User´s Manual Viper 4040

User Manual Viper 4040

ACES Systems/TEC Aviation Division Document Number 4040-OM-01 Revision 3.02 Oct 2012 Part Number 75-900-4040 10737 Lexington Drive – Knoxville, TN 37932-3294 USA – Telephone 865-671-2003– Fax 865-675-1241 – Web www.acessystems.com

Copyright Notice Copyright  by TEC, 2000 - 2012. All rights reserved. No part of this document may be reproduced, transmitted, transcribed, stored in a retrieval system, or translated into any language in any form by any means without the express written permission of TEC. Disclaimer This documentation is provided for information purposes. TEC makes no warranty of any kind with regard to this material, including, but not limited to, the implied warranties of merchantability and fitness for a particular purpose. TEC shall not be liable for errors, omissions, or inconsistencies which may be contained herein or for incidental or consequential damages in connection with the furnishing, performance, or use of this material. Information in this document is subject to change without notice and does not represent a commitment on the part of TEC.

Table of Contents (Revision 3.02, Oct 2012)

1 1.1 1.2 2 2.1 2.2 2.3 2.3.1 2.3.2 2.3.3 2.3.4 2.3.5 2.3.6 2.4 2.4.1 2.4.1.1 2.4.1.2 2.4.2 2.4.2.1 2.4.2.2 2.4.3 2.4.4 2.4.5 2.5 2.5.1 2.5.1.1 2.5.1.2 2.5.1.3 2.5.1.4 2.5.1.5 2.5.1.6 2.5.1.6.1 2.5.1.7 2.5.1.8 2.5.1.9 2.5.1.10 2.5.1.11 2.5.1.12 2.5.2

Preface (Revision 3, Oct 2012) Contact ACES Systems Warranty Calibration and Certification

1 2 3

Introduction (Revision 2, Oct 2012) Notes, Cautions, and Warnings Conventions

1-2 1-2

Analyzer Description (Revision 3, Oct 2012) Keypad Screen Input and Output Ports CHANNEL Ports TACH Ports AUX/COMM Port STROBE Port USB Port BATT CHG Port Additional Standard Equipment Battery Nickel Cadmium (NiCd) equipped analyzers Nickel Metal Hydride (NiMH) equipped analyzers Battery Charger Nickel Cadmium (NiCd) equipped analyzers Nickel Metal Hydride (NiMH) equipped analyzers USB Communications Cable Carrying Case User Manual Optional Equipment Propeller Balancing Kit Manual, ACES Systems Guide to Propeller Balancing 991D-1 Accelerometer 991D-1 Sensor Cable Phototach Tachometer Sensor Cable Propeller Protractor Using the Propeller Protractor Case Bolt Adapter Set Tackle Box Right-Angle Sensor Mount Gram Scale Reflective Tape ACES Systems Balance Placard Serial Communications Cable

2-2 2-5 2-6 2-6 2-6 2-6 2-7 2-7 2-7 2-8 2-8 2-8 2-8 2-9 2-9 2-10 2-11 2-11 2-12 2-12 2-12 2-12 2-13 2-13 2-14 2-14 2-15 2-15 2-16 2-16 2-17 2-17 2-17 2-18 2-18

3 3.1 3.1.1 3.1.2 3.2 3.3 4 4.1 4.1.1 4.1.1.1 4.1.1.2 4.1.1.3 4.1.1.4 4.1.2 4.1.3 4.1.4 4.1.4.1 4.1.4.2 4.1.5 4.1.6 4.1.7 4.1.8 4.1.8.1 4.1.8.2 4.2 4.3 4.3.1 4.3.2 4.3.3 4.4 4.4.1 4.4.2 4.4.3 5 5.1 5.1.1 5.1.1.1 5.1.2 5.1.2.1 5.1.3 5.2 5.2.1 5.2.1.1 5.2.1.2 5.2.1.3 5.2.1.3.1 5.2.1.3.2

Using the VIPER 4040 (Revision 2, Aug 2007) Entering Data Using the Keys Filling in Fields Loading a Setup Main Menu

3-1 3-1 3-2 3-2 3-3

Propeller Balance (Revision 2, Oct 2012) Start Job Prop Balance Setup Prop Balance Setup Screen Edit ICF Sensor Setup Prop Hole Layout Setup Job Identification Engine Information Connect Sensors Connect Sensors Tachometer Setup Start Aircraft Acquiring Data Review Job Balance Solution Set Split Weights Record Split Weights Resume Job Manage Jobs Review Delete Delete All Manage Setups Edit New Delete

4-2 4-3 4-4 4-6 4-7 4-8 4-10 4-11 4-11 4-12 4-12 4-13 4-14 4-14 4-15 4-17 4-17 4-19 4-19 4-20 4-20 4-20 4-21 4-21 4-21 4-21

Main Rotor Track & Balance (Revision 3, Oct 2012) Analyzer Chart Forms Regular Chart Forms Regular Main Rotor Chart Setup Irregular Chart Forms Irregular Main Rotor Chart Setup Tracking Influence Setup Setup Process Main Rotor Setup Main Rotor Setup Screen Tracking Setup Screen Main Rotor Condition Setup Screen Conditions Setup Screen, Example 2 Conditions Setup Screen, Example 3

5-1 5-1 5-2 5-3 5-4 5-6 5-7 5-7 5-7 5-9 5-10 5-11 5-12

2 – Table of Contents

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VIPER 4040 User Manual

5.2.1.4 5.2.1.5 5.2.1.6 5.2.1.6.1 5.2.1.6.2 5.2.1.6.3 5.2.1.6.4 5.2.1.6.5 5.2.1.6.6 5.2.1.6.7 5.3 5.3.1 5.3.2 5.3.3 5.3.4 5.3.5 5.3.5.1 5.3.6 5.3.7 5.3.8 5.3.9 5.3.9.1 5.3.9.2 5.3.10 5.3.11 5.3.12 5.3.12.1 5.3.12.2 5.3.12.3 5.4 5.4.1 5.4.2 5.4.3 5.4.4 6 6.1 6.1.1 6.1.1.1 6.1.2 6.1.2.1 6.2 6.2.1 6.2.2 6.3 6.3.1 6.3.2 6.3.3 6.3.4 6.4 6.4.1

