Pages from A1-555AC-410-060_2023-05-11_08-36-02.pdf

A1-555AC-410-060 001 00

Figure 7. Cabin Flow Valve – Test Setup

1. PRESSURE REGULATOR 9. SHUTOFF VALVE

2. SHUTOFF VALVE 10. PRESSURE GAGE

3. SHUTOFF VALVE 11. SHUTOFF VALVE

4. SHUTOFF VALVE 12. SHUTOFF VALVE

5. PRESSURE GAGE 13. SHUTOFF VALVE

6. CLOSE STOP ADJUSTMENT 14. OPEN STOP ADJUSTMENT

7. PRESSURE REGULATOR

8. SHUTOFF VALVE

15. VALVE TEST CONSOLE POWER SOURCE

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(5) Install butterfly plate (73, figure 9) from upstream side of body assembly (80) with tapered edge toward flow bore.

(6) Secure with washers (75) and screws (74). Tighten screws (74) to a torque of

6.5 to 7.5 in-lbs above run-on torque.

Do not allow butterfly plate to pass beyond closed position as damage may occur to sealing surfaces.

(7) Visually inspect sealing surface to ensure clearance is evenly spaced around sealing surface.

Loosen screws (74) and adjust butterfly plate (73) accordingly.

(8) Secure screws (74) with lockwire.

(9) Remove the four strips of shim stock previously installed.

23. FINAL ASSEMBLY.

EPOXY PRIMER

MIL-PRF-23377 5

a. Coat exposed surfaces of washers (29, 49, and 56) with epoxy primer coating and allow to air dry for 30 minutes. (QA)

24. TESTING AND TROUBLESHOOTING. (Figure 7)

25. Record test results on Form 13461/1. (QA)

NOTE

Ensure total cure of 72 hours has elapsed from the indicated application time of adhesive prior to testing. Actuating valve, or exposing to heat before adhesive is fully cured, can result in inadequate bonding and increased potential for leakage.

26. ELECTRICAL BONDING. (Figure 8)

These instructions are for data collection purposes and do not implement a pass/fail criterion.

a. The resistance between the following points shown in figure 8 shall be measured using milliohm meter.

b. Use milliohm meter to measure resistance between electromagnetic control valve (14, figure 9) case and pin 5 of electromagnetic control valve (14) connector. Record measured resistance.

c. Use milliohm meter to measure resistance between valve flange and pin 5 of electromagnetic control valve (14) connector. Record measured resistance.

27. TORQUE MOTOR INSPECTION TEST.

Electromagnetic torque motor cable, P/N 18D11611-2, is part F-18 valve test power cable kit, P/N 18D11611-1.

a. Connect valve test console power source (15, figure 7) to connector of electromagnetic control valve (14, figure 9) using electromagnetic torque motor cable.

b. Connect regulated air to the supply connection (figure 7) and adjust the regulator to obtain 14 to 16 psig.

Figure 8. Electrical Bonding Test Points

c. Adjust valve test console power source (15, figure 7) current to zero. Output pressure at zero milliamperes should be less than 1.0 psig. (QA)

d. Increase current until output pressure reaches 2.5 psig. Current at 2.5 psig should be 15 to 30 milliamperes. (QA)

e. Increase current until output pressure reaches 8.0 psig. Current at 8.0 psig should be 55 to 70 milliamperes. (QA)

f. Increase current until output pressure reaches 12.0 psig. Current at 12.0 psig should be 83 to 94 milliamperes. (QA)

g. Adjust valve test console power source (15) to duplicate each current reading recorded in previous steps. Record output pressure. Output pressures must be within 5 psig of previous recorded steps. (QA)

h. Adjust valve test console power source (15) current to 50 milliamperes. Record output pressure.

Decrease torque motor controller current to 49 milliamperes. Record output pressure. Measureable change in output pressure required. (QA)

i. Decrease valve test console power source

(15) current to zero milliampere.

j. Reduce supply pressure to zero and remove the electromagnetic torque motor cable from the valve and test console.

28. PRELIMINARY ELECTRICAL TESTS.

a. Insulation Resistance Test. (Figure 1)

Electromagnetic control valve cable, P/N 18D11578-6, test lead cable, P/N 18D11578-3, and insulation/dielectric test box, P/N 18D11578-2, are part of insulation/dielectric test kit, P/N 18D11578- 1.

