F-22TestInstruction_pdf.pdf

FUEL CONTROL ASSEMBLY F-22-D-00-007

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3 ACCEPTANCE TESTING AND FAULT ISOLATION

3.1 Test General Data

Types Of Operations

1. Perform Pump Green Run

2. Pump Performance

3. Oil Bypass Valve & Pressure Switch Testing

4. Metering Valve Adjustment (Delta Pressure Setup)

5. Start Flow Check

6. Metering Valve Calibration Verification

7. Operating Fuel Leakage

8. Relief Valve

9. Filter Inspection and Leak Check

These test instructions (TI) describe calibration and acceptance test procedures to be performed on all production and overhaul fuel control units (FCUs), P/N 3883664 ( -7). Any unit failing to meet the requirements specified in this TI shall be rejected and repaired as required. TEST INSTRUCTION DATA SHEET IS ATTACHED TO THIS MANUAL.

General Test Requirements

The test stand drive shaft shall rotate clockwise (CW) when viewing the FCU from the input end. The unit shall be mounted with the locating pin on the flange at 12 o'clock. The O-ring must be installed in the O-ring groove on the mounting flange.

The locations of the test ports and components are shown in Figures 1 and 2. Install needle valves ahead of all gages and adjust to hold fluctuations to a minimum. Port size shall dictate line size. Keep line lengths to a minimum. Lines shall be rigid or high pressure construction. Oil shall be supplied at 5 ±2 psig for spline lubrication.

Caution: To prevent oil seal damage, the spline cavity must be filled with oil before rotation. Vent all air from cavity through fitting located on top of the adapter.

Observe drain during testing. If fuel leakage is in excess of one drop in 10 minutes, or any oil leakage is observed, conduct a ten-minute leak check at the end of the TI. If leakage is observed during this check, reject the unit. Leakage test will be accomplished after calibration.

All fuel control units will have a new fuel filter installed prior to return to service.

Depreservation (When Required) See Step 3.13

Green Run (When Required)

Green run (Pump Flush and Break-In) is only required when new pump components or housing assemblies are replace. (FN’s 0002, 0037, 0038, 0040)

Pump Performance Run (When Required)

Pump performance run is only required if other tests and calibrations settings will not adjust or maintain limitations.

Accomplish to determine if pump performance influences fuel control test and calibration completion.

Metering Valves All P/N 3883666-3 Metering Valves Must Be Replaced By P/N 3883666-4 MV.

NOTE: DATA POINTS 6 TRHOUGH 33 ARE REQUIRED ON ALL FUEL CONTROLS

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3.2 Instrumentation and Test Equipment Requirements

Required instrumentation is listed below. All instrumentation shall be calibrated.

Instrumentation Requirements

Item Range Accuracy *

Inlet Fuel Pressure 0 to 100 psig ±0.50 percent

Pump Discharge Pressure 0 to 1500 psig ±0.50 percent

Atomizer Inlet Pressure 0 to 1000 psig ±0.50 percent

Metering Valve Pressure Drop 0 to 100 psid ±0.50 percent

Metered Flow Rate 10 to 95 Ib/hr 95 to 1000 Ib/hr

±1 percent ** ±0.5 percent **

* Accuracy specified in percent shall be percent of full scale unless otherwise noted.

** Percent of observed value.

Test Equipment Required.

Item Description Remarks

Atomizer Assembly See paragraph 2.2.1 Required to simulate atomizer back pressure

Test Fluid MIL-T-5624 Grade JP-4 or

MIL-PRF-7024 Type

II(Calibrating Fluid)

Filtered and supplied to fuel control inlet. Temperature to be maintained at 80

±15F

Shutoff Valve Needle Valve Required to back pressure fuel control for green run, pump performance, and relief valve check

Electrical Power 24 Vdc Required to operate metering valve and fuel shutoff valve

Lubricant MIL-L-6081, Grade 1010 Required for preservation

Lubricant MIL-L-7808 or MIL-L-23699 Required for lubrication of drive shaft spline

Lab Relief Valve Set to relieve at 1100±25 psig Prevents over-pressurization of fuel control

Test Block P/N P47A-03-0509 Used for fuel filter bypass valve/pressure switch stand alone test

Mount Pad P/N F19223 Required to mount fuel control to test stand

O-ring P/N M25988/2-011 Used with fuel shutoff solenoid valve adapter

O-rings (2) P/N M25988/2-011 Used with metering valve adapter

O-ring P/N M25988/2-033 Installs between mount flange and mount pad

O-ring P/N M25988/2-910 Used with green run plug

O-ring P/N M25988/2-014 Used with green run plug

O-ring P/N M25988/2-016 Used with green run plug

Torque Motor (T/M)