Main Rotor Adjustment Symbol Setup and Solution Logic Setup Screen Chart Definition Main Rotor Setup Example Main Rotor Setup Screen Tracking Setup Screen Main Rotor Conditions Setup Main Rotor Adjustment Symbol and Solution Logic Setup Vertical: Hover Chart Definition Vertical: FLT 80 – FLT 120 Chart Definition Example 1 Lateral Hover Chart Main Rotor Balance Process Starting a New Job Setup List Job Identification Tracking Selections Connect Sensors Optical Tachometer Setup (Optional) Start Aircraft Select Aircraft Condition Data Acquisition Review Data Track Measurement Check Track - Results Shut Down Engines Review Prior Run(s) Data Solution Screens Example Solution Screen #1 Example Solution Screen #2 Example Solution Screen #3 Main Rotor Manage Data Functions Main Rotor Review Job View Main Rotor Track and Balance View Main Rotor Chart View Main Rotor Chart ICFs Tail Rotor Balance (Revision 3, Oct 2012) Analyzer Chart Forms Regular Chart Forms Regular Tail Rotor Chart Setup Irregular Chart Forms Irregular Tail Rotor Chart Setup Tail Rotor Setup Tail Rotor Setup Screen Tail Rotor Chart Setup Multiple Condition Setup Tail Rotor Setup Screen Tail Rotor Condition Setup Screen First Condition Tail Rotor Chart Setup Screen Second Condition Tail Rotor Chart Setup Screen Tail Rotor Balance Process Starting a New Job

Revision 3.02, Oct 2012

5-13 5-13 5-14 5-15 5-16 5-16 5-17 5-17 5-18 5-19 5-20 5-21 5-22 5-22 5-23 5-24 5-24 5-25 5-26 5-27 5-28 5-28 5-29 5-30 5-30 5-31 5-32 5-33 5-33 5-34 5-34 5-35 5-36 5-37

6-1 6-1 6-2 6-3 6-3 6-5 6-5 6-7 6-8 6-8 6-10 6-11 6-12 6-14 6-14

Table of Contents – 3

6.4.2 6.4.3 6.4.4 6.4.5 6.4.6 6.4.7 6.4.8 6.4.9 6.4.10 6.4.11 6.5 6.5.1 6.5.2 7 7.1 7.1.1 7.1.2 7.1.3 7.1.4 7.1.5 7.1.6 7.1.7 7.1.8 7.1.9 7.1.10 7.1.11 7.1.12 7.1.13 7.1.14 7.1.15 7.1.16 7.1.17 7.1.18 7.1.19 7.1.20 7.1.21 7.1.22 7.1.23 7.1.24 7.1.25 7.2 7.2.1 7.2.2 7.2.3 7.2.4 7.2.5 7.2.6 7.2.7 7.2.8

Setup List Job Identification Connect Sensors Start Aircraft Select Tail Rotor Condition Screen Data Acquisition Shut Down Engines Review Prior Run(s) Data Tail Rotor Suggested/Installed Weights Screen Tail Rotor Re-Solve Feature Tail Rotor Manage Data Functions View Tail Rotor Balance View Tail Rotor Chart

6-15 6-16 6-16 6-17 6-18 6-18 6-20 6-21 6-21 6-22 6-25 6-25 6-25

Fan/Turbine Balance and Fan Blade Optimizer (Revision 3.02, Oct 2012) Fan/Turbine Balance Start Job Setup List Fan/Turbine Balance Setup Screen Incomplete Job Fan/Turbine Balance Setup - General Complete the Fan/Turbine Balance Setup Define Class Weights Balance Plane Information Setup Label Detail Wt Holes - Setup Sensor Information Screen Define Fan/Turbine Balance ICFs Job Identification Screen Engine Information Screen Label Detail Wt Holes - Job Fan/Turbine Balance Equipment Setup Test Tach Power Start Aircraft Set Engine Speed Data Acquisition Shut Down Engines Review Prior Run(s) Data Fan/Turbine Suggested/Installed Weights Function Key Set Number 2 Start Aircraft Quit Job Fan Blade Optimizer Start Job Select Setup List Fan Blade Optimizer Setup Job Identification Screen Engine Information Screen Fan Blade Optimizer Job Screen Fan Blade Optimizer Result screen Complete Blade Placement

7-1 7-1 7-2 7-2 7-3 7-3 7-4 7-8 7-10 7-14 7-14 7-16 7-16 7-17 7-17 7-18 7-19 7-19 7-20 7-21 7-22 7-22 7-23 7-25 7-25 7-25 7-26 7-26 7-27 7-27 7-28 7-29 7-29 7-30 7-31

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VIPER 4040 User Manual

8 8.1 8.1.1 8.1.1.1 8.1.1.2 8.1.1.3 8.1.1.4 8.1.1.5 8.1.1.6 8.1.2 8.1.3 8.1.4

TFE731 Performance (Revision 3, Oct 2012) TFE731 Performance EMS Necessary Equipment Datalogger (JEDA) ACES AvTrend Software RS232-to-RS422 Communications Cable EEC, N2 DEEC, and N1 DEEC Comm Cable(s) Ambient Temperature Probe and Cable Optional sensors and cables Analyzer Operation Information Screens Getting the latest software

8-1 8-1 8-1 8-3 8-3 8-3 8-3 8-4 8-4 8-4 8-13 8-17

9 9.1 9.1.1 9.1.1.1 9.1.1.2 9.1.1.3 9.1.1.4 9.1.2 9.1.3 9.1.4 9.1.5 9.1.6 9.1.7 9.1.8 9.2 9.3 9.3.1 9.3.2 9.3.3 9.4 9.4.1 9.4.2 9.4.3

Vibration Spectrum Survey (Revision 3.01, Oct 2012) Start Job Spectra Setup Spectra Setup Edit Conditions Speeds Limits Job Identification Engine Information Microphone Calibration Select Aircraft Condition Start Component Collecting Data Storing Data Resume Job Manage Jobs Review Delete Delete All Manage Setups Edit New Delete

9-2 9-4 9-4 9-7 9-7 9-9 9-10 9-11 9-12 9-15 9-15 9-15 9-19 9-21 9-22 9-22 9-22 9-22 9-23 9-23 9-23 9-23

Overall Vibration Surveys (Revision 3.01, Oct 2012) Start Job Overall Vibration Setup To Complete the “Overall Vibration Setup” Screen Conditions Speeds Job Identification Engine Information Select Aircraft Condition Start Component Collecting Data Resume Job Manage Jobs Review Delete

10-2 10-4 10-4 10-6 10-7 10-8 10-9 10-9 10-9 10-10 10-11 10-11 10-12 10-12

10 10.1 10.1.1 10.1.1.1 10.1.1.2 10.1.1.3 10.1.2 10.1.3 10.1.4 10.1.5 10.1.6 10.2 10.3 10.3.1 10.3.2

