Securaplane Technologies WCU1002601 WELS Control Unit User Manual MM 0210 01 33 50 01 CMM WCU

Securaplane Technologies, Inc. WELS Control Unit MM 0210 01 33 50 01 CMM WCU

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CAGE Code: 0TMJ9
10800 Mavinee Drive
Tucson AZ 85737 USA
Tel: 1-520-297-0844
Fax 1-520-498-4924
COMPONENT MAINTENANCE MANUAL
WITH
ILLUSTRATED PARTS LIST
WELS CONTROL UNIT
PART NO.
100-2601-01
The technical data in this document (or file) is controlled for export under the Export Administration
Regulations (EAR), 15 CFR Parts 730-774, ECCN: EAR99. Violations of these laws may be subject to fines
and penalties under the Export Administration Act.
Initial Issue: JAN 05/2009
Manual Part Number: MM-0210-01
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SAFETY ADVISORY
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 THE MANUFACTURERS'
OR SUPPLIERS' RECOMMENDATIONS CAN RESULT IN PERSONAL INJURY OR
DISEASE.
WARRANTY/LIABILITY ADVISORY
SECURAPLANE ASSUMES NO RESPONSIBILITY FOR ANY SECURAPLANE EQUIPMENT WHICH IS
NOT MAINTAINED AND/OR REPAIRED IN ACCORDANCE WITH SECURAPLANE’S PUBLISHED
INSTRUCTIONS AND/OR SECURAPLANE’S REPAIR AUTHORIZATION. NEITHER DOES
SECURAPLANE ASSUME RESPONSIBILITY FOR SPECIAL TOOLS AND TEST EQUIPMENT
FABRICATED BY COMPANIES OTHER THAN SECURAPLANE.
INCORRECTLY REPAIRED COMPONENTS CAN AFFECT AIRWORTHINESS OR DECREASE THE LIFE
OF THE COMPONENTS. INCORRECTLY FABRICATED SPECIAL TOOLING OR TEST EQUIPMENT CAN
RESULT IN DAMAGE TO PRODUCT COMPONENTS OR GIVE UNSATISFACTORY RESULTS.
CONFIDENTIALITY NOTICE
This document contains confidential and proprietary information, which is proprietary to Securaplane® and
shall not be copied or reproduced, in whole or in part, or the contents divulged or used for manufacture,
without the specific written permission of Securaplane. Recipient, by acceptance, use, or retention of this
document, acknowledges and agrees to the foregoing and covenants to maintain the contents in confidence.
AIRCRAFT-ON-GROUND (AOG) SERVICE
For AOG service contact Securaplane at Tel: 1-520-297-0844 (US Toll Free: 1-800-279-7327). After
business hours, follow the AOG directions in the recorded message.
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STATEMENTS OF COMPLIANCE
Regulatory Information for WELS Control Unit (WCU) Radio Transceiver
A.
Statements and Conditions of Compliance
(1)
This section contains information relative to domestic and foreign country Regulatory
Approvals for the WELS radio.
USA – FCC Compliance
This device complies with part 15 of the Federal Communications Commission (FCC) Rules.
Operation is subject to the following two conditions:
(1)
This device may not cause harmful interference
(2)
This device must accept any interference received, including interference that may
cause undesired operation.
FCC Section 15.21 statement – “Changes or modifications not expressly approved by the
manufacturer could void the user’s authority to operate the equipment”.
Canada - Industry Canada Statements
This Class B digital apparatus complies with Canadian ICES-003.
Cet appareil numérique de la class B est conforme à la norme NMB-003 du Canada.
Europe – ETSI
Japan –
Argentina –
Israel –
Brazil –
China CCC –
Malta –
Jordan –
India –
Malaysia –
Morocco –
Nigeria –
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RECORD OF REVISIONS
Revision
Number
Issue
Date
Date
Inserted
By
Revision
Number
Revision
Date
Date
Filed
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Temporary
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Number
Page
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Issue Date
By
Date Removed
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SERVICE BULLETIN LIST
Service Bulletin /
Revision Number
Issue Date
Date
Incorporated
or No Effect
Title
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LIST OF EFFECTIVE PAGES
SUBJECT
PAGE
DATE
Title Page
TP1
TP2
JAN 05/2009
BLANK
Safety/ Warranty/
Liability Advisory
SWLA-1
SWLA-2
JAN 05/2009
BLANK
Statements of
Compliance
SOC-1
SOC-2
JAN 05/2009
BLANK
Record of
Revision
ROR-1
ROR-2
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BLANK
Temporary
Revisions
RTR-1
RTR-2
JAN 05/2009
BLANK
Service Bulletin
List
SBL-1
SBL-2
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BLANK
List of Effective
Pages
LEP-1
LEP-2
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JAN 05/2009
Table of
Contents
TOC-1
TOC-2
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JAN 05/2009
Introduction
INTRO-1
INTRO-2
INTRO-3
INTRO-4
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Description and
Operation
10
11
12
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Testing and Fault
Isolation
1001
1002
1003
1004
1005
1006
1007
1008
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SUBJECT
PAGE
DATE
1009
1010
1011
1012
1013
1014
1015
1016
1017
1018
1019
1020
1021
1022
1023
1024
1025
1026
1027
1028
1029
1030
1031
1032
1033
1034
1035
1036
1037
1038
1039
1040
1041
1042
1043
1044
1045
1046
1047
1048
1049
1050
1051
1052
1053
1054
1055
1056
1057
1058
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LIST OF EFFECTIVE PAGES
SUBJECT
PAGE
DATE
Schematics and
Wiring Diagrams
2001
2002
2003
2004
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BLANK
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BLANK
Disassembly
3001
3002
3003
3004
JAN 05/2009
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Cleaning
4001
4002
JAN 05/2009
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Inspection/Check
5001
5002
JAN 05/2009
BLANK
Assembly
7001
7002
7003
7004
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Fits and
Clearances
8001
8002
JAN 05/2009
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Special Tools,
Fixtures,
Equipment and
Consumables
9001
9002
JAN 05/2009
JAN 05/2009
Illustrated Parts
List (IPL)
10001
10002
10003
10004
10005
10006
10007
10008
10009
10010
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15001
15002
JAN 05/2009
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Storage
(Including
Transportation)
SUBJECT
PAGE
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TABLE OF CONTENTS
SECTION
PAGE
DESCRIPTION AND OPERATION
TESTING AND FAULT ISOLATION
1001
SCHEMATICS AND WIRING DIAGRAMS
2001
DISASSEMBLY
3001
CLEANING
4001
CHECK
5001
REPAIR
Not Applicable
ASSEMBLY
7001
FITS AND CLEARANCES
8001
SPECIAL TOOLS, FIXTURES, EQUIPMENT AND CONSUMABLES
9001
ILLUSTRATED PARTS LIST
10001
SPECIAL PROCEDURES
Not Applicable
REMOVAL
Not Applicable
INSTALLATION
Not Applicable
SERVICING
Not Applicable
STORAGE
15001
REWORK
Not Applicable
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LIST OF FIGURES
FIGURE
PAGE
Figure 1. WELS Control Unit (WCU) ..........................................................................................................3
Figure 2. J1 Connector Insert Arrangement .............................................................................................10
Figure 1001. WCU Test Setup .............................................................................................................1005
Figure 1002. WCU Test Program V1.V00 – Comm Menu – Connected State ....................................1007
Figure 1003. WCU Test Program – (Tester) Self Test Menu ...............................................................1008
Figure 1004. WCU Test Program V1.V00 – Comm Menu – Disconnected State ................................1009
Figure 1005. WCU Test Program – WCU AutoRun Menu ...................................................................1011
Figure 1006. WCU Test Program – WCU Main Status Menu ..............................................................1013
Figure 1007. WCU Test Program – Message Menu – Over Voltage ...................................................1014
Figure 1008. WCU Test Program – WCU Outputs Status Menu .........................................................1015
Figure 1009. WCU Test Program – WCU Configuration Menu ............................................................1020
Figure 1010. WCU Test Program – WCU Configuration Menu ............................................................1021
Figure 1011. WCU Test Program – WCU Configuration Menu ............................................................1022
Figure 1012. WCU Test Program – WCU EEPROM Test and Initialization Menu ..............................1026
Figure 1013. WCU Test Program – Message Menu ............................................................................1026
Figure 1014. WCU RF Test Setup ........................................................................................................1028
Figure 1015. WCU Final Verification Test Setup with WELS Test Box PC ..........................................1031
Figure 1016. Message Menu – CAN Message ....................................................................................1032
Figure 1017. WCU Final Verification Test Setup with Interface and ARM Boards ..............................1033
Figure 1018. Equipment Setup for Programming WCU .......................................................................1053
Figure 1019. SAM-PROG v2.3 Menu ...................................................................................................1055
Figure 1020. SAM-PROG Download Status ........................................................................................1056
Figure 2001. WELS Control Unit Schematic ........................................................................................2003
Figure 3001. WELS Battery Unit Removal ...........................................................................................3002
Figure 7001. Front Case Adhesive Channel ........................................................................................7004
Figure 8001. WELS Control Unit Fits and Clearances .........................................................................8002
IPL-Figure 1. WELS Control Unit Assembly .......................................................................................10006
IPL-Figure 2. Electronic Assembly .....................................................................................................10008
LIST OF TABLES
TABLES
PAGE
Table Intro 1. Applicable Documents.................................................................................................. Intro-1
Table 1. Measurement Parameters ............................................................................................................9
Table 2. WCU Connector J1 Pin Assignments .........................................................................................11
Table 3. Leading Particulars .....................................................................................................................12
Table 1001. Technical Support and Data Package(s) / Test Specifications ........................................1001
Table 1002. Special Tools, Fixtures, and Test Equipment ...................................................................1003
Table 1003. WCU Acceptance Test Data Sheet ..................................................................................1035
Table 3001. Consumable Materials ......................................................................................................3001
Table 4001. Consumable Materials ......................................................................................................4001
Table 7001. Consumable Materials ......................................................................................................7001
Table 9001. Consumable Materials ......................................................................................................9001
Table 9002. Special Tools, Fixtures, and Test Equipment ...................................................................9002
Table 10001. Vendor Code List ..........................................................................................................10004
Table 15001. Consumable Materials ..................................................................................................15001
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INTRODUCTION
TASK 33-50-01-99F-801-A01
1.
General Information
SUBTASK 33-50-01-99F-001-A01
A.
Introduction
(1)
This Component Maintenance Manual (CMM) has the maintenance instructions for
the WELS Control Unit (WCU). Securaplane Technologies of Tucson, AZ, U.S.A.
makes the WCU.
(2)
This CMM has the off-aircraft procedures for the WELS Control Unit (WCU). This
CMM is not for use by a mechanic working on a WCU installed on the aircraft. The
WCU must be returned to Securaplane or a facility approved by Securaplane for
repair.
SUBTASK 33-50-01-99F-002-A01
Equipment Identification
(1)
The configuration of the equipment is shown by part number, dash number, series
number, and MOD number marked on the identification label.
NOTE:
Incorporated MOD status is indicated on the WCU identification label by
blackened MOD circle(s).
SUBTASK 33-50-01-99F-003-A01
C.
Applicable Documents
(1)
The reference documents related to the WCU are listed in Table Intro 1.
Table Intro 1. Applicable Documents / TABLE 33-50-01-99A-001-A01
Documents
Document Number
Abbreviated Component Maintenance Manual, WELS
Antenna Unit (WAU), 33-50-02
Securaplane
MM-0211-01
Abbreviated Component Maintenance Manual, WELS
Battery Unit (WBU), 33-50-03
Securaplane
MM-0212-01
Operator’s Manual, Securanet Field Strength
Measurement System, 23-00-01
Securaplane
OM-1013-01
33-50-01
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SUBTASK 33-50-01-99F-004-A01
D.
Product Support Services
(1)
Product support for the WCU is available from Securaplane at:
Securaplane
10831 Mavinee Drive
Tucson AZ 85737 USA
Email: support@securaplane.com
CAGE Code: 0TMJ9
Tel:
1-520-297-0844
Fax
1-520-498-4924
Web: www.securaplane.com
SUBTASK 33-50-01-99F-005-A01
E.
Verification Dates
(1)
Dates of Shop Verification by actual performance:
Testing and Fault Isolation
Disassembly
Assembly
Verified TBD
Verified TBD
Verified TBD
Engineering Technical Review
Completed TBD
SUBTASK 33-50-01-99F-006-A01
F.
Revision Service
(1)
This CMM is written in agreement with the Air Transport Association of America
iSpec 2200 and AECMA Simplified English guidelines.
(2)
A complete revision of this manual will be issued when necessary throughout the
service life of the unit.
(3)
A change bar in the margin will identify the revised text. If the entire page has
changed, a change bar will appear in the lower right corner.
SUBTASK 33-50-01-99F-007-A01
G.
Electrostatic Discharge
(1)
The items susceptible to electrostatic discharge are handled in agreement with
IPC-A-610. Refer to the IPC-A-610C specification Sections 3.2 and 3.3 for the
definition of the standards and conditions.
SUBTASK 33-50-01-99F-008-A01
H.
Maintenance Task Oriented Support System (MTOSS)
(1)
The Maintenance Task Oriented Support System (MTOSS) system uses standard
and unique number combinations to identify maintenance tasks and subtasks. The
MTOSS numbering system includes the ATA chapter-section-subject number as well
as a function code and unique identifiers. The purpose of the MTOSS numbering
system is to provide a means for the automated sorting, retrieval and management
of digitized data.
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SUBTASK 33-50-01-99F-009-A01
J.
Abbreviations
(1)
Abbreviations which may be used in this manual are defined below.
Abbreviation
Nomenclature
Abbreviation
Nomenclature
Ampere
LRU
Line Replaceable Unit
AC
Alternating Current
mA
Milliamperes
AOG
Aircraft on Ground
MAX
Maximum
ASSY
Assembly
MM
Millimeter(s)
ATA
Air Transport Association
MOD
Modification
BITE
Built-in-Test Equipment
NHA
Next Higher Assembly
Celsius and/or Centigrade
No.
Number
CAGE
Commercial and
Government Entity
ORIG
Original
OZ
Ounce
CM
Centimeter(s)
PN
Part Number
CMM
Component Maintenance
Manual
PSIG
Pounds (each) square inch
gage
CONT
Continued
Qty
Quantity
DC
Direct Current
REF
Reference
EIA
Electronic Industry
Association
REV
Revision
Fahrenheit
SB
Service Bulletin
FAA
Federal Aviation
Administration
SI
Standards International
ST
Street
FIG.
Figure
TBD
To Be Determined
FT
Feet
TR
Temporary Revision
Hz
Hertz
TYP
Typical
IEC
International Electrotechnical
Commission
USA
United States of America
IEEE
Institute of Electrical and
Electronics Engineers
Volt(s)
VAC
Volts Alternating Current
INC
Incorporated
VDC
Volts Direct Current
INTRO
Introduction
Watt
IPL
Illustrated Parts List
WAU
WELS Antenna Unit
IRE
Institute of Radio Engineers
WBU
WELS Battery Unit
KG
Kilogram(s)
WCU
WELS Control Unit
KPA
Kilopascal(s)
WELS
LB
Pound(s)
Wireless Emergency Lighting
System
LED
Light Emitting Diode
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DESCRIPTION AND OPERATION
TASK 33-50-01-870-801-A01
1.
Description
SUBTASK 33-50-01-870-001-A01
A.
Introduction
(1)
This section has the physical description and operation for the WELS Control Unit
(WCU).
SUBTASK 33-50-01-870-002-A01
B.
WELS Control Unit (WCU) Radio Transceiver General Design Information
(1)
The WCU radio transceiver utilizes the unlicensed 2.4 GHz Industrial Scientific
Medical (ISM) band and operates in a frequency Hopping Spread Spectrum (FHSS)
mode to combat frequency interference.
(2)
The WCU system frequency band is 2400 to 2483.5 M Hz. The WELS operational
frequency band is comprised of 79 FHSS RF channels spaced 1 MHz apart.
(3)
To comply with out-of-band regulations in each country a guard band is used at the
upper and lower band edge.
•
•
(4)
The lower guard band is 2 MHz
The upper guard band is 3.5 MHz
The design for radio transmitter power is classified as follows:
•
•
•
Minimum design output is 0.25 mW (-6 dBm)
Nominal design output is 1 mW (0 dBm)
Maximum design output 2.5 mW (4 dBm)
(5)
The WCU uses an internal antenna for most installations. The WCU also has a
provision for an external antenna if the WCU is installed in an area of the aircraft not
conducive for operation with the internal antenna.
(6)
The WCU uses one of two antennas depending on the location of the node within the
aircraft. In the nominal case, each node will select its internal antenna. In areas
where signal strength or node placement is an issue, nodes will use the external
antenna.
(7)
Antenna selection is accomplished via pin programming set by the wire harness at
the node location.
(8)
The internal antenna is a ¼ wave microstrip located adjacent to the programmable
switch on the PWB (part of WCU p/n 100-2601-01). The other switch output feeds a
SMA connector on the WCU and connects via coax to the approved external patch
antenna (part number 100-2600-012) positioned to radiate to one or more other
control units. Both antennas are designed and implemented by Securaplane
Technologies. No other external antenna is approved for use on the assembly.
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(9)
The power limits specified are dictated by the class 2 Bluetooth radio transmitter
implemented in the control unit as shown per the following:
Antenna
Gain (dbi)
2402
2480
MHz
MHz
Internal Microstrip
-2.45
-3.4
¼ wave dipole
External
2.73
1.11
Patch
Type
Manufacturer
Power
Notes
Securaplane
Technologies
Securaplane
Technologies
0.25mw (-6dBm)
– 2.5mW (4dBm)
0.25mw (-6dBm)
– 2.5mW (4dBm)
Integrated on
WCU PCB
Replaceable
SUBTASK 33-50-01-870-003-A01
C.
WCU Description
(1)
The WCU is part of the Wireless Emergency Lighting System (WELS). The WELS
system will provide illumination and signage to enable passengers and crew to
evacuate the aircraft in an emergency.
(2)
The WELS system will employ 28 WCU’s to provide standalone short time power to
the emergency lighting on a distributed basis. In addition another WCU may be
installed to control the lights and signs inside the crew rest area.
(3)
Each WCU is electrically identical. However each WCU is configurable to function as
master prime unit, subordinate prime unit, crew rest remote unit, or other remote
units. The configuration (location, class, or function) of a WCU is defined by pin
strapping on its aircraft interface connector in conjunction with a loadable
configuration data base.
(4)
In a baseline configuration, one WCU will be assigned as the prime unit; three
WCU’s will be assigned as subordinate prime units, while all other WCU’s will be
assigned as remote units.
(5)
All prime units will receive airplane status, control state data, configuration database
downloads, BITE requests from the aircraft central computing resource via a wired
CAN Bus. However only the master prime unit can send status to the aircraft central
computer resource via the CAN Bus. No remote unit will be connected to the CAN
Bus. All prime units communicate to the remote units via Bluetooth wireless links. In
addition the prime units communicate to each other also via Bluetooth wireless links.
In some situations where a remote unit or prime unit does not have reliable direct
wireless access to a prime unit its wireless access will be indirect through a nearby
remote unit. This network of interconnected Bluetooth piconets is referred to as a
mesh network.
(6)
The WCU consists of a battery charger powered from the aircraft 115VAC bus, a
battery pack subsystem referred as the WELS Battery Unit (WBU), six lamp drivers
that apply or disconnect battery voltage to separate strings of emergency lights, a
Bluetooth wireless interface, a CAN Bus wired interface, a microprocessor based
controller, a tri level control input which conveys the state of the emergency lighting
system to the prime WCU’s, and pins that are jumpered by the aircraft wire bundle to
convey the hierarchy and lighting load of the WCU.
