground Resistance (7 to case) Ohms 1 max

3.2.2.2 EHSV Resistance (1 to 2) Ohms 28.6 to 34.7

3.2.2.3 LVDT Input Resistance (5 to 6) Ohms 94 to 126

3.2.2.4 LVDT Output Resistance (3 to 4) Ohms 84 to 114

3.4 Polarity Test

3.5 Proof Pressure Test

3.6 Stroke Test Inches 0.99 to 1.01

3.7 LVDT Null Position Test Vrms ± 0.015

3.8 Shaft Seal Leakage Test

3.9 Internal Leakage Test

3.9.3 Retracted cc/min 665 max

3.9.5 Halfway cc/min 665 max

3.9.7 Extended cc/min 665 max

3.10 Stroke Rate Test

3.10.4 Extend Rate in/sec 4.0 min

3.10.7 Retract Rate in/sec 4.0 min

3.11 Shaft Seal Verification Test

Final Result:

Figure 3-1. Test Data Sheet

2G-GTCP331-3-4_changes_withoutcomments.pdf