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Electrical Bonding Following table shows different bonding resistance values. Actual values must be
taken from the maintenance manuals.
Bonding provides a path for return current from the components and provides a
low-impedance path to ground to minimize radio interference from static electrical Table 1: Example
charges collected on the component. Therefore all isolated components are elec-
trically connecting to the aircraft structure. Low-resistance wire (bonding jumper) Bonding Resistance between Resistance
or metal strap are used to connect a structural component or an electrical compo- Primary Structure and: (Milli-Ohm)
nent to the basic structure of an aircraft.
Bonding carries the return current from an electrical component back to the elec- Wing, Stabilizer, Engine and APU-Structure 2
trical power sources like generators, transformer-rectifiers and batteries.
Cabin- Cargo- and Access-Doors, Fuel Tank Access Panels 10
Bonding connects flight control surfaces to the main structure to carry static elec-
trical charge that build up when air flows over the surface into the main structure. Pipes for Fuel, Hydraulic and Air 10 - 500
Bonding prevents sparks that could cause radio interference.
Electrical Components 1 - 10
Testing
Shielding Conduits 5 - 10
In general, most bonding jumpers or ground straps must have each connection
made to have 0.003 ohms or less in resistance. This measurement must be taken Cockpit and Cabin Installations 10 - 500
between the surface being bonded and the bonding jumper.
This test may be performed using an extremely sensitive ohmmeter or a bonding Main Grounding Points of Electrical Power Distribution System 0.05
tester, and should be done any time a connection has been modified, added to or
temporally disconnected.
Figure 1: Bonding Resistance Test
Determination of Bonding Resistance by Low Current Method Figure 2: Determination of Bonding Resistance
• A variable DC current power supply unit feeds a continuous current of
10 Ampere through the bonding connection under test.
• The voltage drop over the bonding is determined with a millivolt meter.
• Calculate the resistance in milli ohm by following formula:
Voltage ( mV )
Bonding Resis tan ce ( mΩ ) = ----------------------------------------
Current ( 10A )
Make sure that the measured values are not higher than the maximum permitted
published in the respective aircraft maintenance manual.
Data summary:
Resistance range: 3.5 mΩ to 199.9 mΩ
(for a loop induced current of 1 Ampere)
Induce current frequency: 1KHz
Current injection source output voltage: 3.5 to 199.9 V
(at induction transformer)
Theory of Operation Figure 6: Good Current Loop and Faulty Current Loop (Interrupted)
The tester is designed to measure the electrical resistance of a closed loop; typi-
cally that formed by a conductive specimen bonded to a conductive structure, by
the induction of an alternating current AC into the loop so formed.
Normal Operation
Current is induced into the loop under test by the generator in the Current Injection
Source, via the Clip-on Transformer (CT1) and flows through the specimen, its
bonding connections with structure and the structure itself. Loop induced current
is detected by the Clip-on Transformer (CT2) and measured by the Multimeter (set
to read current). The generator voltage present at Clip-on Transformer (CT1), that
which gives rise loop induced current, is displayed on the panel meter of the Cur-
rent Injection Source.
Loop resistance (R Loop) is calculated using the formula:
Voltage ( displayed on current injection source )
R Loop = --------------------------------------------------------------------------------------------------------------------------------------------
Current ( measured by multimeter )
Cat: B1 7.4 - 6
PREPARED BY L.FESSAS
Basic Maintenance Module 7 Maintenance Practices
Training Manual 7.4 Avionics General Test Equipment
Examination of Out Of Tolerance Results Figure 10: Setup to locate Shielding Junction Errors
1. Connect the Current Injection Source and the Clip-on Transformer (Inducer)
to the loop under test, as shown.
Prepare the Multimeter, set to read AC volts, with voltage probes connected.
2. Switch on the Current Injection Source and adjust the RANGE and SETTING
controls to give an indication of 100 units on the Built-in Meter.
3. Connect one probe of the Multimeter to an appropriate fixed point on the loop
under test and the second probe to various junctions on the loop. Measure-
ment of a voltage at the first junction, that which is significantly higher than
others indicates a junction of high resistance.
• Example: In figure below, part of a loop formed by components A, B, C, D con-
nected to a structure is shown. One probe of the Multimeter is connected to a
fixed point (structure). The second probe is connected in turn to points D, C,
B and A. At points D and C respectively 0 mV and 2 mV are recorded, whilst
at point B, 60mV is measured. This indicates a high resistance joint between
B and C.
