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GE Druck ADTS 405, Service Manual

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Druck ADTS 405 Service Manual

K171 Issue No. 1

Page ii

Associated Druck Documents:

K114

-

ADTS 405 User Manual

INTRODUCTION

Purpose

This technical manual provides servicing instructions and a parts list to an intermediate level of
maintenance for the Druck ADTS 405 series of air data test systems.

Scope

This technical manual contains a constructional description, a functional description explaining the
theory of operation, dismantling, assembling and testing procedures.  The test equipment and special
tools required for the recommended maintenance level are listed.

Summary of Contents for Druck ADTS 405

Page 1: ...Test Systems Service Manual K0171 GE Sensing Inspection Technologies http www avionteq com Druck GE Sensing ADTS 405 Bench Air Data Test Set Systems aspx To buy sell or trade in this product click on the link below www avionteq com ...

Page 2: ... 2008 General Electric Company All rights reserved ...

Page 3: ...71 Issue No 1 Page i TABLE OF CONTENTS Preliminary pages Table of contents this table Introduction Purpose Scope Glossary Abbreviations Chapter 1 DESCRIPTION 2 DISMANTLING 3 ASSEMBLING 4 TESTING 5 CALIBRATION 6 ILLUSTRATED PARTS LIST ...

Page 4: ...ns and a parts list to an intermediate level of maintenance for the Druck ADTS 405 series of air data test systems Scope This technical manual contains a constructional description a functional description explaining the theory of operation dismantling assembling and testing procedures The test equipment and special tools required for the recommended maintenance level are listed ...

Page 5: ...he connection between to separate keyed or matched equipment parts Dismantle To take apart to the level of the next smaller unit or down to all removable parts Ensure To confirm that a proper condition exists to find out with certainty Examine To perform a critical visual observation or check for specific conditions to test the condition of Fit Correctly attach one item to another Inspect Review t...

Page 6: ...y Repair To restore damaged worn out or malfunctioning equipment to a serviceable usable or operable condition Replace Remove an item and fit a new or a serviced item Reset To put back into a desired position adjustment or condition Service To perform such operations as cleaning lubricating and replenishing to prepare for use Test Ascertain by using the appropriate test equipment that a component ...

Page 7: ...ated airspeed i e That is IEEE 488 Institute of Electrical and Electronic Engineers standard 488 data in Inch kg Kilogram LED Light emitting diode M Magnesium alloy m Metre mA Milliampere max Maximum mbar Millibar min Minute or minimum mm Millimetre mV Millivolts No Number N m Newton metre Para Paragraph Ps Static pressure psi Pounds per square inch Pt Total pressure Qc Differential pressure Ps Pt...

Page 8: ...Druck ADTS 405 Service Manual K171 Issue No 1 Page vi ...

Page 9: ...d communications 22 ARINC 429 Interface special order 23 Altimeter Encoder Interface special order 24 IEEE 488 Interface option E 25 Pump Rack 26 Hand terminal 31 Illustrations fig ADTS 405 General view 1 1 ADTS 405F General view 1 2 ADTS 405 1 3 ADTS 405F Racks 1 4 ADTS 405 and Electronics Rack Internal view 1 5 Controller PCB Schematic 1 6 Ps Manifold Schematic 1 7 Pt Manifold Schematic 1 8 Supe...

Page 10: ... by a computer PC using the front or rear panel IEEE 488 communications interface The front panel contains the operate switch and the mimic panel with LED indicators showing the operation of the two pneumatic channels 3 The pump rack on the ADTS 405F produces pressure and vacuum supplies for the electronics rack and for external connectors Located on the front panel the external connectors provide...

Page 11: ...Druck ADTS 405 Service Manual K171 Issue No 1 Page 1 3 Figure 1 2 General view Figure 1 1 General view ...

Page 12: ...ts Airspeed accuracy 50 knots 0 5 knots 500 knots 0 07 knots Qc range 35 to 2700 mbar abs accuracy 0 015 reading 0 007 FS Special range 35 to 3500 mbar abs accuracy 0 015 reading 0 007 FS Mach number civil 0 to 1 00 military 0 to 6 00 Accuracy Better than 0 005 Rate of climb Generated ranges civil 0 to 6000 ft min military 0 to 15000 ft min Accuracy 1 of value Dimensions ADTS 405 485 mm x 270 mm x...

Page 13: ...Druck ADTS 405 Service Manual K171 Issue No 1 Page 1 5 Figure 1 3 ADTS 405 L N ...

Page 14: ...Druck ADTS 405 Service Manual K171 Issue No 1 Page 1 6 Figure 1 4 ADTS 405F Racks Electronics Rack Pump Rack Case ...

