Curtiss-Wright D51600 Use and care manual

PITOT-STATIC LEAK TESTER
TYPE D51600
Operation & Calibration Manual PIM 417-O
Issue 5 November 2009

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November 2009 Page i
CONTENTS
SUBJECT PAGE
INTRODUCTION ....................................................................................................................... 1
SPECIFICATION ....................................................................................................................... 3
1. PHYSICAL DIMENSIONS..................................................................................................... 3
2. POWER SUPPLY.................................................................................................................. 3
3. OPERATIONAL LIMITS ........................................................................................................ 3
A. Pitot .......................................................................................................................... 3
B. Static ........................................................................................................................ 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 Control Mode .......................................................................................... 12

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C. Setup Mode ............................................................................................................ 12
D. Maintenance Mode................................................................................................. 12
3. OPERATIONAL OVERVIEW .............................................................................................. 12
4. SETUP ................................................................................................................................ 13
5. LEAK TEST MODE ............................................................................................................. 14
6. PRESSURE CONTROL MODE .......................................................................................... 20
7. SETUP MODE..................................................................................................................... 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 Required................................................................................................... 27

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CONTENTS
LIST OF ILLUSTRATIONS
FIG. NO. TITLE PAGE
Figure 1 'Micro Leal' Case Assembly ........................................................................................ 5
Figure 2 'Micro Leak' Pitot-Static Leak Tester........................................................................... 7
Figure 3 PSLT Front Panel...................................................................................................... 11
Figure 4 Initial Power On Screen............................................................................................. 13
Figure 5 Battery Status (80% Power Available) ...................................................................... 13
Figure 6 Menu Option 1........................................................................................................... 14
Figure 7 Selecting 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 Display ................................................................................................... 21
Figure 20 Resetting the Settling Period................................................................................... 22
Figure 21 Password Entry ....................................................................................................... 28
Figure 22 Calibrating at First Set Point ................................................................................... 28
Figure 23 Calibrating at Second Set Point .............................................................................. 29

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This Manual is the proprietary product of Penny & Giles Aerospace Limited and is protected
under international copyright laws. The copying of all or part of this document shall be with
the written permission of the Licensor only.
The operating procedures given in this manual have been written on the 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 this
document without notice, and shall not be responsible for any loss, cost, or damage, including
consequential damage, caused by decisions based on the information in this manual.

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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: [phone]
Facsimile: [phone]
E-mail: [e-mail]

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SPECIFICATION
1. PHYSICAL DIMENSIONS
Overall Dimensions: 192.3 mm x 110 mm x 210 mm
Front Panel: 147.4 mm x 77 mm
Weight: 2.3 kg, maximum
Output Port: push-to-fit pipe
2. POWER SUPPLY
Battery Voltage: 10 x 1.5 V d.c.
Battery Current: 600 mA maximum, 300 mA typical,
> 1.2 Ah recommended
3. OPERATIONAL LIMITS
A. Pitot
Range (wrt Atmosphere): 0 to 430 knots
0 to 10 inHg
0 to 340 mbar
Normal Rate of Change: 47 mbar / minute
Rapid Rate of Change: 114 mbar / minute
Power 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 / minute
Power Fail Rate of Change: < 70 mbar / minute (<2500 ft/min
@ 10000 ft above sea level in 1 litre)
4. INPUT
Ambient Vent Source: -1500 feet (1069 mbar) to
150000 feet (572 mbar)
Pneumatic Pressure from the Aircraft
NOTE: Vacuum performance is reduced above 4500 feet
5. OUTPUT
Pneumatic Load: 5 litres, maximum
(Volume of the Aircraft)