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(7)
The WCU is a small plastic assembly that contains the wireless control unit’s
electronics and replaceable battery pack. The assembly consists of the plastic case,
the printed wire assembly, the battery pack, three Nylatch mounting fasteners, a
battery latch, an I/O interface connector, and an antenna connector. The WCU is
shown in Figure 1.
WELS Control Unit (WCU)
Figure 1 / GRAPHIC 33-50-01-99B-001-A01
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TASK 33-50-01-870-802-A01
2.
Operation
SUBTASK 33-50-01-870-004-A01
A.
WCU Operation
(1)
The WCU requires a Wireless Battery Unit (WBU) in order to operate. The WBU is a
replaceable battery pack that plugs into the WCU.
(2)
115 VAC Input.
(a)
The WCU receives a single phase, 360 to 800 Hz, 100 to 122VAC nominal
(90 to 134VAC abnormal steady state) power from the aircraft to operate the
battery charger portion of the WCU. All other portions of the WCU are
powered from the output side of the battery charger.
(b)
The WCU will not draw an input Volt Amp product in excess of 10.5 VA
during charging of batteries.
NOTE:
10.5VA corresponds to a 115VAC off line charger having a power
factor of 0.8 and efficiency of 75% operating from an input line
filter loading the line with 0.1uF capacitance and delivering 8.2V
at 0.75 A to the battery.
NOTE:
The AC input to the WCU is fused to prevent propagation of
damage in the event of a component failure in the WCU.
(c)
The WCU will employ an input common mode line filter of sufficient order
and low cutoff frequency to prevent common mode voltages and currents
generated by the battery charger from conducting emissions into the aircraft
wire bundle at levels in violation of EMC requirement D6-16050-5 sections
8.1.2, 8.2.1.
(d)
The WCU is capable of withstanding AC voltage transients 156% of nominal
lasting 100ms without damage.
(For Reference Only: A 156% transient corresponds to a 254V peak
difference across the AC input.)
(e)
The WCU monitors for the presence or absence of 115VAC power. This
status reports to the controller block as a switch closure (power present) or a
switch open (power absent) on the digital input line AC_ON#.
NOTE:
(3)
The controller block in turn will convert the switch open to a logic
high via a resistive pull-up. The controller block will use this
status in an algorithm to determine when to activate emergency
lighting. The controller block will not declare the 115VAC as
absent for interruptions of voltage lasting less than 0.25 second.
CAN Interface.
(a)
The WCU supports communications with the aircraft 1Mbps CAN bus via a
CAN 2.0 transceiver and 3 pins on the external connector: CANH, CANL,
CAN_SHIELD. The WCU contains no bus terminations. The CAN_SHIELD
is not grounded at the WCU.
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(4)
(5)
Pin Strapping Inputs.
(a)
The controller block reads the presence or absence of jumpers in the aircraft
wire bundle that tie 5 individual pairs of pins (ID1-ID5 respectively to
ID1_RTN-ID5_RTN respectively) together on the WCU external connector.
The controller block converts this reading into an ID that will point into a
downloaded configuration database as to the class of lighting load the WCU
is expected to support.
(b)
The controller block will also detect the presence or absence of a jumper in
the aircraft wire bundle across the CRTL_ENABLE and
CTRL_ENABLE_RTN pins on the WCU external connector. If the jumper is
present then the WCU is a prime unit and is connected to the CAN bus and
the tri level control line. If the jumper is absent than the WCU is a remote
unit.
System Control Input.
(a)
(6)
Each prime WCU unit measures the DC voltage on the CONTROL pin
relative to the SIGNAL GROUND pin on the WCU external connector to
determine the control state of the WELS. Based on this measurement the
controller block of the prime WCU unit defines the WELS as in one of three
control states:
STATE
MEASURED VOLTAGE
ON
0V to +6V
OFF
>+6V to +15V
ARMED
>+15V
Battery Loop In Out.
(a)
To disconnect the battery charger and other active WCU circuitry from the
battery pack subsystem (WBU) so that the battery pack maintains its charge
whenever the WCU is disconnected from the aircraft wire bundle, the battery
charger bus (VB) and the battery pack bus (B+) will be electrically isolated
and routed to the BATTERY LOOP IN and BATTERY LOOP OUT pins
respectively on the WCU external connector. When the WCU is plugged into
the aircraft wire bundle a jumper in the bundle connects the pins together.
This jumper is of sufficiently short length that it does not intrude into the
lighting zone of the aircraft wire bundle.
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(7)
(8)
Lamp Driver Outputs.
(a)
The WCU will route the battery charger bus (BATTERY LOOP IN pin on the
WCU external connector) to six overcurrent protected switchable lamp
drivers circuits. The six lamp drivers in turn will connect to six pins
(OUT1 – OUT6 respectively) on the WCU external connector. The OUT1 –
OUT6 pins in turn pair up with the OUT1_RTN – OUT6_RTN pins
respectively on the WCU external connector to mate via the aircraft wire
bundle connector to up to six twisted wire pairs in the aircraft wire bundle.
Each twisted wire pair provides power to a set of emergency light fixtures.
The OUT1_RTN – OUT6_RTN pins will connect to the circuit ground plane
which the lamp drivers reside on.
(b)
Each lamp driver will be capable of sourcing 1.18 A continuously (6.9 watts
at 5.85 to 8.2v) with a voltage drop between its input and output not
exceeding 150mv at maximum ambient temperatures yet will trip on a
overcurrent that exceeds 1.5A for more than 400 microseconds. During a trip
the lamp driver will automatically open the connection between its input and
output and report the trip as an active high digital output (OUT_1_OC –
OUT_6_OC) to the controller block. The lamp driver will remain in trip until
the controller block issues an active low reset command (OUT_RESET#)
common to all lamp drivers.
(c)
Each lamp driver will have an active low dedicated digital input
(OUT_1_CMD# – OUT_2_CMD#) which the controller block can use to
command the lamp driver to close the connection between its input and its
output provided the lamp driver is out of trip.
(d)
Each lamp driver will measure the current that it is sourcing and report the
measurement as an analog voltage (OUT1_I – OUT6_I) to the controller
block’s A/D converter. Each lamp driver will detect when its output voltage is
above 2.5v and report the detection as an active low digital output
(OUT_1_VBIT# – OUT_6_VBIT#) to the controller block.
Battery Charger.
(a)
The battery charger is an off line flyback type current mode operated
switching power converter with a magnetically isolated battery level
regulated output controlled via an opto coupler isolated voltage and current
sensing feedback loop.
(b)
The off line converter incorporates full wave AC to DC line rectification,
inrush current limiting and choke input bulk DC filtering to maintain a
minimum AC power factor of 0.8 for all charger output loads up to and
including 0.75A -10% and to limit inrush current during initial application of
115VAC power to 16A peak.
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(9)
(c)
The feedback loop of the converter regulates the output by observing two
error signals, one the difference between the voltage sensed and a voltage
set point and the other the difference between the current sensed and a
current set point. The two error signals after separate loop filter
compensation /amplification are diode OR’d to form the drive signal to the
converter pulse width modulator. An increase in drive voltage reduces the
duty factor of the modulator to reduce current delivered to the output. The
current sensed will also be converted to a low pass filtered analog voltage
CHG_I and sent to the controller block’s A/D converter for further monitoring.
The voltage sensed will also be converted into an analog voltage VF_MON
and sent to the controller block’s A/D converter for further monitoring.
(d)
The current set point will be selectable by the micro controller via a digital
control input LOW_I. The current set point will be 0.75A +/-10%, 0.15A
+/-10% respectively for a logic low, logic high respectively at this input. The
voltage set point will be fixed at 8.2V +/-0.2V.
(e)
The converter will be disabled or enabled by the micro controller via a digital
control input: CHG_DISABLE. A logic high at this input prevents the
converter switch transistor from turning on. A logic low allows normal
operation.
(f)
The converter output will connect to the battery charger bus (VB) through a
series diode to prevent converter circuitry that is powered from the converter
output from discharging the battery pack whenever the converter is disabled
or not receiving AC power. The converter voltage sense will be at the battery
charger bus (VB) side of the series diode. The voltage sense will not draw
more than 150 microamps from the bus when the converter is not operating.
Bluetooth Wireless Interface.
(a)
The WCU will contain a complete, version 2.0 compliant, class 2 power
level, basic rate Bluetooth radio subsystem to support wireless
communications between WCU’s at ranges up to 10 meters maximum.
(b)
The radio subsystem consists of the following components:
•
Integrated Bluetooth baseband controller/ RF transceiver module with
external crystal.
•
RF dielectric BPF to reduce receiver desensitization from out of band
interferences.
•
Antenna switch to connect BPF and transceiver to internal antenna or to
RF connector.
•
Internal Printed Inverted F (PIFA) antenna located at the edge of the
PCB card well away from the battery charger and on the opposite side of
the card from the battery pack (WBU) to optimize the antenna radiation
pattern.
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•
RF connector to allow connection to an external antenna in cases where
the WCU is located next to RF absorbent materials and is unable to
establish a reliable wireless link to any other WCU.
•
Local low noise dual linear voltage regulator preceded by an input LC
ripple filter.
(c)
The WCU will utilize a National Semiconductor LMX5453 integrated
Bluetooth 2.0 baseband controller/ RF transceiver module. The frequency
reference for the module will be a 13.0 MHz crystal with an ESR of <100
ohms for low oscillator sideband noise and with an accuracy of better than
15 ppm from -15 to +55 deg C to insure that the cumulative frequency
accuracy of the complete radio is always within 20 ppm.
(d)
The module will interface to the controller block via its UART port (module
pins TXD, RXD, RTS#, CTS#).
NOTE:
(e)
(f)
(10)
The signal naming of these module pins is as if the module is
Data Terminal Equipment and not Data Set Equipment. That is,
RTS# and TX are outputs whereas CTS# and RX are inputs. To
prevent confusion, the interface lines from the controller block to
module pins TXD, RXD, RTS#, CTS# will be called BT_TXD,
BT_RXD, BT_RTS#, BT_CTS# respectively.
The internal antenna identified earlier in this section will have characteristics
equal to or better than the following:
•
Center Frequency:
2442 MHz
•
Input Impedance:
50 ohms nominal
•
Return Loss vs Frequency:
10 dB min from 2400 to 2485 MHz
•
Peak Gain (typ) vs Frequency:
+ 3dBi at 2442 MHz, 0 dBi at
2402 MHz or 2480MHz.
The external RF connector is a SMA female bulkhead right angle PCB
mount connector.
Controller Block
(a)
The controller block consists of the following components:
•
Atmel AT91SAM7X256 32-bit RISC microcontroller.
•
18.432 MHz crystal to control the frequency of the microcontroller.
•
256kbit serial EEPROM.
•
4Mbit serial FLASH memory.
•
JTAG connector to load the initial program.
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(b)
•
DEBUG PORT connector for initial debugging.
•
POR chip to initialize the microcontroller at power up.
•
8 channel analog mux to select and route one of the OUT_1 to OUT_6
signals to an A/D input of the microcontroller.
•
CAN Bus 2.0 transceiver.
•
Dual linear voltage regulator to convert the battery charger bus voltage
(VB) to supply voltages (3.3V, 5V) required for all digital logic within the
WCU except the Bluetooth wireless block.
The Atmel microcontroller internal features include a CAN interface,
64kbytes of SRAM, 256kbytes of FLASH memory, an 8 channel 10-bit
resolution ADC, etc. The integral non-linearity, offset error, and gain error of
the ADC is +/- 3, +/- 2, +/-2 bits maximum respectively. Assuming the ADC
reference is connected to the 3.3V (+/- 2.9 %) output of the dual linear
regulator then the input scaling/ADC chain will measure the following
parameters to within the uncertainties shown in Table 1.
Table 1. Measurement Parameters / TABLE 33-50-01-99A-002-A01
Parameter
Sensed
Measurement
Uncertainty
Value
Input Scaling
Sys cntrl i/p
voltage
12V
0.1350 V/V
+/- 4.0 %
(CONTROL – CONTROL_RETURN)
Lamp driver
current
1.0A
2.0 volts/amp
+/- 3.9 %
(via OUT_1 – OUT_6 signals)
Charger output
current
0.75A
3.16volts/amp
+/- 3.6 %
(via CHG_I signal)
Charger bus
voltage
8.4V
0.3329 V/V
+/- 3.4 %
(VB)
NOTE:
The uncertainties listed here were estimated from a statistical assumption that all contributions to
the total uncertainty are statistically independent and that the variance of the total uncertainty is
equal to the sum of the variances of the individual contributors.
(c)
The microcontroller will shutdown or enables the 5V output of the dual linear
regulator by applying a logic low or logic high respectively to the
5V_ENABLE digital input of the regulator.
NOTE:
The 3.3V output of this regulator is always enabled since this
output provides the supply voltage to the microcontroller.
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SUBTASK 33-50-01-870-005-A01
B.
WCU External Electrical Interfaces
(1)
The WCU has two electrical connectors. The I/O Interface Connector, designated J1,
brings in airplane power and signals as well as sends out power to the emergency
lights and signs. The Antenna Connector, designated J4, is used to connect to the
Wireless Antenna Unit in locations where the remote antenna is needed. See
Figure 2 for the WCU J1 connector layout.
NOTE:
If the WAU is not needed install the dust cap on the antenna connector.
J1 Connector Insert Arrangement
Figure 2 / GRAPHIC 33-50-01-99B-002-A01
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(2)
The J1 pin out assignments is shown in Table 2.
Table 2. WCU Connector J1 Pin Assignments / TABLE 33-50-01-99A-003-A01
J1 Pin
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
Signal
115 VAC
115 VAC Return
Reserved
Driver # 1
Driver # 1 Return
Driver # 2
Driver # 2 Return
Driver # 3
Driver # 3 Return
Driver # 4
Driver # 4 Return
Driver # 5
Driver # 5 Return
Driver # 6
Driver # 6 Return
ID # 1
ID # 1 Return
Reserved
Reserved
Reserved
ID # 2
ID # 2 Return
ID # 3
ID # 3 Return
ID # 4
ID # 4 Return
ID # 5
ID # 5 Return
Battery Loop Out
Battery Loop In
Control Enable
Control Enable Return
CANH
CANL
CAN Shield
Control Return
Control
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TASK 33-50-01-870-803-A01
3.
Leading Particulars
SUBTASK 33-50-01-870-006-A01
A.
WCU Leading Particulars
(1)
The leading particulars for the WCU are shown in Table 3.
Table 3. Leading Particulars / TABLE 33-50-01-99A-004-A01
Parameter
Specification
Power:
Input voltage
115 VAC
Physical:
Height
2.06 inches (52.32 mm) maximum
(including the plunger and grommet)
Width
4.43 inches (112.52 mm) maximum
Length
6.02 inches (152.91 mm) maximum
Weight
0.51 ± 0.05 lbs (0.23 ± 0.023 kg)
(Without WELS Battery Unit)
Bluetooth:
Wireless interface
Version 2.0 compliant, class 2 power level
Range
10 meters maximum
Frequency band
ISM band of 2.4 to 2.485 GHz
Maximum transmit lever
+4dBm
Operating Environment
MINIMUM
MAXIMUM
-67°F (-55°C)
185°F (85°C)
Short Term Operation
-40°F (-40°C)
158°F (70°C)
Continuous Operation
5°F (-15°C)
131°F (55°C)
Normal Ground Operation
–
113°F (45°C)
Normal Flight Operation
–
86°F (30°C)
Case Temperature
–
203°F (95°C)
Ground Survival
Temperature
Connectors:
J1 Circular Connector
BACC63CU15-35PN (MIL Standard D38999/20MD35PN)
J1 Mating Connector
BACC63CT15-35SN (MIL Standard D38999/26MD35SN)
J4 Antenna Connector
SMA RF Connector, mates with WELS Antenna Unit
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TESTING AND FAULT ISOLATION
TECHNICAL SUPPORT AND DATA PACKAGE
1.
Introduction
A.
2.
This section describes the Return-To-Service test (RTS) for the Unit-Under-Test (UUT).
The RTS is derived from the Technical Support and Data Package (TSDP) shown in
Table 1001.
Technical Support and Data Package (TSDP)
A.
The TSDP and Test Specification can be ordered from the address shown in paragraph 3.
The Test Specification is the basis for the specified TSDP and the shop verified procedure in
this CMM.
Technical Support and Data Package(s) / Test Specifications
Table 1001
UUT
PART NUMBER
100-2601-01
3.
TEST SPECIFICATION
PART NUMBER/REVISION
210-2601-03 / Rev C
TSDP
PART NUMBER/REVISION
291-0001-01 / Rev –
Ordering Information
A.
The TSDP can be ordered from:
Securaplane
10831 Mavinee Drive
Tucson AZ 85737 USA
Email: support@securaplane.com
CAGE Code: 0TMJ9
Tel:
1-520-297-0844
Fax
1-520-498-4924
Web: www.securaplane.com
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TESTING AND FAULT ISOLATION
TASK 33-50-01-99F-802-A01
1.
General Information
SUBTASK 33-50-01-99F-010-A01
A.
Introduction
WARNING:
BEFORE MATERIALS CALLED OUT IN THIS PUBLICATION ARE USED,
KNOW THE HANDLING, STORAGE, AND DISPOSAL PRECAUTIONS
RECOMMENDED BY THE MANUFACTURER OR SUPPLIER. FAILURE
TO FOLLOW THE MANUFACTURERS’ OR SUPPLIERS’
RECOMMENDATIONS CAN RESULT IN PERSONAL INJURY OR
DISEASE.
CAUTION:
THESE PROCEDURES MUST BE DONE AT A STATIC-FREE
WORKSTATION IN ORDER TO PREVENT DAMAGE TO
ELECTROSTATIC SENSITIVE COMPONENTS.
CAUTION:
THIS UNIT HAS ASSEMBLIES THAT ARE SUSCEPTIBLE TO DAMAGE
FROM INCORRECT HANDLING. DO NOT DROP OR HIT THE UNIT
DURING THESE PROCEDURES.
CAUTION:
THESE PROCEDURES MUST BE DONE IN A CLEAN ENVIRONMENT IN
ORDER TO PREVENT DAMAGE TO MECHANICAL COMPONENTS.
(1)
This section has the testing and fault isolation information for the WELS Control Unit
(WCU).
TASK 33-50-01-94B-801-A01
2.
Equipment and Materials
SUBTASK 33-50-01-94A-001-A01
A.
Consumable Materials
(1)
No consumable materials are needed for Testing and Fault Isolation procedures.
SUBTASK 33-50-01-94B-001-A01
B.
Special Tools, Fixtures, and Test Equipment
(1)
Special tools and test equipment used during the Testing and Fault Isolation
procedures are shown in Table 1002.
NOTE:
Equivalent alternatives can be used.
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Special Tools, Fixtures, and Test Equipment
Table 1002 / TABLE 33-50-01-99A-005-A01
Equipment
Characteristics
WELS Test Box
WCU Main Test Cable
Battery Simulator Module
Battery Simulator Cable
WELS Battery Unit (Fully Charged
to 8.4 Volts)
Standard FF RS232
Communication Serial Cable
(DB9 to DB9)
Computer
TE-1128-01
160-2275-01
TE-2637-01
TE-2633-01
100-2602-01
WCU Test Program, V1.V00
WCU Main Test Code
(8MB Flash-U35)
WCU RF Test Code
WELS 787 Operational SW Code
BlueTest2 Software
Bluetooth Test Set
Adapter Cable (and windows
driver)
Direct Connection Antenna Cable
Omnidirectional Antenna
Digital Multimeter
J-Link (USB to JTAG
Debugger/Programmer)
SAM-PROG v2.3 (or later)
Accuracy
AK152-2-R
Commercially
available
Microsoft Windows XP
Professional Operating
System with (2) available USB
Ports and (1) available Serial
Port.
512 MB RAM (memory)
10 MB of hard disk space
available. PC must also have
access to a printer.