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Table of Contents – 5

10.3.3 10.4 10.4.1 10.4.2 10.4.3 11 11.1 11.1.1 11.1.1.1 11.1.1.2 11.1.1.3 11.1.1.4 11.1.1.5 11.1.2 11.1.3 11.1.4 11.1.5 11.1.6 11.1.7 11.1.8 11.2 11.3 11.3.1 11.3.2 11.3.3 11.4 11.4.1 11.4.2 11.4.3 11.4.4 12 12.1 12.1.1 12.1.2 12.1.3

Delete All Manage Setups Edit New Delete

10-12 10-13 10-13 10-13 10-13

Transient Vibration Surveys (Revision 3, Oct 2012) Start Job Transient Survey Setup Config Speeds Parameters (Parms) Plots Limits Job Identification Engine Information Start Engine Microphone Calibration Select Aircraft Condition Collecting Data Storing Data Resume Job Manage Jobs Review Delete Delete All Manage Setups Edit New Delete Select Setup for Remote Job

11-2 11-4 11-7 11-8 11-9 11-11 11-11 11-14 11-14 11-15 11-15 11-19 11-19 11-23 11-25 11-25 11-26 11-26 11-26 11-27 11-27 11-27 11-27 11-28

Monitor Spectrum (Revision 3, Oct 2012) Spectra Setup Monitor Spectrum Setup Screen Speeds Monitor

12-1 12-1 12-4 12-6

13

Monitor Magnitude and Clock (Revision 1, Aug 2007)

14

Monitor Magnitude and Phase (Revision 1, Aug 2007)

15 15.1.1 15.1.2 15.1.3

Monitor Overall (Revision 2, Aug 2007) Overall Vibration Setup Screen Speeds Monitor

16

Check Track (Revision 3, Oct 2012)

17

Transfer Data with PC (Revision 1, Aug 2007)

18

Miscellaneous Items (Revision 3.01, Oct 2012)

6 – Table of Contents

15-1 15-4 15-5

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VIPER 4040 User Manual

18.1 18.1.1 18.1.2 18.1.3 18.1.4 18.1.5 18.1.6 18.1.7 18.1.8 18.1.9 18.1.10 18.1.11 18.1.12 18.1.13 18.1.14 19 19.1 19.2 19.3 19.4 19.5 19.6 19.7 19.8 19.9 19.10 20 20.1 20.2

Miscellaneous Items Setup Sensors Set Date and Time Set Power-Off Timeout Set Job Count Limit Check Battery Analyzer Information Database Information Erase Entire Database USB Information Erase Orphaned Transient Spectra Bus Test EMS Comm Test Show Welcome Screen Enable Memory Leak Tests

18-1 18-2 18-5 18-7 18-8 18-9 18-10 18-12 18-13 18-13 18-13 18-14 18-14 18-14 18-14

Equipment and Accessory Setup and Troubleshooting (Revision 3, Aug 2007) Battery Charger and Battery Cables LaseTach Phototach Propeller Protractor Reflective Tape (3M Tape, Type 7610) Vibration Sensors Optical Tachometer Reinitializing the Analyzer Troubleshooting Ground Loop Issues

19-1 19-5 19-6 19-6 19-6 19-7 19-8 19-8 19-8 19-9

Reading Spectrum and Scales (Revision 2, Oct 2012) Reading the X and Y Plotted Vibration Spectrum Reading the Converging Vibration Indicator Scale

20-1 20-2

21

Printing (Revision 3, Oct 2012)

22

Specifications for Model 4040 Viper (Revision 3, Oct 2012)

Revision 3.02, Oct 2012

Table of Contents – 7

Preface (REVISION 3, OCT 2012)

Contact ACES Systems General For general information regarding ACES Systems products and services, contact one of the international representatives listed at: http://www.acessystems.com/worldreps.htm.

Technical Support For technical support please use the contact information found at: http://www.acessystems.com/contact.htm. If you require assistance with an operational problem with the analyzer, please have as much detailed information as possible available before contacting ACES Systems. The support staff will answer questions about the operation and care of your equipment, assist you in troubleshooting a problem, and help you overcome common application difficulties whenever possible. If it becomes necessary for your equipment to be returned to us for any reason, you will be issued a return number during the technical support contact.

Feedback ACES Systems depends on information from our customers to continue the attributes of quality, dependability and simplicity associated with our products. We invite you to contact our Technical Support office using the information found at: http://www.acessystems.com/contact.htm to express your opinions, comments and suggestions concerning the design and capability of your analyzer.

Warranty The ACES Systems’ Viper Model 4040 Analyzer is warranted to be free of defects in material and workmanship for a period of 60 months (5 years) following the purchase date. Warranty does not cover the analyzer unless it is properly used, stored, and maintained in accordance with the provisions of this manual. Accessories are warranted for a period of 12 months (1 year). The original manufacturer may cover individual accessories not manufactured or assembled by TEC for longer periods. The required annual calibration must be complied with to validate the terms of this warranty. Warranty replacement and / or repair will not be honored on any unit which is overdue an annual calibration at the time of the warranty claim. If your calibration is overdue and no warranty claim is being made, you need only have your overdue calibration completed to re-validate your warranty. Warranty is limited to supplying Purchaser with replacement or repair of any unit or accessory item which, in TEC's opinion, is defective. All repaired or replacement parts will be warranted only for the unexpired period of the basic warranty. All warranty work will be on a return-to-the-factory basis. Shipping cost to the factory will be borne by the Purchaser. Warranty shall not apply to any product that, in the judgment of TEC, has been subjected to misuse or neglect, or has been repaired or altered outside the TEC factory in any way, which may have impaired its safety, operation, or efficiency, or to any product that has been subjected to accidental damage. Warranty does not cover any cost incurred by Purchaser as the result of the purchase of TEC products. Nor does Warranty cover cost incurred by Purchaser for labor charges for replacement of parts, adjustments, or repairs or any other work performed by the Purchaser or his agents on, or connected with, TEC-supplied products. Warranty is expressly in lieu of any and all other warranties or representations, expressed or implied, and of any obligations or liabilities of TEC to the Purchaser arising from the use of said products, and no agreement or understanding varying or extending the same will be binding upon TEC unless in writing, signed by an authorized representative of TEC. TEC reserves the right to make changes in design or additions to, or improvements in, products at any time without imposing any liability on itself to install the same in any product manufactured or supplied prior thereto.