Page 15: ...l appropriate solenoid valves pressure transducers and pneumatic output connectors Also located in this rack are the controller PCB for each channel computer PCB IEEE 488 PCB key pad and display PCB ARINC 429 PCB and a power supply unit PSU Manifold Control computer PCB IEEE 488 PCB Controller PCB Ps Pressure input connection Humidity sensor cable Vacuum input connection printer connection IEEE 48...

Page 16: ...te to the altitude speed rate of climb or engine intake condition demanded at the hand terminal The valves also equalise air pressure to give a zero reading during a self test routine when the test system is isolated from the aircraft air data systems Both channels have protection valves controlled by the microcomputer when energised the valves close isolating the test system from the aircraft sys...

Page 17: ...ich is a silicon strain gauge pressure transducer giving a voltage output proportional to the pressure applied This voltage is amplified by the signal conditioning circuits given further gain depending on the mode of operation by the gain switching circuits and then subtracted from the inner loop set point and amplified in the error amplifier The resulting error signal is frequency compensated to ...

Page 18: ...Druck ADTS 405 Service Manual K171 Issue No 1 Page 1 10 Figure 1 6 Controller PCB Schematic Figure 1 7 Ps Manifold Schematic ...

Page 19: ...mode to control mode When the controller is off the switch is in the measure position connecting amplifier A across the input and output of the frequency compensation circuit The output of the frequency compensation circuit is forced to zero ensuring that no pulses will be applied to the pressure and vacuum valves when the controller is switched on When the controller is selected on the set point ...

Page 20: ...contained in two EPROM located on the computer PCB The computer PCB provides direct communication with the hand terminal and an internal communications ring in the form of RS422 differential drivers and receivers It also provides a direct interface for the Centronics parallel printer output connector on the front panel The motherboard distributes the data address and control bus to the control com...

Page 21: ...n external connector provides for one transmit and one receive channel A connector fitted to the front panel provides connection to the aircraft ARINC 429 data bus Altimeter Encoder Interface special order 24 The altimeter encoder interface receives the 10 bit digital code from the altimeter enabling the ADTS 405 to display the decoded altitude value and the applied aeronautical value A connector ...

Page 22: ...reciprocating pistons on a central eccentric One piston head is configured for pressure and the other three for vacuum Reed valves in the piston heads control the direction of air flow One of the vacuum heads provides an initial rough vacuum that in turn feeds the other two vacuum heads The output of the pressure head is cooled and then passed through a coalescing filter to extract any condensed w...

Page 23: ...ion for each system function An electroluminescent panel provides back lighting for a twenty character by four line liquid crystal display An internal microprocessor controls the display All key functions are held in EPROM an audio tone sounds to confirm a valid key press The hand terminal connects to the ADTS 405 through the front panel connector extension cables allow the hand terminal to be use...

Page 24: ...Druck ADTS 405 Service Manual K171 Issue No 1 Page 1 16 ...

Page 25: ...9 IEEE 488 Interface PCB 11 Altimeter Encoder Interface PCB 13 ARINC 429 Interface 15 Front Panel 17 Mimic Panel 23 Power Supply Unit 31 Pump Rack ADTS 405F 39 Pump Front Panel 45 Pump and Motor Assembly 48 Fan 56 PSU Motor Controller Assembly 59 Illustrations fig IEEE 488 Interface PCB 2 1 Front Panel 2 2 Output Fitting 2 3 Power Supply Unit Installation 2 4 Pump Rack Details 2 5 ...

Page 26: ...the rear Controller PCB Note This is part of the Controller Manifold Assembly comprising this component and the manifold as a matched set 6 The controller PCB are located at each side the chassis removal procedures are identical Disconnect the four connectors from the bottom of the PCB 7 Unscrew and remove the four nyloc nuts and collect the four nylon spacers Remove the controller PCB PCB retaini...

Page 27: ...Druck ADTS 405 Service Manual K0171 Issue No 1 Page 2 3 IEEE 488 Interface PCB wing nut wing nut PCB retaining bar retaining clip spigot spigot securing screws Figure 2 1 Location of the Interface PCB ...

Page 28: ...ck ADTS 405 Service Manual K0171 Issue No 1 Page 2 4 Figure 2 2 Front Panel Front panel Manifold assembly IEEE 488 interface connector panel Mimic panel humidity sensor PSU Front panel key pad and display ...

Page 29: ...ve the five screws and shake proof washers securing base plate to front panel along front edge of base plate Restore rack to the correct way up 20 Unscrew and remove the four screws securing front panel to rear chassis These are located above and below each handle 21 Carefully lower the front panel until it is in a horizontal position on the bench 22 Start to carefully separate the front panel fro...