050-0224-07341 Rev 050-0232-08031 Rev -
Commercially
available
050-0230-07341 Rev 050-0211-08237 Rev Version 1.0.0 Rev 1 (or later)
Anritsu MT8852A
National Instruments
GPIB-USB-HS
Pasternack PN PE3876-60
(5 feet in length
recommended)
Antenova PN 2010B4844-01
True RMS Multimeter
0 to 10 VDC (Fluke 87)
IAR Systems
V0TMJ9
V0TMJ9
V0TMJ9
V0TMJ9
VU4252
VU4252
V64667
V53919
1%
Atmel Corp
V53919
V89536
V1QQS1
V1FN41
33-50-01
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Source or
(CAGE)
V0TMJ9
V0TMJ9
V0TMJ9
V0TMJ9
V0TMJ9
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TASK 33-50-01-700-801-A01
3.
Test Procedures
SUBTASK 33-50-01-700-001-A01
A.
Test Requirements
(1)
Do all tests with the test unit at the following conditions, unless otherwise specified
by an individual test procedure.
Ambient room temperature
Humidity
Input Voltage
+68 to 86°F (+20 to 30°C)
Ambient up to 85% relative
115.0 ± 5 VAC
(2)
Regularly examine and certify instrument accuracy/calibration in accordance with
applicable government and commercial specifications.
(3)
Visually inspect the unit for signs of missing, broken, bent or cracked parts.
Damaged parts must be replaced before the unit is tested.
(4)
Unless otherwise specified, all tolerances are ±1%.
(5)
Disassemble the WCU to subassembly level per the DISASSEMBLY section.
(6)
The test setup for the WCU is shown in Figure 1001.
NOTE:
Before any tests are performed, ensure the WELS Battery Unit (WBU) is
not still installed in the WCU. If the battery is installed continue to the
DISASSEMBLY section for battery removal instructions.
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WCU Test Setup
Figure 1001 / GRAPHIC 33-50-01-99B-003-A01
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TASK 33-50-01-700-802-A01
4.
WCU Test Procedures
NOTE:
This section contains the test procedures for verifying the correct performance of the
WCU.
NOTE:
The initial WCU Test Set Up uses the WELS Test Box to provide DC power (Simulated
Battery Power) to the UUT. The setup uses the “Battery Simulator Board” to measure the
WCU regulated voltages, battery EEPROM verification, battery temperature read back
and to support JTAG programming of the WCU microcontroller.
NOTE:
Record all measurements on the WCU Acceptance Test Data Sheet in Table 1003.
SUBTASK 33-50-01-700-002-A01
A.
WELS Test Box Calibration Test
The WELS Test Box performs a Self-Test on power up. The Self-Test results are
displayed on the WCU TEST PROGRAM (Tester) Self-Test Menu in the Windows
WCU Test Program. Refer to Figure 1001 for test setup.
NOTE:
(1)
Connect the standard FF RS232 serial cable between the Test Box Serial Connector
(SC1) and the PC serial port (COM1) connector. Do not connect the remaining
cables.
(2)
Connect AC Power cable to the AC connector on to the WELS Test Box but do not
power up the Test Box at this time. Ensure the “AC ARM / AC DISABLE” switch on
the top of the Test Box is set to “AC DISABLE”. All 6 of the ID switches should be
set to the “TEST” position.
(3)
Turn ON the WELS Test Box “MAIN POWER” switch.
(4)
Power-up the PC and log in. Run the Windows WCU Test Program on the PC.
(a)
The WCU Test Program will automatically establish a connection between
the WCU Test Program and the WELS Test Box. Refer to the WCU Test
Program V1.V00 – Comm Menu as shown in Figure 1002.
(b)
Once a good connection is established the Tester Status box will switch from
“FLT” to “OK”, the UUT box will display “99” and the RX Status indicator will
display a flashing green dot. Refer to Figure 1002.
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WCU Test Program V1.V00 – Comm Menu – Connected State
Figure 1002 / GRAPHIC 33-50-01-99B-004-A01
(5)
Verify the following results in the WCU Test Program – (Tester) Self Test Menu.
Refer to Figure 1003.
NOTE:
The WCU Test Program – (Tester) Self Test Menu automatically displays
the same time as the WCU Test Program V1.V00 – Comm Menu.
(a)
Verify the A/D and Mux Signals report 3300mV +/-50mv (3.3V RB column)
and 0mV +/-25mV (GND RB column). Record voltages and Pass/Fail results
on the Data Sheet.
(b)
Verify the Control Voltage +/- reports 10000mV +/-500mV (+ Input column)
and 0mV +/-50mV (– Input column). Record voltages and Pass/Fail results
on the Data Sheet.
NOTE:
If these readings are out-of-tolerance, repair the WELS Test
Hardware before continuing.
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WCU Test Program – (Tester) Self Test Menu
Figure 1003 / GRAPHIC 33-50-01-99B-005-A01
(6)
Disconnect the communication link between the WCU Test Program and the WELS
Test Box by clicking on the “Disconnect TB” button in the WCU Test Program
V1.V00 - Comm Menu. Refer to Figure 1002.
(a)
Once the connection has ended the Tester Status box will switch from “OK”
to “FLT”, the UUT box will display “?” and the RX Status indicator will be
blank. Refer to Figure 1004.
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WCU Test Program V1.V00 – Comm Menu – Disconnected State
Figure 1004 / GRAPHIC 33-50-01-99B-006-A01
(7)
Turn OFF the Test Box “MAIN POWER” switch. Leave AC Power Cable connected
to Test Box.
SUBTASK 33-50-01-700-003-A01
B.
Initial WCU Power-Up
NOTE:
Refer to Figure 1001 for the test setup.
(1)
Carefully install the Battery Simulator Module in the WCU battery slot making sure
not to bend any connector pins.
(2)
Connect the WCU Main Test Cable from the WCU Main connector on the WELS
Test Box to the WCU I/O connector on the WCU under test.
(3)
Connect the Battery Simulator Cable from the WCU Battery connector on the WELS
Test Box to the DC Power Connector on the Battery Simulator Module.
(4)
Leave the Test Box “MAIN POWER” switch set to OFF and “AC ARM / AC
DISABLE” switch set to “AC DISABLE”.
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(a)
Using a Multimeter, verify greater than 5 Meg ohms resistance between the
following Test Box Interface Board Test Points. Record resistance values
and Pass/Fail results on the Data Sheet.
a) GND and ACL
c) BAT GND and ACL
b) GND and ACH
d) BAT GND and ACH
BE SURE TO DISCONNECT THE MULTIMETER FROM THE TEST
POINTS BEFORE CONTINUING.
CAUTION:
(5)
Ensure the “AC ARM / AC DISABLE” switch on top of the Test Box is in the “AC
DISABLE” position.
(6)
Turn ON the WELS Test Box “Main Power” switch.
NOTE:
The following instructions reference information presented in WCU Test Program
– Comm Menu. Refer to Figure 1002.
(7)
Click on the “Connect TB” button in the WCU Test Program – Comm Menu to
establish a connection between the WCU Test Program and the WELS Test Box.
(8)
Once a good connection is established the Tester Status box will switch from “FLT”
to “OK”, the UUT box will display “99” and the RX Status indicator will display a
flashing green dot.
(9)
The following menus will need to be displayed before continuing:
Display Self Test
Display UUT Main Status
Display UUT Outputs
Display UUT Config
Display UUT EEPROM
Display Message Menu
Display Program AutoRun
(10)
Select each menu that needs to be displayed by checking the box next to each Menu
description in the Menus section of the WCU Test Program V1.V00 – Comm Menu.
(11)
Click on the “Display Checked Menus” button to display the menus that are
selected.
NOTE:
The following instructions reference information presented in WCU Test Program
- AUTORUN MENU – Playback Macro Tab as shown in Figure 1005.
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WCU Test Program – WCU AutoRun Menu
Figure 1005 / GRAPHIC 33-50-01-99B-007-A01
(12)
Select file name “WCU_RecordC.log” in the Record Name dropdown menu.
(13)
Click on the “Open Playback File” button.
(14)
The “Next Message” button is used from this point to perform the following steps. Do
not follow the manual steps in this procedure unless you are troubleshooting. Follow
the instructions that are displayed in both the “Step Play Comments” and “Step Play
Line(s)” windows of the WCU Test Program – WCU AutoRun Menu – Playback
Macro Tab. Continue from the RF Tests section after the automated process is
complete.
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NOTE:
The following steps have been automated to streamline the test processes and to
ensure that all of the test steps are completed. Though this procedure was also
written to support manual test processes the operator is required to use the
automated test process. The manual test processes should only be used for
troubleshooting purposes. The automated test process is not fully automated at
this time. The operator must click the “Next Message” button to step through
each individual test process. Disregard any other command buttons that are
called out in the preceding sections. The “Next Message” button is the only
button that is used during the automated test process. The operator must flip
manual switches on the WELS Test Box when prompted to do so.
WHEN RUNNING THE AUTOMATED TEST PROCESS DO NOT CLICK
ON ANY OTHER COMMAND BUTTONS EXCEPT FOR THE “Next
Message” BUTTON. CLICKING ON ANY OTHER BUTTON WILL VOID THE
AUTOMATED TEST.
CAUTION:
(15)
Click on the “Next Message” button to begin the step through the following sections.
(16)
Turn ON the DC power by clicking on the “Turn DC On” button in the MAIN STATUS
MENU. Refer to Figure 1006.
(17)
(a)
Verify the MAIN STATUS MENU, OUTPUTS STATUS MENU and
CONFIGURATION MENU, continue to flash the message “Waiting on UUT
Reply” in the UUT Status area of each menu window. Record Pass/Fail
result on the Data Sheet.
(b)
Verify VB+/LD is 0mV +/-25mv in the Tester Status - ReadBk column.
Record voltage and Pass/Fail result on the Data Sheet.
(c)
Verify V3.3 is 0mV +/-50mv in the Tester Status - ReadBk column. Record
voltage and Pass/Fail result on the Data Sheet.
Turn OFF the DC power by clicking on the “Turn DC Off” button in the MAIN
STATUS MENU.
SUBTASK 33-50-01-700-004-A01
C.
WCU Communication and Read Back Test
NOTE:
The following instructions reference information presented in WCU Test Program
- MAIN STATUS MENU as shown in Figure 1006 and OUTPUTS STATUS MENU
as shown in Figure 1008.
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WCU Test Program – WCU Main Status Menu
Figure 1006 / GRAPHIC 33-50-01-99B-008-A01
(1)
Switch the “AC ARM / AC DISABLE” switch on the top of the Test Box to the “AC
ARM” position.
(2)
Turn ON the AC power by clicking on the “Turn AC On” button in the MAIN STATUS
MENU.
The MAIN STATUS MENU, OUTPUTS STATUS MENU and CONFIGURATION
MENU, will display read back values in the UUT Status area once CAN
communication is established between the WELS Test Box and the UUT. If the
Menu windows continue to flash the “Waiting on UUT Reply” message, after AC
power has been turned on, the Test Software may not have been loaded into the
Microcontroller Flash Memory. Refer to the “Write Main Test Software to
Microcontroller Flash Memory” in the Test Software Programming Procedure
section for instructions on how to download the test software.
NOTE:
(3)
Verify the following results in the MAIN STATUS MENU. Reference Figure 1006.
(a)
Verify Control V is 10000mV +/-500mV in the UUT Status – ReadBk column.
Record voltage and Pass/Fail result on the Data Sheet.
(b)
Verify AC ON/ON state is “Y” in both the UUT Status and Tester Status –
State columns. Record Pass/Fail result on the Data Sheet.
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(c)
Verify charger state is “E” in the UUT Status – State column. Record
Pass/Fail result on the Data Sheet.
(d)
Verify VB+/LD is 8000mV +/-500mv in the UUT Status - ReadBk column.
Record voltage and Pass/Fail result on the Data Sheet.
(e)
Verify VB+/LD is 8000mV +/-500mv in the Tester Status - ReadBk column.
Record voltage and Pass/Fail result on the Data Sheet.
(f)
Verify VB+/OV ReadBk voltage is less than 100mv in the Tester Status ReadBk column. Record voltage and Pass/Fail result on the Data Sheet.
(g)
Verify V3.3 is 3300mV +/-100mV in the Tester Status – ReadBk column.
Record voltage and Pass/Fail result on the Data Sheet.
(h)
Verify VREF 2.5 is 2500mV +/-100mV in the UUT Status – ReadBk column.
Record voltage and Pass/Fail result on the Data Sheet.
(j)
Verify V2.8 is 2800mV +/-100mV in the UUT Status – ReadBk column.
Record voltage and Pass/Fail result on the Data Sheet.
(k)
Verify that there are no Over-Voltage conditions reported in the
MESSAGE MENU. Record Pass/Fail result on the Data Sheet. Refer to
Figure 1007 for an example of an Over-Voltage failure condition.
WCU Test Program – Message Menu – Over Voltage
Figure 1007 / GRAPHIC 33-50-01-99B-009-A01
(4)
Using a Digital Multimeter, verify the following on the Battery Simulator Module:
Use TP “GND” as ground reference when measuring voltage at TP V3p3.
NOTE:
(5)
(a)
Verify TP V3p3 measures 3300mV +/-100mV. Record voltage and Pass/Fail
result on the Data Sheet.
(b)
Verify 3.3V value recorded in section C.(3)(g) of Data Sheet is within +/15mV of the value recorded in section C.(4)(a) of Data Sheet. Record
Pass/Fail result on the Data Sheet.
Verify the following results in the OUTPUTS STATUS MENU. Refer to Figure 1008.
(a)
Verify OUT 1 through OUT 6 states are “D” in the UUT Status – EN/DIS
column. Record Pass/Fail result on the Data Sheet.
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(b)
Verify Output voltages for OUT 1 through OUT 6 are less than 100mV in the
Tester Status - ReadBack column. Record Output voltages and Pass/Fail
results on the Data Sheet.
WCU Test Program – WCU Outputs Status Menu
Figure 1008 / GRAPHIC 33-50-01-99B-010-A01
(6)
Turn ON the DC power by clicking on the “Turn DC On” button in the MAIN STATUS
MENU.
(7)
Enable the WCU battery by clicking on the “E” button in the MAIN STATUS MENU –
Bat EN/EN - “CMD” column. Verify that the Bat EN/EN state changes from “D” to “E”
in the UUT Status – State column.
(8)
Select “MED” from the MAIN STATUS MENU “CMD” column drop down menu for
VB+/LD to enable the Medium charger load. Verify that the state changes to “M” in
the Tester Status – State column for VB+/LD.
(a)
Verify the Chgr I value is 500mA +/-200mA in the MAIN STATUS MENU –
UUT Status – ReadBk column. Record Charge Current value and Pass/Fail
result on the Data Sheet.
(b)
Record, on the Data Sheet, the current VB+/LD voltage reported in the MAIN
STATUS MENU – Tester Status – ReadBk column.
(c)
Verify VB+/LD drop is less than 500mV by subtracting VB+/LD value logged
on Data Sheet section C.(8)(c) from VB+/LD value logged on Data Sheet
section C.(3)(e). Record voltage drop and Pass/Fail result on the Data
Sheet.
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(9)
Disable the battery charger by clicking on the “D” button in the MAIN STATUS
MENU – Charger - “CMD” column. Verify that the state changes from “E” to “D” in
the UUT Status – State column for Charger.
Make sure the CAN bus communication remains stable when the Battery Charger
is turned off. If CAN bus communication is lost, the MAIN STATUS MENU,
OUTPUTS STATUS MENU and CONFIGURATION MENU will flash the message
“Waiting on UUT Reply”. This is only a status notification, not a failure.
NOTE:
(10)
(a)
Record, on the Data Sheet, the current VB+/LD voltage reported in the MAIN
STATUS MENU – Tester Status – ReadBk column.
(b)
Verify VB+/LD drop is greater than 150mV by subtracting VB+/LD value
logged on Data Sheet section C.(9)(a) from VB+/LD value logged on Data
Sheet section C.(3)(e). Record voltage drop and Pass/Fail result on the Data
Sheet.
Enable the battery charger by clicking on the “E” button in the MAIN STATUS MENU
– Charger - “CMD” column. Verify that the state changes from “D” to “E” in the UUT
Status – State column for Charger.
(a)
(11)
Turn OFF the AC power by clicking on the “Turn AC Off” button in the MAIN
STATUS MENU. Verify that the state changes from “Y” to “N” in the UUT Status
State column and the Tester Status State column as shown in Figure 1006.
Make sure the CAN bus communication remains stable when AC Power is turned
off. If CAN bus communication is lost, the MAIN STATUS MENU, OUTPUTS
STATUS MENU and CONFIGURATION MENU, will flash the message “Waiting
on UUT Reply”.
NOTE:
(12)
Verify the Chgr I value is 500mA +/-200mA in the MAIN STATUS MENU –
UUT Status – ReadBk column. Record Charge Current value and Pass/Fail
result on the Data Sheet.
(a)
Record, on the Data Sheet, the current VB+/LD voltage reported in the MAIN
STATUS MENU – Tester Status – ReadBk column.
(b)
Verify VB+/LD drop is greater than 150mV by subtracting VB+/LD value
logged on Data Sheet section C.(11)(a) from VB+/LD value logged on Data
Sheet section C.(3)(e). Record voltage drop and Pass/Fail result on the Data
Sheet.
Turn ON the AC power by clicking on the “Turn AC On” button in the MAIN STATUS
MENU. Verify that the state changes from “N” to “Y” in both the UUT Status and
Tester Status – State columns.
(a)
Verify Charger state is “E” in the UUT Status – State column. Record
Pass/Fail result on the Data Sheet.
(b)
Verify the Chgr I value is 500mA +/-200mA in the MAIN STATUS MENU –
UUT Status – ReadBk column. Record Charge Current value and Pass/Fail
result on the Data Sheet.
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(13)
(14)
(15)
Select “HIGH” from the MAIN STATUS MENU “CMD” column drop down menu for
VB+/LD to enable the High charger load. Verify that the state changes to “H” in the
UUT Status – State column for VB+/LD.
(a)
Record, on the Data Sheet, the current VB+/LD voltage reported in the MAIN
STATUS MENU – Tester Status – ReadBk column.
(b)
Verify VB+/LD drop is less than 1000mV by subtracting VB+/LD value
logged on Data Sheet section C.(13)(a) from VB+/LD value logged on Data
Sheet section C.(3)(e). Record voltage drop and Pass/Fail result on the Data
Sheet.
(c)
Verify the Chgr I value is greater than 500mA in the MAIN STATUS MENU –
UUT Status – ReadBk column. Record Charge Current value and Pass/Fail
result on the Data Sheet.
Change the charge mode from high to low by clicking the “L” button in the MAIN
STATUS MENU – Chgr I - “CMD” column.
(a)
Verify Chgr I state is “L” in the UUT Status – State column. Record
Pass/Fail result on the Data Sheet.
(b)
Verify the Chgr I value is less than 200mA in the MAIN STATUS MENU –
UUT Status – ReadBk column. Record Charge Current value and Pass/Fail
result on the Data Sheet.
Select “OFF” from the MAIN STATUS MENU “CMD” column drop down menu for
VB+/LD to disable charger load.
(a)
Verify VB+/LD state is “0” in the TESTER Status – State column. Record
Pass/Fail result on the Data Sheet.
SUBTASK 33-50-01-700-005-A01
D.
WCU Battery Temperature Test
The following instructions reference information presented in WCU Test Program
- MAIN STATUS MENU as shown in Figure 1006.
NOTE:
(1)
Click on the “Fetch Temp” button in the Wels Test Program – MAIN STATUS MENU
to read back the battery temperature. The battery temperature will be displayed in
Celsius.
(a)
Record the battery temperature in Celsius on the Data Sheet.
(b)
Verify the battery temperature is within +7/-2°C of the room ambient
temperature recorded on the Data Sheet. Record Pass/Fail result on the
Data Sheet.
SUBTASK 33-50-01-700-006-A01
E.
