Pages from 03-75HP-5_2023-05-11_08-36-21.pdf

NAVAIR 03-75HP-5 007 00

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1. SUPPORT EQUIPMENT REQUIRED.

Specification or Part Number Nomenclature

Local Manufacture Actuator Test Circuit (see figure 1)

Local Manufacture Pneumatic Test (see figure 2) Set-up

Local Manufacture Motor Test Circuit (see figure 3)

P/N TE-9034-1 (96421) Weston/Borg-. . .

Warner: Protractor Plate (or equivalent)

P/N TE-9034-2 (96421) BYLB50494-Series:. . .

Protractor Plate (or equivalent)

P/N TE-9034-3 (96421) BYLB50495-Series:. . .

Protractor Plate (or equivalent)

P/N LT-3080-02 (70210) Motor Torquemeter. . .

(or equivalent)

Model M5, 400-Hz (24655) VARIAC (24655).

Commercial Digital Voltmeter, 4 digit accuracy Commercial VTVM, 0 to 15 VDC Model No. 260-6XLP Multimeters (2 ea)

(24655) (or equivalent) Model No. 412 (05624) Dielectric Strength

Tester, 0 to 1,500

VAC

Local Manufacture Cable Assembly (18 (see figure 4) gauge)

Model No. UTMT 1−1−1 Torque Test Machine. . .

P/N 253760

P/N 18D8196−1 Adapter Plate Mount (96916)

2. VA LV E A N D A C T U AT O R A S S E M B LY

FUNCTIONAL TEST.

3. PRELIMINARY SET-UP PROCEDURES.

Ensure valve assembly and voltage equipment are properly grounded.

a. Connect valve to Actuator Test Circuit.

b. Set S2 (VALVE DIRECTION) switch to OFF.

c. Set S4 (PULSE) switch to MAINTAINED ON.

d. Set S5 (VALVE LIMIT SWITCH LIGHTS) switch to OFF.

e. Set S1 (AC POWER) switch to ON (observe that lamp L1 comes on).

f. Adjust VARIAC to adjust voltage across pins C and H to zero.

g. Set S3 switch (DC POWER) to ON (observe that lamp L5 comes on).

h. Connect DIGITAL VDC METER to terminals K and B.

i. Adjust VDC power supply to obtain 8.997

�0.003 VDC.

j. Read VAC voltage readings on VAC METER to �0.1 VAC.

4. MINIMUM STARTING VOLTAGE.

a. Select S2 switch to OPEN.

b. Slowly adjust VARIAC voltage to 50 VAC.

c. Operate valve to approximately 45 degrees open.

d. Adjust VARIAC voltage to 5 VAC.

e. Observe that valve operates towards OPEN.

f. Select S2 switch to CLOSE.

g. Observe that va lve operates towards

CLOSE.

h. Select S2 switch to OFF.

i. LIMITS: Valve must operate towards open and closed at 5 VAC minimum (this does not apply at full closed or full opened positions).

5. MAXIMUM OPERATING CURRENT.

a. Adjust VARIAC until VAC METER reads 50

VAC.

b. Select S5 switch to ON.

NOTE

If either L4 or L3 lamps activate to ON, refer to WP 004 01 or WP 004 02 for the removal or disabling of switch (46, figure 1, WP 009 01)/[27, figure 3, WP 009 02].

c. Select S2 switch to OPEN and operate valve to fully open.

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d. Observe AMP METER output during open-ing operation.

e. Select S2 switch to CLOSE and operate valve to fully closed.

f. Observe AMP METER output during closing operation.

g. Select S2 switch to OFF.

h. Select S5 switch to OFF.

i. LIMITS: 0.054 AMPS (maximum) control or fixed phase.

6. TIMING.

a. Select S2 switch to OPEN and operate valve to fully open.

b. Select S2 switch to OFF.

c. Select S2 switch to CLOSE.

d. Measure time from FULL OPEN to FULL

CLOSE.

e. Select S2 switch to OPEN.

f. Measure time from FULL CLOSE to FULL

OPEN.

g. Select S2 switch to OFF.

h. LIMITS:

BYLB50494Series and BYLB50495Series:

95 seconds (maximum) each direction.

40D980 and 40D990: 75 to 115 seconds each direction.

