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Curtiss-Wright D51600 Operation & Calibration Manual Download Page 7

PIM 417-O 

 

PITOT-STATIC LEAK TESTER TYPE D51600

 

Issue 5 
November 2009 

 

Page 1 

INTRODUCTION 

 

This manual describes the operation and calibration of the Penny & Giles Aerospace Limited Pitot-
Static Leak Tester (PSLT) Type 051600. The PSLT, known as the 'Micro Leak', provides 1 st Line leak 
testing of aircraft altitude and airspeed systems. It also provides limited pressure control for the 
functional testing of pneumatic switches.  
 
If any difficulty is experienced in the use of this manual, contact the following for assistance:  
 
Customer Support  
Penny & Giles Aerospace Limited  
1 Airfield Road  
CHRISTCHURCH  
Dorset BH233TH  
UK 
 
Telephone: +44 (0) 1202 409409  
Facsimile: +44 (0) 1202 484846  
E-mail: [email protected]  

Summary of Contents for D51600

Page 1: ...PITOT STATIC LEAK TESTER TYPE D51600 Operation Calibration Manual PIM 417 O Issue 5 November 2009 ...

Page 2: ......

Page 3: ...ic 3 4 INPUT 3 5 OUTPUT 3 6 ACCURACY At 25 C 4 7 RESOLUTION 4 8 TEMPERATURE RANGE 4 9 HUMIDITY RANGE 4 10 RELIABILITY 4 11 TRANSPORTATION 4 12 ACCESSORIES 4 DESCRIPTION 7 1 INTRODUCTION 7 2 GENERAL DESCRIPTION 7 3 CASE 8 4 FRONT PANEL 8 5 PANEL ELECTRONIC CIRCUIT PEC 8 6 BATTERY PACK 8 7 PNEUMATIC ASSEMBLY 9 OPERATION 11 1 INTRODUCTION 11 2 OPERATIONAL MODES 12 A Leak Test Mode 12 B Pressure Contr...

Page 4: ...E 21 8 MAINTENANCE MODE 22 9 BATTERY REPLACEMENT 23 A General 23 B Replacement 24 C Storage 24 D Disposal 24 10 BATTERY CHARGER 24 A General 25 B Applying Power to the Charger 25 C Charging Batteries 25 D Troubleshooting 26 CALIBRATION 27 1 INTRODUCTION 27 2 EQUIPMENT REQUIRED 27 3 CALIBRATION PROCEDURE 27 4 POST CALIBRATION FUNCTIONAL CHECKS 29 LIST OF TABLES TABLE NO TITLE PAGE Table 1 Equipment...

Page 5: ...ng Operational Mode 15 Figure 8 Selecting Units of Measurement 15 Figure 9 Default Set Point 16 Figure 10 Pre Pressurisation Screen 17 Figure 11 System Pressurisation 18 Figure 12 Test Aborted 18 Figure 13 Venting 18 Figure 14 Settling Period 19 Figure 15 Coarse Leak Check 19 Figure 16 Checking Period 19 Figure 17 Leak Test Completed 20 Figure 18 System Pressurisation 21 Figure 19 Leak Rate Displa...

Page 6: ...e assumption that personnel performing the procedures have received training of a standard adequate to enable them to do so and are qualified in the appropriate operating techniques Such personnel are deemed also to be competent to act at all times with due regard to the safety of themselves and of the equipment Penny Giles Aerospace Limited reserve the right to modify or revise all or part of thi...

Page 7: ...o Leak provides 1 st Line leak testing of aircraft altitude and airspeed systems It also provides limited pressure control for the functional testing of pneumatic switches If any difficulty is experienced in the use of this manual contact the following for assistance Customer Support Penny Giles Aerospace Limited 1 Airfield Road CHRISTCHURCH Dorset BH233TH UK Telephone 44 0 1202 409409 Facsimile 4...

Page 8: ...PIM 417 O PITOT STATIC LEAK TESTER TYPE D51600 Issue 5 November 2009 Page 2 THIS PAGE IS INTENTIONALLY BLANK ...

Page 9: ...ower Fail Rate of Change 80 mbar minute 47 knots min 400 knots in 1 litre B Static Range wrt Atmosphere 0 to 430 knots 0 to 10 inHg 0 to 340 mbar 0 to 10000 feet Normal Rate of Change 56 mbar minute 1670 ft min 0 ft 2500 ft min 15000 ft Normal Rate Operating in Feet 1670 feet minute Rapid Rate of Change 136 mbar minute 3600 ft min 0 ft 6000 ft min 15000 ft Rapid Rate Operating in Feet 4000 feet mi...

