annunciator dim/test unit (adu) part no. 92-7001-x and sub

Annunciator Dim/Test Unit (ADU)

Part No. 92-7001-X and sub-assemblies

Component Maintenance Manual with

Parts List

AEROVATION INC / AVIONICS ENGINEERING SERVICES, INC. 2060 E. AIRPORT DRIVE

TUCSON, ARIZONA 85756 (520) 308-6409

Cage Code: 5CYQ0

COMPONENT MAINTENANCE MANUAL 31-52-100 with Illustrated Parts List for ADU (92-7001-X) Rev IR

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LOG OF REVISIONS

REV NO.

PAGE NO.

EFF DATE

DESCRIPTION

APPROVED

IR ALL 05/27/2021 Initial Release. D.S. Billings – FAA PAH Accountable Manager.


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TABLE OF CONTENTS

1.0 INTRODUCTION ................................................................. 4 2.0 DESCRIPTION AND OPERATION………………...................... 6

3.0 DRAWINGS…………………………........................................... 12 4.0 TEST FIXTURES……………………........................................... 29

5.0 TEST PROCEDURES……………….......................................... 34 6.0 INSTRUCTIONS FOR CONTINUED AIRWORTHINESS……… 42 7.0 DISASSEMBLY……………………............................................ 43 8.0 CLEANING………….................................................................. 44 9.0 ASSEMBLY……………………………………………………....... 45

10.0 SPECIAL TOOLS, FIXTURES AND EQUIPMENT.................... 46 11.0 PARTS LISTS………………..……………………………............ 46

12.0 INSTRUCTIONS FOR STORAGE, LIMITS……………………. 46 AND ENVIRONMENTAL RESTRICTIONS

APPENDIX A – Quick Reference Parts List……………………………... 47


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1.0 INTRODUCTION

Aerovation Inc. formally authorizes the release of this CMM per FAA Order 1270.1A Freedom of Information Act Program (FOIA) to owners, operators, repair stations and maintenance providers having an interest in maintaining this article. Applicable 14 CFR requirements of Parts 21, 43 and 145 must be observed by individuals using this data. This document and all information and expression contained herein may be used by persons required by Federal Aviation Regulation 14 CFR Part 21.50 to comply with any of the terms of those instructions. An ICA is contained herein in section 6.0.

1.1 Export and Precautionary Data This document contains unrestricted technical data and may be exported under license

exception TSU/OTS in accordance with EAR Section 740.13(a). This commodity or technology may be exported from the United States in accordance with the Export Administration Regulations. Diversion contrary to U.S. law is prohibited. Statutory references to the Export Administration Regulations (EAR) are found in the eCFR, Title 15, Chapter VII, subchapter C. ECCN: 7A994d. Schedule B Number: 8803.30.0010 (NLR) No License required.

1.2 Special Precautions Warnings, cautions and notes in this manual are as follows: - A WARNING is an operation or maintenance procedure or condition that, if not followed, can

cause injury or death. - A CAUTION is an operation or maintenance procedure or condition that, if not followed, can cause damage to the equipment. - A NOTE provides data that simplifies the work or directions of a procedure. WARNING: Before you use a materiel, consult the manufacturers’ material data safety

sheets (MSDS) for safety information. Some materials can be dangerous. CAUTION: Do not use materiel that is not equivalent to those specified herein.

Materiel that is not equivalent can cause damage to the equipment and may void the warranty.

CAUTION: These articles contain items that are electrostatic discharge sensitive

(ESDS). Use appropriate industry precautions and procedures to keep the risk of damage to a minimum when handling, removing or inserting parts or assemblies.

CAUTION: The ADU is a precision aircraft article. Exercise caution when handling it,

as with any precision instrument. Follow instructions for storage or shipment and protection from damage (section 12.0).