2 - Preface

Viper 4040 User Manual

Calibration and Certification Your ACES Systems equipment is calibrated and certified per NIST standards, effective the date of shipment. TEC requires the unit to be calibrated by TEC or a TEC authorized service facility on an annual basis to insure accuracy and currency of installed electronic components. In addition, the vibration sensors, pressure and temperature transducers (if applicable) should also be calibrated on an annual basis or when dropped, damaged or suspect of improper operation. The analyzer will be identified as calibrated by a sticker stating the date of calibration and next due date of calibration. A certificate of calibration will be provided to you to verify compliance to inspectors. A permanent record of your calibration is maintained by TEC. You may obtain a copy of your calibration by contacting ACES Systems. A calibration reminder letter will be sent to you approximately 30 days prior to the expiration of your calibration. For information about calibration services please visit: http://www.acessystems.com/returnprocess.htm and/or http://www.acessystems.com/servicecenters.htm. NOTE The annual calibration is required in order to comply with the terms of the 5-year warranty. See “Warranty” in this section for details.

3 - Preface

Chapter 1 Introduction (Revision 2, Oct 2012)

The ACES Systems’ Viper 4040 Analyzer is a versatile tool that automates the task of turbine fan trim balance, propeller balance, provides automated rotor track and balancing adjustments or provides raw data for use with polar charts, performs vibration surveys, TFE731 Performance runs, (in conjunction with the ACES 1752B JEDA) and transient analysis. Engine, airframe, propeller, or rotor-specific setups can be loaded and stored into the analyzer by the user, then recalled to automatically configure the analyzer for the task at hand. These “Setups” store influence coefficients for balancing functions, which the analyzer updates with each balance job to minimize the number of required runs for balancing fans, propellers, rotors, or shafts. The analyzer is capable of true, four-channel simultaneous data acquisition and provides full graphic-spectrum capabilities including on screen display of limits and component identification taken from an installed fault frequency database. The Viper 4040 allows you to print spectra and balance jobs directly to a serial printer, and with the use of a serial-to-parallel converter, to a parallel printer for inclusion in aircraft records or as file copies. (See chapter 21 of this manual for details on printing.) The analyzer also has a USB port if your PC is so equipped. Survey spectra and balance reports can be transferred directly to a personal computer for storage, trending, or manipulation for inspection or troubleshooting purposes via the companion software ACES AvTrend. Overall, the analyzer is designed as a lightweight, portable unit with accuracy and ease of use as primary design goals. The subsequent chapters of this manual explain the functions and features of the analyzer, supporting information, and troubleshooting. The remainder of this chapter presents tips on effectively using the manual.

1.1 - Notes, Cautions, and Warnings Throughout this manual you will encounter “notes, cautions, and warnings.” They will be in BOLD capital print centered above a short paragraph. The information in the paragraph is defined as follows for each of the three categories. NOTE Information considered essential to emphasize for clarity or to ensure the related procedure is correctly accomplished. CAUTION Information that if not heeded, may result in the damage or faulty operation of equipment. WARNING Information that if not heeded, may result in damage or destruction of equipment and/or injury to personnel.

1.2 - Conventions The following are writing conventions used throughout the manual to describe certain concepts. 1. This manual indicates keys/keystrokes in square brackets. For example: [ENTER], [CLR], [5], [F1]. 2. The term “select,” as used in this manual, means to highlight the item on the current menu by using the arrow keys, then pressing the [ENTER] key. 3. The term “Setup,” as used in this manual, means the complete set of information entered into the analyzer or created with AvTrend and electronically stored in the analyzer’s memory or in the AvTrend software files for the purpose of completing a balance, vibration analysis, or track function. This stored information may then be downloaded from AvTrend to the analyzer, or if stored in the analyzer already, recalled from a “Setup” menu presented for the various functions to rapidly configure the analyzer based on the information contained in the Setup. 4. The term “Job,” as used in this manual, means the stored Setup information plus the collected balance, vibration, track, and/or spectral data, and recorded corrective action taken (if applicable) to correct an undesirable condition. In other words, it is a record of the analyzer configuration, acquired data, computed data, and user entered data used in the course of completing the maintenance task.

1-2 – Introduction 1

Viper 4040 User Manual

5. The “Banner” is the uppermost portion of the screen display, which defines its relationship to the currently-running analyzer function. The “Highlight Bar” is the darkened bar (controlled by the use of the arrow keys, [⇓] and [⇑]) used to identify and select the current menu item. (See figure below.) These screens and their selection options are referred to as “banner screen menus” throughout the text of this manual. The example screen below, for instance, is the “Main Menu” banner screen.

6. The term “field” as used in this manual refers to an area that requires input. Fields appear on various screens as areas delineated by boxes with either pointed ends (< >) or square ends ([ ]). Data is entered into the field in one of two ways, either by using the keypad to type data or by using the [⇒] key to “toggle” or move among the selections that are preset for the field. 7. The term “Tracker,” as used in this manual refers to the ACES Systems’ Model 540, the Model 540-2 Optical Tracker, or the Model 550 TraXTM.

1 Introduction – 1-3

Chapter 2 Analyzer Description (Revision 3, Oct 2012)

This chapter gives you a brief tour of the analyzer. It describes the various keys and their functions, the input and output ports, and the standard accessories supplied with the analyzer. Optional accessories are discussed later in the chapter in Section 2.5. A

1

B

2

COMM

3

C

4

D

Model 4040

ACES S YS T E MS

ON/ OFF

B A C K U P

MAIN MENU

F1

F2

F3

F4

PRINT

1 ABC

2 DEF

3 GHI

HELP

4 JKL

5 6 MNO PQR

7 8 STU VWX

9 YZ*

1 ABC

SPACE +/-

. @%#

F5

CLEAR

E N T E R

2.1. Keypad The analyzer keypad consists of 31 function keys. (See Chapter 3, “Using the Viper 4040 Analyzer” for keypad operation.)

ON/ OFF

2.1.1.

Located at the top left of the analyzer keypad, the [ON/OFF] key, when pressed once and released, turns the analyzer power on or off. The analyzer incorporates a power conservation function. If no activity (keystroke) occurs within ten minutes following the on keystroke, the analyzer will automatically shut off. If activity does occur within ten minutes, the analyzer remains on for thirty minutes with no activity before automatically shutting off. As long as a keystroke is detected at least once every thirty minutes thereafter, the analyzer remains powered until the [ON/OFF] key is pressed to turn power off, or the battery’s charge expires.

MAIN MENU

2.1.2.

The [MAIN MENU] key is used as a means to quickly return to the main menu (the first menu that appears when the analyzer is powered on) without the necessity of multiple steps. When pressed momentarily then released, this key produces the same action as turning the analyzer power off, then back on. The key may be used to escape screens where [BACKUP] will consume too much time for the user. Pressing the [MAIN MENU] key causes all in-progress functions to cease and incomplete balance or survey data to be lost in whole or in part. Holding the [MAIN MENU] key down for more than two seconds will turn the analyzer off.