Page 10: ... Failure 15000 hours Mean Time To Repair 40 minutes 11 TRANSPORTATION The equipment is supplied in a robust Acrilonitrile Butadiene Styrene ABS carrying case dimensions 485 mm x 305 mm x 190 mm weight 2 6 kg when empty The equipment is air transportable Maximum unpressurised altitude is 30 000 feet 12 ACCESSORIES The PSLT is normally supplied as part of the Micro Leak Case Assembly Type D51601 NSN...

Page 11: ...PIM 417 O PITOT STATIC LEAK TESTER TYPE D51600 Issue 5 November 2009 Page 5 Figure 1 Micro Leal Case Assembly ...

Page 12: ...PIM 417 O PITOT STATIC LEAK TESTER TYPE D51600 Issue 5 November 2009 Page 6 THIS PAGE IS INTENTIONALLY BLANK ...

Page 13: ... B Functional checking of aircraft airspeed and altitude switches C Normal Rapid Rate Control D Remote reprogramming maintenance checking utilising secure Infra Red IR communications Manufacturer Mode only Figure 2 Micro Leak Pitot Static Leak Tester The PSLT is user friendly being simple in operation and its built in microcontroller enables the unit to function with minimal Operator intervention ...

Page 14: ...ned to allow operation with a gloved hand The front panel incorporates a clear screen which provides impact protection to the LCD The LCD has an inherent Polaroid fitter and the display is backlit to enable visibility in all degrees of background light The LCD display comprises 2 lines of 20 characters in black on a green background Full graphic and alpha numeric capability is provided and the sof...

Page 15: ... connection to the aircraft a breather port and the reference port for the transducer The output port which projects externally from the case is sealed against leaks and is protected by a blanking cap which is attached to it by lanyard to minimise loose object hazards The pump is of oil free diaphragm construction sealed against normal operating environmental conditions It is driven by d c motor a...

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Page 17: ...on initiating an automatic vent if one is detected All PSLT functions can be accessed and controlled via menu screens and the front panel keypad see Figure 3 Figure 3 PSLT Front Panel Six membrane keys are provided A PWR Applies power to the equipment B Nudges parameter values by set increments C Nudges parameter values by set decrements D SEL Selects menu option Pitot or Static mode of operation ...

Page 18: ...d D Maintenance Mode The Maintenance Mode gives access to six Maintenance Menus These menus are not part of normal operating procedure but are used to interrogate Built In Test parameters during maintenance operations They are accessed during power up by pressing the START key at the same time as the PWR key Use of this mode is required during PSLT calibration 3 OPERATIONAL OVERVIEW Once the test ...

Page 19: ... leak tight B Apply power to the PSLT by pressing the PWR key The system performs an internal self diagnostic test routine and the screen displays the version of software installed Figure 4 For a short time during power up an initial battery status indicator will be displayed Figure 5 providing the Operator with an estimate of percentage battery life available 20 to 100 in 20 steps Figure 4 Initia...

Page 20: ...gy remaining in the Battery Pack is down to approx 15 minutes operation the exact life remaining depends on the individual batteries employed and the operations previously undertaken then the BATT LOW flag will be displayed on the lower left hand side of the screen The flag indication flashes continuously whilst displayed D The PSLT can be manually powered down in any of the screens In addition pr...

Page 21: ...ious tests The SEL key is used to select different units Press once to select inches of mercury inHg and twice to select millibar mbar Pressing a third time returns the display to knots If the Static mode has been selected a fourth option of feet is available appearing after millibar Figure 8 Selecting Units of Measurement CAUTION WHEN CARRYING OUT STATIC LEAK TESTS IN KNOTS CARE MUST BE TAKEN AS ...

Page 22: ...mented in 5 mbar steps up to 340 mbar J When units are feet values are incremented decremented by an initial step of 500 between 0 feet and 500 feet and thereafter in 100 feet steps up to 10000 feet Static only K If the Static mode is selected and the preferred units are feet then the Pressure Of The Day POTD must be entered following the setting of the Set Point value This provides the PSLT diffe...

Page 23: ...n using discrete key presses rather than pressing and holding i e having pressed START to initiate system pressurization pressing START a second time selects the faster rate while pressing it a third time returns the system to the normal rate and so on CAUTION WHEN THE FAST RATE IS SELECTED AND THE PSLT IS OPERATING IN THE STATIC MODE USING MILLIBARS INCHES OF MERCURY OR KNOTS THE PUMP MAY GENERAT...

Page 24: ... system vents to atmosphere at a rate of 47 mbar minute for Pitot or 56 mbar rnlnute for Static As with the START key paragraph 5 M it is possible to use the STOP key to select a faster vent rate of 114 mbar minute or 136 mbar minute respectively While the system is venting the screen displays the pressure remaining in the system Figure 13 When the system has vented the screen will display the cap...