Page 30: ...r components 30 Carefully remove the manifold Display and key pad panel 31 Disconnect the ribbon cable connector and two pin connector from the display 32 Unscrew and remove the four screws and washers securing the display to the front panel Remove the display and key pad Power Supply Unit Figure 2 4 33 The PSU is contained in a metal enclosure at the right hand side of the rear chassis To gain ac...

Page 31: ...e right hand side of rear chassis 39 Unscrew and remove the four screws securing the PSU to the front panel 40 Remove the PSU and cover It may help to carefully lever top cover upwards at a point near the six pin connector Figure 2 4 Power Supply Unit Installation Side panel Front panel A C power connector D C power connector option C Controller PCB mounting detail Nylon spacer Nylon spacer Nyloc ...

Page 32: ...hassis together carefully lay pump unit on its side 49 The front panel can now be carefully pulled slightly away from the chassis to give better access to other components Pump and Motor Assembly Figure 2 5 50 Disconnect the pressure pipe between the bowl filter on the pump assembly and the rear of the rack 51 Disconnect the vacuum line between the pump assembly and the unit rack by removing the s...

Page 33: ...plain washers securing fan cover to fan 58 Unscrew and remove the four hexagonal socket cap screws securing the fan to the front panel this breaks the water seal Remove the fan PSU Motor Controller Assembly 59 Cut and remove any tyraps securing the cable looms attached to the PSU 60 Disconnect the electrical connectors from the PSU and motor controller 61 Unscrew and remove the two screws and plai...

Page 34: ...ice Manual K0171 Issue No 1 Page 2 10 Figure 2 5 ADTS 405F pump rack details Power supply unit Controller PCB Motor connectors Auxiliary pneumatic connectors Power input connector Cover Fan Bowl filter Pump motor assembly ...

Page 35: ...or Assembly 11 Pump Front Panel 17 ADTS 405 and Electronics Rack ADTS 405F 19 Power Supply Unit 19 Manifold Assembly 25 Mimic Panel 29 Front Panel 30 IEEE 488 Interface PCB 32 Altimeter Encoder Interface PCB 35 ARINC 429 Interface 38 Computer PCB 41 Controller PCB 46 Cover 48 Final Assembly ADTS 405F 49 Pump Rack 49 Electronics Rack 51 Illustrations fig Solenoid valves 3 1 ...

Page 36: ...ry of the fan 6 Locate the fan on the front panel of the pump rack and secure with the four hexagonal socket cap screws and washers 7 Insert the red and black cables into the outer sleeving and route the cable to the terminal block under the front panel 8 Crimp a terminal connector to each cable 9 Connect each cable to the terminal block Slide the insulating sleeve over each connection 10 Pull the...

Page 37: ...A B A B 1 A B 5 B 6 A A B 8 B A A 7 B 4 Humidity sensor connections Solenoid Valve Cable Colour 1 Pt channel A B yellow black 2 A B orange black 3 A B brown black 4 A B red black 5 Ps channel A B yellow black 6 A B orange black 7 A B black brown 8 A B black red Table 3 1 Solenoid Valves Humidity sensor connections ...

Page 38: ...B with the four spacers and nuts 23 Secure the PSU cover to the rear panel of the rack with the four screws and shakeproof washers 24 Connect the nine pin connector to the PSU cover Manifold Assembly Figure 3 1 25 Locate the manifold on the front panel and secure with the two screws 26 Position the connectors through the slots in the side panels 27 Carefully insert the output fittings through the ...

Page 39: ...herboard and align the holes in the PCB bracket with the rear panel of the rack 35 Secure the PCB with the two screws and plain washers 36 Connect the ribbon cable connector to the top edge of the PCB and secure with the two clips Altimeter Encoder Interface PCB Note Make sure the PCB connections are correctly aligned on the motherboard 37 Carefully insert the PCB into motherboard and align the ho...

Page 40: ...PCB on the appropriate side panel and connect the connectors to the controller PCB 49 Secure each controller PCB with four nylon spacers and nyloc nuts Cover 50 Slide the cover over the rear of the assembled rack align the holes and secure the cover with the eighteen screws and shakeproof washers Note This completes the assembly of the ADTS 405 Final Assembly ADTS 405F Pump Rack 51 Place the cable...

Page 41: ...ervice Manual K171 Issue No 1 Page 4 1 Chapter 4 Testing CONTENTS Para STANDARD SERVICEABILITY TEST General 1 Procedure 2 FUNCTIONAL TEST Introduction 8 Procedure 10 IEEE 488 Interface test 19 IEEE 488 test Program 20 ...