Output Section
NOTE:
The following instructions reference information presented in WCU Test Program
- MAIN STATUS MENU as shown in Figure 1006 and OUTPUTS STATUS MENU
as shown in Figure 1008.
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(1)
Verify OUT 1 through OUT 6 Output Current values are less than 25mA in the
OUTPUTS STATUS MENU - UUT Status – OUT CUR column. Record Output
Current values and Pass/Fail results on the Data Sheet.
The following steps will need to be performed for Output 1 through Output 6.
NOTE:
(2)
Turn on the Output being tested by clicking on the “N” button in the OUTPUTS
STATUS MENU - “CMD” column that corresponds to the Output being tested. Verify
that the state of the CMD column changes from “N” to “Y” for the Output being
tested.
(3)
Verify the following results in the OUTPUTS STATUS MENU. Refer to Figure 1008.
(a)
Verify EN/DIS state is “E” in the UUT Status – EN/DIS column for the Output
being tested. Record Pass/Fail result on the Data Sheet.
(b)
Verify ACT/INA state is “A” in the UUT Status – ACT/INA column for the
Output being tested. Record Pass/Fail result on the Data Sheet.
(c)
Verify Output Current is 1100mA +/-200mA in the UUT Status – OUT CUR
column for the Output being tested. Record Output Current and Pass/Fail
result on the Data Sheet.
(d)
Verify Output voltage is 7500mV +/-500mV in the Tester Status – ReadBack
column for the Output being tested. Record Output voltage and Pass/Fail
result on the Data Sheet.
(4)
Apply a short to the Output being tested by clicking on the “N” button in the
OUTPUTS STATUS MENU - O SHORT - “CMD” column.
(5)
Verify the following results in the OUTPUTS STATUS MENU. Refer to Figure 1008.
(6)
(7)
(a)
Verify OVR/NRM state is “Y” in the UUT Status – OVR/NRM column for the
Output being tested. Record Pass/Fail result on the Data Sheet.
(b)
Verify Output Current is 0mA +/-25mA in the UUT Status – OUT CUR
column for the Output being tested. Record Output Current and Pass/Fail
result on the Data Sheet.
Verify for all other Outputs the following results in the OUTPUTS STATUS MENU.
Refer to Figure 1008.
(a)
Verify EN/DIS state is “D” in the UUT Status – EN/DIS column for all other
Outputs. Record Pass/Fail results on the Data Sheet.
(b)
Verify ACT/INA state is “I” in the UUT Status – ACT/INA column for all other
Outputs. Record Pass/Fail results on the Data Sheet.
(c)
Verify Output voltage is 0mV +/-10mV in the Tester Status – ReadBack
column for all other Outputs. Record Output voltages and Pass/Fail results
on the Data Sheet.
Remove the short to the Output being tested by clicking on the “Y” button in the
OUTPUTS STATUS MENU – O SHORT - “CMD” column.
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(8)
Clear the short to the Output being tested by clicking on the “CLR” button in the
OUTPUTS STATUS MENU – O SHORT - “CMD” column.
(a)
(9)
Turn off the Output being tested by clicking on the “Y” button in the OUTPUTS
STATUS MENU - “CMD” column that corresponds to the Output being tested.
(a)
(10)
Verify OVR/NRM state is “N” in the OUTPUTS STATUS MENU - UUT Status
– OVR/NRM column for the Output being tested. Record Pass/Fail result on
the Data Sheet.
Verify that the state of the CMD column changes from “Y” to “N” for the
Output being tested. Record Pass/Fail result on the Data Sheet.
Make sure to complete steps E.(2) through E.(9)(a) for Output 1 through Output 6
before moving on to the next section.
SUBTASK 33-50-01-700-007-A01
F.
Configuration / ID Signals Test
NOTE:
The following instructions reference information presented in WCU Test Program
- CONFIGURATION MENU as shown in Figure 1009, Figure 1010, and
Figure 1011.
NOTE
The WCU Test Program – Configuration Menu is displayed when the Display
Checked Menus is selected on the WCU Test Program V1.V00 Comm Menu.
Refer to Figure 1002.
(1)
Make sure ID Switches on Test Box are in the “TEST” position.
(2)
Click on the “Pattern 1” button in the CONFIGURATION MENU.
(3)
Verify the following in the CONFIGURATION MENU:
(a)
Verify the UUT Status – STATE column alternates between H & L beginning
at ID 1 with “L” and ending at IDrtn with “L”. Refer to Figure 1009. Record
Pass/Fail results on the Data Sheet.
(b)
Verify the Tester Status – READBACK column values alternate between
2100mV +/-100mV and 300mV +/-100mV, beginning with ID 1 with 300mV
+/-100mV and ending at IDrtn with 300mV +/-100mV. Refer to Figure 1009.
Record READBACK voltage and Pass/Fail results on the Data Sheet.
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WCU Test Program – WCU Configuration Menu
Figure 1009 / GRAPHIC 33-50-01-99B-011-A01
(4)
Click on the “Pattern 2” button in the CONFIGURATION MENU.
(5)
Verify the following in the CONFIGURATION MENU:
(a)
Verify the UUT Status – STATE column alternates between H & L beginning
at ID 1 with “H” and ending at IDrtn with “H”. Refer to Figure 1010. Record
Pass/Fail results on the Data Sheet.
(b)
Verify the Tester Status – READBACK column values alternate between
2100mV +/-100mV and 300mV +/-100mV, beginning with ID 1 with 2100mV
+/-100mV and ending at CTRLen with 300mV +/-100mV. IDrtn READBACK
value should be 3300mV +/-100mV. Refer to Figure 1010. Record
READBACK voltage and Pass/Fail results on the Data Sheet.
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WCU Test Program – WCU Configuration Menu
Figure 1010 / GRAPHIC 33-50-01-99B-012-A01
(6)
Verify the following in the CONFIGURATION MENU. Refer to Figure 1011.
(7)
Ground the ID_1RTN signal by selecting “1” from the “CMD” column drop down
menu for rtnGND.
(8)
(9)
(a)
Verify IDrtn drops to 0mV +/-100mV in the Tester Status – READBACK
column. Record voltage and Pass/Fail result on the Data Sheet.
(b)
Verify rtnGND reports ID_1RTN GRD in the CONFIGURATION MENU –
Tester Status – READBACK column. Record Pass/Fail result on the Data
Sheet.
Ground the ID_2RTN signal by selecting “2” from the “CMD” column drop down
menu for rtnGND.
(a)
Verify IDrtn drops to 0mV +/-100mV in the Tester Status – READBACK
column. Record voltage and Pass/Fail result on the Data Sheet.
(b)
Verify rtnGND reports ID_2RTN GRD in the CONFIGURATION MENU –
Tester Status – READBACK column. Record Pass/Fail result on the Data
Sheet.
Ground the ID_3RTN signal by selecting “3” from the “CMD” column drop down
menu for rtnGND.
(a)
Verify IDrtn drops to 0mV +/-100mV in the Tester Status – READBACK
column. Record voltage and Pass/Fail result on the Data Sheet.
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(b)
(10)
(11)
(12)
Verify rtnGND reports ID_3RTN GRD in the CONFIGURATION MENU –
Tester Status – READBACK column. Record Pass/Fail result on the Data
Sheet.
Ground the ID_4RTN signal by selecting “4” from the “CMD” column drop down
menu for rtnGND.
(a)
Verify IDrtn drops to 0mV +/-100mV in the Tester Status – READBACK
column. Record voltage and Pass/Fail result on the Data Sheet.
(b)
Verify rtnGND reports ID_4RTN GRD in the CONFIGURATION MENU –
Tester Status – READBACK column. Record Pass/Fail result on the Data
Sheet.
Ground the ID_5RTN signal by selecting “5” from the “CMD” column drop down
menu for rtnGND.
(a)
Verify IDrtn drops to 0mV +/-100mV in the Tester Status – READBACK
column. Record voltage and Pass/Fail result on the Data Sheet.
(b)
Verify rtnGND reports ID_5RTN GRD in the CONFIGURATION MENU –
Tester Status – READBACK column. Record Pass/Fail result on the Data
Sheet.
Clear the ground to ID_5RTN signal by selecting “Off” from the “CMD” column drop
down menu for rtnGND.
(a)
Verify IDrtn READBACK returns to 3300mV +/-100mV in the Tester Status –
READBACK column. Record voltage and Pass/Fail result on the Data Sheet.
WCU Test Program – WCU Configuration Menu
Figure 1011 / GRAPHIC 33-50-01-99B-013-A01
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SUBTASK 33-50-01-700-008-A01
G.
Control Voltage Test
The following instructions reference information presented in WCU Test Program
- MAIN STATUS MENU as shown in Figure 1006.
NOTE:
(1)
(2)
(3)
(4)
Select “ON” from the MAIN STATUS MENU “CMD” column drop down menu for
Control V.
(a)
Record, on the Data Sheet, the current Control V value reported in the MAIN
STATUS MENU – UUT Status – ReadBk column.
(b)
Verify Control V + input is 0mV +/-125mV and – input is 0mV +/-50mV in the
MAIN STATUS MENU - Tester Status – ReadBk column. Record input
voltages and Pass/Fail result on the Data Sheet.
(c)
Verify the Control V value recorded in section G.(1)(a) of Data Sheet is
within +/- 250mV of the Control V (+ Input) value recorded in section G.(1)(b)
of Data Sheet. Record Pass/Fail result on the Data Sheet.
Select “OFF” from the MAIN STATUS MENU “CMD” column drop down menu for
Control V.
(a)
Record, on the Data Sheet, the current Control V value reported in the MAIN
STATUS MENU – UUT Status – ReadBk column.
(b)
Verify Control V + input is 10000mV +/-500mV and – input is 0mV +/-50mV
in the MAIN STATUS MENU - Tester Status – ReadBk column. Record
voltages and Pass/Fail result on the Data Sheet.
(c)
Verify the Control V value recorded in section G.(2)(a) of Data Sheet is
within +/- 250mV of the Control V (+ Input) value recorded in section G.(2)(b)
of Data Sheet. Record Pass/Fail result on the Data Sheet.
Select “ARM” from the MAIN STATUS MENU “CMD” column drop down menu for
Control V.
(a)
Record, on the Data Sheet, the current Control V value reported in the MAIN
STATUS MENU – UUT Status – ReadBk column.
(b)
Verify Control V + input is 20000mV +/- 500mV and – input is 0mV +/-50mV
in the MAIN STATUS MENU - Tester Status – ReadBk column. Record
voltages and Pass/Fail result on the Data Sheet.
(c)
Verify Control V ReadBk value recorded in section G.(3)(a) is greater than
18000mV. Record Pass/Fail result on the Data Sheet.
Select “OFS” from the MAIN STATUS MENU “CMD” column drop down menu for
Control V.
(a)
Record, on the Data Sheet, the current Control V value reported in the MAIN
STATUS MENU – UUT Status – ReadBk column.
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(b)
Verify Control V + input is 20000mV +/- 500mV and – input is 5000mV +/200mV in the MAIN STATUS MENU - Tester Status – ReadBk column.
Record voltages and Pass/Fail result on the Data Sheet.
(c)
Verify the Control V value recorded in section G.(4)(a) is within +/- 500mV of
the Control V + input voltage minus the Control V - input voltage recorded in
section G.(4)(b) of the Data Sheet. Record voltage difference between +
input and – input and Pass/Fail result on the Data Sheet.
Example:
(+ input) – (- input) = Control V in UUT ReadBk column
or
20000mV – 5000mV = 15000mV
SUBTASK 33-50-01-700-009-A01
H.
EEPROM Test
NOTE:
The following instructions reference information presented in WCU Test Program
– WCU EEPROM Test and Initialization Menu – EEPROM TEST MENU as shown
in Figure 1012 and the MESSAGE MENU as shown in Figure 1013.
NOTE:
Make sure each test has finished before starting the next test. The EEPROM 3
test takes the longest to complete (Approximately 14 seconds).
(1)
Run the EEPROM 1 Quick Test by clicking the “Perform EEPROM1 QTest” button in
the WCU EEPROM Test and Initialization Menu – EEPROM TEST MENU. When the
test is complete the program will report Pass or Fail in the EEPROM TEST MENU –
UUT Status – Quick Test Result column. The MESSAGE MENU will also report
EEPROM 01 test results.
(a)
Verify the EEPROM TEST MENU reports a “PASS” in the UUT Status –
Quick Test Result column for EEPROM 1 and verify the MESSAGE MENU
reports the following message:
EEPROM 01 Test Results A5 A5 00 00 00 00 00 00
(b)
(2)
Record Pass/Fail result on the Data Sheet.
Run the EEPROM 2 Quick Test by clicking the “Perform EEPROM2 QTest” button in
the WCU EEPROM Test and Initialization Menu – EEPROM TEST MENU. When the
test is complete the program will report Pass or Fail in the EEPROM TEST MENU –
UUT Status – Quick Test Result column. The MESSAGE MENU will also report
EEPROM 02 test results.
(a)
Verify the EEPROM TEST MENU reports a “PASS” in the UUT Status –
Quick Test Result column for EEPROM 2 and verify the MESSAGE MENU
reports the following message:
EEPROM 02 Test Results A5 A5 00 00 00 00 00 00
(b)
Record Pass/Fail result on the Data Sheet.
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(3)
Run the EEPROM 1 Full Test by clicking the “Perform EEPROM1 FTest” button in
the WCU EEPROM Test and Initialization Menu – EEPROM TEST MENU. When the
test is complete the program will report Pass or Fail in the EEPROM TEST MENU –
UUT Status – Full Test Result column. The MESSAGE MENU will also report
EEPROM 01 test results.
(a)
Verify the EEPROM TEST MENU reports a “PASS” in the UUT Status – Full
Test Result column for EEPROM 1 and verify the MESSAGE MENU reports
the following message:
EEPROM 01 Test Results 00 00 00 00 00 00 00 00
(b)
(4)
Record Pass/Fail result on the Data Sheet.
Run the EEPROM 2 Full Test by clicking the “Perform EEPROM2 FTest” button in
the WCU EEPROM Test and Initialization Menu – EEPROM TEST MENU. When the
test is complete the program will report Pass or Fail in the EEPROM TEST MENU –
UUT Status – Full Test Result column. The MESSAGE MENU will also report
EEPROM 02 test results.
(a)
Verify the EEPROM TEST MENU reports a “PASS” in the UUT Status – Full
Test Result column for EEPROM 2 and verify the MESSAGE MENU reports
the following message:
EEPROM 02 Test Results 00 00 00 00 00 00 00 00
(b)
(5)
Record Pass/Fail result on the Data Sheet.
Run the EEPROM 3 Full Test by clicking the “Perform EEPROM3 FTest” button in
the WCU EEPROM Test and Initialization Menu – EEPROM TEST MENU. When the
test is complete the program will report Pass or Fail in the EEPROM TEST MENU –
UUT Status – Full Test Result column. The MESSAGE MENU will also report
EEPROM 03 test results.
(a)
Verify the EEPROM TEST MENU reports a “PASS” in the UUT Status – Full
Test Result column for EEPROM 3 and verify the MESSAGE MENU reports
the following message:
EEPROM 03 Test Results 00 00 00 00 00 00 00 00
(b)
Record Pass/Fail result on the Data Sheet.
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WCU Test Program – WCU EEPROM Test and Initialization Menu
Figure 1012 / GRAPHIC 33-50-01-99B-014-A01
WCU Test Program – Message Menu
Figure 1013 / GRAPHIC 33-50-01-99B-015-A01
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NOTE:
The first part of the automated test is now completed. The RF Test section is not
automated and needs to be run manually. The second part of the automated test supports
the Final Verification of WCU After WELS Software is Downloaded section.
SUBTASK 33-50-01-700-010-A01
J.
RF Test
The previous tests tested the bulk of the board circuitry with a special test
program designed to easily test the various board interfaces. The RF Test
requires that RF software be loaded to drive the RF module.
NOTE:
CAUTION:
NOTE:
THE RF TEST REQUIRES THAT NO BLUETOOTH EMITTERS BE
OPERATING WITHIN 32.8 FEET (10 METERS) OF THE TEST SET.
The following software load process must be completed before proceeding:
(1)
Load the RF software per the “Write RF Software to Microcontroller Flash Memory”
procedure in the Test Software Programming Procedure section.
(2)
Setup the WELS test equipment as shown in Figure 1014.
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WCU RF Test Setup
Figure 1014 / GRAPHIC 33-50-01-99B-016-A01
NOTE:
ID1, ID2, ID3, ID4, ID5 and CTRLen are switches located on the WELS
Test Box interface board. These switches can be selected for the
following positions; CLOSED, OPEN, or TEST.
NOTE:
This section of the test will check the internal antenna (Antenna 1)
performance.
(3)
Set ID1, ID2, ID3, ID4, ID5 and CTRLen switches on the WELS Test Box to the
“OPEN” position.
(4)
Attach the Omnidirectional Antenna to RF port on the Anritsu Bluetooth Test Set.
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(5)
Place the WCU under test within 6 inches of the Omnidirectional Antenna attached
to the Anritsu Bluetooth Test Set.
(6)
Turn ON the AC power by clicking on the “Turn AC On” button in the WELS Test
Program – WCU Main Status Menu. Verify that the AC ON/ON State is “Y” in the
Tester Status column.
(7)
Turn ON the DC power by clicking on the “Turn DC On” button in the WELS Test
Program – WCU Main Status Menu. Verify that the Bat EN/EN State is “Y” in the
Tester Status column.
(8)
Turn on the Anritsu Bluetooth Test Set and wait for it to complete the power up
sequence.
The following instructions reference information presented in BlueTest2 Program.
NOTE:
(9)
Run the BlueTest2 program on the PC.
NOTE:
The Blue Test 2 program will appear as an icon on the desktop when it is
loaded from its original media (CD or internet) to the computer.
(10)
In the BlueTest2 “system configuration” menu click the “Check Configuration”
button.
(11)
Click “OK” button when prompted to “Make sure all the Bluetooth Test Sets are
powered on”.
(12)
Click “OK” button in the “EDR Message” window.
(13)
Click “OK” button in “System Confirmation” window.
(14)
Select the “Run Bluetooth Test” menu tab.
(15)
Click “OK” button in the “Run Test” window.
(16)
In “Script to Run” dropdown menu select “User Script 10”.
(17)
Click "Run Test” button and wait for test to complete.
This test may take several minutes to complete.
NOTE:
(a)
Verify that all tests have passed. Record Pass/Fail result on the Data Sheet.
(18)
Click “View Test Report” button to generate report.
(19)
Click “Print” button to print report. This report is to be kept with the data sheets for
the WCU under test.
(20)
Close the Report Window by clicking on the “X” in the top right-hand corner of the
window.
NOTE:
(21)
This section of the test will check the external antenna (Antenna 2) performance.
Set ID1, ID2, ID3, ID4, and CTRLen switches on the WELS Test Box to the “OPEN”
position.
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(22)
Set ID5 switch on the WELS Test Box to the “CLOSED” position.
(23)
Attach Direct Connection Antenna Cable between RF Port on the Anritsu Bluetooth
Test Set and the External Antenna Connector (J4) on the WCU.
The following instructions reference information presented in BlueTest2 Program.
NOTE:
(24)
In “Script to Run” dropdown menu select “User Script 3”.
(25)
Click ”Run Test” button and wait for test to complete.
This test may take several minutes to complete.
NOTE:
(a)
Verify that all tests have passed. Record Pass/Fail result on the Data Sheet.
(26)
Click “View Test Report” button to generate report.
(27)
Click “Print” button to print report. This report is to be kept with the data sheets for
the WCU under test.
(28)
Turn OFF the DC power by clicking on the “Turn DC Off” button in the WELS Test
Program – MAIN STATUS MENU.
(29)
Turn OFF the AC power by clicking on the “Turn AC Off” button in the WELS Test
program - MAIN STATUS MENU.