• Alternatively the multimeter probes may be connected across each adjoining
pair of points.
• A to B, B to C, C to D, D to structure. The high resistance joint will produce a
high voltage. In this sample B to C = 58mV
Figure 9: Location of Shielding Junction Errors
Air Data Pitot Static Test Sets Manually operated Test Set
To verify the correct function of the Air data Computers and Instruments mainte- There is a wide variety of different testers varying from those with hand pumps to
those with electric pumps and computers.
nance facilities needs the appropriate equipment. This equipment is used:
• To read the errors of Altimeter and Airspeed-Indicators. Figure 12: DPS-500 / TS 4463p , from Cobra Systems.
• After disconnection of Pitot/Static-Lines leak test must be performed. Fully Automatic tester with remote control, Electronic Displays ,
The art of test equipment has a wide variation. Roller-Pumps (for leak-test only), Keyboard and programming features.
Hand-driven Pumps, electric driven and computer controlled units are available.
Figure 11: Roller Pump with Static Port Adapter (Used for Leak Test only)
• For all pitot- and static-test use approved adapters for connecting the hoses
to pitot tubes and static ports. If connections inadvertent falls off, damage of
the instruments or airdata computers can be the result!
• Drain holes and opposite static ports must be closed during test. Don’t forget
to remove the adhesive red tape or adapter after the test is finished!
• Example: Static pressure: 20’000 ft Pitot pressure: 320 kts
maximum Leak rate: 100ft/min 2kts/min
• If static pressures tests over 10’000 ft has to be performed, Pitot (Pt) must also
be connected to the pitot tube, to prevent damage of airspeed indicators and
airdata computers.
Via balancing valve the static pressure is equalized to both side of pressure
diaphragm inside aircraft instruments and computers.
Air Data Tester Front Panel (Sextant 301) Figure 15: Sextant 301 Air Data Tester Front Face
The painted front panel plate is labelled in two languages and comprises:
• Self-sealing static pressure Ps output couplings with locating pins 9
• Self-sealing total pressure Pt output couplings with locating pins 10
• Handle for manual actuation of the pump supplying the HP and LP 17
• Pressure selector 14 providing an HP, ATM pressure or LP intake
in the two channels Ps and Pt
• Static pressure Ps intake valve 12
• Total pressure Pt intake valve 13
• Balancing valve of the two pressure channels Ps and Pt 11
• Connector for the external 28 VDC electricity supply 2
with a connector cover 1 for storage battery versions
• Front panel cover 21 for versions without the connector
• Power switch:
– 3-position: Charge, 0 (off), 1 (on) connected to an LED 4 that lights up
during the battery charging time for storage battery versions 3
– 2-position: 0 (off), 1 (on) for primary battery versions 20
• 2-position unit selector: ft ft/min kts or m m/s km/h 5
• 3-position switch with 1 unstable position: Init and 2 stable positions: Std
(Standard), QFE 6
• Digital display block 7
• 2 compartments for storage batteries 18 or
primary batteries 22 depending on the version
• Pressure coupling for an externally generated HP 15
• Pressure coupling for an externally generated LP 16
• Carrying handles 8 and 19
Automatic Air Data Tester (Sextant 410) Figure 16: Sextant 410 Air Data Tester Front Face
Pressure test unit
1. High pressure gauge showing the high pressure HP.
2. Fuse 1A to protect 9 VAC (RCDU power supply).
3. Fuse 1. 5A mains protection.
4. Remote Control Display Unit.
5. Failure warning light.
6. IEEE connector (to connect an external computer with standard IEEE port).
7. Address switches (used to select address in automatic mode.
8. Openings using screwdrivers to the Ps and Pt channel venting valves.
9. Pt warning light (Pt pressure is available).
10. Ps warning light (Ps pressure is available).
11. Black Ps self-sealing pneumatic coupling.
12. Red Pt self-sealing pneumatic coupling.
These needle valves can be separately adjusted by the user in order to select the
venting speed.
13. On/Off switch.
14. Main Power on indicator light of the generator.
15. Vacuum gauge showing the low pressure value BP.
Remote and Control Display Unit Figure 17: Sextant 410 RCDU
The man-machine interface was developed based on a software using multiple
windows with drop-down menus activated by the operator.
The RCDU is made up of:
• 320 x 240 pixel monochrome screen managed in graphic mode
• Keypad with 23 keys
• Potentiometer for adjusting brightness
• Connector for a parallel output (printer)
The screen is composed of:
• 12 keys: 0 . . .9 used to define the order values, program and acceptance
numbers.