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1.3 Content Data

How to use this manual a) The instructions in this manual provide all data necessary to perform all recommended

maintenance functions to place the ADU in serviceable condition. Standard maintenance procedures and elementary electronic procedures or instructions for technicians are not provided in this manual.

b) It is recommended that tests in TESTING and FAULT ISOLATION be accomplished prior to

article disassembly. Unit cover may be removed for preliminary inspection and to access any circuit card test points. These tests reveal the condition of the article and provide a logical path for troubleshooting/repair. Further disassembly may be required to gain access to test points or components for final fault isolation.

c) Related and reference publications/data are listed below. Annunciator Dim /Test Unit - Installation Data and Description and Theory of Operation,

Document 92-0003-06, Rev E. Aerovation Inc. / AES Inc., Tucson, Arizona. Abbreviations for Use on Drawings and in Text, ASME Y1.1 (1989). American National

Standards Institute, New York, NY. National Institute of Standards and Technology (NIST) – ISO/IEC 17025 or ANSI Z540-1,

General Requirements for the Competence of Testing and Calibration Laboratories. MIL-STD-45662A, Calibration Systems Requirements MIL-I-46058C, Insulating Compound, Electrical (for Coating Printed Circuit Assemblies)

(Humiseal 1B73). Kester Solder Sn60Pb40 Specification and MSDS ISO/DIS 11014. Kester Soldering Flux SP44 Specification and MSDS ISO/DIS 11014. MIL-STD-2000A, Standard Requirements for Soldered Electrical and Electronics

Assemblies MIL-STD-1686C, Electrostatic Discharge Control Program for Protection of Electrical and

Electronic parts, Assemblies and Equipment ESDS S20.20, Quality Management for Electrostatic Discharge


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2.0 DESCRIPTION AND OPERATION

The Annunciator Dim / Test Unit (ADU) is designed to provide a dedicated source for annunciator power, dimming and testing. The ADU is fabricated using a ½ ATR short dwarf chassis with a removable cover. Unit weight is 2.0 lbs. The unit houses two separate P.C. boards. This allows one ADU to supply isolated power sources for both pilot and copilot annunciators. Each P.C. board contains 25 diode isolated test lines, one adjustable power supply for dimming 28VDC logic and one adjustable dimming circuit for ground logic. The ADU is available in three versions: P/N 92-7001-1, P/N 92-7001-2 and P/N 92-7001-3. P/N 92-7001-1 The -1 ADU houses two identical circuit boards that are independent from each other. Annunciator output power is supplied from the Annunciator +28VDC circuit breaker through a normally closed relay contact. When Dim mode is selected, annunciator power is routed through a variable power circuit that is capable of supplying +28VDC to +10VDC. It is factory set to +14VDC. Power from this circuit is then routed to seven diode isolated power outputs, each capable of handling 0.4 Amps. Total current draw from this circuit is not to exceed 1.5 Amps at +28VDC. Each board has 25 diode isolated inputs that are grounded during annunciator test mode. The ADU is designed so that the Bright / Dim and Test mode functions can be triggered by either +28VDC or ground logic. Each board also contains a variable ground potential circuit for dimming. During normal operation (bright mode) a ground is supplied through a normally closed relay contact. When Dim mode is selected the ground potential is routed through a variable regulator circuit that is adjustable from +0.0VDC to +18VDC, which is routed thru the normally open relay contact. This circuit is also factory set to +14VDC. Total current draw on this circuit is limited to 0.5 amps at +28.0VDC. There is only one output available from this circuit with no test function or diode isolation. Connector - DBX2MA-67P67P-34B-000X (special keyed) Mating connector - DPX2MA-67S67S-33B-0001 (re-key to match unit) Power requirements - 2.0 amps at +28.0 VDC per card. Use 3 amp circuit breaker. Isolated inputs - 25 per card dedicated to gnd test circuit. (50 total)


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2.0 DESCRIPTION AND OPERATION (cont)

92-7001-1 Block Diagram / Interconnect

The -1 ADU has all of the 25 diode isolated inputs on each board for the ground trigger circuit. Test mode (relay K2 – hexagon “B”) sets those outputs to ground potential.


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The -1 and -2 ADU's are identical except the -2 reserves 5 of the 25 diode isolated inputs on each board for the positive trigger circuit. Test mode (relay K2 hexagon “A”) sets those outputs (jumper TP-2 to TP-3) to +28.0VDC.