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6. ACCURACY (At +25°C)
Pitot Leak Accuracy: ± 0.3% FSO (340 mbar) or
± 0.6 knot/minute @ 430 knots
Static Leak Accuracy: ± 0.3% FSO (340 mbar) or
± 37 feet @ 10000 feet above sea level
Maximum Internal Leak Offset:
Pitot: 0.3 mbar / minute (0.18 knot / minute @
430 knots) with 1 litre external volume
Static: 0.3 mbar / minute (11 feet / minute @
10000 feet) with 1 litre external volume
7. RESOLUTION
Pitot Set Point Display/Control: 5 knots
Pitot Actual Pressure Display: 1 knot
Static Set Point Display/Control: 500 feet
Static Actual Pressure Display: 50 feet
8. TEMPERATURE RANGE
Operating: -20°C to +70°C
Storage: -40°C to +70°C
9. HUMIDITY RANGE
Able to withstand: 85% R.H. at 40°C
10.RELIABILITY
Mean Time Before 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
6C/4920-99-5736969) Figure 1 Figure 1which comprises:
A. ABS Carrying Case (NSN 6C/6160-99-9965244, Penny & Giles Part W109100)
B. The 'Micro Leak' PSLT Type 051600 (NSN 6C/4920-99-5736968)
C. Two Rechargeable Battery Packs (NSN 6C/6130-99-8752912, Penny & Giles Part W109263-
2)
D. Battery Charger (NSN 6C/6130-99-2191440, Penny & Giles Part 005101245)
E. Mains Lead (NSN 6C/5995-99-8419116, Penny & Giles Part 130900003)
F. 2m length of 12.7mm OD, 6.35mm Bore, Yellow PVC Hose (NSN 6C/4720-99-7269158,
Penny & Giles Part 301006041)
G. Operation and Calibration Manual PIM 417-O.

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Figure 1 'Micro Leal' Case Assembly

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DESCRIPTION
1. INTRODUCTION
The Penny & Giles 'Micro Leak' Pitot-Static Leak Tester (PSLT) is a microprocessor-controlled system
which primarily generates pitot and static pressures in order to leak test air data equipment to ensure
leak rates are compliant with standards specified for it. The PSLT is also capable of providing
functional testing of pneumatic switches.
The PSLT (Figure 2) is a robust, battery-powered, portable instrument with state-of-the-art
microprocessor control, offering the following features:
A. Leak testing of aircraft pitot and static systems.
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.
The PSLT comes complete in its own carrying case which is of rugged construction and which has
space to house accessories such as the hose, spare battery packs, a battery charger (if applicable),
and the operating manual.
2. GENERAL DESCRIPTION
The PSLT is of modular design to facilitate easy repair. It comprises the following main assemblies:
A. Case
B. Front Panel Assembly
C. Panel Electronic Circuit (PEC)
D. Battery Pack
E. Pneumatic Assembly.

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3. CASE
The yellow plastic case is constructed in three parts for ease of manufacture and repair. The two
mating sides and the front panel are secured together with silicone 0- ring seals embedded between to
protect against ingress of dirt and moisture. An internal conductive coating provides protection against
EMC. The case material offers good resistance to abrasion and to moisture absorption, and provides
excellent short-term heat resistance in the absence of external stresses. It also offers resistance to a
wide range of organic, chemical, lubricant and fuel contaminants. The ports at the base of the case are
protected from damage by moulded feet which protrude beyond them. Similarly, the keys and display
on the front panel are all recessed below moulded shoulders for maximum protection. A shoulder strap
is provided with the PSLT for ease of carrying, and leaves the Operator's hands free for operating the
keys.
4. FRONT PANEL
The front panel comprises a six-key membrane keypad, a Liquid Crystal Display (LCD) and an Infra-
Red (IR) transceiver for use with the Communications Mode. IR communications provides secure
hands off, no connection remote programming and test facilities. The tactile keys are sealed to IP66
and key spacing is designed 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 software is designed so that all PSLT "functions can be
accessed and controlled from the menus presented on the! front panel display. Located each side of
the main display are four yellow tabs bearing captions in black letters. The captions apply to the flags
displayed on screen during operation.
5. PANEL ELECTRONIC CIRCUIT (PEC)
Mounted underneath the front panel and forming part of the front panel assembly is a multi-layer Panel
Electronic Circuit (PEC), on which a microcontroller and other electronic components are mounted.
The microcontroller controls all functions of the PSLT.
The PEC provides the interconnections between the various PSLT assemblies.
6. BATTERY PACK
There are two battery options available:
1) The use of a battery pack containing NiMH cells and integrated with a gas gauge (12.5V).
2) The use of a battery holder fitted with 10 size AA (or MN 1500) dry cell batteries (15V).
The batteries are housed within a centrally-located battery compartment and electrical connections are
made by means of a power lead which feeds into the battery compartment from the cavity above and
terminates in a three-way connector.