SUBTASK 33-50-01-700-010-A01
K.
Final Verification of WCU After WELS Software is Downloaded
The following software load process must be completed before proceeding:
NOTE:
(1)
Load the WELS software per the Operational Software Programming Procedure
section.
(2)
Setup the WELS test equipment as shown in Figure 1015.
CAUTION:
ENSURE THE WELS BATTERY UNIT IS FULLY CHARGED TO 8.1 VOLTS
BEFORE INSTALLING INTO THE WCU UNDER TEST. THE OUTPUTS
ARE DESIGNED TO TURN OFF IF THE BATTERY VOLTAGE DROPS
BELOW 6500mV. USING A FULLY CHARGED BATTERY WILL PREVENT
FALSE FAILURES, RELATED TO LOW BATTERY VOLTAGE, FROM
OCCURRING.
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WCU Final Verification Test Setup with WELS Test Box PC
Figure 1015 / GRAPHIC 33-50-01-99B-017-A01
(3)
Set ID1, ID2, ID3, ID4 and ID5 switches on the WELS Test Box to the “OPEN”
position.
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(4)
Set CTRLen switch on the WELS Test Box to the “CLOSED” position.
NOTE:
(5)
The following instructions reference information presented in WCU Test Program
- MAIN STATUS MENU as shown in Figure 1006 and OUTPUTS STATUS MENU
as shown in Figure 1008.
Turn ON the AC power by clicking on the “Turn AC On” button in the WELS Test
Program - MAIN STATUS MENU. Verify that the AC ON/ON State column is “Y” in
the Tester Status column.
The values reported in the UUT Status columns for the Main Status Menu and
Outputs Status Menu are not valid and will either be starred or 9999.
NOTE:
(6)
Monitor all 6 Output voltages reported in the OUTPUTS STATUS MENU – Tester
Status – ReadBack column for a minimum of 15 seconds and verify the following.
(a)
(7)
Verify Output voltages remain at 0mV +/-25mV in the OUTPUTS STATUS
MENU - Tester Status – ReadBack column for all Outputs. Record Output
voltages and Pass/Fail results on the Data Sheet.
Click on the “Op Can” button in the Message Menu to enable CAN communication
between WCU under test and WCU Test Program. Refer to Figure 1016.
(a)
Verify that the following CAN messages appear in the “Message Menu”. The
4 digits in BOLD, will change for each CAN message received.
RX CID : 0320 0803, RX Msg (0-3): 0 0 6 0
(b)
Record Pass/Fail result on the Data Sheet.
Message Menu – CAN Message
Figure 1016 / GRAPHIC 33-50-01-99B-018-A01
(8)
Turn OFF the AC power by clicking on the “Turn AC Off” button in the WELS Test
program - MAIN STATUS MENU.
(9)
Setup the WELS test equipment as shown in Figure 1017.
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WCU Final Verification Test Setup with Interface and ARM Boards
Figure 1017 / GRAPHIC 33-50-01-99B-019-A01
(10)
Ensure the WCU Interface Board and ARM Switch Board are configured as follows:
(a)
Install a jumper in CTRLen position and remove jumpers from all other
positions on the WCU Interface Board (TE-2627-01).
(b)
Switch the S1 AC switch to the “OFF” position on the WCU Interface Board
(TE-2627-01).
(c)
Switch the S1 switch on the ARM Switch Board (TE-2628-01) to the “UP” 8V
(OFF) position.
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(d)
Ensure that the AC power cable from the WCU Interface Board is plugged
into a 110VAC / 60Hz outlet.
(11)
Install a fully charged Battery Unit (100-2602-01) into the WCU under test.
(12)
The following steps are performed to verify that the WELS Software has been loaded
correctly.
(13)
Turn ON the AC power to the WCU by switching the S1 AC switch to the “ON”
position on the WCU Interface Board (TE-2627-01).
(14)
Switch the S1 switch on the ARM Switch Board (TE-2628-01) to the “MIDDLE” 0V
(ON) position.
(a)
(15)
Switch the S1 switch on the ARM Switch Board (TE-2628-01) to the “DOWN” 20V
(ARM) position.
(a)
(16)
Verify that all six output LED’s (D1 through D6) on the WCU Interface Board
are off. Record Pass/Fail result on the Data Sheet.
Turn OFF the AC power to the WCU by switching the S1 AC switch to the “OFF”
position on the WCU Interface Board (TE-2627-01).
(a)
(17)
Verify that all six output LED’s (D1 through D6) on the WCU Interface Board
are illuminated. Record Pass/Fail result on the Data Sheet.
Verify that all six output LED’s (D1 through D6) on the WCU Interface Board
are illuminated. Record Pass/Fail result on the Data Sheet.
Switch the S1 switch on the ARM Switch Board (TE-2628-01) to the “UP” 8V (OFF)
position.
(a)
Verify that all six output LED’s (D1 through D6) on the WCU Interface Board
are off. Record Pass/Fail result on the Data Sheet.
(18)
Disconnect the WCU under test and complete all associated paper work.
(19)
If the WCU does not successfully complete the WCU Test Procedures, remove and
replace the Control PWA and repeat the WCU Test Procedures.
(20)
If after replacing the Control PWA the WCU does not successfully complete the
WCU Test Procedures, remove and replace the Combined Interface PWA. Repeat
the WCU Test Procedures.
(21)
If the WCU successfully completes the WCU Test Procedures, no further tests are
required. The unit can be returned to service.
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Table 1003. WCU Acceptance Test Data Sheet / TABLE 33-50-01-99A-006-A01
Make a copy of this WCU test data sheet and record the
following parameters when specified in the test procedures.
Date
WCU P/N
100-2601-01
MOD Status
WCU S/N
Tested By
Room Temperature in Celsius
WELS Test Box P/N
TE-1128-01
Room Humidity
S/N
Calibration Date
Bluetooth Test Set Model #
S/N
Calibration Date
DMM Model #
S/N
Calibration Date
INSTRUCTIONS: Enter all voltage and current values in millivolts and milliamps. Verify that each test result either
Passes or Fails by checking the appropriate box.
4.A
WELS TEST BOX CALIBRATION TEST
Verify the A/D and Mux Signals report 3300mV +/-50mv (3.3V RB
4.A.(5)(a)
column) and 0mV +/-25mV (GND RB column).
Signal
Tester Status
3.3V
RB
GND
RB
PASS
FAIL
PASS
FAIL
A/D Ch4, A/D Ch 5
MUX1 Ch6, MUX 1 CH 7
MUX2 Ch6, MUX 2 CH 7
MUX3 Ch6, MUX 3 CH 7
4.A.(5)(b)
Verify the Control Voltage +/- reports 10000mV +/-500mV (+ Input
column) and 0mV +/-50mV (– Input column).
Tester Status
+Input
-Input
Control Voltage +/-
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Table 1003. WCU Acceptance Test Data Sheet (Continued)
4.B
4.B.(4)(a)
INITIAL WCU POWER-UP
Using the Multimeter, verify greater than 5 Meg ohms resistance
between the following Test Box Interface Board Test Points.
ohms
PASS
FAIL
PASS
FAIL
Read
Bk
PASS
FAIL
Read
Bk
PASS
FAIL
Read
Bk
PASS
FAIL
a) GND and ACL
b) GND and ACH
c) BAT GND and ACL
d) BAT GND and ACH
Verify the MAIN STATUS MENU, OUTPUTS STATUS MENU and
4.B.(16)(a) CONFIGURATION MENU, continue to flash the message “Waiting
on UUT Reply” in the UUT Status area of each menu window.
4.B.(16)(b)
Verify VB+/LD is 0mV +/-25mv in the Tester Status - ReadBk
column.
4.B.(16)(c) Verify V3.3 is 0mV +/-50mv in the Tester Status - ReadBk column.
4.C
4.C.(3)(a)
WCU COMMUNICATION AND REEDBACK TESTS
Verify Control V is 10000mV +/-500mV in the UUT Status –
ReadBk column.
4.C.(3)(b)
Verify AC ON/ON state is “Y” in both the UUT Status and Tester
Status – State columns.
PASS
FAIL
4.C.(3)(c)
Verify Charger state is “E” in the UUT Status – State column.
PASS
FAIL
4.C.(3)(d)
Verify VB+/LD is 8000mV +/-500mv in the UUT Status - ReadBk
column.
Read
Bk
PASS
FAIL
4.C.(3)(e)
Verify VB+/LD is 8000mV +/-500mv in the Tester Status - ReadBk
column.
Read
Bk
PASS
FAIL
4.C.(3)(f)
Verify VB+/OV ReadBk voltage is less than 100mv in the Tester
Status - ReadBk column.
Read
Bk
PASS
FAIL
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Table 1003. WCU Acceptance Test Data Sheet (Continued)
4.C.(3)(g)
Verify V3.3 is 3300mV +/-100mV in the Tester Status – ReadBk
column.
Read
Bk
PASS
FAIL
4.C.(3)(h)
Verify VREF 2.5 is 2500mV +/-100mV in the UUT Status – ReadBk
column.
Read
Bk
PASS
FAIL
4.C.(3)(j)
Verify V2.8 is 2800mV +/-100mV in the UUT Status – ReadBk
column.
Read
Bk
PASS
FAIL
4.C.(3)(k)
Verify that there are no Over-Voltage conditions reported in the
MESSAGE MENU.
PASS
FAIL
PASS
FAIL
PASS
FAIL
PASS
FAIL
Read
Back
PASS
FAIL
PASS
FAIL
TP
V3p3
4.C.(4)(a) Verify TP V3p3 measures 3300mV +/-100mV.
Verify 3.3V value recorded in section 4.C.(3)(g) of Data Sheet is
4.C.(4)(b) within +/-15mV of the value recorded in section 4.C.(4)(a) of Data
Sheet.
4.C.(5)(a)
Verify OUT 1 through OUT 6 states are “D” in the UUT Status –
EN/DIS column.
4.C.(5)(b)
Verify Output voltages for OUT 1 through OUT 6 are less than
100mV in the Tester Status - ReadBack column.
OUT 1
OUT 2
OUT 3
OUT 4
OUT 5
OUT 6
4.C.(8)(a)
Verify the Chgr I value is 500mA +/-200mA in the MAIN STATUS
MENU – UUT Status – ReadBk column.
Read
Bk
4.C.(8)(b)
Record the current VB+/LD voltage reported in the MAIN STATUS
MENU – Tester Status – ReadBk column.
Read
Bk
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Table 1003. WCU Acceptance Test Data Sheet (Continued)
4.C.(8)(c)
Verify VB+/LD drop is less than 500mV by subtracting VB+/LD
value logged on Data Sheet section 4.C.(8)(c) from VB+/LD value
logged on Data Sheet section 4.C.(3)(e).
VB+/LD
Drop
4.C.(9)(a)
Record the current VB+/LD voltage reported in the MAIN STATUS
MENU – Tester Status – ReadBk column.
Read
Bk
4.C.(9)(b)
Verify VB+/LD drop is greater than 150mV by subtracting VB+/LD
value logged on Data Sheet section 4.C.(9)(a) from VB+/LD value
logged on Data Sheet section 4.C.(3)(e).
4.C.(10)(a)
4.C.(11)(a)
PASS
FAIL
VB+/LD
Drop
PASS
FAIL
Verify the Chgr I value is 500mA +/-200mA in the MAIN STATUS
MENU – UUT Status – ReadBk column.
Read
Bk
PASS
FAIL
Record the current VB+/LD voltage reported in the MAIN STATUS
MENU – Tester Status – ReadBk column.
Read
Bk
PASS
FAIL
PASS
FAIL
PASS
FAIL
VB+/LD
Drop
PASS
FAIL
Read
Bk
PASS
FAIL
Verify VB+/LD drop is greater than 150mV by subtracting VB+/LD
4.C.(11)(b) value logged on Data Sheet section 4.C.(11)(a) from VB+/LD value
logged on Data Sheet section 4.C.(3)(e).
VB+/LD
Drop
4.C.(12)(a) Verify Charger state is “E” in the UUT Status – State column.
4.C.(12)(b)
Verify the Chgr I value is 500mA +/-200mA in the MAIN STATUS
MENU – UUT Status – ReadBk column.
Read
Bk
4.C.(13)(a)
Record the current VB+/LD voltage reported in the MAIN STATUS
MENU – Tester Status – ReadBk column.
Read
Bk
Verify VB+/LD drop is less than 1000mV by subtracting VB+/LD
4.C.(13)(b) value logged on Data Sheet section 4.C.(13)(a) from VB+/LD value
logged on Data Sheet section 4.C.(3)(e).
4.C.(13)(c)
Verify the Chgr I value is greater than 500mA in the MAIN STATUS
MENU – UUT Status – ReadBk column.
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Table 1003. WCU Acceptance Test Data Sheet (Continued)
4.C.(14)(a) Verify Chgr I state is “L” in the UUT Status – State column.
4.C.(14)(b)
Verify the Chgr I value is less than 200mA in the MAIN STATUS
MENU – UUT Status – ReadBk column.
Read
Bk
4.C.(15)(a) Verify VB+/LD state is “0” in the TESTER Status – State column.
4.D
4.D.(1)(a)
WCU BATTERY TEMPERATURE TEST
Record the battery temperature in Celsius.
4.D.(1)(b)
Verify the battery temperature is within +7/-2°C of the room ambient
temperature recorded on the Data Sheet.
4.E
4.E.(1)
PASS
FAIL
PASS
FAIL
PASS
FAIL
PASS
FAIL
PASS
FAIL
Temp
OUTPUT SECTION
Verify OUT 1 through OUT 6 Output Current values are less than
25mA in the OUTPUTS STATUS MENU - UUT Status – OUT CUR
column.
OUT
CUR
OUT 1
OUT 2
OUT 3
OUT 4
OUT 5
OUT 6
OUT 1 RESULTS
4.E.(3)(a)
Verify EN/DIS state is “E” in the UUT Status – EN/DIS column for
Out 1.
PASS
FAIL
4.E.(3)(b)
Verify ACT/INA state is “A” in the UUT Status – ACT/INA column
for Out 1.
PASS
FAIL
4.E.(3)(c)
Verify Output Current is 1100mA +/-200mA in the UUT Status –
OUT CUR column for Out 1.
PASS
FAIL
OUT
CUR
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Table 1003. WCU Acceptance Test Data Sheet (Continued)
4.E.(3)(d)
Verify Output voltage is 7500mV +/-500mV in the Tester Status –
ReadBack column for Out 1.
4.E.(5)(a)
Verify OVR/NRM state is “Y” in the UUT Status – OVR/NRM
column for Out 1.
4.E.(5)(b)
Verify Output Current is 0mA +/-25mA in the UUT Status – OUT
CUR column for Out 1.
4.E.(6)(a)
Verify EN/DIS state is “D” in the UUT Status – EN/DIS column for
all other Outputs.
Read
Back
OUT
CUR
PASS
FAIL
PASS
FAIL
PASS
FAIL
PASS
FAIL
PASS
FAIL
PASS
FAIL
OUT 2
OUT 3
OUT 4
OUT 5
OUT 6
4.E.(6)(b)
Verify ACT/INA state is “I” in the UUT Status – ACT/INA column for
all other Outputs.
OUT 2
OUT 3
OUT 4
OUT 5
OUT 6
4.E.(6)(c)
Verify Output voltage is 0mV +/-10mV in the Tester Status –
ReadBack column for all other Outputs.
Read
Back
OUT 2
OUT 3
OUT 4
OUT 5
OUT 6
4.E.(8)(a)
Verify OVR/NRM state is “N” in the OUTPUTS STATUS MENU UUT Status – OVR/NRM column for Out 1.
PASS
FAIL
4.E.(9)(a)
Verify that the state of the CMD column changes from “Y” to “N” for
Out 1.
PASS
FAIL
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COMPONENT MAINTENANCE MANUAL
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Table 1003. WCU Acceptance Test Data Sheet (Continued)
OUT 2 RESULTS
Verify EN/DIS state is “E” in the UUT Status – EN/DIS column for
4.E.(3)(a)
Out 2.
PASS
FAIL
PASS
FAIL
4.E.(3)(b)
Verify ACT/INA state is “A” in the UUT Status – ACT/INA column
for Out 2.
4.E.(3)(c)
Verify Output Current is 1100mA +/-200mA in the UUT Status –
OUT CUR column for Out 2.
OUT
CUR
PASS
FAIL
4.E.(3)(d)
Verify Output voltage is 7500mV +/-500mV in the Tester Status –
ReadBack column for Out 2.
Read
Back
PASS
FAIL
4.E.(5)(a)
Verify OVR/NRM state is “Y” in the UUT Status – OVR/NRM
column for Out 2.
PASS
FAIL
4.E.(5)(b)
Verify Output Current is 0mA +/-25mA in the UUT Status – OUT
CUR column for Out 2.
PASS
FAIL
4.E.(6)(a)
Verify EN/DIS state is “D” in the UUT Status – EN/DIS column for
all other Outputs.
PASS
FAIL
PASS
FAIL
OUT
CUR
OUT 1
OUT 3
OUT 4
OUT 5
OUT 6
4.E.(6)(b)
Verify ACT/INA state is “I” in the UUT Status – ACT/INA column for
all other Outputs.
OUT 1
OUT 3
OUT 4
OUT 5
OUT 6
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Table 1003. WCU Acceptance Test Data Sheet (Continued)
4.E.(6)(c)
Verify Output voltage is 0mV +/-10mV in the Tester Status –
ReadBack column for all other Outputs.
Read
Back
PASS
FAIL
OUT 1
OUT 3
OUT 4
OUT 5
OUT 6
4.E.(8)(a)
Verify OVR/NRM state is “N” in the OUTPUTS STATUS MENU UUT Status – OVR/NRM column for Out 2.
PASS
FAIL
4.E.(9)(a)
Verify that the state of the CMD column changes from “Y” to “N” for
Out 2.
PASS
FAIL
PASS
FAIL
PASS
FAIL
OUT 3 RESULTS
Verify EN/DIS state is “E” in the UUT Status – EN/DIS column for
4.E.(3)(a)
Out 3.
4.E.(3)(b)
Verify ACT/INA state is “A” in the UUT Status – ACT/INA column
for Out 3.
4.E.(3)(c)
Verify Output Current is 1100mA +/-200mA in the UUT Status –
OUT CUR column for Out 3.
OUT
CUR
PASS
FAIL
4.E.(3)(d)
Verify Output voltage is 7500mV +/-500mV in the Tester Status –
ReadBack column for Out 3.
Read
Back
PASS
FAIL
4.E.(5)(a)
Verify OVR/NRM state is “Y” in the UUT Status – OVR/NRM
column for Out 3.
PASS
FAIL
4.E.(5)(b)
Verify Output Current is 0mA +/-25mA in the UUT Status – OUT
CUR column for Out 3.
PASS
FAIL
OUT
CUR
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COMPONENT MAINTENANCE MANUAL
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Table 1003. WCU Acceptance Test Data Sheet (Continued)
4.E.(6)(a)
Verify EN/DIS state is “D” in the UUT Status – EN/DIS column for
all other Outputs.
PASS
FAIL
PASS
FAIL
PASS
FAIL
OUT 1
OUT 2
OUT 4
OUT 5
OUT 6
Verify ACT/INA state is “I” in the UUT Status – ACT/INA column for
4.E.(6)(b)
all other Outputs.
OUT 1
OUT 2
OUT 4
OUT 5
OUT 6
Verify Output voltage is 0mV +/-10mV in the Tester Status –
4.E.(6)(c)
ReadBack column for all other Outputs.
Read
Back
OUT 1
OUT 2
OUT 4
OUT 5
OUT 6
4.E.(8)(a)
Verify OVR/NRM state is “N” in the OUTPUTS STATUS MENU UUT Status – OVR/NRM column for Out 3.
PASS
FAIL
4.E.(9)(a)
Verify that the state of the CMD column changes from “Y” to “N” for
Out 3.