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The -3 ADU reserves 9 of the 25 diode isolated inputs on each board for the positive trigger circuit. Test mode (relay K2 hexagon “A”) sets these outputs (via jumper TP-2 to TP-3) to +28.0VDC.


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ADU MECHANICAL LAYOUT

P/N 92-7001-X


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ANNUNCIATOR DIM UNIT LAYOUT (View looking down at top of unit with cover removed)


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3.0 DRAWINGS

ADU DRAWING LIST

DRAWING No.

REV

DESCRIPTION

RELEASED

92-7001

IR

Annunciator Dim/Test Unit (ADU) Top Level Assembly

07/23/19

92-7001-20

A

Chassis Modification, ADU

9/14/92

92-7001-30

B

Bracket Fabrication, ADU

9/27/96

92-7001-40

B

ADU Wiring Harness

3/01/02

92-7001-50

C

ADU Wiring Harness Installation

2/23/04

92-7001-60

D

ADU Dim /Test Circuit Card

12/09/08

92-7001-90

B

ADU Circuit Card Installation

07/23/19

92-7001-100

A

ADU Data Plate Installation and Definition

3/25/94

96-7001-130

A

ADU Hole Information

12/17/08


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4.0 TEST FIXTURE


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5.0 TEST PROCEDURES 5.0 This specification establishes the operational requirements the Annunciator Dim / Test Unit, P/N

92-7001-X, must meet to ensure the assembly is in proper operating condition. Also contained herein is the detailed test procedure to test for these requirements.

5.1 General Test Procedures

Detailed troubleshooting procedures are not contained in this manual. If a test failure occurs, the applicable schematics may be used to isolate the malfunction to component or circuit level.

Isolation procedures may require that an electrical part be checked. Visual inspection is the first step; if no evidence is found then conventional electrical checks must be accomplished.

5.3 Power Sources

28 Volts DC, (± .5 VDC) for power applied to card inputs. 5.5 TEST REQUIREMENTS

Prior to and when performing the detailed tests contained in the tables, observe these test requirements.

5.6 All tests shall be performed on 100 percent of the units manufactured. 5.7 Record the serial numbers, part number, and the results of the tests specified herein. 5.8 All tests shall be performed under conditions of 24 degrees C, ± 10 C, 90 percent relative humidity

maximum, and between 22 and 32 inches of mercury atmospheric pressure. 5.9 All output voltages shall be measured with respect to DC ground unless otherwise specified. 5.10 All voltage results not otherwise specified herein to have tolerances of +/- 10% of the stated

specification. 5.11 TEST FORMAT DESCRIPTION

TEST Tests are numbered in sequence. Multiple readings required within a single test will be numbered X.1, X.2, etc. Reference to the entire test will be in the form X or X.0.

ADJ Identifies appropriate resistor to adjust on the P.C. Card to obtain the specific

outputs of the test.

OUTPUTS Unit under test shall meet these requirements during either initial test cycle (manufacturing) or field testing and troubleshooting.

TECH Space for technician sign off.

TP( ) Test points on unit under test.

TJ( ) Test jacks on the ADU Test Set.


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5.0 TEST PROCEDURES (cont) 5.12 TEST EQUIPMENT REQUIRED

The following test equipment is required to accomplish this test procedure: 5.12.1 Digital Voltmeters (DVM’s). 5.12.2 A.D.U. Test Set, P/N 92-7001-120 5.12.3 Power Supply, 28 Volts DC (3 ampere capability minimum) 5.13 TEST PROCEDURES

Initial Setup - verify that the ADU Test Set switches are set to the following: 5.13.1 Annunciator Test Off 5.13.2 BRT / DIM BRT 5.13.3 GND DIM Test Off 5.13.4 -1 Assy / -2 Assy To appropriate selection per Test Appendix (A, B, C)

5.14 On P/N 92-7001-1 ADU's verify that the part number of the P.C. boards installed are 92-7001-61. Also

verify that TP(1) AND TP(2) are jumpered together on each P.C. board.