Simulator

Slave 3883666-All or T/M equivalent resistance load

Used for setting start flow pulse current

Green Run/ Pump Performance Plug

P/N F19223-5 Replaces Delta-P valve/High pressure filter for pump performance run and green run

Plug P/N F19223-11 Replaces Solenoid (On/Off Sw) valve for green run only

Cover P/N F19223-XX (TBD Required to cover metering valve for green run only

Plug (Lee Cuta) P/N PLRA281 0010A Replaces fuel control relief valve during green run only (Internal in housing)

Plug P/N P47A-03-0515 Replaces fuel filter bypass valve/pressure switch for green run only

Equivalent equipment may be substituted.

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Atomizer Simulator Test Required

The atomizer simulator shall have a primary crack pressure of 5 to 30 psid, and a secondary crack pressure of 110 to 140 psid, and shall meet the following flow requirements:

Pressure, psid Flow, lb/hr

70 33 to 35.5

150 122.5 to 131

400 306 to 330

Fuel Ports and Components

Figure 1

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Fuel Ports and Components Cont.

Figure 2

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3.3 Test Type - Pump Green Run

Note: For New Pumps and Housing Only. Green run should be performed prior to installation of the metering valve (MV), differential pressure regulator/ high pressure filter, fuel shutoff solenoid valve (FSOV), fuel filter bypass/pressure switch, and the pressure relief valve to prevent contamination of these components during green run.

(a) Install FSOV P/N F19223-11 plug in place of FSOV.

(b) Install Green/Pump performance run plug, P/N 19223-5 in place of differential pressure valve and high pressure filter.

(c) Install block-off plate P/N 19223-XX(TBD) in place of the fuel metering valve.

(d) Remove relief valve, if installed using Lee Cuta removal tool.

(e) Install relief valve plug, P/N PLRA2810010A, in place of fuel control relief valve.

(e) Install P47A-03-0514 plug in place of filter bypass valve/pressure switch.

(f) Install fuel filter housing; ensure the filter is not installed for green run.

(g) Install fuel control on test stand per Figure 3. Fill spline cavity with oil before rotation and record on data sheet.

(h) Operate fuel pump at speeds/time durations specified on Green Run Data Sheet.

(i) Set fuel pump discharge pressure by adjusting the hand valve (Figure 3).

Caution: EXERCISE CAUTION WHEN OPERATING HAND VALVE, LET PRESSURE STABALIZE TO EACH DATA POINT TO

PREVENT OVERPRESSURIZATION OF FUEL CONTROL.

(j) Following green run data sheet, completely flush all cavities of the FCU housing to remove chips and other foreign objects.

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Green Run and Pump Performance Set-Up

Figure 3

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3.4 Test Type – Pump Performance

Note: Pump performance run is only required if other tests and calibrations settings will not adjust or maintain limitations. Accomplish to determine if pump performance influences fuel control test and calibration completion.

(a) Pump performance is accomplished with all components installed, including the inlet fuel filter, except delta-P regulator and high pressure filter.

(b) Remove Delta P regulator and High pressure Filter, install F19223-5 plug.

(c) Operate unit at the speeds and discharge pressures specified on the Pump Performance data sheet.

(d) Set fuel pump discharge pressure by adjusting the hand valve (Figure 3).

(e) If unit does not meet minimum requirement, reject the unit for rework. Inspect for shipping, cracks, tip wear or scoring, and cut/wore-out packings. Also inspect for leaking fuel shut-off solenoid valve. Replace FCU assembly components, perform pump performance test. Perform green run if any pump components are replaced.

Note: Pump performance can be performed on the fuel control calibration test setup (Figure 4). The delta-P valve and pump screen must be replaced with the in le t adap te r F19223 -5 ; the fuel control discharge port must be capped. The hand valve bypassing the atomizer simulator must be open and the FSOV must be deenergized.

3.5 Test Type – Oil Bypass / Pressure Switch

Before performing the following tests, remove filter bypass pressure switch from fuel control and install into test block P47A-03- 0509. Supply clean-filtered calibration fluid to the port marked “INLET”. The outlet port shall be at ambient pressure at all times.

(a) Pressure switch test - Connect ohmmeter to Pins A and B. Resistance with zero-psig inlet pressure shall be a maximum of 1.0 ohm.