(1) Connect electromagnetic control valve connector (14, figure 9) to P2 of electromagnetic control valve cable.

(2) Stack banana plugs P1-A and P1-C of electromagnetic control valve cable.

(3) Connect stacked banana plugs to J1 Positive test point of insulation/dielectric test box.

(4) Connect P4 TP1 of test lead cable to J2 TP1 of insulation/dielectric test box.

(5) Connect P3 Positive of test lead cable to positive lead of megohmmeter.

(6) Connect P1 GND of electromagnetic control valve cable to J1 GND test point of insulation/dielectric test box.

(7) Connect P4 GND of test lead cable to J2 GND insulation/dielectric test box.

(8) Connect P3 GND of test lead cable to negative lead of megohmmeter.

Voltages used can cause arcing which may result in severe burns. Remove watches, rings, and other jewelry.

High/dangerous voltage may cause severe shock or death on contact during testing of equipment. Use caution and avoid contact with energized components.

(9) Set voltage selector range switch on megohmmeter to 500 Volts Direct Current (VDC).

Apply 500 VDC for a period of 2 minutes.

Resistance indicated on range scale indicator shall equal or exceed 100 megohms. No arcing, flashover, or other evidence of insulation breakdown is allowed. (QA)

(10) Reduce voltage to zero VDC and disconnect both leads of test cable and electromagnetic control valve cable from electro-magnetic control valve connector (14) and megohmmeter.

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b. Dielectric Strength Test. (Figure 1)

Electromagnetic control valve cable, P/N 18D11578-6, test lead cable, P/N 18D11578- 3, and insulation/dielectric test box P/N 18D11578-2, are part of insulation/dielectric test kit, P/N 18D11578-1.

(1) Connect electromagnetic control valve connector (14, figure 9) to P2 of electromagnetic control valve cable.

(2) Stack banana plugs P1-A and P1-C of electromagnetic control valve cable.

(3) Connect stacked banana plugs to J1 Positive test point of insulation/dielectric test box.

(4) Connect P4 TP1 of test lead cable to J2 TP1 of insulation/dielectric test box.

(5) Connect P3 Positive of test lead cable to positive lead of AC Hypot.

(6) Connect P1 GND of electromagnetic control valve cable to J1 GND test point of insulation/dielectric test box.

(7) Connect P4 GND of test lead cable to J2 GND insulation/dielectric test box.

(8) Connect P3 GND of test lead cable to negative lead of AC Hypot.

Voltages used can cause arcing which may result in severe burns. Remove watches, rings, and other jewelry. High/dangerous voltage may cause severe shock or death on contact during testing of equipment. Use caution and avoid contact with energized components.

(9) Turn on AC Hypot as follows:

(a) When using AC Hypot, P/N 3605, set AC Hypot input power switch to ON. Set range selection switch to kilovoltmeter range selection.

If AC Withstand test type is not selected, dielectric strength test results will not be valid.

b. When using AC Hypot, P/N 3770, turn Hypot tester power switch on and select the AC Withstand (ACW) test type.

(10) Set output voltage to change from 0 to 1050 VRMS (60 Hz. nom.) over a period of 3 to 5 seconds, apply voltage for 60 seconds minimum, and then return to 0 VRMS (60 Hz. nom.) over a period of 3 to 5 seconds. No arcing, sparking, or leakage current in excess of 0.5 milliampere (mA) is allowed. (QA)

(11) Turn off AC Hypot as follows:

(a) When using AC Hypot, P/N 3605, set AC Hypot input power switch to ON/OFF switch to the OFF position.

(b) When using AC Hypot, P/N 3770, turn Hypot tester power switch OFF.

(12) Disconnect both ends of both leads of test cable and electromagnetic control valve cable from electromagnetic control valve (14) connector and AC Hypot.

29. PROOF PRESSURE TESTING.

30. Proof Pressure Test Setup.

a. Install upstream and downstream flow plates to the valve test console.

b. Install valve test adapters on valve test console.

Install valve between valve test adapters using packings and clamps.

c. Connect a pressure regulator (1, figure 7), shutoff valve (3), vent flow measuring section, with shutoff valves (2 and 4) and pressure gage (5) to regulated supply connection.

d. Connect total air flow measuring section and regulator (7) to upstream section of valve test console.