PASS
FAIL
PASS
FAIL
PASS
FAIL
PASS
FAIL
OUT 4 RESULTS
Verify EN/DIS state is “E” in the UUT Status – EN/DIS column for
4.E.(3)(a)
Out 4.
4.E.(3)(b)
Verify ACT/INA state is “A” in the UUT Status – ACT/INA column
for Out 4.
4.E.(3)(c)
Verify Output Current is 1100mA +/-200mA in the UUT Status –
OUT CUR column for Out 4.
OUT
CUR
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Table 1003. WCU Acceptance Test Data Sheet (Continued)
4.E.(3)(d)
Verify Output voltage is 7500mV +/-500mV in the Tester Status –
ReadBack column for Out 4.
4.E.(5)(a)
Verify OVR/NRM state is “Y” in the UUT Status – OVR/NRM
column for Out 4.
4.E.(5)(b)
Verify Output Current is 0mA +/-25mA in the UUT Status – OUT
CUR column for Out 4.
4.E.(6)(a)
Verify EN/DIS state is “D” in the UUT Status – EN/DIS column for
all other Outputs.
Read
Back
OUT
CUR
PASS
FAIL
PASS
FAIL
PASS
FAIL
PASS
FAIL
PASS
FAIL
PASS
FAIL
OUT 1
OUT 2
OUT 3
OUT 5
OUT 6
4.E.(6)(b)
Verify ACT/INA state is “I” in the UUT Status – ACT/INA column for
all other Outputs.
OUT 1
OUT 2
OUT 3
OUT 5
OUT 6
4.E.(6)(c)
Verify Output voltage is 0mV +/-10mV in the Tester Status –
ReadBack column for all other Outputs.
Read
Back
OUT 1
OUT 2
OUT 3
OUT 5
OUT 6
4.E.(8)(a)
Verify OVR/NRM state is “N” in the OUTPUTS STATUS MENU UUT Status – OVR/NRM column for Out 4.
PASS
FAIL
4.E.(9)(a)
Verify that the state of the CMD column changes from “Y” to “N” for
Out 4.
PASS
FAIL
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COMPONENT MAINTENANCE MANUAL
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Table 1003. WCU Acceptance Test Data Sheet (Continued)
OUT 5 RESULTS
Verify EN/DIS state is “E” in the UUT Status – EN/DIS column for
4.E.(3)(a)
Out 5.
PASS
FAIL
PASS
FAIL
4.E.(3)(b)
Verify ACT/INA state is “A” in the UUT Status – ACT/INA column
for Out 5.
4.E.(3)(c)
Verify Output Current is 1100mA +/-200mA in the UUT Status –
OUT CUR column for Out 5.
OUT
CUR
PASS
FAIL
4.E.(3)(d)
Verify Output voltage is 7500mV +/-500mV in the Tester Status –
ReadBack column for Out 5.
Read
Back
PASS
FAIL
4.E.(5)(a)
Verify OVR/NRM state is “Y” in the UUT Status – OVR/NRM
column for Out 5.
PASS
FAIL
4.E.(5)(b)
Verify Output Current is 0mA +/-25mA in the UUT Status – OUT
CUR column for Out 5.
PASS
FAIL
4.E.(6)(a)
Verify EN/DIS state is “D” in the UUT Status – EN/DIS column for
all other Outputs.
PASS
FAIL
PASS
FAIL
OUT
CUR
OUT 1
OUT 2
OUT 3
OUT 4
OUT 6
4.E.(6)(b)
Verify ACT/INA state is “I” in the UUT Status – ACT/INA column for
all other Outputs.
OUT 1
OUT 2
OUT 3
OUT 4
OUT 6
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COMPONENT MAINTENANCE MANUAL
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Table 1003. WCU Acceptance Test Data Sheet (Continued)
4.E.(6)(c)
Verify Output voltage is 0mV +/-10mV in the Tester Status –
ReadBack column for all other Outputs.
Read
Back
PASS
FAIL
OUT 1
OUT 2
OUT 3
OUT 4
OUT 6
4.E.(8)(a)
Verify OVR/NRM state is “N” in the OUTPUTS STATUS MENU UUT Status – OVR/NRM column for Out 5.
PASS
FAIL
4.E.(9)(a)
Verify that the state of the CMD column changes from “Y” to “N” for
Out 5.
PASS
FAIL
PASS
FAIL
PASS
FAIL
OUT 6 RESULTS
Verify EN/DIS state is “E” in the UUT Status – EN/DIS column for
4.E.(3)(a)
Out 6.
4.E.(3)(b)
Verify ACT/INA state is “A” in the UUT Status – ACT/INA column
for Out 6.
4.E.(3)(c)
Verify Output Current is 1100mA +/-200mA in the UUT Status –
OUT CUR column for Out 6.
OUT
CUR
PASS
FAIL
4.E.(3)(d)
Verify Output voltage is 7500mV +/-500mV in the Tester Status –
ReadBack column for Out 6.
Read
Back
PASS
FAIL
4.E.(5)(a)
Verify OVR/NRM state is “Y” in the UUT Status – OVR/NRM
column for Out 6.
PASS
FAIL
4.E.(5)(b)
Verify Output Current is 0mA +/-25mA in the UUT Status – OUT
CUR column for Out 6.
PASS
FAIL
4.E.(6)(a)
Verify EN/DIS state is “D” in the UUT Status – EN/DIS column for
all other Outputs.
PASS
FAIL
OUT
CUR
OUT 1
OUT 2
OUT 3
OUT 4
OUT 5
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COMPONENT MAINTENANCE MANUAL
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Table 1003. WCU Acceptance Test Data Sheet (Continued)
4.E.(6)(b)
Verify ACT/INA state is “I” in the UUT Status – ACT/INA column for
all other Outputs.
PASS
FAIL
PASS
FAIL
OUT 1
OUT 2
OUT 3
OUT 4
OUT 5
4.E.(6)(c)
Verify Output voltage is 0mV +/-10mV in the Tester Status –
ReadBack column for all other Outputs.
Read
Back
OUT 1
OUT 2
OUT 3
OUT 4
OUT 5
4.E.(8)(a)
Verify OVR/NRM state is “N” in the OUTPUTS STATUS MENU UUT Status – OVR/NRM column for Out 6.
PASS
FAIL
4.E.(9)(a)
Verify that the state of the CMD column changes from “Y” to “N” for
Out 6.
PASS
FAIL
PASS
FAIL
4.F
CONFIGURATION / ID SIGNALS TEST
Verify the UUT Status – STATE column alternates between H & L
4.F.(3)(a)
beginning at ID 1 with “L” and ending at IDrtn with “L”.
State
ID 1
ID 2
ID 3
ID 4
ID 5
CTRLen
IDrtn
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Table 1003. WCU Acceptance Test Data Sheet (Continued)
Verify the Tester Status – ReadBack column values alternate
between 2100mV +/-100mV and 300mV +/-100mV, beginning with
4.F.(3)(b)
ID 1 with 300mV +/-100mV and ending at IDrtn with 300mV +/100mV.
READ
BACK
PASS
FAIL
State
PASS
FAIL
PASS
FAIL
ID 1
ID 2
ID 3
ID 4
ID 5
CTRLen
IDrtn
Verify the UUT Status – STATE column alternates between H & L
4.F.(5)(a)
beginning at ID 1 with “H” and ending at IDrtn with “H”.
ID 1
ID 2
ID 3
ID 4
ID 5
CTRLen
IDrtn
Verify the Tester Status – READBACK column values alternate
between 2100mV +/-100mV and 300mV +/-100mV, beginning with
4.F.(5)(b)
ID 1 with 2100mV +/-100mV and ending at CTRLen with 300mV +/100mV. IDrtn READBACK value should be 3300mV +/-100mV.
READ
BACK
ID 1
ID 2
ID 3
ID 4
ID 5
CTRLen
IDrtn
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COMPONENT MAINTENANCE MANUAL
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Table 1003. WCU Acceptance Test Data Sheet (Continued)
4.F.(7)(a)
Verify IDrtn drops to 0mV +/-100mV in the Tester Status –
READBACK column.
4.F.(7)(b)
Verify rtnGND reports ID_1RTN GRD in the CONFIGURATION
MENU – Tester Status – READBACK column.
4.F.(8)(a)
Verify IDrtn drops to 0mV +/-100mV in the Tester Status –
READBACK column.
4.F.(8)(b)
Verify rtnGND reports ID_2RTN GRD in the CONFIGURATION
MENU – Tester Status – READBACK column.
4.F.(9)(a)
Verify IDrtn drops to 0mV +/-100mV in the Tester Status –
READBACK column.
4.F.(9)(b)
Verify rtnGND reports ID_3RTN GRD in the CONFIGURATION
MENU – Tester Status – READBACK column.
4.F.(10)(a)
Verify IDrtn drops to 0mV +/-100mV in the Tester Status –
READBACK column.
4.F.(10)(b)
Verify rtnGND reports ID_4RTN GRD in the CONFIGURATION
MENU – Tester Status – READBACK column.
4.F.(11)(a)
Verify IDrtn drops to 0mV +/-100mV in the Tester Status –
READBACK column.
4.F.(11)(b)
Verify rtnGND reports ID_5RTN GRD in the CONFIGURATION
MENU – Tester Status – READBACK column.
4.F.(12)(a)
Verify IDrtn READBACK returns to 3300mV +/-100mV in the Tester
Status – READBACK column.
READ
BACK
READ
BACK
READ
BACK
READ
BACK
READ
BACK
READ
BACK
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PASS
FAIL
PASS
FAIL
PASS
FAIL
PASS
FAIL
PASS
FAIL
PASS
FAIL
PASS
FAIL
PASS
FAIL
PASS
FAIL
PASS
FAIL
PASS
FAIL
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COMPONENT MAINTENANCE MANUAL
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Table 1003. WCU Acceptance Test Data Sheet (Continued)
4.G
CONTROL VOLTAGE TEST
The current Control V value reported in the MAIN STATUS MENU
4.G.(1)(a)
– UUT Status – ReadBk column.
Verify Control V + input is 0mV +/-125mV and – input is 0mV +/4.G.(1)(b
50mV in the MAIN STATUS MENU - Tester Status – ReadBk
column.
Read
Bk
+ input
- input
Verify the Control V value recorded in section 4.G.(1)(a) of Data
4.G.(1)(c) Sheet is within +/- 250mV of the Control V (+ Input) value recorded
in section 4.G.(1)(b) of Data Sheet.
4.G.(2)(a)
The current Control V value reported in the MAIN STATUS MENU
– UUT Status – ReadBk column.
Verify Control V + input is 10000mV +/-500mV and – input is 0mV
4.G.(2)(b
+/-50mV in the MAIN STATUS MENU - Tester Status – ReadBk
column.
The current Control V value reported in the MAIN STATUS MENU
– UUT Status – ReadBk column.
Verify Control V + input is 20000mV +/- 500mV and – input is 0mV
4.G.(3)(b
+/-50mV in the MAIN STATUS MENU - Tester Status – ReadBk
column.
4.G.(3)(c)
Verify Control V ReadBk value recorded in section 4.G.(3)(a) is
greater than 18000mV.
4.G.(4)(a)
The current Control V value reported in the MAIN STATUS MENU
– UUT Status – ReadBk column.
Verify Control V + input is 20000mV +/- 500mV and – input is
4.G.(4)(b
5000mV +/-200mV in the MAIN STATUS MENU - Tester Status –
ReadBk column.
+ input
- input
PASS
FAIL
PASS
FAIL
PASS
FAIL
PASS
FAIL
PASS
FAIL
PASS
FAIL
Read
Bk
+ input
- input
Read
Bk
+ input
- input
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FAIL
Read
Bk
Verify the Control V value recorded in section 4.G.(2)(a) of Data
4.G.(2)(c) Sheet is within +/- 250mV of the Control V (+ Input) value recorded
in section 4.G.(2)(b) of Data Sheet.
4.G.(3)(a)
PASS
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Table 1003. WCU Acceptance Test Data Sheet (Continued)
Verify the Control V value recorded in section 4.G.(4)(a) is within
4.G.(4)(c) +/- 500mV of the Control V + input voltage minus the Control V input voltage recorded in section 4.G.(4)(b) of the Data Sheet.
Voltage
Diff.
PASS
FAIL
PASS
FAIL
PASS
FAIL
PASS
FAIL
PASS
FAIL
PASS
FAIL
4.J.(17)(a) Verify that all tests have passed.
PASS
FAIL
4.J.(25)(a) Verify that all tests have passed.
PASS
FAIL
4.H
EEPROM TEST
Verify the EEPROM TEST MENU reports a “PASS” in the UUT
Status – Quick Test Result column for EEPROM 1 and verify the
4.H.(1)(a) MESSAGE MENU reports the following message:
EEPROM 01 Test Results A5 A5 00 00 00 00 00 00
Verify the EEPROM TEST MENU reports a “PASS” in the UUT
Status – Quick Test Result column for EEPROM 2 and verify the
4.H.(2)(a) MESSAGE MENU reports the following message:
EEPROM 02 Test Results A5 A5 00 00 00 00 00 00
Verify the EEPROM TEST MENU reports a “PASS” in the UUT
Status – Full Test Result column for EEPROM 1 and verify the
4.H.(3)(a) MESSAGE MENU reports the following message:
EEPROM 01 Test Results 00 00 00 00 00 00 00 00
Verify the EEPROM TEST MENU reports a “PASS” in the UUT
Status – Full Test Result column for EEPROM 2 and verify the
4.H.(4)(a) MESSAGE MENU reports the following message:
EEPROM 02 Test Results 00 00 00 00 00 00 00 00
Verify the EEPROM TEST MENU reports a “PASS” in the UUT
Status – Full Test Result column for EEPROM 3 and verify the
4.H.(5)(a) MESSAGE MENU reports the following message:
EEPROM 03 Test Results 00 00 00 00 00 00 00 00
4.J
RF TEST
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COMPONENT MAINTENANCE MANUAL
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Table 1003. WCU Acceptance Test Data Sheet (Continued)
4.K
FINAL VERIFICATION OF WCU AFTER WELS SOFTWARE IS DOWNLOADED
Verify Output voltages remain at 0mV +/-25mV in the OUTPUTS
Read
4.K.(6)(a) STATUS MENU - Tester Status – ReadBack column for all
Back
Outputs.
PASS
FAIL
PASS
FAIL
4.K.(14)(a Verify that all six output LED’s (D1 through D6) on the WCU
Interface Board are illuminated.
PASS
FAIL
4.K.(15)(a Verify that all six output LED’s (D1 through D6) on the WCU
Interface Board are off.
PASS
FAIL
4.K.(16)(a Verify that all six output LED’s (D1 through D6) on the WCU
Interface Board are illuminated.
PASS
FAIL
4.K.(17)(a Verify that all six output LED’s (D1 through D6) on the WCU
Interface Board are off.
PASS
FAIL
OUT 1
OUT 2
OUT 3
OUT 4
OUT 5
OUT 6
Verify that the following CAN message appears in the “Message
Menu”. The 4 digits below, that are in BOLD, will change in each
4.K.(7)(a) CAN message received.
RX CID : 0320 0303, RX Msg (0-4): 0 0 0 0
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COMPONENT MAINTENANCE MANUAL
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TASK 33-50-01-700-802-A01
4.
Test Software Programming Procedure
This section contains the test software programming procedures for the WCU.
NOTE:
SUBTASK 33-50-01-700-011-A01
A.
Write Main Test Software to Microcontroller Flash Memory
(1)
The test setup for programming the WCU is shown in Figure 1018.
Equipment Setup for Programming WCU
Figure 1018 / GRAPHIC 33-50-01-99B-020-A01
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NOTE:
The following instructions reference information presented in WCU Test Program
V1.V00 – Comm Menu – Connected State as shown in Figure 1002 and WCU
Test Program - MAIN STATUS MENU as shown in Figure 1006.
(2)
Turn ON the WELS Test Box “MAIN POWER” switch.
(3)
Run the Windows WCU Test Program on the PC.
(4)
The WCU Test Program will automatically establish a connection between the WCU
Test Program and the WELS Test Box. Refer to the WCU Test Program V1.V00 –
Comm Menu as shown in Figure 1002.
(5)
Once a good connection is established the Tester Status box will switch from “FLT”
to “OK”, the UUT box will display “99” and the RX Status indicator will display a
flashing green dot. Refer to Figure 1002.
(6)
The following menu will need to be displayed before continuing:
Display UUT Main Status
(7)
Select the menu that needs to be displayed by checking the box next to the Menu
description in the Menus section of the WCU Test Program V1.V00 – Comm Menu.
(8)
Click the “Display Checked Menus” button to display the menu that is selected.
(9)
Turn ON the AC power by clicking on the “Turn AC On” button in the MAIN STATUS
MENU as shown in Figure 1006.
(10)
Turn ON the DC power by clicking on the “Turn DC On” button in the MAIN STATUS
MENU as shown in Figure 1006.
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COMPONENT MAINTENANCE MANUAL
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SAM-PROG v2.3 Menu
Figure 1019 / GRAPHIC 33-50-01-99B-021-A01
NOTE:
The following instructions reference information presented in the SAM-PROG
Software Program as shown in Figure 1019 and Figure 1020.
(11)
Start the SAM-PROG software application on the PC.
(12)
Click on the “Browse” button and select the “welsapp.bin” file. The “welsapp.bin”
file is located at the following location:
H: \ RELEASE \ 050 \ 0232 \ 08031
(13)
Check “None” for the PIO indicator for successful programming option.
(14)
Select “18432000” as the Crystal Oscillator Frequency (Hz).
(15)
Check the “Auto-mode” option box.
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COMPONENT MAINTENANCE MANUAL
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(16)
NOTE:
(17)
Click on the “Yes” button to connect to target and write to flash memory.
During the flash memory download the “In progress:” and “Active Connection:”
status will be “1”.
Once the download is complete, SAM-PROG will report whether the download was
successful or not. Refer to Figure 1020.
SAM-PROG Download Status
Figure 1020 / GRAPHIC 33-50-01-99B-022-A01
(18)
Close the SAM-PROG program by clicking on the “EXIT” button.
(19)
Turn OFF the AC power by clicking on the “Turn AC Off” button in the WELS Test
Program - MAIN STATUS MENU as shown in Figure 1006.
(20)
Turn OFF the DC power by clicking on the “Turn DC Off” button in the WELS Test
Program – MAIN STATUS MENU as shown in Figure 1006.
SUBTASK 33-50-01-700-012-A01
B.
Write RF Software to Microcontroller Flash Memory
(1)
NOTE:
The test setup for programming the WCU is shown in Figure 1018.
The following instructions reference information presented in WCU Test Program
V1.V00 – Comm Menu – Connected State as shown in Figure 1002 and WCU
Test Program - MAIN STATUS MENU as shown in Figure 1006.
(2)
Turn ON the WELS Test Box “MAIN POWER” switch.
(3)
Run the Windows WCU Test Program on the PC.
(4)
The WCU Test Program will automatically establish a connection between the WCU
Test Program and the WELS Test Box. Refer to the WCU Test Program V1.V00 –
Comm Menu as shown in Figure 1002.
(5)
Once a good connection is established the Tester Status box will switch from “FLT”
to “OK”, the UUT box will display “99” and the RX Status indicator will display a
flashing green dot. Refer to Figure 1002.
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(6)
The following menu will need to be displayed before continuing:
Display UUT Main Status
(7)
Select the menu that needs to be displayed by checking the box next to the Menu
description in the Menus section of the WCU Test Program V1.V00 – Comm Menu.
(8)
Click the “Display Checked Menus” button to display the menu that is selected.
(9)
Turn ON the AC power by clicking on the “Turn AC On” button in the MAIN STATUS
MENU as shown in Figure 1006.
(10)
Turn ON the DC power by clicking on the “Turn DC On” button in the MAIN STATUS
MENU as shown in Figure 1006.