(b) Pressure switch test - Starting at zero psig, gradually increase inlet pressure while monitoring the ohmmeter. The pressure switch shall open, creating an open circuit at an inlet pressure of 5±1 psig.

(c) Crack test - Starting at zero psig, gradually increase inlet pressure while monitoring the flow from outlet.

Record the pressure when flow from outlet cracks (open), pressure must be 8 psig minimum. Flow must exceed 10 cc/min.

(d) Reseat test - Reduce pressure gradually, record the value valve reseats. Reseat of unit flow from outlet is 5 psig minimum. Flow from outlet must be less than 10 cc/min.

(e) Leakage test - Reduce inlet pressure to zero, then apply 2 ±0.5-psig inlet pressure and monitor outlet flow for 5 minutes. Leakage shall not exceed 2 drops/min.

Note: Replace fuel bypass valve/pressure switch if limits are not met in any of the above tests.

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Fuel Control Calibration and Adjustment

Figure 4

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3.6 Test Type – Metering Valve Calibration / Adjustment

(a) Set the pump inlet pressure, pump speed and MV current per data sheet.

(b) Adjust the Metering Valve at the MV adjustment screw as necessary to meet the requirements on the data sheet.

The adjustment gain is approximately 36 lb/hr per turn CW. Exercise the MV – 0mA to 100mA, and then 100mA to 0mA after each adjustment.

(c) Reduce speed to zero rpm and turn solenoid and MV current OFF.

3.7 Test Type – Start Flow

Note: If possible, this test should be performed after the FCU and its components have cooled to room temperature.

(a) Set the pump inlet pressure, pump speed, and MV current per the data sheet.

(b) Connect MV simulator to Pins C and D of the MV cable. Adjust power supply to 216mA. Turn OFF power supply and remove MV simulator then connect power cable to MV electrical connection on fuel control. Cycle the MV current ON-OFF switch once, from OFF to ON to OFF within one second or less.

(c) With power supply OFF, reduce current to 0mA. Turn power supply ON and increase current to 90mA.

Record, ensure value is within limits on Data Sheet.

Note: If required value cannot be achieved or maintained, replace metering valve assembly.

3.8 Test Type – Metering Valve Calibration Verification

Note: FCU fuel output temperature shall be 105-120F.

(a) Set the pump inlet pressure, pump speed, and MV current per the data sheet. Record on Data Sheet.

Note: If metered flow is out of limits at any point, adjust the differential pressure shims as necessary, not to exceed .160 maximum. It may be necessary to replace the Delta-P valve spring to achieve limits. Increasing shim dimension will increase flow. If shims are adjusted, cycle metering valve after adding or removing Delta-P shims.

3.9 Test Type – Operating Fuel Leakage

(a) Energize the FSOV.

(b) Set the pump inlet pressure, pump speed and MV current per the data sheet.

(c) Observe the fuel control drain for ten minutes. Leakage shall not exceed one drop in 10 minutes. If leakage is observed, clean drain port and retest. If FCU is still leaking at drain port, reject the unit. Disassemble, inspect/replace packings, seals/seal rotor, drive gear-shaft and dimensional requirements.

3.10 Test Type – Relief Valve

Caution: DO NOT EXCEED 1000 PSIG. DO NOT OPERATE UNIT WITH VALVE CLOSED FOR MORE

THAN 15 SECONDS.

(a) Set the pump inlet pressure, pump speed, and MV current per the data sheet.

(b) Close the hand valve on the discharge of the FCU and verify that PN pressure does not exceed the data sheet value. Replace valve if limits are not achieved.

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3.11 Test Type – Fuel Shutoff Solenoid Valve

(a) Turn off the power to the fuel shutoff valve, disconnect the FCU discharge tube, and allow fuel to drain from the fitting. Using a collection device or monitor leakage for five minutes.

Note: If leakage in five minutes exceeds three drops, replace the fuel shutoff valve.

3.12 Test Type – Filter Inspection and Leak Check

After testing the unit, remove and inspect the fuel inlet filter. If there is evidence of foreign particles, install a new filter; otherwise, reinstall the original element. After checking the filter, pressurize the inlet to 60 psig for one minute to verify that there is no leakage. If leakage is observed, replace the O-ring on the filter bowl.

3.13 Depreservation Procedures

If a preserved unit is to be operated on the test stand, the unit shall first be depreserved as follows to avoid contamination of test fluid with oil:

(a) Install the fuel control on a test stand.