7. EXTERNAL LEAKAGE.

a. Connect valve to Pneumatic Test Setup.

b. Connect valve to Actuator Test Circuit.

c. Close downstream shutoff valve.

d. Ensure VARIAC is adjusted to 50 VAC.

e. Select S2 switch to OPEN and operate valve to FULL OPEN.

f. Select S2 switch to OFF.

g. BYLB50494-Series: Apply 30 psig to valve.

h. BYLB50495-Series: Apply 17.2 psig to valve.

h1. 40D980 and 40D990: Apply 17.5 psig to valve.

i. Apply soap solution to valve joints.

j. Inspect for evidence of external leakage.

k. Clean off excessive soap solution.

I. LIMITS: No external leakage is allowed.

8. INTERNAL LEAKAGE.

a. Relieve air pressure from valve by adjusting pressure regulator to zero.

b. Open downstream shutoff valve.

c. Apply 17.5 psig to valve inlet.

d. Select S2 switch to CLOSE and operate valve to full closed.

e. Select S2 switch to OFF.

f. Measure (internal) leakage on flowmeter.

g. LIMITS:

BYLB50494-Series and 40D980: 0.10 PPM

(1.34 SCFM) maximum.

BYLB50495-Series and 40D990: 0.10 PPM

(1.34 SCFM) maximum.

9. UNSEALING EXCURSION.

a. Relieve air pressure from valve by adjusting pressure regulator to zero.

b. Remove valve from actuator test circuit and Pneumatic Test Set-up.

c. Install protractor plate on valve.

d. Reconnect valve to Pneumatic Test Set-up and to actuator test circuit.

e. Select S2 switch to CLOSE and operate valve to fully closed.

f. Apply 17.5 psig to valve inlet.

g. Select S2 switch to OFF.

h. Ensure valve pointer reflects correct butter-fly position.

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i. Adjust VARIAC until VAC METER reads 10

VAC.

NOTE

Select S4 switch to MOMENTARY ON as required to fine tune leakage rate.

j. Select S2 switch to OPEN and operate valve to a downstream flowrate of 0.3 � 0.1 PPM (4.0

SCFM �1.31 SCFM).

k. Select S2 switch to OFF.

I. Measure angle on protractor plate from the full closed position.

m. LIMITS:

40D990: 3.0 degrees (maximum).

40D980: 5.0 degrees (maximum).

n. Relieve air pressure from valve by adjusting pressure regulator to zero.

o. Remove valve from Pneumatic Test Set-up.

10. GEAR BACKLASH.

a. Adjust VARIAC to 50 VAC.

b. Select S4 switch to MAINTAINED ON.

c. Select S2 switch to OPEN.

d. Operate valve to approximately 45 degrees open.

e. Select S2 switch to OFF.

f. Remove valve from Actuator Test Circuit.

g. Apply light pressure on butterfly with fingers.

h. Measure total gear backlash.

i. LIMITS: 2 degrees (maximum).

j. Remove protractor and reinstall valve point-er.

11. ACTUATOR ASSEMBLY FUNCTIONAL TEST

PROCEDURES.

12. DIELECTRIC STRENGTH TEST.

Ensure servo motor and voltage equip-ment are properly grounded.

a. Connect all pins together except pin F.

b. Connect one lead of the dielectric strength tester to connector tied pins and the other to valve and actuator assembly case ground.

c. Apply 500 VAC, 60 HZ for one minute minimum.

d. LIMITS: There must be no dielectric break-down.

13. PRELIMINARY SET-UP PROCEDURES. Per-form procedures in paragraph 3.

14. MINIMUM STARTING VOLTAGE. Perform pro-cedures in paragraph 4, except step “i” which should read as follows:

i. LIMITS: Actuator must operate towards both open and closed at 4 VAC minimum.

15. NO-LOAD TIMING: BARBER-COLMAN VALVES.

a. Adjust VARIAC to 50 VAC.

b. Select S2 switch to OPEN.

c. Measure time for one revolution of actuator output shaft.

d. Select S2 switch to CLOSE.

e. Measure time for one revolution of actuator output shaft.

f. Select S2 switch to OFF.

g. LIMITS: One revolution in 56 seconds (or less) each direction.

16. NO-LOAD TIMING: WESTON/BORG-WARNER

VALVES.

a. Adjust VARIAC to 50 VAC.

b. Select S2 switch to OPEN.

c. While measuring the time for actuator to travel from FULL CLOSED to FULL OPEN, select S2 switch to CLOSE.

d. Select S2 switch to OFF.

e. While measuring the time for actuator to travel from FULL OPEN to FULL CLOSED, select S2 switch to OPEN.

f. Select S2 switch to OFF.

g. LIMITS: Actuator output shaft must rotate from FULL OPEN/CLOSED to FULL CLOSED/ OPEN in a time of 68 to 112 seconds.