5.15 On P/N 92-7001-2 ADU's verify that the part number of the P.C. boards installed are 92-7001-62. Also verify that TP(2) AND TP(3) are jumpered together on each P.C. board.

5.16 On P/N 92-7001-3 ADU's verify that the part number of the P.C. boards installed are 92-7001-63. Also verify that TP(2) AND TP(3) are jumpered together and the foil between CR49's anode and TP(1) is broken on each PC board.

5.17 Turn power supply on and verify: +28 VDC ± .25 VDC.

5.18 Turn power supply off and connect the unit under test to test harness.

5.19 Record part number and serial number of unit under test on data sheet.

5.20 Turn +28 VDC power supply on and using the appropriate Appendix, adjust the ADU to specifications, test all circuits and record results.


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Appendix A – ADU p/n 92-7001-1 Final Acceptance Test (sht 1) TST

PROCEDURE

PLUG A

PLUG B

A.

Select -1 Assy.

B.

Monitor +27.65 VDC (+.25)at TJ (16A),(17A) and +28 VDC (+.25) at (8A).

C.

Monitor GND at TJ (1A) and (2A).

D.

Select DIM mode. 1. Adj. R5 for +14.0 VDC at TJ (16A)& (17A).

E.

Jumper TJ (1A) and (1B).

F.

Select GND Dim Test. 1. GND Annunciator should light.

2. Adj. R6 for +14.75 VDC at TJ (GND DIM).

G.

Return GND Dim Test switch to off.

H.

Select BRT mode. (Jumper 15A to 15B)

I.

Select Test mode with Annunciator Test switch. 1. Annunciators 1 through 20 should light.

J.

Jumper (16A) to (28 / 14VDC Comm). 1. Annunciators 21 through 25 should light.

2. Current draw should be 0.68A (+0.05)

K.


2. Current draw should increase to 0.73A (+0.05)

L.

Select DIM mode. 1. All annunciators should dim.

2. Current draw should decrease to 0.53A (+0.05)

3. Verify voltage at (17A) +13.85 VDC.


M.

Open GND Dim Test switch. 1. GND Dim Annunciator should extinguish.

2. Current draw should drop to 0.51A (+0.05)


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Appendix A – ADU p/n 92-7001-1 Final Acceptance Test (sht 2)

TST

PROCEDURE

PLUG A

PLUG B

N.

Open Annunciator Test switch. 1. Annunciators 1 through 25 should extinguish.

O.

Apply a GND to TJ's (1) through (25) one at a time and verify that the appropriate annunciator illuminates. TJ (1) should illuminate annunciator 1, etc.

P.

Return BRT / DIM switch to BRT.

Q.

Turn power supply off.

Numerical voltage and current results are based on test set using standard Applied Avionics/Aerospace Optics Vivisun series 95 or 99 series annunciators with 28 Vdc T-1 lamps (Vivisun p/n 14-104 or MS3338-6839 - 25 milliamp electro-luminescent) bulbs in the Vivisun annunciator assembly. Use of 28 Vdc LED style illumination in the test set annunciators will decrease numerical amperage values from stated test specification results by approximately 75%.


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Appendix B – ADU p/n 92-7001-2 Final Acceptance Test (sht 1)

TST

PROCEDURE

PLUG A

PLUG B

A.

Select -2 Assy.

B.

Monitor +27.65 VDC (+.25)at TJ (16A), (17A) and +28 VDC at (8A).

C.


D.

Select Dim mode. 1. Adj. R5 for +14.0 VDC at TJ (16A) & (17A).

E.

Jumper TJ (1A) to (1B) and (15A) to (15B)

F.

Select GND Dim Test. 1. GND DIM Annunciator should light. 2. Adj. R6 for +14.75 VDC at TJ (GND DIM).

G.

Return GND Dim Test switch to off.

H.

Select BRT mode.

I.



J.



K.

Select Dim mode. 1. Annunciators 1 through 25 should dim.

2. GND/DIM Annunciator should dim.





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Appendix B – ADU p/n 92-7001-2 Final Acceptance Test (sht 2)

TST

PROCEDURE

PLUG A

PLUG B

L.