Page 42: ...as below where x is the issue number of the installed software version number DK 126 Version x xx Display Power Up Please Wait 4 Check the power up message displays as below where x is the issue number of the installed software version number 3 The ADTS 405 will display any errors that are detected Check that the power up sequence continues through the following stages without error Self Test Meas...

Page 43: ...ed values Pump unit 6 Switch on the pump unit 1 Press CONTROL to go to control mode Enter an altitude aim of 5000 ft by pressing 5 0 0 0 ENTER 2 Enter an airspeed aim of 500 knots by pressing SPEED 5 0 0 ENTER 3 Check that these aim values are achieved Completion 7 On successful completion of this test procedure switch off the unit and the power supply ...

Page 44: ...3 Check power indicator is ON Check the display shows the power up message as below where x is the issue number of the installed software version number 11 The ADTS 405 will display any errors that are detected Check that the power up sequence continues through the following stages without error Self Test Measuring Ground Pressures Equalizing System Pressures 12 Check that the display then changes...

Page 45: ...ity 15 This section verifies the control stability 1 Press CONTROL to turn the pressure controllers ON AIM replaces LEAK MEASURE on the display 2 Enter a Ps aim of 510 mbar with a rate of change of 204 mbar min by pressing the following Ps 5 1 0 ENTER Ps RATE 2 0 4 ENTER 3 Enter a Qc aim of 0 mbar with a rate of change of 204 mbar min by pressing the following Qc 0 ENTER RATE 2 0 4 ENTER 4 Press P...

Page 46: ...the pressure controllers ON The display shows AIM in place of LEAK MEASURE 2 Enter a Ps aim of 1016 mbar by pressing Ps 1 0 1 6 ENTER 3 Enter a Qc aim of 272 mbar by pressing Qc 2 7 2 ENTER Wait for the aim values to be achieved then wait for 1 min 4 Press LEAK MEASURE to turn the controllers OFF 5 Press RATE TIME and select WAIT 05 00 TIME 01 00 Observe that the WAITING time is shown on the displ...

Page 47: ...8 Switch off the unit and disconnect the PC and IEEE 488 cable IEEE 488 test program 20 The following test program should be implemented on an IBM PC or compatible computer The test program is shown in pseudo code The exact details of the commands depend on the actual IEEE 488 interface card used and the language used for programming 1 Definitions string1 SOURCE STATE OFF one space between STATE a...

Page 48: ...Druck ADTS 405 Service Manual K171 Issue No 1 Page 4 8 ...

Page 49: ...Druck ADTS 405 Service Manual K171 Issue No 1 Page 5 1 Chapter 5 Calibration CONTENTS Para General 1 Introduction 2 Rate calibration 8 Calibration check 10 Procedure 17 Completion 18 ...

Page 50: ...ode of operation of the ADTS 405 Three different calibration functions are provided Calibration Check 4 This is used to verify accuracy of the calibration without adjusting it Rate Calibration 5 This is used to adjust the control transducers to the main transducer to ensure accurate rate control Rate calibration does not affect ADTS 405 pressure measurement accuracy Main Calibration 6 This is used...

Page 51: ... the ADTS 405 to generate the required pressures for calibration The AIM value and RATE of change of pressure can be entered as required To use this mode vacuum and dry air must be connected External 2 In this mode the ADTS 405 is in measure mode This should only be used when the pressure standard generates the pressure Channel selection 13 Select the channel for checking Ps channel absolute 14 Th...

Page 52: ...by qualified personnel 4 Press F 2 Calibration check 5 Switch on the pump unit 6 Select the pressure source internal 7 Set the channel to be checked Ps Pt Ps and Pt 8 Select the combined channel check Ps and Pt Note For only checking the Ps channel use the values in table 5 2 9 Enter the first aim value in table 5 1 and record the value on the pressure standard 10 Repeat this for further values in...

Page 53: ...3 10 2 345 4 20 4 691 5 30 5 1033 6 38 7 1311 7 50 9 1724 8 63 1 2137 9 77 4 2621 10 89 6 3034 11 103 4 3502 Table 5 1 Table 5 2 Calibration Check Points Ps Calibration Check Points both channels Point Calibration Pressure inHg mbar 1 1 34 2 5 1 173 3 10 2 345 4 15 3 518 5 20 4 691 6 25 4 860 7 30 5 1033 8 38 7 1311 9 50 9 1724 10 63 1 2137 11 80 2709 Point Calibration Pressure inHg mbar 1 1 34 2 ...