17. POLARITY: BARBER-COLMAN VALVES.

NOTE

Note direction of rotation of actuator output gear (40, figure 1, WP 009 01) as viewed from actuator output shaft end.

If viewed from the end butterfly shaft (10 or 11, figure 2, WP 009 01), polarity requirements are reversed.

a. Adjust VARIAC to 50 VAC.

b. Select S2 switch to OPEN.

c. Note direction of actuator output shaft rotation.

d. Select S2 switch to CLOSE.

e. Note direction of actuator output shaft rotation.

f. Select S2 switch to OFF.

g. LIMITS: OPEN — Counterclockwise rotation.

CLOSED — Clockwise rotation.

18. POLARITY: WESTON/BORG-WARNER VALVES.

NOTE

Note direction of rotation of output shaft (21, figure 1, WP 009 02) as viewed from actuator output shaft end.

a. Adjust VARIAC to 50 VAC.

b. Select S2 switch to OPEN.

c. Note direction of actuator output shaft rotation.

d. Select S2 switch to CLOSE.

e. Note direction of actuator output shaft rotation.

f. Select S2 switch to OFF.

g. LIMITS: OPEN — Counterclockwise rotation.

CLOSED — Clockwise rotation.

19. POTENTIOMETER LINEARITY CHECK.

a. Connect VTVM to read voltage across pins K and G.

b. Select S4 switch to MAINTAINED ON.

NOTE

Observe VTVM for any erratic movement of needle.

c. Select S2 switch to OPEN. Operate valve to FULL OPEN.

d. Select S2 switch to CLOSE. Operate valve to FULL CLOSE.

e. LIMITS: No erratic movements on VTVM needle.

f. Select S2 switch to OFF.

g. Adjust VARIAC to 10 VAC.

NOTE

If necessary, select S4 switch to MO- MENTARY ON to fine tune valve posi-tions.

h. Select S2 switch to OPEN and operate valve to butterfly positions listed in table 1.

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Table 1. Valve Operation

Valve Angle (Degrees)

VDC Acceptable Limit Pins K and G

0 (CLOSED) 0.03 to 0.21 (or 0.12 � .09)

45 4.35 to 4.65 (or 4.50 � .15)

90 � 3 (OPEN) 8.82 and 8.97 (or 8.90 + .07/ − .08)

i. LIMITS: See table 1.

j. Select S2 switch to OFF.

k. Select S3 switch to OFF.

l. Remove valve from Actuator Test Set-up.

20. S E R V O M O T O R F U N C T I O N A L T E S T

PROCEDURES.

21. CONTINUITY.

NOTE

Refer to respective wiring diagrams in WP 006 01 and WP 006 02 to identify fixed and control phase wiring schematic.

a. Measure resistance across fixed phase.

b. Measure resistance across control phase.

c. LIMITS: Maximum resistance for each phase is 1240 ohms.

22. STARTING VOLTAGE/POLARITY.

Ensure servo motor and voltage equip-ment are properly grounded.

NOTE

If servo motor wiring is still connected to electrical connector, connect electrical connector to Actuator Test Set-up. Do not add another capacitor since capacitor is already included internally in actuator assembly.

a. Connect servo motor to Actuator Test Circuit or Motor Test Circuit.

b. Select S2 switch to OPEN if using Actuator Test Circuit or connect VAC power supply if using Motor Test Circuit.

c. Adjust VARIAC until VAC voltage reads approximately zero.

d. Slowly increase VARIAC voltage until motor just begins to operate. Note direction of rotation of pinion gear on motor as viewed from pinion gear end.

e. LIMITS: Motor must operate by 3.0 VAC minimum. Direction of rotation shall be clockwise when viewed from pinion gear end.

f. Select S2 switch to OFF if using Actuator Test Circuit or disconnect VAC power supply if using Motor Test Circuit.

23. ACTUATOR TORQUE CHECK: BARBER−

COLMAN VALVES.

a. Install actuator assembly (3) on torque test machine using adapter plate mount.

b. Connect actuator assembly to motor test circuit, as shown in figure 3.

c. Apply 115 VAC/400 HZ to motor test circuit.

d. Measure the current drawn by the actuator assembly. Maximum limit for current is 0.4 amps and minimum torque is 5.0 inch−pounds.

e. Disconnect actuator assembly from motor test circuit and remove from torque test machine.

f. If actuator assembly fails test, disassemble and check for damaged or binding gears, loose electrical connections, or any other possible cause for failure. Repair accordingly.

Figure 1. Actuator Test Circuit

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Figure 2. Pneumatic Test Setup.