2. Current draw should drop to .51A (+0.05)

M.

Remove jumper between TJ (1A) and (1B). 1. Annunciators 21-25 should extinguish.


N.


O.


P.

Jumper TJ (1A) to (1B).

Q.

Apply +28VDC to TJ's (21) through (25) one at a time and verify that the appropriate annunciator illuminates. TJ (21) should illuminate annunciator 21, etc.

R.

Return BRT/DIM switch to BRT.

S.




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Appendix C – ADU p/n 92-7001-3 Final Acceptance Test (sht 1)

TST

PROCEDURE

PLUG A

PLUG B

A.

Select -2 Assy.

B.

Monitor +27.65 VDC (+.25) at TJ (16A),(17A) and +28 VDC at (8A).

C.


D.

Select Dim mode. 1. Adj. R5 for +14.0 VDC at TJ (16A) & (17A).

E.

Jumper TJ (1A) to (1B) and TJ (2A) to (15B).

F.

Select GND DIM Test. 1. GND DIM Annunciator should illuminate.

2. Adj. R6 for +14.75 VDC at TJ (2A).

G.

Return GND DIM TEST switch to off.

H.

Select BRT mode.

I.



J.



K.

Select Dim mode. 1. All annunciators should dim.




L.




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Appendix C – ADU p/n 92-7001-3 Final Acceptance Test (sht 2)

TST

PROCEDURE

PLUG A

PLUG B

M.

Remove jumper between TJ (1A) and (1B). 1. Annunciators 21 through 25 should extinguish.


N.


O.

Jumper TJ (1A) to (1B).

P.


Q.

Apply 28VDC to TJ's (17) through (25) one at a time and verify that the appropriate annunciator illuminates. TJ (17) should illuminate annunciator 17, etc.

R.

Return BRT/Dim switch to BRT.

S.




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6.0 Instructions for Continued Airworthiness (14 CFR 23.1529, 25.1529, 27.1529, 29.1529)

Annunciator Dim/Test Unit (ADU) Part numbers: 92-7001-1, 92-7001-2, 92-7001-3 Modification of an aircraft by Supplemental Type Certificate or Form 337 obligates the aircraft owner/operator to include the maintenance information provided by this document in the operator’s Aircraft Maintenance Manual and the operator’s Aircraft Scheduled Maintenance Program. 6.1 Maintenance Manual information for the Annunciator Dim/Test Unit is contained in Aerovation Inc. Installation Data and Description of Theory of Operation, Document No. 92-0003-06, available on the Aerovation Inc. website. (www.aerovationinc.com) and this document. 6.2 The ADU is a Line Replaceable Unit (LRU). Appropriate installed part number(s) should be placed into the aircraft operator’s appropriate airplane Illustrated Parts Catalog (IPC). 6.3 Wiring diagram information of the ADU interfaces should be placed into the aircraft operator’s appropriate airplane Wiring Diagram Manuals. 6.4 Revision to this document will be accomplished via website notification and posted on the Aerovation Inc. website. 6.5 Airworthiness Limitations The Airworthiness Limitations Section is FAA approved and specifies maintenance required under 14 CFR 43.16 and 91.403 of the Federal Aviation Regulations unless an alternative program has been FAA approved.

6.6 Scheduled Maintenance Program - Task Action Aircraft operator tasks to be added to an aircraft maintenance program are as follows: Recommended Periodic Scheduled Servicing Tasks: None Required Recommended Periodic Scheduled Preventative Maintenance: None Required Tests/Checks to Determine System Condition and/or Latent Failures: None Required Recommended Periodic Inspections: None Required Recommended Periodic Structural Inspections: None Required Recommended Replacement Interval: None Required

In the event of failure of the Annunciator Dim/Test Unit, the owner, operator or cognizant maintenance personnel or facility shall remove the unit and return it to Aerovation, Inc. or an appropriately rated FAA Repair Station for repair or replacement.

http://www.aerovationinc.com/


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7.0 Disassembly 7.1 Introduction

This section contains disassembly procedures to remove the assemblies from the unit.