B A C K U P

2.1.3.

The [BACKUP] key allows the user to back up one step in the current running procedure to make corrections or immediate changes. The [BACKUP] key is also used to escape an active screen where no other options for exit are available.

2-2 - Analyzer Description 2

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4040 Viper User Manual

F1

2.1.4.

Five function keys ([F1], [F2], [F3], [F4], and [F5]) are located directly below the analyzer’s screen. Five small rectangular boxes on the screen directly above the keys define their use as it corresponds to each screen. The purpose of each key may change from screen to screen. If any of the screen boxes are blank, the box’s corresponding key has no function in that screen.

F1

2.1.5.

Two contrast keys are located to the left and right of the main body of keys above the [BACKUP] and [ENTER] keys. The left or decrease key is used to lower the screen contrast and the right key (shown above) which is visually opposite, to increase the screen contrast. These keys are fully functional for all phases of operation when the analyzer is powered. Each key press will produce an incremental increase or decrease in the screen contrast.

PRINT F1

2.1.6.

The [PRINT] key is inoperative at this time.

F1

2.1.7.

The [BACKLIGHT] key, when pressed once, turns the LCD backlight on or off.

Revision 3, Oct 2012

2 Analyzer Description – 2-3

E N T E R

2.1.8.

The [ENTER] key is pressed to accept data or a menu selection and set that selection into motion. The key is used in survey and balance procedures to proceed to the next step.

HELP

2.1.9.

Pressing the [HELP] key allows you to access guidance and/or examples of information that can be entered into the current field.

5 MNO

2.1.10. The ten alphanumeric keys (0 through 9 / A through ?) are used to input alphanumeric values into the analyzer. A single press followed by a one-second delay returns the numeric value (first character) of the key. Two rapid presses followed by a one second delay returns the second character (first of the three alpha characters) of the key. Three or four rapid presses followed by a one-second delay, returns the third or fourth (second or third alpha) characters of the key, respectively. For example, if you want to type the letter “N” which is the third character on its corresponding key, press the key three times rapidly, and then stop for one second. The letter “N” should appear on the screen.

CLR

2.1.11. The [CLR] key is used to clear input in the current field.

2.1.12. The four arrow keys ([UP], [DOWN], [LEFT], and [RIGHT) are used to select, move between fields and positions within a field, or highlight menu items on screen. They are also used in various functions to "toggle" between choices, to increase or decrease screen values and graphic display sizes, and to change the field value or cursor position.

2-4 - Analyzer Description 2

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4040 Viper User Manual

. @%#

2.1.13. The symbols key ([. @%&]) has multiple functions. The “.” is used for placement of a decimal in fractional numbers such as 98.6. The other characters on this key are used as they would be in normal text such as “54 grams @ 230 degrees” or “3% error,” or “Left & Right propellers.” To type any of the symbols on this key, follow the same procedure described in the preceding paragraphs that are used for the alphanumeric keys.

SPACE +/-

2.1.14. The [SPACE] key is used to enter a separating space in a text line. When entering numeric values the plus (+) and minus (-) portions of the key are used to change a positive number to a negative value or a negative number to a positive value.

2.2. - Screen The full graphics Liquid Crystal Display (LCD) screen is how the analyzer communicates with the user. In computer terminology, the screen is the “graphical user interface.” The screen displays messages, menus, selection lists, graphic illustrations, and survey plots. The display is 2.9 inches high by 3.85 inches wide. It is an adjustable-contrast, backlit LCD with a 320 x 240 dot-matrix display. Although the screen displays various font sizes dependent on the current function, a typical screen such as the main menu it is capable of displaying 40 columns and 20 lines of text at one time. The backlight is turned on automatically when the analyzer is powered up and can be turned off and on using the backlight key. Screen contrast is controlled by pressing one of the two contrast keys to the left and right sides of the main body of keys. NOTE If the analyzer is exposed to extremes in temperature, either heat or cold, the LCD may darken or lighten to a point that it cannot be clearly read. If this occurs, adjust the contrast to compensate for the change. If this fails to return the LCD to a viewable state, remove the unit to an ambient room temperature of 65 – 85 degrees F. The LCD should return to its previous state in approximately 30 minutes.

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CHANNEL A

TACH 1 CHANNEL B

TACH 2 AUX/COMM

TACH 3 CHANNEL C

CHANNEL D

TACH 4

2.3. - Input and Output Ports

There are nine input/output ports on the top end panel of the analyzer, as shown in the figure above: four “CHANNEL” (vibration channel) inputs, four “TACH” (tachometer) inputs, and one “AUX/COMM” (auxiliary/communication) input/output port.

2.3.1. CHANNEL Ports The four vibration CHANNEL inputs will accept acceleration, velocity, or displacement sensor signals. All vibration CHANNEL inputs are six-pin MS socket connectors. The default configuration for a two-plane balance on a single engine is “CHANNEL A” for the front sensor and “CHANNEL B” for the rear sensor. For a two engine, dual plane balance, the default configuration is the same for engine one and engine two defaults to “CHANNEL C” for the front sensor and “CHANNEL D” for the rear sensor. The user within the SETUP function can change these default values as necessary. Any of the four channels may be specified in the SETUP function as the input for a single plane balance job. The six-pin connector enables the analyzer to provide sensor power as required to the sensor being used.

2.3.2. TACH Ports The four “TACH” inputs are three-pin female receptacle connectors. They will accept either a raw tachometer speed reference signal or a Transistor-Transistor Logic (TTL) level speed signal. Power (+12V) is provided on one pin of the tachometer connector to power optical speed sensors such as the Phototach or LASETACH. The inputs will also accept a variable configuration (low tooth, high tooth, offset tooth) monopole input and use the odd tooth as a once-per-rev for balancing and speed indication purposes. The tach inputs will also accept tachometer generator and magnetic pickups.

2.3.3. AUX/COMM Port The “AUX/COMM” or Auxiliary and Communications port is a 6-pin MS type male connection used for serial communications between the analyzer and a personal computer or

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modem. This port is also used to connect an ACES Systems’ Model 550 TraXTM or Model 540 Series Optical Trackers. Three additional input / output ports are provided on the left side panel of the analyzer. They are the STROBE, USB and BATT/CHG ports.