• ESCAPE used to Exit from the window displayed and return to the menu at a
higher level menu.
• DELETE used to delete the last numerical value entered and not yet validat-
ed. It can also be used to delete line in certain auxiliary functions.
• PAUSE used to stop the change in progress when in generator mode.
• UP and DN keys used to change zones in a window and to decrease or in-
crease the generated pressures.
• 4 keys: UP, DN, LH and RH used to move the cursor in a menu.
• ? / EXEC used for obtaining information if there is an error message (M ?) or
for executing an order (EXEC).
• ENTER used to validate the current command or value.
Description
The Model 43 THRULINE, is a portable unit contained in a die cast aluminum
housing, with a formed metal enclosure on the back which is easily removed. In-
cluded with the unit is a leather carrying strap, four rubber shock feet on the base,
and four rubber bumpers on the back, which allow the Model 43 to stand or lie flat
when used.
A shielded cable connects the microammeter to the dc jack which is attached to
the side of the RF line section casting. This cable, nearly three feet long, permits
removal of the RF line section from the Wattmeter housing. Meter connections
may be maintained with any installations outside of the housing. This permits per-
manent additional installations to be made. See Section 3, INSTALLATION.
To make measurements, the cylindrical shaped Plug-In Element is inserted into
the line section socket and rotated against one stop.
These contacts make connection with the spring finger of the de jack only when
the Plug-In Element is in the precise forward or reverse position, and with the index
pin on the Element on the lower level of the line section castingface against its re-
spective stop.
Usage
The wattmeter will be connected with coax cables between the transmitter and the
associated aircraft antenna.
Different Plug-In elements for 25 W, 50W and 100W are used. The Arrow on the
Plug-In elements shows the direction of the RF-power, forward- or reflected power.
VOR, LOC, GP, Marker and VHF-COM Tester Six-digit counter indicates the RF frequency of the signal generator on any band,
the frequency of a COMM transmitter under test, any external signal input from 1
The NAV-402AP is a bench and ramp test set designed to meet the electronic MHz to at least 300 MHz, or the VOR bearing selected by Bearing Select Switch-
functional test requirements of Category I, II, and III ILS Systems, Communication es.
(COMM), Navigation (NAV), and Marker (MKR) Systems.
RF power meter is built-in to measure COMM transmitter power from 0-10W or 0-
The tester contains features to allow testing of sophisticated autopilot systems. 100W either peak or average power by selecting a switch position located on the
These features include: automatic LOC DDM (Difference in Depth of Modulation) Front Panel. A COMM transmitter demodulation output permits viewing or listening
automatic sweep, two crystal controlled VOR frequencies; and two crystal control- to COMM modulation.
led, paired LOC and GS frequencies.
Modulation Meter measures Signal Generator Percent of Modulation on any fre-
It is housed in a compact, portable case and includes a signal generator with a var- quency band from 0-30% or 0-100%. Front Panel controls permit quick setting of
iable attenuator which can be connected to the equipment under test by a radiated modulation percentages.
signal from a self-contained antenna or by a coax line. It can be operated under
either crystal frequency control or in variable frequency mode in each band. A 90° bearing check monitor allows quick verification of basic VOR bearing from
the VOR demodulated signal.
The RF generator can be modulated internally by a 1020 Hz Ident tone, Marker,
VHF Omnidirectional Range (VOR), Localizer (LOC) or Glide Slope (GS) tones, or A nickel-cadmium battery and built-in charging system permit completely portable
by an external signal. operation up to 2 hours continuous duty. Any time the set is plugged to an AC line,
the battery is being charged. In battery operation, an automatic timer turns the set
Figure 21: NAV402AP Navigation/Communication - Radio Tester off after 6 to 10 minutes. The set can be recycled by pressing power switch to BAT
position.
PREPARED BY L.FESSAS
Cat: B1 7.4 - 16
ATC Transponder / DME Tester Basic Maintenance Module 7 Maintenance Practices
Training Manual 7.4 Avionics General Test Equipment
Positioning of the Antenna The position of the test set is not too critical. For optimum results however, obsta-
For proper results the test set antenna must be ‘in sight’ of the ATC or TCAS an- cles must be located outside the main antenna lobe. Distance to the antenna must
tenna. The Mode-S transponders and the TCAS computer are connected to two be between 6 and 300 feet (1,8 to 90 meters). Signal strength is adjusted automat-
antennas, that both must be able to exchange valid signals, only one antenna may ically.
be checked at a time. Thus the antennas must be in the signal beam of the test set Figure 25: Avoiding of signal reflections
one by one. During testing the upper antenna, the lower one must be shielded. But
shielding the upper antenna during the lower antenna test is not so easy. Using
the aircraft fuselage as a barrier between the test set and the upper antenna
solves the problem.