CAUTION: THESE PROCEDURES MUST BE DONE AT A STATIC-FREE WORK STATION IN ORDER TO PREVENT DAMAGE TO ELECTROSTATIC SENSITIVE COMPONENTS.

CAUTION: THIS UNIT CONTAINS ASSEMBLIES THAT ARE SUSCEPTIBLE TO DAMAGE FROM INCORRECT HANDLING. DO NOT DROP OR HIT UNIT DURING THESE PROCEDURES.

THESE PROCEDURES MUST BE DONE IN A CLEAN ENVIRONMENT IN ORDER TO PREVENT DAMAGE TO MECHANICAL COMPONENTS.

7.2. General

CAUTION: DISASSEMBLY REQUIRES ELECTROSTATIC DISCHARGE CONTROL PRECAUTIONS TO PREVENT DAMAGE TO ELECTROSTATIC DISCHARGE SENSITIVE ITEMS.

A. Techniques for Handling Electrostatic Discharge Sensitive Equipment

Refer to the Introduction section for guidelines to proper handling of Electrostatic Discharge Sensitive (ESDS) assemblies during disassembly, repair, assembly, test setup,

troubleshooting and storage.

B. Assumptions

Testing and Fault Isolation procedures will be used to establish the condition of the unit or most probable cause of its malfunction. This is to determine the extent of disassembly required without completely tearing down and rebuilding the unit.

The disassembly procedures are intended to support removal of user-replaceable items at the work bench. Unless otherwise noted, the unit should be disconnected from its test connector before disassembly. The assumed starting point for each disassembly procedure is a fully assembled unit. Utilize the ADU Top Level Assembly, 92-7001 and ADU Chassis Modification, 92-7001-20 for teardown of the chassis. Utilize ADU Circuit Card Assembly, 92-7001-90 for removal/re-installation of circuit cards.


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8.0 Cleaning 8.1 General

The unit does not require any scheduled cleaning. 8.2 Required Materials Tools, Fixtures, and Equipment

NOTE: Equivalent substitutes may be used for listed items. Item Manufacturer

Alcohol, isopropyl Commercially available (Federal Specification TT-1-735) Lint-free fabric (Woven or non-woven material) Tissue wiper (Low in lint, absorbent, non-abrasive, and anti-static)

(Kimberly-Clark Kaydry® EX-L Laboratory Wipers) Flux Off ES1631 (12 oz aerosol) Chemtronics

Flux Off Rosin ES 835B, ES1035, ES10356B Chemtronics 8.3 Cleaning Procedures

CAUTION: DO NOT ALLOW FLUID TO MIGRATE TO THE INTERIOR OF THE UNIT. DAMAGE TO UNIT CAN OCCUR.

Exterior Cleaning

(1) Wipe with a clean lint-free fabric or tissue wiper moistened with isopropyl alcohol. (2) Dry with a clean lint-free fabric or tissue wiper. (3) Let the case stand open (or with cover removed) until any remaining moisture evaporates before assembling the unit.

Interior Cleaning (1) Put a dry lint-free wipe over reworked area and scrub through the wipe using an acid brush wet with Flux Off

until clean. (2) Visually check the area for any sign of contamination; if contamination remains repeat step (1). (3) Dry reworked area as follows:

- Allow Flux Off to evaporate, - Blot area with a lint free wipe, or - Dry with compressed air equipped with an air ionizing nozzle.


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9.0 Assembly 9.1 Introduction

This section contains assembly procedures to install the assemblies in the unit. The assembly procedures are intended to support assembly and installation of user-replaceable items at the work bench. Unless otherwise noted, the unit should be removed from its mounting and external connectors should be disconnected before performing assembly procedures.

WARNING: BEFORE THE MATERIALS CALLED OUT IN THIS PUBLICATION ARE USED, KNOW THE HANDLING, STORAGE AND DISPOSAL PRECAUTIONS RECOMMENDED BY THE MANUFACTURER OR SUPPLIER. FAILURE TO COMPLY WITH THESE RECOMMENDATIONS CAN RESULT IN PERSONAL INJURY OR DISEASE. OBTAIN MSDS DATA SHEETS.