STROBE

USB

BATT / CHG

2.3.4. STROBE Port The “STROBE” port is for connection of a strobe light for manual, visual tracking of rotor or propeller blades. The analyzer provides a trigger for the strobe through this port. Power (28V DC) for the strobe must be provided from outside the analyzer, usually from a ship’s power source. The strobe and necessary cables are available as optional equipment from ACES Systems.

2.3.5. USB Port The USB port is provided for USB applications and future development. The port is a 4-pin MS connector. Interface cables to standard USB applications are available from ACES Systems.

2.3.6. BATT CHG Port The “BATT CHG” (Battery Charge) port is used in conjunction with the battery charger supplied with the analyzer. Your analyzer will come with either a 110V or 220V charger according to your geographical requirements.

WARNING When using the Nickel Cadmium (NiCd) battery charger, do not leave the battery attached (on charge) for a period of more than 14 hours. To do so may result in damage to the battery and/or analyzer.

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WARNING The protective cap on the “BATT CHG” port must remain in place during periods when the charging unit is not connected. The two pins of the charging input are active at all times and may be shorted by unintentional contact with a conductor if the cap is not in place.

2.4.

Additional Standard Equipment

When you purchase a Viper Model 4040 Analyzer, several accessories come with the analyzer as standard equipment. These items are described in the following paragraphs.

2.4.1. Battery The primary power source for the analyzer is its internal battery. There are two power supply configurations available. 2.4.1.1. Nickel Cadmium (NiCd) equipped analyzers For analyzers S/N 01xxx the original power source is a custom designed 12-volt nickel cadmium (NiCd) battery rated at 2.3 Amp hours. This means that a fully charged battery will supply power at the rate of 2.3 Amps for one hour or at the rate of 1 Amp for 2.3 hours. Typically, a fully charged battery will provide power for 6 hours of continuous analyzer operation while powering all four available sensors. Power is proportionally increased with the use of fewer sensors and accessories. A minimum of 8 hours charging time is required for a full charge. As with any battery, age, usage, and environmental conditions may eventually necessitate battery replacement. We do not recommend you change the battery yourself because of the possibility of damage to other components. Contact ACES Systems for details about return and replacement of the internal battery. 2.4.1.2. Nickel Metal Hydride (NiMH) equipped analyzers For analyzers S/N 02xxx the internal battery is a custom designed 12-volt nickel metal hydride (NiMH) battery rated at 2.7 Amp hours. This means that a fully charged battery will supply power at the rate of 2.7 Amps for one hour or at the rate of 1Amp for 2.7 hours. The difference in battery technology removes the "memory effect" associated with NiCd batteries. The analyzers in this serial number group also have integrated "smart-charger" technology. The battery can be fully cycled (charged and discharged), or partially discharged prior to recharge, or any combination of the two methods and the smart-charging circuit combined with the NiMH chemistry will result in having 100% battery capacity available. This removes the need for periodic deep discharge/re-charge cycles associated with properly maintaining NiCd batteries. The NiMH batteries, combined with the proper charger, require just 4 hours for a full charge, but can be left on charge indefinitely. After a 4-hour (or less) full charge, the charger switches to "top-off" mode for another 2 hours to ensure that the battery is fully charged to 100% capacity. At the end of the top-off period, the charger switches to tricklecharge mode which is simply counter-acting the self-discharge of the battery pack. For analyzers S/N 03xxx the internal battery is a custom designed 12-volt nickel metal hydride (NiMH) battery rated at 4.5 Amp hours. This means that a fully charged battery will

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supply power at the rate of 4.5 Amps for one hour or at the rate of 1Amp for 4.5 hours. The difference in battery technology removes the "memory effect" associated with NiCd batteries. The analyzers in this serial number group also have integrated "smart-charger" technology. The battery can be fully cycled (charged and discharged), or partially discharged prior to recharge, or any combination of the two methods and the smart-charging circuit combined with the NiMH chemistry will result in having 100% battery capacity available. This removes the need for periodic deep discharge/re-charge cycles associated with properly maintaining NiCd batteries. The NiMH batteries, combined with the proper charger, require just 4 hours for a full charge, but can be left on charge indefinitely. After a 4-hour (or less) full charge, the charger switches to "top-off" mode for another 2 hours to ensure that the battery is fully charged to 100% capacity. At the end of the top-off period, the charger switches to tricklecharge mode which is simply counter-acting the self-discharge of the battery pack.

2.4.2. Battery Charger WARNING The Viper was not intended to be operated during the charging cycle. Individual power requirements must be examined on a case by case basis. Operation of the Viper with the charger energized and connected may affect acquired readings.

Each power supply configuration described above has a specific battery charger available to recharge the internal battery. 2.4.2.1. Nickel Cadmium (NiCd) equipped analyzers The analyzer’s internal battery must be charged periodically. This is accomplished using the battery charger included as standard equipment with your analyzer and shown in the photograph below. The 12-Volt DC battery charger is used to charge the 4040’s nickel cadmium batteries. The charger has an input of 100-240VAC, 50-60Hz. The output is 18VDC, 670mA. The charger has a two-prong outlet connector and cord that plugs into the charging unit and into a wall outlet. The cord is a standard, 16-gage electrical appliance cord and is 6 feet long. The analyzer connector end is an MS, three-pin female, quarter turn lock type connector, constructed of aluminum alloy and coated with olive drab chromate for corrosion protection.

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2.4.2.2.

Nickel Metal Hydride (NiMH) equipped analyzers

The analyzer’s internal battery must be charged periodically. This is accomplished using the battery charger included as standard equipment with your analyzer and shown in the photograph below. The 12-Volt DC battery charger is used to charge the 4040’s Nickel Metal Hydride batteries. The charger has an input of 100-240VAC, 50-60Hz. The output is 19VDC, 3.1A. Depending on the available voltage, the charger will be configured with either an 110VAC or 220VAC input cord to allow the charging unit to be plugged into a wall outlet. The cord is a standard, 16-gage electrical appliance cord and is 6 feet long. The analyzer connector end is an MS, three-pin female, threaded type connector, constructed of aluminum alloy and coated with olive drab chromate for corrosion protection.

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2.4.3. USB Communications Cable An optional USB Communications cable is available for use with the Model 4040 Viper. The cable has a standard USB Type A connector at one end and an MS 4-socket connector at the other. This cable is configured to connect directly to your analyzer at the 4-pin “USB” port at one end and to a standard USB Type A connection to a computer on the other end. Once connected to a personal computer, you can transfer data to and from the analyzer for use with AvTrend software, which is supplied with the analyzer. NOTE The Viper cannot directly communicate with peripherals, such as a printer, because the analyzer lacks the necessary driver for proper communication.