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The front cover to the battery compartment is removeable and is fitted with a polypropylene retaining
strap, or lanyard. Sealing is provided by a neoprene foam seal and the cover is secured to the case
using two 90 degree, or % turn, slotted Dzus fasteners. The battery compartment covers are
manufactured from nickel-plated aluminium alloy and when the batteries are sealed within the
compartment, they are fully protected against the environment.
During operation, the system monitors power usage and provides a front panel indication when the
energy levels drop below 15 minutes (approximately) of available power.
7. PNEUMATIC ASSEMBLY
The pump, pressure sensor, and valves are mounted on a pneumatic block which is attached to a
metal baseplate to form a single pneumatic assembly; eliminating the need for unnecessary pipework
and connectors. The block, which is manufactured out of aluminium alloy, is hollowed out to form a
180ml. volume reservoir which dampens out pressure pulses and aids control stability. Galleries are
machined in the block to interconnect the pump, pressure sensor, valves and outlet ports.
The baseplate of the pneumatic assembly is secured to one half of the case. There are three
pneumatic ports: the output port for 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 and is capable of delivering up to ± 500 mbar to the output port at
a rate of 4 litres/minute at atmospheric pressure.
Within the PSLT are four miniature d.c. solenoid valves operated from four Pulse Width Modulated
(PWM) ports. Two 3/2 changeover valves control the direction of air flow. The third valve (normally-
closed) is used to vent the controlled pressure to atmosphere during a Vent Cycle. The fourth valve is
a normally-open vent valve with restricted orifice. This provides a slow vent to safely reduce the
system pressure to atmosphere in the event of either a power failure or an overpressure condition.
Pressure measurements are made by a differential silicon transducer connected on one side to
atmosphere (via the reference port), and the other to the controlled pressure source (aircraft pneumatic
systems) via the output port. The transducer interfaces wi1th the microcontroller via an Analogue-to-
Digital Converter (ADC). The transducer has integral signal conditioning and temperature
compensation. The operating range is -340 mbar to 340 mbar and typical compensated accuracy is ±
0.3% Full Scale Output (FSO).

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OPERATION
1. INTRODUCTION
The PSLT is designed to perform the following basic functions:
A. Positive and negative pressure generation
B. Differential pressure measurement
C. Pressure rate control
D. Control of Set Point pressure
E. Accurate measurement of external leak: rate
F. Automatic timing during tests.
Throughout the operations cycle, the PSLT Built-In Test Equipment (BITE) carries out self-diagnostic
checks to accurately assess the output states of the battery and the Transducer dedicated supply. It
also monitors pressure to detect an Overpressure condition, 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; and the preferred measuring
units for each test or pressure control sequence. Is used within a test to skip from one
stage to the next. In Pressure Control Mode is used to toggle between the pressure
monitor and leak rate displays.
E. START Initiates all tests and pressure control sequences. When pressed in conjunction with
the PWR key during power up, gives access to a Maintenance Mode.
F. STOP Aborts the test and initiates a Vent Cycle.