CAUTION: THESE PROCEDURES MUST BE DONE AT A STATIC-FREE WORK STATION IN ORDER TO PREVENT DAMAGE TO ELECTROSTATIC SENSITIVE COMPONENTS. THIS UNIT CONTAINS ASSEMBLIES THAT ARE SUSCEPTIBLE TO DAMAGE FROM INCORRECT HANDLING. DO NOT DROP OR HIT UNIT DURING THESE PROCEDURES. CAUTION: THESE PROCEDURES MUST BE DONE IN A CLEAN ENVIRONMENT IN ORDER TO PREVENT DAMAGE TO MECHANICAL COMPONENTS.

9.2 General

A. Techniques for Handling Electrostatic Discharge Sensitive Equipment Refer to the Introduction section for guidelines to proper handling of Electrostatic Discharge Sensitive assemblies during disassembly, repair, assembly, test setup, troubleshooting, and storage.

B. Assumptions

The assembly procedures are intended to support assembly and installation of items at the work bench. Unless otherwise noted, the unit should be removed from its mounting and external connectors should be disconnected before performing assembly procedures.

The assumed starting point for each procedure is a unit that has been either disassembled just enough to remove the component to be installed or one which has been reassembled to the point of installing the component. Utilize ADU Circuit Card Installation drawing, 92-7001-90 for installation of circuit cards and 92-7001 for top level details. If chassis repair is required, utilize the Chassis Modification drawing, 92-7001-20 for repairs. For internal wiring harness repairs, utilize 92-7001-40 ADU Wiring Harness drawing.


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10.0 Special Tools, Fixtures, and Equipment

This section lists the special tools, fixtures and equipment needed to perform the procedures in the publication.

NOTE: Equivalent substitutes may be used for listed items. An electronics service set of small hand tools are required. The most common required tools are listed below. Most repair stations have these on hand as standard equipment. No special directions/instructions are applicable to any of these standard tools. Tyco-Amp crimpers instructions are available on-line at www.te.com. Daniels crimpers instructions are also available on-line at www.dmctools.com. The ADU test fixture (section 4.0) requires local fabrication.

Item Manufacturer

ESD workbench mats and wrist-strap Any Power supply, DC (Output 3.0A at 0 to 30VDC) Any Digital Voltmeters (Fluke 87-5, 28 II) or equivalent (DC volts, ohms, ammeter) Any Wire Cutters (IGAN-170) IGAN Screwdriver, Phillips head (size as applicable to screw size #4, #6, #8) Any Nut driver, deep well socket (3/16) Any Screwdriver, slot head (size as appropriate to screw head size) Any Nut drivers, standard U.S. set 1/8” to 1/2 “) Any Wire stripper (24 awg – 20 awg) (11063W) or equivalent Klein Tools

Wire Crimper – AF8 (M22520/1-01) Daniels Mfg Turret Head – TH1A (M22520/1-02) Daniels Mfg Certi-Crimp 2 - 59300 (MS25036 ring terminals) Tyco/Amp Certi-Crimp 2 - 91516-1 (Amp MODUIV contacts) Tyco/Amp Weller Soldering Station (70 W minimum & 350 C) Weller or equivalent Standard solder station misc tools/materiel (Flux, 60/40 Pb solder, etc) Any ADU Test Fixture (For drawings, data and schematics for test fixture see Section 4.0). This may be locally fabricated and adapted as required to meet testing requirements.

11.0 PARTS LIST

Refer to the individual drawings callouts in section 3.0 for parts required for repair or fabrication of ADU. A chart is provided in Appendix A for quick reference that incorporates the suitable part substitutions derived from 89-0005-15 Electrical Hardware Substitution document. Circuit board fabrication may be done at any circuit card fabrication facility that can meet the drawing requirements. Aerovation/AES has used Prototron Circuits Southwest in Tucson, Arizona as our qualified source, as they have all templates on hand for circuit card fabrication/replacement.