2.4.4. Carrying Case The analyzer carrying case is constructed of expanded ABS plastic. The case is durable and protects its contents from the elements when closed and latched. Clean the case with a mild soap solution and coat with an ARMOR ALL type protectant to preserve appearance. The case has a limited lifetime warranty from the original manufacturer. (ARMOR ALL is a registered trademark of the Clorox Company.) The case is airtight when the purge valve is closed (turned clockwise to its limits). If the case is transported between the varying pressure altitudes, such

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as those that occur during air travel, the case may be difficult to open due to pressure differential. If there is a pressure differential between the exterior and interior of the case, open the purge valve by turning it counterclockwise. This will allow the pressure to equalize and ease the task of opening the case.

2.4.5. User Manual This user manual is current when you receive it with the analyzer. To verify that your manual is current, visit our web site at www.acessystems.com or call ACES Systems at the number listed at the front of this manual.

2.5. Optional Equipment Because the Viper Model 4040 Analyzer is so diverse in its capability, many accessories such as helicopter-specific sensor mounts, blade tracking devices, airframe interface cables, and numerous vibration sensors are available for use with it. For various Turbofan, Rotary Wing and Engine applications, contact ACES Systems directly to inquire about available accessories for your particular needs. Because of the diversity of this application, many accessories are available that are too numerous to list concisely in this manual. Unlike turbofan or rotary wing applications, most propeller balancing applications use common accessories, so ACES Systems has assembled a propeller balancing kit, described below, which can be purchased with the Viper 4040 Analyzer.

2.5.1. Propeller Balancing Kit The propeller balancing kit contains all the necessary items to complete a single-engine, single-plane propeller balance. If your requirements are multiple-plane balance on a singleengine or multiple-engines balancing, additional equipment will be required. The items in the propeller balancing kit are described below. 2.5.1.1. Manual, ACES Systems Guide to Propeller Balancing The ACES Systems Guide to Propeller Balancing provides FAA approved procedures and practices for completing a propeller balance job in lieu of airframe or propeller manufacturers’ written instructions. The guide includes instructions on installing vibration sensors, photo tachometers, and reflective tape; information on selecting the proper trim weights, attaching trial weights, attaching permanent weights; and other hints for simplifying the balance job. The guide does not provide information on using the analyzer. Review this user’s manual for detailed information on the analyzer’s operation.

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2.5.1.2. 991D-1 Accelerometer Although the Model 4040 will support a full range of vibration sensors, the 991D-1 accelerometer (see the illustration above) was selected as the standard for use with the propeller balance kit due to its rugged construction, accuracy, cost, and range of operation. A single sensor is supplied with the propeller balancing kit. Additional sensors may be purchased separately. The output of the 991D-1 accelerometer is 20 mV per g. The 991D-1 is pre-programmed in the analyzer’s sensor setup list. The operating temperature range is -50 to + 120 degrees C. The three-pin connector is a MIL-C -26482, and the mating connector is a Bendix PT06-83S. The mounting stud is 1/4 x 28. Although the sensor is rugged, it can be damaged when dropped on hard surfaces. Use care when installing the sensor, as you would with other electronic components.

2.5.1.3. 991D-1 Sensor Cable The 991D -1 sensor cable, shown above, is a 25-foot (50-foot optional) shielded and Tefloncoated four-conductor cable. The three-pin MS female connector on one end of the cable mates to the 991D -1 sensor. The six-pin MS male connector mates to one of the four (CHANNEL A, B, C, or D) available vibration-input ports on the analyzer. Contact ACES Systems for other sensor, cable, or adapter options.

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2.5.1.4. Phototach The Phototach is a short-range optical sensor used in acquiring speed and phase angle data. Its optimum range is 12 to 18 inches from the target (reflective tape, 3M 7610). It is supplied with a three-inch by three-inch base. An optional camera type swivel mount is available from ACES Systems. Hardware (screw, nut, and washers) for assembly of the supplied mount is contained in the tackle box which is also supplied with the propeller balance kit. The three-pin MS connector attaches directly to the Phototach cable. Other speed/phase sensors that can be used with the analyzer can be purchased separately. They include the ACES Systems’ LASETACH, Magnetic Interrupter, or specific-application speed interfaces. Call ACES Systems for further information.

2.5.1.5. Tachometer Sensor Cable The tachometer sensor cable connects the analyzer to a Phototach, an ACES Systems’ LASETACH, or an interface for optional speed sensors such as a magnetic pickup or pulse generator. The cable is a three-wire shielded cable, insulated in a bright yellow, petroleumresistant jacket. Attached to one end of the cable is a female three-pin bulkhead type socket connector. On the opposite end of the cable is a male three-pin, quarter-turn-locking MS connector. The connectors are constructed of aluminum alloy with olive drab chromate coating for corrosion resistance. The male end connects to the tach input of any ACES Systems’ analyzer/balancer or to the female end of another cable of the same type. The opposite (female, bulkhead) end will accept another 10-320-0126 cable for extension or connect to an aircraft or sensor interface. There is a 50-ft. and a 25-ft. variant of this cable. The 25-ft. cable was built generally for propeller balancing applications, which normally require less distance to the sensors. When using this cable to connect to older versions of the Phototach, LASETACH, or to any other speed-sensing device, an interface appropriate to the application may be required. New-design LASETACHs with the part number 10-100-

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1300 and new-design Phototachs with part number 10-100-1773 have a socket connector that connects directly to the bulkhead connector end of this cable.

2.5.1.6. Propeller Protractor The propeller protractor is designed to measure angles in a typical propeller/spinner assembly. As illustrated in the figure above left, each of the seven circles on the protractor contains four angles. The angle at each circle location can be determined by reading the upright number (for example the 30 degree location in the illustration). The circles are located at 30-degree increments with unmarked 15-degree incremental lines between them. Since the analyzer can be configured to calculate solution angles relative to the vibration sensor or reflective tape, both methods are presented here. The propeller protractor pictured above right is a complete circle. This is divided into fivedegree increments. Every 30 degrees, the angle is identified by text. Every 45 degrees, the angle is printed in a circular identifier. Place the propeller protractor over the spinner with the proper direction of rotation side facing you as indicated by the text and an arrow. Since the analyzer can be configured to calculate solution angles relative to the vibration sensor or reflective tape, both methods are described in more detail below. 2.5.1.6.1. Using the Propeller Protractor

For correct use of the protractor when measuring relative to the vibration sensor, do the following: WARNING Always ensure mag switches are off prior to any movement of the propeller

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1. Rotate the propeller with the reflective tape until it is directly in front of the Phototach. 2. With the propeller in this position, place the protractor over the spinner with the Rotation indicator pointing in the direction of rotation (forward looking aft) and one of the 360 degree points aligned with the position of the vibration sensor. 3. Read the upright numbers in the circles, and then interpolate values of the unmarked incremental lines to locate the desired angle. For correct use of the protractor when measuring relative to the reflective tape: 1. Place the protractor over the spinner with the Rotation indicator pointing in the direction of rotation (forward looking aft) and one of the 360 degree points aligned with the position of the reflective tape. 2. Read the upright numbers in the circles, and then interpolate values of the unmarked incremental lines to locate the desired angle. NOTE If the angle is out of range for the position of the protractor, rotate the protractor 90 degrees (right or left as appropriate) at a time until you can read the correct angle.