NOTE:
The following instructions reference information presented in the SAM-PROG
Software Program as shown in Figure 1019 and Figure 1020.
(11)
Start the SAM-PROG software application on the PC.
(12)
Click on the “Browse” button and select the “welsapp.bin” file. The “welsapp.bin”
file is located at the following location:
H: \ RELEASE \ 050 \ 0230 \ 07341
(13)
Check “None” for the PIO indicator for successful programming option.
(14)
Select “18432000” as the Crystal Oscillator Frequency (Hz).
(15)
Check the “Auto-mode” option box.
(16)
Click on the “Yes” button to connect to target and write to flash memory.
NOTE:
During the flash memory download the “In progress:” and “Active Connection:”
status will be “1”.
(17)
Once the download is complete, SAM-PROG will report whether the download was
successful or not. Refer to Figure 1020.
(18)
Close the SAM-PROG program by clicking on the “EXIT” button.
(19)
Turn OFF the AC power by clicking on the “Turn AC Off” button in the WELS Test
Program - MAIN STATUS MENU as shown in Figure 1006.
(20)
Turn OFF the DC power by clicking on the “Turn DC Off” button in the WELS Test
Program – MAIN STATUS MENU as shown in Figure 1006.
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TASK 33-50-01-700-803-A01
5.
Operational Software Programming Procedure
This section contains the operational software programming procedures for the WCU.
NOTE:
SUBTASK 33-50-01-700-013-A01
A.
Write WELS Software to the Microcontroller Flash Memory
(1)
The test setup for programming the WCU is shown in Figure 1018.
(2)
Install the WELS Software (Built Code).
NOTE:
The following instructions reference information presented in the SAM-PROG
Software Program as shown in Figure 1019 and Figure 1020 and the WCU Test
Program - MAIN STATUS MENU as shown in Figure 1006.
(3)
Turn ON the AC power by clicking on the “Turn AC On” button in the WELS Test
Program - MAIN STATUS MENU. Verify that the AC ON/ON State column is “Y” for
both the UUT Status and Tester Status.
(4)
Turn ON the DC power by clicking on the “Turn DC On” button in the WELS Test
Program - MAIN STATUS MENU.
(5)
Run the SAM-PROG program on the PC.
NOTE:
The SAM-PROG program will appear as an icon on the desktop when it is loaded
from its original media (CD or internet) to the computer.
(6)
Perform the following steps in the SAM-PROG menu:
(7)
Click on the “Browse” button and select the “welsapp.bin” file. The “welsapp.bin”
file is located at the following location:
H: \ RELEASE \ 050 \ 0211 \ 0211-08237 / welsapp / config_flash_debug_7x_ver2 / exe
(8)
Check “None” for the PIO indicator for successful programming option.
(9)
Select “18432000” as the Crystal Oscillator Frequency (Hz).
(10)
Check the “Auto-mode” option box.
(11)
Click on the “Yes” button to connect to target and write to flash memory.
NOTE:
During the flash memory download the “In progress:” and “Active Connection:”
status will be “1”.
(12)
Once the download is complete, SAM-PROG will report whether the download was
successful or not. Refer to Figure 1020.
(13)
Close the SAM-PROG program by clicking on the “EXIT” button.
(14)
Turn OFF the AC power by clicking on the “Turn AC Off” button in the WELS Test
Program - MAIN STATUS MENU as shown in Figure 1006.
(15)
Turn OFF the DC power by clicking on the “Turn DC Off” button in the WELS Test
Program – MAIN STATUS MENU as shown in Figure 1006.
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SCHEMATICS AND WIRING DIAGRAMS
TASK 33-50-01-99F-803-A01
1.
General Information
SUBTASK 33-50-01-99F-011-A01
A.
Introduction
(1)
This section has the schematics for the WELS Control Unit (WCU). The WCU
schematic is shown in Figure 2001.
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INTENTIONALLY
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WELS Control Unit Schematic
Figure 2001 / GRAPHIC 33-50-01-99B-023-A01
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DISASSEMBLY
TASK 33-50-01-99F-804-A01
1.
General Information
SUBTASK 33-50-01-99F-012-A01
A.
Introduction
WARNING:
BEFORE MATERIALS CALLED OUT IN THIS PUBLICATION ARE USED,
KNOW THE HANDLING, STORAGE, AND DISPOSAL PRECAUTIONS
RECOMMENDED BY THE MANUFACTURER OR SUPPLIER. FAILURE
TO FOLLOW THE MANUFACTURERS’ OR SUPPLIERS’
RECOMMENDATIONS CAN RESULT IN PERSONAL INJURY OR
DISEASE.
CAUTION:
DISASSEMBLY MUST BE DONE WITH PROPER ESD PRECAUTIONS.
FAILURE TO FOLLOW THIS CAUTION MAY RESULT IN DAMAGE TO
THE UNIT.
CAUTION:
THIS UNIT HAS ASSEMBLIES THAT ARE SUSCEPTIBLE TO DAMAGE
FROM INCORRECT HANDLING. DO NOT DROP OR HIT THE UNIT
DURING THESE PROCEDURES.
CAUTION:
THESE PROCEDURES MUST BE DONE IN A CLEAN ENVIRONMENT IN
ORDER TO PREVENT DAMAGE TO MECHANICAL COMPONENTS.
(1)
This section has the disassembly information for the WELS Control Unit (WCU).
(2)
Disassemble in a dry, bright, clean room.
(3)
Be careful to prevent damage to parts that can be used again.
(4)
Make sure the WELS battery unit has been removed from the WCU. See the WELS
Battery Unit Removal procedures in the DISASSEMBLY section.
Discard the circular connector gasket and the SMA connector gasket.
NOTE:
TASK 33-50-01-94B-802-A01
2.
Equipment and Materials
SUBTASK 33-50-01-94A-002-A01
A.
Consumable Materials
(1)
Consumable materials used during the Disassembly procedures are shown in
Table 3001.
NOTE:
Equivalent alternatives can be used.
Table 3001. Consumable Materials / TABLE 33-50-01-99A-007-A01
Name
Cleaning Cloth
Isopropyl alcohol
Specification or
Part Number
Lint-free
Federal Specification TT-I-735
Source or
(CAGE)
Commercially available
Commercially available
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SUBTASK 33-50-01-94B-002-A01
B.
Special Tools, Fixtures, and Test Equipment
(1)
No special tools, fixtures, or test equipment are needed for Disassembly procedures.
TASK 33-50-01-060-801-A01
3.
Disassembly Procedures
SUBTASK 33-50-01-060-001-A01
A.
WELS Battery Unit Removal
NOTE:
(1)
The following procedures are required to remove the battery from the WCU only if
the battery is still installed.
Insert standard 3/32 inch hex key or similar size tool into battery latch hole. See
Figure 3001.
NOTE:
The tool needs to fit into a 0.125 inch (3.18MM) diameter hole.
(2)
Lift battery latch with tool.
(3)
Grip the battery pack on both sides and pull out.
WELS Battery Unit Removal
Figure 3001 / GRAPHIC 33-50-01-99B-024-A01
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SUBTASK 33-50-01-060-002-A01
B.
Disassemble the WCU Assembly
NOTE:
Refer to the IPL Figure 1 for an illustration of the WCU assembly
Numbers in parenthesis ( ) refer to item numbers on the illustration.
(1)
Remove three plungers (20) and three grommets (30) from the tabs located on the
unit.
(2)
If the nameplate label (40) or RF transceiver label (50) is damaged, peel the
damaged label from the unit.
NOTE:
(3)
Clean the peeled area with a lint free cloth dampened with isopropyl alcohol and
allow the cleaned area to air dry.
NOTE:
(4)
If the nameplate label (40) is removed, mark the new label with the
identification information from the old label.
Do not remove the nameplate label (40) or RF transceiver label (50)
unless it is damaged.
Remove the male connector cap (60), nut and washer from the J4 antenna
connector located on the front case (90).
NOTE:
The nut and washer are part of the SMA connector as shown in
IPL Figure 2.
(5)
Remove four screws (80), four lock washers (90) and four flat washers (100) from
the front case (70).
(6)
Use a razor blade knife to cut the adhesive located on the edges where the front
case (70) meets the back case (230).
(7)
Grasp the locking tabs on the front case (70), squeeze the locking tabs together and
pull the front case away from the back case (230).
(8)
Pull the adhesive from the front case (70) and the back case (230). Clean the peeled
area with a lint free cloth dampened with isopropyl alcohol and allow the cleaned
area to air dry.
(9)
Remove the circular connector gasket (110) and the SMA connector gasket (120)
from the electronic assembly (130). Discard gaskets.
(10)
Remove two screws (140), two lock washers (150) and two flat washers (160) from
the electronic assembly (130).
(11)
Remove the electronic assembly (130) from the back case (230).
(12)
Remove two screws (180), two lock washers (190) and two flat washers (200) from
the inside of the back case (230) and remove the battery clip bracket (170).
(13)
Remove the battery clip (210) and the compression spring (220) from the back
case (230).
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SUBTASK 33-50-01-060-003-A01
C.
Disassemble the Electronic Assembly
NOTE:
Refer to the IPL Figure 2 for an illustration of the electronic assembly.
Numbers in parenthesis ( ) refer to item numbers on the illustration.
(1)
Remove one screw (20), one lock washer (30) and one flat washer (40) from the
combined interface PWA (10).
(2)
Remove the combined interface PWA (10) from the control PWA (50).
NOTE:
The nut (70) and washer (80) are part of the SMA connector (60) and are
procured with the SMA connector (60).
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COMPONENT MAINTENANCE MANUAL
100-2601
CLEANING
TASK 33-50-01-99F-805-A01
1.
General Information
SUBTASK 33-50-01-99F-013-A01
A.
Introduction
WARNING:
BEFORE MATERIALS CALLED OUT IN THIS PUBLICATION ARE USED,
KNOW THE HANDLING, STORAGE, AND DISPOSAL PRECAUTIONS
RECOMMENDED BY THE MANUFACTURER OR SUPPLIER. FAILURE
TO FOLLOW THE MANUFACTURERS’ OR SUPPLIERS’
RECOMMENDATIONS CAN RESULT IN PERSONAL INJURY OR
DISEASE.
CAUTION:
THESE PROCEDURES MUST BE DONE AT A STATIC-FREE
WORKSTATION IN ORDER TO PREVENT DAMAGE TO
ELECTROSTATIC SENSITIVE COMPONENTS.
CAUTION:
THIS UNIT HAS ASSEMBLIES THAT ARE SUSCEPTIBLE TO DAMAGE
FROM INCORRECT HANDLING. DO NOT DROP OR HIT THE UNIT
DURING THESE PROCEDURES.
CAUTION:
THESE PROCEDURES MUST BE DONE IN A CLEAN ENVIRONMENT IN
ORDER TO PREVENT DAMAGE TO MECHANICAL COMPONENTS.
(1)
This section has general procedures recommended by Securaplane to clean the
WELS Control Unit (WCU). There is no disassembly required to clean the unit.
TASK 33-50-01-94B-803-A01
2.
Equipment and Materials
SUBTASK 33-50-01-94A-003-A01
A.
Consumable Materials
(1)
Consumable materials used during the Cleaning procedures are shown in
Table 4001.
NOTE:
Equivalent alternatives can be used.
Table 4001. Consumable Materials / TABLE 33-50-01-99A-008-A01
Name
Specification or
Part Number
Source or
(CAGE) Code
Cleaning Cloth
MIL-C-85043
Commercially available
SUBTASK 33-50-01-94B-003-A01
B.
Special Tools, Fixtures, and Test Equipment
(1)
No special tools, fixtures, or test equipment are needed for Cleaning procedures.
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TASK 33-50-01-100-801-A01
3.
Cleaning Procedures
SUBTASK 33-50-01-100-001-A01
A.
Cleaning Practices
(1)
Each part must be cleaned with the procedures in this section or the equivalent
procedures used by an approved overhaul facility.
(2)
These procedures agree with good shop procedures as used by the Securaplane
facility. Clean parts are important to satisfactory operation.
(3)
Use clean, dry lint-free cleaning cloth to dry parts.
SUBTASK 33-50-01-100-002-A01
B.
External Cleaning
NOTE:
(1)
Cleaning is limited to external cleaning only.
Clean the outside surfaces of the unit with a cleaning cloth.
NOTE:
(2)
Use approved static sensitive bags for part storage after cleaning. Do not
use tape, loose plastic, or rags to protect clean parts.
Install dust cap (supplied with unit) on the J1 and J4 connector to protect against
contamination and thread damage.
NOTE:
Use approved caps, plugs and barrier materials for part storage after
cleaning. Do not use tape, loose plastic, or rags to protect clean parts.
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100-2601
INSPECTION/CHECK
TASK 33-50-01-99F-806-A01
1.
General Check Information
SUBTASK 33-50-01-99F-014-A01
A.
Introduction
(1)
This section has the general procedures to check the WELS Control Unit (WCU).
There is no disassembly required to check the unit.
TASK 33-50-01-94B-804-A01
2.
Equipment and Materials
SUBTASK 33-50-01-94A-004-A01
A.
Consumable Materials
(1)
No consumable materials are needed for the Check procedures.
SUBTASK 33-50-01-94B-004-A01
B.
Special Tools, Fixtures, and Test Equipment
(1)
No special tools, fixtures, or test equipment are needed for Check procedures.
TASK 33-50-01-210-801-A01
3.
Check Procedures
SUBTASK 33-50-01-210-001-A01
A.
Internal Visual Checks
(1)
There are no internal visual checks.
NOTE:
Internal visual checks can only be done at an approved Securaplane
facility.
SUBTASK 33-50-01-210-002-A01
B.
External Visual Checks
(1)
Check the unit for nicks, cracks, scores, dents, scratches, corrosion, or broken welds
that may affect the unit’s operation.
(2)
Check the identification, information, and instruction labels and make sure they are
legible and securely attached.
(3)
Check the connectors for broken, bent, or loose pins. Make sure the connectors are
mounted correctly.
(4)
Check the chassis assembly for loose or missing fasteners.
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ASSEMBLY
TASK 33-50-01-99F-807-A01
1.
General Information
SUBTASK 33-50-01-99F-015-A01
A.
Introduction
WARNING:
BEFORE MATERIALS CALLED OUT IN THIS PUBLICATION ARE USED,
KNOW THE HANDLING, STORAGE, AND DISPOSAL PRECAUTIONS
RECOMMENDED BY THE MANUFACTURER OR SUPPLIER. FAILURE
TO FOLLOW THE MANUFACTURERS’ OR SUPPLIERS’
RECOMMENDATIONS CAN RESULT IN PERSONAL INJURY OR
DISEASE.
CAUTION:
ASSEMBLY MUST BE DONE WITH PROPER ESD PRECAUTIONS.
FAILURE TO FOLLOW THIS CAUTION MAY RESULT IN DAMAGE TO
THE UNIT.
CAUTION:
THIS UNIT HAS ASSEMBLIES THAT ARE SUSCEPTIBLE TO DAMAGE
FROM INCORRECT HANDLING. DO NOT DROP OR HIT THE UNIT
DURING THESE PROCEDURES.
CAUTION:
THESE PROCEDURES MUST BE DONE IN A CLEAN ENVIRONMENT IN
ORDER TO PREVENT DAMAGE TO MECHANICAL COMPONENTS.
(1)
This section has the procedures to assemble the WELS Control Unit (WCU).
(2)
Check the parts for damage. Refer to the INSPECTION/CHECK section.
(3)
Assemble in a dry, bright, clean room.
NOTE:
A new circular connector gasket and SMA connector gasket is required.
TASK 33-50-01-94B-805-A01
2.
Equipment and Materials
SUBTASK 33-50-01-94A-005-A01
A.
Consumable Materials
(1)
Consumable materials used during the Assembly procedures are shown in
Table 7001.
NOTE:
Equivalent alternatives can be used.
Table 7001. Consumable Materials / TABLE 33-50-01-99A-009-A01
Name
Silicone Adhesive Clear
Cleaning Cloth
Isopropyl alcohol
Specification or
Part Number
(3145) MIL-A-46146
MIL-C-85043
Federal Specification TT-I-735
Source or
(CAGE)
Commercially available
Commercially available
Commercially available
SUBTASK 33-50-01-94B-005-A01
B.
Special Tools, Fixtures, and Test Equipment
(1)
No special tools, fixtures, or test equipment are needed for the Assembly
procedures.
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TASK 33-50-01-460-801-A01
3.
Assembly Procedures
SUBTASK 33-50-01-460-001-A01
A.
Assemble the Electronic Assembly
NOTE:
(1)
Refer to the IPL Figure 2 for an illustration of the electronic assembly.
Numbers in parenthesis ( ) refer to item numbers on the illustration.
Install the combined interface PWA (10) to the control PWA (50).
NOTE:
(2)
Make sure to fully mate all header connectors.
Install one screw (20), one lock washer (30) and one flat washer (40) through the
combined interface PWA (10) and into the control PWA (50). Tighten screw to 2 – 3
lb-in (0.2 – 0.3 N-m).
NOTE:
The nut (70) and washer (80) are part of the SMA connector (60) and are
procured with the SMA connector (60).
SUBTASK 33-50-01-460-002-A01
B.
Assemble the WCU Assembly
NOTE:
(1)
Refer to the IPL Figure 1 for an illustration of the WCU assembly
Numbers in parenthesis ( ) refer to item numbers on the illustration.
Install the battery clip (210), the compression spring (220), and the battery clip
bracket (170) to the back case (230).
NOTE:
(2)
Install two flat washers (200), two lock washers (190), and two screws (180) through
the inside of the back case (230) and into the battery clip bracket (170). Tighten
screws to 4 – 5 lb-in (0.5 – 0.6 N-m).
NOTE:
(3)
Insert the spring (220) into the counterbore hole on the battery clip (210).
Align the spring between the ribs on the back case when installing the
battery clip.
Check for correct spring operation after the battery clip bracket has been
secured to the unit.
Install the electronic assembly (130) into the back case (230).
NOTE:
The electronic assembly slides into card guides located in the back case.
(4)
Install two flat washers (160), two lock washers (150), and two screws (140) through
the electronic assembly (130) and into the back case (230). Tighten screws to
4 – 5 lb-in (0.5 – 0.6 N-m).
(5)
Install a new circular connector gasket (110) and a new SMA connector gasket (120)
onto the electronic assembly (130).
(6)
Place the front case (70) with the locking tabs pointing upwards.
(7)
Apply adhesive (3145) around the entire channel on the front case (70). See Figure
7001 for front case channel location.
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(8)
Grasp the locking tabs on the front case (70), squeeze the locking tabs together and
push the front case onto the back case.
(9)
Clean the excess adhesive from the external surfaces of the front case (70) and
back case (230). Use Isopropyl alcohol and a clean cloth to remove excess
adhesive.
(10)
Install four flat washers (100), four lock washers (90), and four screws (80) to the
front case (70). Tighten screws to 4 – 5 lb-in (0.5 – 0.6 N-m).
(11)
Install one washer and one nut on the J4 antenna connector located on the front
case (70). Tighten nut to 5.5 – 6.5 lb-in (0.6 – 0.7 N-m).
NOTE:
The nut and washer are part of the SMA connector as shown in
IPL Figure 2.
(12)
Install the male connector cap (60) on the J4 antenna connector located on the front
case (70). Tighten cap to 5.5 – 6.5 lb-in (0.6 – 0.7 N-m).
(13)
If previously removed, install a new nameplate label (40) or RF transceiver label (50)
onto the back case (230).
NOTE:
If the nameplate label is replaced, mark the new label with the
identification information from the old label.
(14)
Install three plungers (20) and three grommets (30) to the tabs located on the back
case (230).
(15)
Continue to the TESTING AND FAULT ISOLATION section.
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Front Case Adhesive Channel
Figure 7001 / GRAPHIC 33-50-01-99B-025-A01
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COMPONENT MAINTENANCE MANUAL
100-2601
FITS AND CLEARANCES
TASK 33-50-01-99F-808-A01
1.