12.0 INSTRUCTIONS FOR STORAGE, LIMITS AND ENVIRONMENTAL RESTRICTIONS

The ADU may be stored within any enclosed facility that has dedicated warehouse space with shelving to accommodate its size. The ADU should be packaged within a sealed plastic ESDS bag for dust, ESDS and moisture protection. The ADU environmental storage conditions limits are as follows: Temperature: -55C to + 70C (- 67 F to +158 F) Humidity: 1% to 99% Atmospheric Pressure: 15.35 psi to 7.64 psi (-1000 feet to +15,000 feet) ADU Components storage: Same as above. This article contains items that are electrostatic

discharge sensitive (ESDS). Use appropriate industry precautions and procedures to keep the risk of damage to a minimum when handling, removing or inserting parts or assemblies.

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http://www.dmctools.com/


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APPENDIX A – Quick Reference Parts List This list incorporates the suitable part substitutions derived from 89-0005-15 Electrical Hardware Substitution (internal proprietary document) referenced in section 3.0 drawings.

Part Nomenclature Designator Vendor(s) 92-7001-60 PC Board (ADU) none Prototron Circuits

HFW4A1201K01 or HFW5A1201K00 4A or 5A, 2-pole Relay K1, K2 Tyco/Amp or Comm Inst.

TL431ILP Voltage Ref VR2 T.I. or ON Semi

TIP125 PNP Transistor Q1 ON Semi , Multicomp

2N3906 PNP Transistor Q2 ON Semi, Multicomp

RL20S241G 240 ohm R1 Dale

RN55D2101F 2.1K ohm R2 Dale

RN70C1001F (was RN65E1001F) 1K ohm R3, R4 Dale

RTR24DP103M or RTR24DP103P or RTR24DP103R 10K ohm pot R5, R6 Bourns

RNC55H6191FS 6.19K ohm R7 Dale

MF60D or MF-1/2D 1 ohm 1% R9, R10, R11 KOA

UVZ1H010MDH 1uf 50V C1 Nichicon

CK06BX104K 0.1 uf 100v C2 Kemet

1N4005 Power Diode CR1 thru CR59

Motorola, ON Semi,

Multicomp

2-103801-0 or 2-103149-0 or 7-146308-0 (pb Free) 40 Pin Connector (M) none Tyco/Amp

271AB (was EG&G) Heat sink none Wakefield

507302B00000 or 273AB (Wakefield -was EG&G) Heat sink none Aavid Thermalloy

MS51957-15 Screw 4/40 x 1/2 none QPL

MS21083C04 or MS21042-04 No. 4 Nut none QPL

LM350T 0-30V Reg VR1 Motorola or Fairchild

1-87483-9 or 1-87483-0 40 Pin Connector (F) none Tyco/Amp

RP20899G2 Relay Pad used with K1, K2 Tyco/Amp

92-7001-40 Wiring Harness none local fabrication

92-7001-20/A ADU Chassis none Churchill

DSX2G22S22S0001 (was DPXME67P67P34B0001) Chassis Connector none Air Electro

56-77-8 (was 808853A001 - Motorola) Mila Insulator none Aavid Thermalloy

7721-15N (was B51547F019 Motorola) Nylon Bushing none Aavid Thermalloy

92-7001-100 Name Plate ADU none Nameplate Inc.

MS35649-224 No. 2 Nut none QPL

NAS1640-2 or MS35338-134 No. 2 lock washer none QPL

86016-5 or 86016-2 (drawing 92-7001-40) Contact, mod IV 24-20 none Tyco/Amp

M22759/16-24-9 (drawing 92-7001-40) Wire, 24 awg None QPL

M22759/16-22-9 (drawing 92-7001-40) Wire 22 awg none QPL

M22759/16-20-9 (drawing 92-7001-40) Wire 20 awg none QPL

MS25036-149 (or 36152 Amp) Flag note 7 & 8:

drawing 92-7001-50 Ring Term none QPL

MS51957-14 Screw 4/40 x .375 none QPL

MS51957-8

2/56 x 5/8 Panhead

Screw none QPL

DPXB-60-1 (for shipping only) Dust Covers none Itt Cannon

annunciator dim/test unit (adu) part no. 92-7001-x and sub

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