Connect shutoff valve (9), case leakage measuring section with shutoff valves (8 and 11) and pressure gage (10) upstream.

e. Connect shutoff valve (12) and port leakage measuring section vented to ambient, upstream from shutoff valve (13) to downstream section of valve test console.

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f. Connect torque motor controller to electro-magnetic control valve. Connect torque motor controller to the test console using torque motor controller power cable.

g. Ensure pressure regulator and all shutoff valves are closed.

31. Proof Pressure Test.

32. Butterfly Open Proof Pressure Test.

a. Cover valve with ballistic blanket.

b. Valve test console safety shield shall be closed.

c. Open shutoff valve (9, figure 7). Adjust pressure regulator (7) to obtain 25 to 27 psig indicated on pressure gage (10). Maintain for 2 minutes.

d. Any evidence of deformation or deterioration shall be cause for rejection. (QA)

e. Adjust regulator (7) to zero psig. Close shutoff valve (9).

33. Butterfly Closed Proof Pressure Test.

a. Cover valve with ballistic blanket.

b. Valve test console safety shield shall be closed.

c. Open shutoff valves (3, 9, and 13, figure 7).

Adjust torque motor controller to apply 98 to 102 milliamperes to electromagnetic control valve (14, figure 9). Adjust pressure regulator (1, figure 7) to obtain 14 to 16 psig indicated on pressure gage (5).

Adjust pressure regulator (7) to obtain 25 to 27 psig indicated on pressure gage (10). Maintain for 2 minutes.

d. Any evidence of deformation or deterioration shall be cause for rejection. (QA)

34. PRELIMINARY ADJUSTMENTS.

a. Open Stop Adjustment.

(1) Observe butterfly plate (73, figure 9). Plate must be in streamline position.

(2) Visual position indicator shall indicate

OPEN. (QA)

(3) If necessary, loosen nut (35) and adjust setscrew (38) to obtain streamline position. Tighten nut (35) to a torque of 15 to 16 in-lbs above run-on torque.

b. Close Stop Adjustment.

(1) Connect a pressure regulator (1, figure 7), pressure gage (5) and an air supply source to the regulated supply connection. Connect valve test console power source (15) to connector of electromagnetic control valve (14, figure 9) using electromagnetic torque motor cable.

(2) Connect case leakage, port leakage and vent flow measuring sections as shown in figure 7.

(3) Open shutoff valve (3). Apply 96 to 100 milliamperes to electromagnetic control valve. Adjust pressure regulator (1) to apply 14 to 16 psig to regulated supply connection. Position indicator shall indicate CLOSE. (QA)

(4) If necessary, loosen nut (4, figure 9) and adjust setscrew (13) to obtain closed position.

Tighten nut (4) to a torque of 15 to 16 in-lbs above run-on torque.

(5) Disconnect air supply, pressure regulator (1, figure 7), pressure gage (5) and electromagnetic torque motor cable.

35. FUNCTIONAL TEST.

36. Functional Test Setup. (Figure 7)

Test facility air source shall be capable of supplying a 40 micron filtered air pressure of 15 to 16 psig, at an air temperature of 40° to 120°F and an air flow of 41 lb/min.

a. Remove the upstream and downstream flow plates from the valve test console.

b. Install blank-off plates.

c. Install upstream and downstream valve test adapters on valve test console.

d. Install packings on upstream and downstream flanges of the valve.

e. Connect upstream adapter and upstream valve flange with voss clamp. Adjust crank handle to mate downstream flange of valve to downstream adapter; connect with wig-o-flex clamp.

f. Connect pressure regulator (1, figure 7), shutoff valve (3), vent flow measuring section, with shutoff valves (2 and 4) and pressure gage (5) to regulated supply connection.

g. Connect total air flow measuring section and pressure regulator (7) to valve test holder upstream.

Connect shutoff valve (9), case leakage measuring section with shutoff valves (8 and 11) and pressure gage (10) upstream.

h. Connect shutoff valve (12) and port leakage measuring section vented to ambient, upstream from shutoff valve (13).

i. Connect valve test console power source

(15) to connector of electromagnetic control valve using electromagnetic torque motor cable.

j. Ensure all test console shutoff valves are in the closed position before continuing with testing.