General Information
SUBTASK 33-50-01-99F-016-A01
A.
Introduction
(1)
This section has the Fits and Clearances for the WELS Control Unit (WCU).
(2)
The WCU dimensions are shown in Figure 8001.
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COMPONENT MAINTENANCE MANUAL
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WELS Control Unit Fits and Clearances
Figure 8001 / GRAPHIC 33-50-01-99B-026-A01
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COMPONENT MAINTENANCE MANUAL
100-2601
SPECIAL TOOLS, FIXTURES, EQUIPMENT AND CONSUMABLES
TASK 33-50-01-99F-809-A01
1.
General Information
SUBTASK 33-50-01-94A-006-A01
A.
Consumable Materials
(1)
Consumable materials used are shown in Table 9001.
Equivalent alternatives can be used.
NOTE:
Table 9001. Consumable Materials / TABLE 33-50-01-99A-010-A01
Name
Specification or
Part Number
Silicone Adhesive Clear
Cleaning Cloth
(3145) MIL-A-46146
MIL-C-85043
Isopropyl alcohol
Federal Specification TT-I-735
Static Sensitive Bag
–
Source or
CAGE Code
Commercially available Assembly
Commercially available Disassembly
Assembly
Cleaning
Storage
Commercially available Disassembly
Assembly
Commercially available Storage
33-50-01
FCC DRAFT 2-4-09
Use
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COMPONENT MAINTENANCE MANUAL
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SUBTASK 33-50-01-94B-006-A01
B.
Special Tools, Fixtures, and Test Equipment
(1)
Special tools, fixtures, and test equipment used are shown in Table 9002.
NOTE:
Equivalent alternatives can be used.
Table 9002. Special Tools, Fixtures, and Test Equipment / TABLE 33-50-01-99A-011-A01
Equipment
Characteristics
WELS Test Box
WCU Main Test Cable
Battery Simulator Module
Battery Simulator Cable
WELS Battery Unit (Fully
Charged to 8.4 Volts)
Standard FF RS232
Communication Serial Cable
(DB9 to DB9)
Computer
TE-1128-01
160-2275-01
TE-2637-01
TE-2633-01
100-2602-01
WCU Test Program, V1.V00
WCU Main Test Code
(8MB Flash-U35)
WCU RF Test Code
WELS 787 Operational SW Code
BlueTest2 Software
Bluetooth Test Set
Adapter Cable (and windows
driver)
Direct Connection Antenna Cable
Omnidirectional Antenna
Digital Multimeter
J-Link (USB to JTAG
Debugger/Programmer)
SAM-PROG v2.3 (or later)
Source or
(CAGE)
V0TMJ9
V0TMJ9
V0TMJ9
V0TMJ9
V0TMJ9
Testing
Testing
Testing
Testing
Testing
AK152-2-R
Commercially
available
Testing
Microsoft Windows XP
Professional Operating System
with (2) available USB Ports and
(1) available Serial Port.
512 MB RAM (memory)
10 MB of hard disk space
available. PC must also have
access to a printer.
050-0224-07341 Rev 050-0232-08031 Rev -
Commercially
available
Testing
V0TMJ9
V0TMJ9
Testing
Testing
V0TMJ9
V0TMJ9
VU4252
VU4252
V64667
Testing
Testing
Testing
Testing
Testing
V53919
Testing
050-0230-07341 Rev 050-0211-08237 Rev Version 1.0.0 Rev 1 (or later)
Anritsu MT8852A
National Instruments
GPIB-USB-HS
Pasternack PN PE3876-60
(5 feet in length recommended)
Antenova PN 2010B4844-01
True RMS Multimeter 0 to 10 VDC
1% accuracy (Fluke 87)
IAR Systems
V53919
V89536
Testing
Testing
V1QQS1
Testing
Atmel Corp
V1FN41
Testing
33-50-01
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COMPONENT MAINTENANCE MANUAL
100-2601
STORAGE (INCLUDING TRANSPORTATION)
TASK 33-50-01-99F-811-A01
1.
General Information
SUBTASK 33-50-01-99F-022-A01
A.
Introduction
WARNING:
BEFORE MATERIALS CALLED OUT IN THIS PUBLICATION ARE USED,
KNOW THE HANDLING, STORAGE, AND DISPOSAL PRECAUTIONS
RECOMMENDED BY THE MANUFACTURER OR SUPPLIER. FAILURE
TO FOLLOW THE MANUFACTURERS’ OR SUPPLIERS’
RECOMMENDATIONS CAN RESULT IN PERSONAL INJURY OR
DISEASE.
CAUTION:
THESE PROCEDURES MUST BE DONE AT A STATIC-FREE
WORKSTATION IN ORDER TO PREVENT DAMAGE TO
ELECTROSTATIC SENSITIVE COMPONENTS.
CAUTION:
THIS UNIT HAS ASSEMBLIES THAT ARE SUSCEPTIBLE TO DAMAGE
FROM INCORRECT HANDLING. DO NOT DROP OR HIT THE UNIT
DURING THESE PROCEDURES.
CAUTION:
THESE PROCEDURES MUST BE DONE IN A CLEAN ENVIRONMENT IN
ORDER TO PREVENT DAMAGE TO MECHANICAL COMPONENTS.
(1)
This section has the storage and shipping procedures recommended by
Securaplane for the WELS Control Unit (WCU).
(2)
Refer to the CLEANING section before storing the WCU.
TASK 33-50-01-94B-806-A01
2.
Equipment and Materials
SUBTASK 33-50-01-94A-007-A01
A.
Consumable Materials
(1)
Consumable materials used during the Storage procedures are shown in
Table 15001.
NOTE:
Equivalent alternatives can be used.
Table 15001. Consumable Materials / TABLE 33-50-01-99A-013-A01
Name
Specification or
Part Number
Source or
(CAGE) Code
Cleaning Cloth
MIL-C-85043
Commercially available
Static Sensitive Bag
–
Commercially available
33-50-01
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COMPONENT MAINTENANCE MANUAL
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SUBTASK 33-50-01-94B-007-A01
B.
Special Tools, Fixtures, and Test Equipment
(1)
No special tools, fixtures, or test equipment are needed for Storage procedures.
TASK 33-50-01-550-801-A01
3.
Storage/Transportation Procedures
SUBTASK 33-50-01-550-001-A01
A.
Prepare the WCU for Storage or Transportation
(1)
Clean the external surfaces with a clean, lint-free cloth.
(2)
Put dust caps (supplied with unit) on the WCU connector J1 and J4 to protect
against contamination.
SUBTASK 33-50-01-550-002-A01
B.
Storage Conditions
NOTE:
Store the WCU in the same ESD bag and shipping box as shown in the
transportation procedures.
(1)
Store the unit at an ambient temperature of 77°F (25°C) and with humidity (less than
70%) to minimize the possibility of moisture contamination of the unit.
(2)
Store the unit in a non-corrosive area away from high temperatures, dust, moisture,
and fumes.
SUBTASK 33-50-01-550-003-A01
C.
Transportation Procedures for Returning the WELS Control Unit to Securaplane
(1)
Put the WCU in an appropriately sized ESD bag and then wrap the unit in bubble
wrap.
(2)
Use the Securaplane shipping box (PN S-968) or equivalent to transport the WCU.
(3)
The packaging label for each shipping box will include the following information:
Securaplane Technologies
0TMJ9 (along with the bar code IAW ISO/TS 21849)
WELS Control Unit
100-2601-01 (along with the bar code IAW ISO/TS 21849)
S836Z300-200
Quantity
Unit(s) serial number (along with the bar code IAW ISO/TS 21849)
Date of Manufacture
Purchase order number
(4)
Include a failure report with the aircraft type and the WCU serial number.
33-50-01
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COMPONENT MAINTENANCE MANUAL
100-2601
ILLUSTRATED PARTS LIST
TASK 33-50-01-99F-810-A01
1.
Illustrated Parts List Introduction
SUBTASK 33-50-01-99F-017-A01
A.
General Information
(1)
The Illustrated Parts List (IPL) provides a breakdown of assemblies, subassemblies
and detail parts of the unit. All parts are listed, except for parts which lose their
identities by being permanently fastened to other parts or are part of an assembly
not subject to disassembly.
(2)
Bulk materials such as safety or electrical wire and tape, and consumable materials
such as adhesives, sealants, lubricants, solder, paint, and primer are not included in
the detailed parts lists. These materials are identified in the materials list at the
beginning of each section.
(3)
To find a part number when the part number is unknown, locate the part on the
illustration and note the item number. Locate the item number on the detailed parts
list. The part number will be shown on the same line. In some instances there are
gaps in item number sequence and the item numbers are not sequential.
SUBTASK 33-50-01-99F-018-A01
B.
Explanation of Columns, Terms and Symbols in the Illustrated Parts List (IPL)
(1)
(2)
FIG. & ITEM NO. column: The figure and item numbers key the detailed parts list to
the applicable illustration. The first number represents the figure number of the
illustration. The item number corresponds to an item number on the illustration.
(a)
An item number not on the illustration is identified by a dash (-) preceding
the item number.
(b)
An item number followed by an alphabetical character such as A, B, C, etc.,
indicates the part listed is similar to the same item number without the
alphabetical character. The difference could be each part is used for a
different next higher assembly (NHA) or is an equivalent part. This will be
noted in the NOMENCLATURE or EFF CODE columns.
PART NUMBER column: This column contains the original manufacturer's part
number of the assembly, subassembly, or detail part listed. Part numbers in this IPL
are those of Securaplane, Tucson, Arizona, or are standard parts unless a
Commercial and Government Entity (CAGE) code appears in the NOMENCLATURE
column. Refer to paragraph 4 for details. The following phrases may be used in this
column:
(a)
NONPROC followed by an assigned number (for example NONPROC01) is
used when no part number exists for the assembly. NONPROC assemblies
are not procurable and may not be ordered. However, the detail parts of the
assembly are procurable and may be ordered, unless otherwise specified.
(b)
REF followed by an assigned number (for example REF001) is used when
the part number of the part is more than fifteen digits. The original part
number with more than fifteen digits is listed in the NOMENCLATURE
column and is the part number to be used when ordering the part.
33-50-01
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(3)
AIRLINE STOCK NO. column: This column is reserved for airline stock numbers and
accommodates eleven characters.
(4)
NOMENCLATURE column: This column identifies the parts being listed by noun
name followed by modifiers when applicable. This column also provides the following
information.
(a)
The relationship of each listed item to its next higher assembly (NHA) is
shown by an indenture code. Each listed item is placed in the
NOMENCLATURE column one indenture (one dot) to the right of the
assembly to which it belongs. Items at equal indentures are all components
of a single assembly or subassembly. An example of the indenture code
system is shown below.
Assembly or Installation Descriptive Title
Assembly
Attaching Parts for Assembly
Detail Parts for Assembly
Subassembly
Attaching Parts for Subassembly
Detail Parts for Subassembly
Sub-Subassembly
Attaching Parts for Sub-Subassembly
Detail Parts for Sub-Subassembly
(b)
(c)
Symbols used with the exception of effectivity and CAGE codes are as
follows:
(ATTACHING PARTS) Designates start of each group of attaching
parts.
-------*-------
Designates end of each group of attaching parts.
The following phrases may be used in this column:
ALT identifies the part is an alternate. The part is fully
interchangeable in form, fit, and function with other item numbers
shown.
NP identifies this part is Non-Procurable.
DELETED identifies a part is no longer used.
REPLD BY identifies the part is replaced and is two-way
interchangeable with the item number shown. However, either part
may be used.
REPLS identifies the part replaces and is two-way interchangeable
with the item number shown. However, either part may be used.
33-50-01
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COMPONENT MAINTENANCE MANUAL
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SUPSD BY identifies the part is superseded and is one-way
interchangeable with the item number shown. The old part can be
used as replacement only where the old part was installed.
SUPSDS identifies the part supersedes and is one-way
interchangeable with the item number shown. The new part number
can be used as replacement for both the old or new parts.
(5)
EFF CODE column: This column is used to show interchangeability relationships. It
identifies different configurations in each figure and shows how parts relate to item 1
(or an alpha variant of item 1) in that figure only. A code letter A through Z (but not I
and O) identifies each configuration. The same code is used in this figure to show all
parts for a specified configuration. If a part is used on all configurations in that figure,
the EFF CODE column is blank.
(6)
UNITS PER ASSY column: This column shows the quantity of each item used on
one next higher assembly, subassembly or sub-subassembly. Quantities shown for
attaching parts are the number required for the related part, subassembly or
assembly and, therefore, may not be the total quantity used for the end item of the
detailed parts list. The following letters may be used in this column:
(7)
(a)
AR indicates "as required" and refers to variable quantity items such as
shims, spacers or similar items.
(b)
RF indicates "reference" and refers to items and their quantities which are
listed elsewhere and are provided here as a reference only.
Abbreviations
(a)
Standard abbreviations used in the IPL agree with MIL-STD-12.
33-50-01
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COMPONENT MAINTENANCE MANUAL
100-2601
SUBTASK 33-50-01-99F-019-A01
C.
Vendor (CAGE) Codes (V____)
(1)
Vendor codes, specified by the letter “V”, are shown in the nomenclature column of
the DPL to identify the manufacturer of non-Securaplane parts.
(2)
The CAGE codes for the manufacturers of the parts, materials, special tools, and
test equipment which may be referenced in this CMM are contained in Table 10001.
Table 10001. Vendor Code List / TABLE 33-50-01-99A-012-A01
Code
Vendor
Code
Vendor
VU4252
Anritsu EMEA LTD
200 Capability Green
Luton, United Kingdom LU1 3LU
V0TMJ9
Securaplane Technologies Inc.
10800 N. Mavinee Drive
Tucson, AZ 85737 USA
V1FN41
Atmel Corporation
2325 Orchard Pkwy
San Jose, CA 95131-1034 USA
V1QQS1
IAR Systems Software Inc.
1065 E. Hillsdale Blvd
Foster City, CA 94404-1613 USA
V53919
Pasternack Enterprises Inc
1851 Kettering
Irvine, CA 92614-5617 USA
V64667
National Instruments Corporation
11500 N. Mopac Expy Bldg B
Austin, TX 78759-3504 USA
V89536
Fluke Corporation
6920 Seaway Blvd.
Everett, WA 98203-5829 USA
SUBTASK 33-50-01-99F-020-A01
D.
Equipment Designator Index
(1)
The Equipment Designator Index contains all equipment designators included in the
Detailed Parts Lists. The equipment designators are listed alphabetically. The
equipment designator index shows the applicable figure and item number where that
specific equipment designator can be found.
SUBTASK 33-50-01-99F-021-A01
E.
Numerical Index
(1)
The Numerical Index contains all part numbers included in the Detailed Parts Lists.
The part numbers are listed first alphabetically, then by numerical sequence.
Referring to the Numerical Index with a known part number, the figure, item number,
and total units per assembly can be found.
33-50-01
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COMPONENT MAINTENANCE MANUAL
100-2601
NUMERICAL INDEX
PART NUMBER
100-2601-01
101-2601-03
120-2869-02
120-2870-01
120-2871-01
120-2872-01
120-4091-01
140-2601-02
140-2660-03
160-2274-04
160-2274-04
180-0349-01
190-0352-01
340-0001-01
373-0005-01
500-02560.250S
500-04400.250S
500-04400.3125S
500-04400.375S
520-02000.157S
520-04000.250S
520-04000.250S
520-04000.250S
522-02000.188S
522-04000.200S
522-04000.200S
522-04000.200S
566-0003-01
569-NY5P55150
569-0113-01
570-NY5G5520
89610-1143
89611-0529
AIRLINE PART
NUMBER
FIGURE
NUMBER
ITEM
NUMBER
-1
-10
230
70
210
170
120
50
10
130
-1
50
40
60
60
20
180
140
80
40
100
160
200
30
90
150
190
220
20
110
30
80
70
33-50-01
FCC DRAFT 2-4-09
TOTAL
REQUIRED
RF
RF
RF
RF
Page 10005
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COMPONENT MAINTENANCE MANUAL
100-2601
WELS Control Unit Assembly
Figure 1 / GRAPHIC 33-50-01-99B-027-A01
33-50-01
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COMPONENT MAINTENANCE MANUAL
100-2601
FIG. &
ITEM
NO.
-1
-10
20
30
40
50
60
70
PART NUMBER
100-2601-01
101-2601-03
569-NY5P55150
570-NY5G5520
190-0352-01
180-0349-01
373-0005-01
120-2870-01
AIRLINE
STOCK
NO.
NOMENCLATURE
1234567
WELS CONTROL UNIT
. WELS CONTROL UNIT ASSY (NP)
. . PLUNGER, PANEL FASTENER
. . GROMMET, PANEL FASTENER
. . LABEL, NAMEPLATE, WCU
. . LABEL, RF TRANSCEIVER
. . CAP, MALE CONNECTOR
. . CASE, FRONT
80
90
100
500-04400.375S
522-04000.200S
520-04000.250S
. .
. .
. .
110
569-0113-01
. .
120
130
120-4091-01
160-2274-04
. .
. .
140
150
160
500-04400.3125S
522-04000.200S
520-04000.250S
. .
. .
. .
170
120-2872-01
. .
180
190
200
500-04400.250S
522-04000.200S
520-04000.250S
. .
. .
. .
210
220
120-2871-01
566-0003-01
. .
. .
230
120-2869-02
. .
(ATTACHING PARTS)
SCREW, 4-40 ¼ PHIL PAN SS
WASHER, #4 .2 LOCK SS
WASHER, #4 .25 FLAT SS
-------*------GASKET, CIRCULAR
CONNECTOR
GASKET, SMA CONNECTOR
ELECTRONIC ASSY
(SEE FIGURE 2 FOR
BREAKDOWN)
(ATTACHING PARTS)
SCREW, 4-40 5/16 PHIL PAN SS
WASHER, #4 .2 LOCK SS
WASHER, #4 .25 FLAT SS
-------*------BRACKET, BATTERY CLIP
(ATTACHING PARTS)
SCREW, 4-40 ¼ PHIL PAN SS
WASHER, #4 .2 LOCK SS
WASHER, #4 .25 FLAT SS
-------*------CLIP, BATTERY
SPRING, COMPRESSION
(.180 IN OD X .625 LON)
CASE, BACK
EFF
CODE
UNITS
PER
ASSY
RF
- ITEM NOT ILLUSTRATED
33-50-01
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COMPONENT MAINTENANCE MANUAL
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Electronic Assembly
Figure 2 / GRAPHIC 33-50-01-99B-028-A01
33-50-01
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COMPONENT MAINTENANCE MANUAL
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FIG. &
ITEM
NO.
-1
10
PART NUMBER
160-2274-04
140-2660-03
20
30
40
500-02560.250S
522-02000.188S
520-02000.157S
50
60
140-2601-02
340-0001-01
70
89611-0529
80
89610-1143
AIRLINE
STOCK
NO.
NOMENCLATURE
1234567
ELECTRONIC ASSY
(SEE FIGURE 1 FOR NHA)
. PWA, COMBINED INTERFACE
(ATTACHING PARTS)
. SCREW, 2-56 X ¼ PAN PHIL SS
. WASHER, #2 3/16 LOCK SS
. WASHER, #2 .157 SS
-------*------. PWA, CONTROL
. . CONNECTOR, RF SMA RIGHT
ANGLE BULKHEAD JACK
. . . NUT, SMA CONNECTOR (NP)
FOR SPARES
REPLACEMENT ORDER
340-0001-01
. . . WASHER, LOCK, SMA
CONNECTOR (NP)
FOR SPARES
REPLACEMENT ORDER
340-0001-01
EFF
CODE
UNITS
PER
ASSY
RF
- ITEM NOT ILLUSTRATED
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COMPONENT MAINTENANCE MANUAL
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INTENTIONALLY
LEFT BLANK
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