Page 25: ...IL caption together with the failure rate Figure 15 This screen will continue to be displayed until accepted by the Operator This may be in one of several ways If the failure is due to something simple like a poor hose connection then once rectified the Operator can press either the START key to return to the beginning of the test or the SEL key to continue the test from the point of failure To ab...

Page 26: ...ent is left powered up then 5 seconds after the system has successfully vented the display reverts back to the Main Menu 1 ready to initiate new tests 6 PRESSURE CONTROL MODE A The Pressure Control Mode is used to 1test the accuracy of Airspeed and Altitude indicators and switches Whl3n the opening screen for Main Menu 2 is displayed press the START key to initiate pressure control The display pro...

Page 27: ...is used to set up timiing parameters within the system Default values are set for the settling period the checking period and the power down period The settling period and the checking period are part of the Leak Test Mode The settling period is the time the system waits from when the set pressure is achieved before continuing with the test The checking period is the time during which the leakage ...

Page 28: ...NCE MODE The Maintenance Mode is accessed whilst the PSLT is powering up by pressing the START key and holding it down while pressing the PWR key The screen displays the caption Maintenance Menu 1 CONTRAST CONTROL Six menus are available A Maintenance Menu 1 CONTRAST CONTROL B Maintenance Menu 2 PRESSURE MONITOR C Maintenance Menu 3 CALIBRATION D Maintenance Menu 4 INTERACTIVE TEST E Maintenance M...

Page 29: ... BURNS TO EYES OR SKIN IF THE BATIERIES ARE PUNICTURED IN ANYWAY IN CASE OF CONTACT RINSE AFFECTED AREA MMEDIATELYWITH PLENTY OF WATER AND SE EK MEDICAL ADVICE ADDITIONALLY MANGANESE DIOXIDE IS HARMFUL WHEN INHALED WHEN DRY AND IF SWALLOWED IN CASE OF ACCIDENT SEEK MEDICAL AID IMMEDIATELY A General The recommended batteries for use with the PSLT are Duracell LR6 Alkaline Manganese Dioxide Batterie...

Page 30: ...exposure to storage temperatures above 45 C is acceptable Stored batteries should be kept in the their original packaging and contact with metal objects should be avoided to prevent any risk of short circuiting which might result in leakage or in extreme cases battery explosion D Disposal These batteries contain insufficient quantities of mercury cadmium and lead to be subject to EC requirements o...

Page 31: ... is applied to the charger as follows 1 Connect the charger to the mains supply using the standard IEC mains lead supplied 2 On the charger press the rear panel rocker switch to the ON position The front panel power indicator green LED should illuminate C Charging Batteries CAUTION ONCE CHARGING HAS COMMENCED IT IS ESSENTIAL NOT TO DISCONNECT THE BATTERY PACKS FROM THE CHARGER UNTIL CHARGING IS CO...

Page 32: ...rcuitry within the charger The charger thus fails to detect the presence of the battery packs and will not commence the charging sequence To overcome this problem the battery detect circuitry within the charger needs to be overridden This is done by switching the rocker switch on the charger rear panel to the ON position prior to applying power to the charger a reversal of the normal sequence Once...

Page 33: ...ure over the range 340 mbar with an accuracy of 0 01 mbar or better 2 Power Supply Unit PSU for the Pressure Controller 3 Flexible Push On Hose Sized to fit 7 mm outside diameter coupling 3 CALIBRATION PROCEDURE Pressure sensing within the PSLT is carried out by a silicon differential pressure transducer which provides a voltage output directly proportional to the measured pressure The PSLT softwa...

Page 34: ...tion Figure 22 The value displayed for the current pressure should be zero but will vary depending on whether there is any pressure residue in the system Figure 22 Calibrating at First Set Point D There are five calibration Set Points 340 mB 170 mB 0 mB 170 mB and 340 mB E Set the Pressure Controller to generate a pressure of 340 mbar Allow the Controller to stabilise at the control point F When t...

Page 35: ...idually calibrated M Press the STOP key to exit the Calibration routine at any stage and return to the Maintenance Menu 3 screen Following Calibration the equipment is subjected to a functional check to confirm that calibration has been carried out correctly 4 POST CALIBRATION FUNCTIONAL CHECKS A Select Maintenance Menu 2 PRESSURE MONITOR NOTE Within this menu pressure is monitored in mbar only B ...

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Page 38: ...Penny Giles Aerospace Ltd 1 Airfield Road Christchurch Dorset BH23 3TH UK Tel 44 1202 409409 Fax 44 1202 484846 Registered in England No 2336358 VAT Registration No 806 6586 08 ...

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