37. Case Leakage Test.

Blank-off plates need to be installed when performing case leakage test.

a. Open shutoff valve (9, figure 7), adjust pressure regulator (7) to obtain 10 to 12 psig indicated on pressure gage (10). Open shutoff valve (3), adjust pressure regulator (1) to obtain 14 to 16 psig on pressure gage (5).

b. Adjust valve test console power source (15) to apply 49 to 51 milliamperes to electromagnetic control valve.

c. Open shutoff valves (8 and 11), slowly close shutoff valve (9). Open shutoff valves (2 and 4), slowly close shutoff valve (3).

d. Observe case leakage measuring section and vent flow measuring section. Combined total shall not exceed 0.144 lb/min. (QA)

e. Adjust valve test console power source (15) to reduce current to electromagnetic control valve to 0 milliampere. Adjust pressure regulators (1 and 7) to reduce pressure gage (5 and 10) to 0 psig. Close shutoff valves (2, 4, 8 and 11).

38. Construct Functional Test Setup.

a. Remove valve connections. Remove valve from the valve test console.

b. Remove upstream and downstream valve test adapters.

c. Remove blank-off plates from the valve test console.

d. Install upstream and downstream flow plates to the valve test console.

e. Bolt upstream and downstream valve test adapters onto valve test console.

f. Install packings on upstream and downstream flanges of the valve.

g. Connect upstream adapter and upstream valve flange with voss clamp. Adjust crank handle to mate downstream flange of valve to downstream adapter. Connect with wig-o-flex clamp.

h. Connect pressure regulator (1, figure 7), shutoff valve (3), vent flow measuring section, with shutoff valves (2 and 4) and pressure gage (5) to regulated supply connection.

i. Connect total air flow measuring section and pressure regulator (7) to valve test holder upstream.

Connect shutoff valve (9), case leakage measuring section with shutoff valves (8 and 11) and pressure gage (10) upstream.

j. Connect shutoff valve (12) and port leakage measuring section vented to ambient, upstream from shutoff valve (13).

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k. Connect valve test console to connector of electromagnetic control valve (14, figure 9) using electromagnetic torque motor cable.

39. Port Leakage Test.

a. Open shutoff valve (3, figure 7) and adjust pressure regulator (1) to obtain 14 to 16 psig indicated on pressure gage (5).

b. Open shutoff valves (9 and 13) and adjust pressure regulator (7) to obtain 10 to 12 psig indicated on pressure gage (10).

c. Adjust shutoff valve (13) to obtain 39 to 41 Ib/min indicated on total air flow measuring section.

d. Adjust valve test console power source (15) to apply 96 to 100 milliamperes to electromagnetic control valve. Readjust pressure regulators (1 and 7) to ensure pressures set in steps a. and b. are still within limits.

e. Open shutoff valve (12), slowly close shutoff valve (13).

f. Observe port leakage measuring section.

Port leakage shall be 1.5 to 1.7 lb/min. (QA)

g. If port leakage is not as specified, adjust setscrew (13, figure 9) to obtain limits specified.

Tighten nut (4) to a torque of 15 to 16 in-lbs above run-on torque.

h. Adjust pressure regulators (1 and 7, figure 7) to obtain 0 psig indicated on pressure gages (5 and 10), and close shutoff valves (3, 9 and 12). Adjust valve test console power source (15) to 0 milliampere.

40. Functional Test.

a. Open shutoff valve (3, figure 7), adjust pressure regulator (1) to obtain 14 to 16 psig indicated on pressure gage (5).

b. Open shutoff valves (9 and 13), adjust pressure regulator (7) to obtain 10 to 12 psig indicated on pressure gage (10).

c. Adjust shutoff valve (13) to obtain 39 to 41 ppm indicated on total air flow measuring section.

d. Adjust valve test console power source (15) to apply 96 to 100 milliamperes to electromagnetic control valve. Open shutoff valve (12) and slowly close shutoff valve (13). Readjust pressure regulators (1 and 7) to ensure pressures set in steps

a. and b. are still within limits.

e. Adjust valve test console power source (15) to slowly reduce current to electromagnetic control valve until port leakage measuring section indicates

2.0 lb/min. Current indicated at valve test console power source (15) shall not be less than 70 milliamperes. (QA)

f. Attach protractor to actuator housing (59, figure 9) to indicate butterfly plate (73) position.

g. Open shutoff valve (13, figure 7), close shutoff valve (12). Adjust shutoff valve (13) to obtain 39 to 41 lb/min at total air flow measuring section.