(b) Plug all ports in the fuel system except fuel pump inlet and fuel control discharge.

(c) Supply a source of fuel or calibration fluid to fuel pump inlet at a pressure of 5 to 25 psig.

(d) Operate the pump at 500 rpm maximum until only test fluid flows from the fuel control discharge.

Note: Fluid flowing from unit during depreservation shall not be return and contaminate the test stand reservoir.

3.14 Preservation Procedures

Note: The fuel control shall be preserved with clean filtered MIL-L-6081, Grade 1010 or Univolt-Sixty preservation oil.

(a) Connect oil supply to the fuel inlet port by a low-pressure source.

(b) Drive the input shaft at a speed of 500 rpm maximum until clear oil flows from the fuel control discharge fitting.

(c) Drain oil from the fuel control and plug all fittings. Some residual oil is permitted.

Sheet 1 of 2

DATA SHEET

FCU PUMP

PERFORMANCE AND

FCU CALIBRATION

Used With:

F-22-D-00-007

P/N 3883664-7 S/N ________________ Technician: ________________________________________ Date: ____________________

Spline cavity filled with oil before rotation

Data Point

Para.

No. Test Type

Pump Inlet

Pressure, ±1 psig

Pump Speed, ±10 rpm

Metering Valve

Current, ±0.1 mA

PD or PN Pressure, psig Metered Fuel Flowrate, lb/hr Metering Valve Delta-P *, psid

Required Actual Required Actual Required Actual

1 3.3 Pump Gr een Run

Per DS-3883664

2 3.4 Pump Performance

5 1200 150 ± 5 PD 50 min

3 5 3900 200 ± 5 PD 385 min

4 5 7100 400 ± 5 PD 700 min

5 5 7100 700 ± 5 PD Record

6 3.5 (a) Pressure Switch Test 1.0 ohm max

7 3.5 (b) Pressure Switch Test 5±1 psig 8 3.5 (c) Crack Test 8 psig min 9 3.5 (d) Reseat Test 5 psig min

10 3.5 (e) Leakage Test 2 drop/min max

11 3.6 MV Calibration 5 7100 104.1 40-42

12 3.7 Start Flow Check

5 950 216 OFF-ON-

OFF

13 5 950 90 30-36

14 3.8 Metering Valve Calibration Verification

5 7100 50 0-38

15 5 7100 90 31-41

16 5 7100 140 59-83

17 5 7100 190 106-133

18 5 7100 240 151-183

19 5 7100 290 196-237

20 5 7100 340 240-300

21 5 7100 440 330-400

22 5 7100 500 380-445

23 5 7100 440 330-400

24 5 7100 340 240-300

25 5 7100 290 196-237

26 5 7100 240 151-183

27 5 7100 190 106-133

28 5 7100 140 59-83

29 5 7100 110 40-54

Technician may be required to adjust Delta-p Valve shims if limits drift out limits

Sheet 2 of 2

DATA SHEET

FCU CALIBRATION Used With:

F-22-D-00-007

Data Point

Para.

No. Test Type

Pump Inlet

Pressure, ±1 psig

Pump Speed, ±10 rpm

Metering Valve

Current, ±0.1 mA

PD or PN Pressure, psig Metered Fuel Flowrate, lb/hr Metering Valve Delta-P *, psid

Required Actual Required Actual Required Actual

30 3.9 Operating Fuel Leakage

5 7100 100 Accept_____ Reject_____

31 25 7100 100 Accept_____ Reject_____

32 3.10 Relief Valve 5 7100 200 1000 max PN

33 3.11 Fuel Shutoff Valve

25 0 0 3 drops max

* Engineering Request Only

Used With Page 1 of 1 F-22-D-00-007

DATA SHEET FCU

GREEN RUN

P/N 3883664-___ S/N ____________ Technician ___________________________ Date ___________________

Spline cavity filled with oil before rotation

Pump Inlet Pressure, ±1 psig

Pump Speed, ±10 rpm

Pump Discharge Pressure, ± =5 psig

Time Duration, min

Observed Fuel Flowrates, lb/hr

Required Flow

10005 50 2

5 1000 100 2

5 3000 100 2

5 3000 200 2

5 3000 300 2

60005 300 2

5 6000 400 2

5 6000 500 2

71005 500 2

5 7100 700 2

71005 900 2

12005 150 50 min

5 3900 200 385 min

71005 400 700 min

71005 700

1) Increase pressure slowly. Approximately 5 psig per second.

2) Open hand valve prior to changing speed.