The Portable Data Loader (PDL) is a device used to load data bases and opera-
tional programs into an aircraft‘s Flight Management Computers and other avion-
ics subsystems. The PDL is designed to meet the requirements pertaining to the
portable version of the data loader listed in the ARINC Report 615.
The PDL is housed in an aluminium case and is designed to be lightweight and
rugged. The top of the case includes storage space for cables and disks and can
be removed during operation.
The front panel contains a backlit LCD display. four function push buttons and
three discrete LED annunciators to indicate power and status. The push button
function keys are not required for normal operation but provide optional functions
such as self test and disk directory information.
The PDL uses the 3.5 inch floppy storage media specified in ARINC Report 615.
Both high and low density MS DOS disks formatted for 1.44 MB and 720 KB ca-
pacity can be used.
Two cables are provided with the PDL The primary cable links the PDL to ARINC
615 high speed load devices and an adapter cable interfaces the PDL to ARINC
603 devices.
The PDL contains two independent ARINC 429 serial bus transmitters and four in-
dependent receivers, each capable of either high speed (100 Kbits/second) or low
speed (12.5 Kbits/second) operation. An RS232 serial bus interface is available
through the J1 connector or through a separate 'D' type connector.
ARINC Report 615 is a commercial aircraft bus specification defining loading pro-
tocols. The specification includes the use of a high speed ARINC 429 bus and au-
tomatic protocol for up loading and down loading data to and from avionics
devices.
ARINC Report 615 allows provisions for various loading methods but defines cer-
tain protocol that require Iittle operator intervention. In most cases, the operator is
only required to turn the unit on and install the floppy disk containing the data files.
Features
• Library of Loadable Software Airplane Parts on a
Mass Storage Device (80Mbyte Solid State Memory).
• Capable of supporting loadable software for an entire fleet.
• Interface to PMAT 2000 via Ethernet link for fast transfer to libraries.
• Provide user with the ability to select airplane loads by aircraft type,
tail number, LRU type, or software part number.
• Updating and storage/editing capability via Loadstar.
Benefits
• Eliminates need to use floppy disks at the flight line.
• Load times will be reduced for large loads that require multiple disks
(no swapping required by operator).
• Future updates of PDL operational program performed in the field
no EPROM's need to be swapped.
Portable Maintenance Access Terminal Figure 28: PMAT Rear and Top view
The PMAT 2000 is the perfect “on-the-spot” cost effective solution for all onboard
electronic aircraft maintenance, service, and data loading applications. Capable of
over 5 hours of portable operation on a single battery charge, this unit combines
integrated electronic maintenance manuals, wiring diagrams, Fault Isolation Man-
uals, on board fault code access, hard drive based ARINC 615 data loading, and
a variety of custom applications in a single, easy-to-use tool.
Main Menu
The main menu is displayed after boot up. The main menu is the default display.
The user can select any function from the main menu. The available functions are
shown on the figure below.
ARINC 429 Micro DITS Reader Figure 30: Micro DITS Reader
Today aircraft avionics system is using the Digital Information Transfer System
(DITS) like ARIN429, ARINC 571 and ARINC 629. Common of all this buses is that
the data transfer from one unit to the other units occurs over two wires in serial for-
mat.
To verify that the desired data is correct the Micro-DITS Tester can be used in line
maintenance and avionics workshop. For example M56BAM SFENA/SEXTANT.
It is used for checking 32-bit serial transmissions.
After selecting the Label and Identifier, any of the display modes may be chosen
by means of the Keyboard.
Connections
Decoded Display
• Line Voltage 115 VAC 400 Hz or 230 VAC 50 Hz or internal battery.
• Display of the information corresponding to the selected Label in hexadecimal
• Signal to be verified at connections A and B between 5 - 6.5 Volt 200 KOhm.
or data value.
• Display of Sign/Status Matrix (SSM) and Source Destination Identifier (SDI). Binary Display
• Display of update interval and Message Parity. • Display of 32-bit word in real time.
• Display and storage of a word transmitted once only. (Snapshot)
https://www.youtube.com/watch
?v=gSSStJkH8cE
ARINC 429 serial triggering and
decode.