Adjust valve test console power source (15) to apply 96 to 100 milliamperes to electromagnetic control valve. Readjust pressure regulators (1 and 7) to ensure pressures set in steps a. and b. are still within limits. (QA)

h. Adjust valve test console power source (15) to reduce current to 60 milliamperes. Record current and angle indicated on protractor.

i. Adjust valve test console power source (15) to reduce current to 40 milliamperes. Record current and angle indicated on protractor.

j. Adjust valve test console power source (15) to reduce current, until position indicator reaches full OPEN position. Current indicated at valve test console power source (15) shall be within 15 to 30 milliamperes. (QA)

k. Adjust valve test console power source (15) to increase current until protractor indicates position recorded in step i. Current indicated at valve test console power source (15) shall be within 32 to 48 milliamperes. (QA)

l. Adjust valve test console power source (15) to increase current until protractor indicates position recorded in step h. Current indicated at valve test console power source (15) shall be within 52 to 68 milliamperes. (QA)

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m. Adjust valve test console power source (15) to increase current until position indicator reaches full CLOSE position. Open shutoff valve (12), slowly close shutoff valve (13). Port leakage measuring section shall indicate less than 2.0 lb/min. Current indicated at valve test console power source (15) shall be within 85 to 95 milliamperes. (QA)

n. Adjust pressure regulators (1 and 7) to obtain 0 psig indicated on pressure gages (5 and 10), and close shutoff valves (3, 9 and 13). Adjust valve test console power source (15) to reduce current to electromagnetic control valve to 0 milliampere.

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41. Actuation Time Test.

a. Open shutoff valve (3, figure 7), adjust pressure regulator (1) to obtain 14 to 16 psig indicated on pressure gage (5).

b. Open shutoff valves (9 and 13), adjust pressure regulator (7) to obtain 10 to 12 psig indicated on pressure gage (10).

c. Adjust shutoff valve (13) to obtain 39 to 41 ppm indicated on total air flow measuring section.

d. Adjust valve test console power source (15) to apply 96 to 100 milliamperes to electromagnetic control valve. Readjust pressure regulators (1 and 7) to ensure pressures set in steps a. and b. are still within limits. (QA)

e. Instantly reduce current applied to electromagnetic control valve to 0 milliampere, simultaneously time butterfly plate (73, figure 9) travel to open position, indicated on position indicator. Opening time shall be 1.25 seconds maximum. (QA)

f. Instantly apply 96 to 100 milliamperes to electromagnetic control valve, simultaneously time butterfly plate (73) travel to closed position, indicated on position indicator. Closing time shall be 1.25 seconds maximum. (QA)

g. Adjust valve test console power source (15, figure 7) to reduce current to electromagnetic control valve to 0 milliampere. Adjust pressure regulators (1 and 7) to reduce pressure gages (5 and 10) to 0 psig. Close shutoff valves (3, 9 and 13).

h. Remove valve from test console.

41a. FINAL ASSEMBLY.

a. Install lockwire and seal (3) from nut (4) to housing assembly (59). (QA)

b. Install lockwire and seal (34) from nut (35) to screw (31). (QA)

42. TROUBLESHOOTING.

The following troubleshooting procedures relate to malfunctions found during testing of the valve. When reference is made to inspect a particular part, refer to INSPECTION, DISASSEMBLY and ASSEMBLY. If troubleshooting procedures necessitate any disassembly, removal or replacement of valve components, all testing and adjustment procedures shall be performed before returning valve to service.

a. If unable to obtain minimum port leakage after adjustment, do the following:

(1) Inspect for uniform clearance between the butterfly plate (73, figure 9) and the valve body (80) by the amount of light observed passing through. If the butterfly plate (73) is not centered within the body (80), loosen screws (74) and adjust accordingly.

(2) Check for warped or damaged butterfly plate (73) or warped or damaged flow bore on the body (80). Refer to INSPECTION and replace accordingly if dimensional criteria is not met.

b. If unable to obtain butterfly plate (73) positions required at various currents applied, check for ruptured diaphragm (52), broken spring (54) or blocked passages in servo housing assembly (24).

Refer to CLEANING.

c. If unable to obtain requirements for case leakage, check for worn or damaged shaft assembly

(76) and worn or damaged body assembly (80) bore for shaft assembly (76).

d. If unable to obtain requirements for opening and closing times, check connections for electromagnetic control valve (14), binding or damaged bearings (81) in body assembly (80) and warped or damaged shaft assembly (76).