Page 54: ...Druck ADTS 405 Service Manual K171 Issue No 1 Page 5 6 ...

Page 55: ...ice Manual K171 Issue No 1 Page 6 1 Chapter 6 Illustrated Parts List CONTENTS Para Introduction 1 Parts List 5 Index of Part Numbers 6 Illustrations fig ADTS 405F Electronics Rack 6 1 ADTS 405F Pump Rack 6 2 ADTS 405 6 3 ...

Page 56: ...cement parts 2 In general parts are listed in order of disassembly and are indented to show their relationship to the next higher assembly 3 Numerical indexes are provided to assist in locating part numbers in the Parts List 4 Items that are non procurable are indicated in the QTY column by the letters NP Items that are for reference are indicated by the letters ref Items that are not illustrated ...

Page 57: ...Druck ADTS 405 Service Manual K171 Issue No 1 Page 6 3 Figure 6 1 ADTS 405F Electronics Rack 3 1 10 6 4 3 4 2 7 5 11 ...

Page 58: ...Druck ADTS 405 Service Manual K171 Issue No 1 Page 6 4 Figure 6 2 ADTS 405F Pump Rack 4 2 3 1 ...

Page 59: ... ADTS405 1729 63 M0 1 range 4 1A Controller PCB Ps NP matched with item 4 3A 4 2A Controller PCB Pt NP matched with item 4 3A 4 3A Manifold assembly NP 5 Computer PCB ADTS405 1729 66 M0 1 6 Power Supply Unit AC ADTS405 1729 71 M0 1 6A Power Supply Unit AC DC option C ADTS405 1729 72 M0 1 alternative to item 6 7 IEEE 488 Interface PCB option E ADTS405 1729 69 M0 1 8 PCB Altimeter Encoder Interface ...

Page 60: ...1728 62 M0 1 2 Pump motor Assembly ADTS405F 1728 85 M0 1 3 PSU Motor Controller Assembly NP Mod 00 Superseded by items 3 1A an 3 2A 3 1A PSU Pump Universal AC ADTS405F 1728 73 M1 1 Mod 01 Supersedes item 3 3 2A Controller Brushless Motor ADTS405F 1728 74 M1 1 Mod 01 Supersedes item 3 4 Fan ADTS405F 1728 77 M0 1 5 Parts List contd ...

Page 61: ...Druck ADTS 405 Service Manual K171 Issue No 1 Page 6 7 Figure 6 3 ADTS 405 6 4 10 5 11 9 3 2 3 3 ...

Page 62: ...ly Unit AC ADTS405 1729 71 M0 1 5A Power Supply Unit AC DC option C ADTS405 1729 72 M0 1 alternative to item 5 6 PCB IEEE 488 Interface option E ADTS405 1729 69 M0 1 7 PCB Altimeter Encoder Interface special order ADTS405 1729 89 M0 1 8 PCB ARINC 429 Interface special order ADTS 405 1729 88 M0 1 9 Mimic Panel ADTS405 1729 70 M0 1 10 PCB Display and Key pad ADTS405 1729 80 M0 1 matched with item 11...

Page 63: ...33 11 M0 1 5 Cable Assembly 18M 59ft option A ADTS405F 1728 42 M0 1 6 Cable Assembly 30M 100ft option A ADTS405F 1533 12 M0 1 7 Cable Assembly 46M 150ft option A ADTS405F 1533 13 M0 1 8 Cable Assembly Power 5M 16ft ADTS405F 1728 43 M0 1 9 Kit Service ADTS405F 1728 44 M0 1 10 Hose Assembly Static 2 5M 8ft ADTS405F 1728 50 M0 1 11 Hose Assembly Pitot 2 5M 8ft ADTS405F 1728 51 M0 1 12 Kit Hose Adapto...

Page 64: ...5 M0 ADTS405 1729 29 M0 ADTS405 1729 63 M0 ADTS405 1729 64 M0 ADTS405 1729 65 M0 ADTS405 1729 66 M0 ADTS405 1729 69 M0 ADTS405 1729 70 M0 4 4 4 6 4 7 4 1 3 2 4 2 4 3 4 5 4 8 4 9 4 10 4 11 2 1 2 3 1A 2 3 2A 4 4 2 2 4 12 1 4A 1 4 3 3 1 5 3 4 1 7 3 6 1 10 3 9 ADTS405 1729 71 M0 ADTS405 1729 72 M0 ADTS405 1729 78 M0 ADTS405 1729 79 M0 ADTS405 1729 80 M0 ADTS405 1729 81 M0 ADTS405 1729 82 M0 ADTS405 17...

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