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2. OPERATIONAL MODES
Five modes of operation are available. Three primary operational modes are available following normal
power up, while a fourth, subsidiary, mode is accessed during power up by pressing the PWR key with
the START key. The fifth mode, the Communications mode, utilises the front panel IR transceiver to
establish a serial communications link between the PSLT and a remote PC for use in downloading
software and for ATE. This mode is for Manufacturer's use only and no further information shall be
provided within this manual.
A. Leak Test Mode
The Leak Test Mode (Main Menu 1) is used for leak testing the aircraft pneumatic systems. Within this
mode, the Operator may select which channel is tested, Pitot or Static, in which units of measurement
the test is conducted, and is able to set individual values for the test parameters.
B. Pressure Control Mode
The Pressure Control Mode (Main Menu 2) is used for controlling pressure in order to test aircraft
airspeed and altitude instruments and switches. The Operator is provided with the same facilities as in
Leak Test Mode.
C. Setup Mode
The Setup Mode (Main Menu 3) provides the Operator with the ability to alter the default times for
Settling Period, Checking Period, and Power Down Period.
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 conditions have been selected and the START key pressed, the PSLT automatically
carries out the required sequence without further Operator intervention, although the Operator may opt
for a faster rate of pressurization by keeping the START key held down until the selected Set Point has
been reached. As the Set Point approaches, the faster rate is abandoned and the PSLT controls to the
Set Point at the normal rate. The rate of pressure increase or decrease is automatically controlled to
within prescribed limits of accuracy. On reaching the Set Point, the PSLT initiates a volume settlement
period for a user defined time (default 2 minutes) and then measures the rate of leakage in the
selected units of measurement over a further check period (default 3 minutes), calculating and
displaying the resultant leakage rate on completion. If required, the SEL key may be used to skip from
one stage to the next. The test may be terminated at any time via the STOP key. Pressed once, it
gives access to the Pressure Monitor Mode. Pressed a second time it initiates a Vent Cycle to return
the equipment to normal atmospheric pressure.

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For tests where accurate absolute pressure measurement is required, i.e. for Static tests
measured in feet, the Operator must enter the Pressure Of The Day (POTD). The PSLT will
automatically recalibrate itself to carry out precision measurement to the point selected.
4. SETUP
CAUTION: ENSURE THAT THE HOSE FROM THE PSLT IS CONNECTED TO THE
CORRECT AIRCRAFT SYSTEM. FAILURE TO DO SO MAY RESULT IN
DAMAGING PRESSURES BEING APPLIED TO THE SYSTEM UNDER
TEST.
A. Connect the PSLT port to the pitot or static system under test and ensure the connection is
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 Initial Power On Screen
Figure 5 Battery Status (80% Power Available)
C. Following successful completion of the self-test routine, the screen displays the
first main menu, Menu 1, Leak Test ( Figure 6 ). The menu option required is
selected by pressing the SEL key. Pressing once when Menu 1 is displayed calls
up Menu 2, Pressure Control. Pressing a second time calls up Menu 3, Setup.
Pressing a third time calls up Menu 1 again, and so on.

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Figure 6 Menu Option 1
NOTES: 1. If the self-test routine detects a fault the screen will not display the
first main menu. Instead a fault message is displayed, together with
a fault code. In the event of a fault message appearing on the
screen, contact Penny & Giles at the address given on page 1 of this
manual, quoting the code displayed.
2. Whilst in a main menu screen, the +/- keys may be used to increase
or decrease screen contrast to suit ambient lighting conditions.
3. At this time the VENTED flag is visible on the left- hand side of the
screen, whilst on the right-hand side the flag for the current (last
set) mode, either Pitot or Static, is displayed. (The flag shown in Fig.
6 is for Pitot, which is the default mode for the first power up of the
equipment.)
4. If the energy 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, provided the
system is vented, the equipment will automatically power down if the Operator fails to interact
with any interactive screen within a defined period. The duration of this period, known as the
Power Down Period, may be changed by the Operator within Menu 3.
5. LEAK TEST MODE
A. When the opening screen for Main Menu 1 is displayed press the START key to initiate the
Leak Test Routine. The display prompts the Operator to select the mode type and displays
the current mode, e.g. 'Currently PITOT' {Figure 7).
NOTE: The first time the PSLT operates, the default mode is Pitot.
Thereafter, the default mode is the last mode selected in previous tests.