2.5.1.7. - Case Bolt Adapter Set An eight-piece case bolt adapter set with nut sizes 1/4 to 7/16 NF and NC threads is included in the propeller balancing kit. The stud portion is a 1/4 x 28 thread. To use the bolts/nuts during a typical propeller balance, select the adapter from the set to match the case bolts of a typical opposed engine. Attach the adapter nut end to the exposed case bolt threads then slide the right angle mount over the stud end and secure with the supplied nut. You will require two sets of the adapters for dual-engine balancing. 2.5.1.8. Tackle Box A multi-compartment, high impact plastic, tackle box is included with the propeller balancing kit. The box has ample storage space for vibration sensors, vibration sensor mounts, and the case bolt adapter set. It may also serve as storage for AN washers used as balance weights.

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2.5.1.9. Right-Angle Sensor Mount The right-angle sensor mount shown in the left portion of the illustration above is made of anodized aluminum and designed to be mounted directly on the engine case bolt or to the case bolt adapter, shown in the right portion of the illustration above. The mount has a 1/4 x 28-threaded hole for the vibration sensor and a 5/16 unthreaded hole for the case bolt adapter stud. 2.5.1.10. Gram Scale A 150-gram capacity scale is included with the propeller balancing kit for weighing the washers or trim weights used in balancing. Read the operating instructions enclosed with the scale carefully prior to its use. 2.5.1.11. Reflective Tape The reflective tape supplied with the propeller balancing kit is used as a tachometer trigger for the Phototach to generate a once-per-rev pulse used in speed readings and balancing calculations. The reflective tape (3M 7610) supplied with the propeller balancing kit was selected because of its excellent reflective quality and performance under varied operating conditions. Using a lower quality tape will cause inaccurate tachometer readings or unreliable phase information. The tape is manufactured by the 3M Company and is the only tape we recommend for use with the system. Contact ACES Systems for replacement tape. (See Chapter 15, “Equipment and Accessory Setup and Troubleshooting” for additional information for high RPM)

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NOTICE: This aircraft's power train rotating components compose an indexed assembly. The propeller was dynamically balanced using:

2.5.1.12. ACES Systems Balance Placard A placard similar to the one shown above is included in the propeller balancing kit. This or a similar placard should be attached to the spinner bulkhead upon completion of balancing to show that the propeller has been dynamically balanced and is indexed to the crankshaft of the engine.

2.5.2. Serial Communications Cable An optional serial communications cable for data transfer with a personal computer is available for use with the analyzer. The cable has both a standard DB25F and a DB9F connector at one end and an MS 6-pin socket connector at the other. This cable is configured to connect directly to your analyzer at the 6-pin “COMM” port at one end and to a standard DB25M or DB9M pin for connection on the other end. Once connected to a personal computer, you can transfer data to and from the analyzer for use with the AvTrend software, which is supplied with the analyzer.

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Chapter 3 Using the Viper 4040 Analyzer (Revision 2, Aug 2007)

3.1. – Entering Data Data is entered into the analyzer in one of three ways: by typing data using the keypad, transferring data from a personal computer using AvTrend software, or indirectly by selecting from preset options. The methods of inputting data are described in the following sections.

3.1.1. - Using the Keys The analyzer keypad has 25 function keys, 12 of which are multiple-character, alphanumerically labeled. The multiple-character labeled keys, 1ABC through SPACE +/will generate each of the characters on the label and insert it into the current field position of the analyzer screen. To generate the first character, on an alphanumeric key, use the arrow keys to place the cursor in the desired field. Press the key one time, and then pause for two seconds. The first character of the key should appear in the active field To generate the second character on an alphanumeric key, press the key twice rapidly, then pause for two seconds. The second character should appear on the screen. Repeat this process for each letter on the key, with the number of times you press the key equivalent to the character’s position on the key. Note that some fields are formatted to accept numeric values only. Multiple presses of a key while the cursor is in such a field will produce multiples of the numeric key value only.

5 MNO For example, to type the number “5”, press the key once, wait for two seconds. The number “5” should appear on the screen. To type the letter “N”, press the key three times rapidly, and then wait for two seconds. The letter “N” should appear on the screen. The insert position of the character being typed is indicated on screen by the cursor. The cursor may be moved to any position in the current field using the left or right arrow keys. If placed in an existing text string, a key stroke of any alpha numeric character key will insert the character into the string at the current cursor position and move existing text to the right one character position.

3.1.2. - Filling in Fields Data is entered into areas of the screen called fields. Some fields are represented by boxes with pointed ends (). These fields are called “toggle” fields because you must use the [⇐ ⇒] keys to toggle, or move, between several preset selections available in the field. Some of the fields are represented by boxes that have square-ends ([ ]). The square-end boxes are text entry boxes. You must enter or edit text in these boxes using the keys as described in the previous section. If you wish to change text already in place in these fields, place the cursor in the field you wish to change then press the [CLR] key once for each character in the field you wish to remove and replace. Use the [⇑ ] and [⇓] keys to move from field to field.

3.2.

- Loading a Setup

A “Setup” is a group of instructions defined by you, the user, downloaded from the ACES web site, or acquired from another user and stored in the analyzers’ memory for rapid analyzer configuration. This group of instructions combined with certain optional information and analyzer-calculated data allows the analyzer to be custom-configured for virtually any engine/airframe combination in a matter of seconds following initial entry of the information. See the ACES AvTrend User Manual for specific instruction on downloading setups from the ACES web site. Steps in the process of loading and using various setups are explained throughout Chapters 4 through 14 of this manual which address each of the main categories of the analyzer’s functions. All of the main categories of the analyzer’s functions are accessed from the analyzer’s main menu and directly correspond to selections on this menu.

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3.3. - Main Menu The main menu is the first menu to be displayed when the analyzer is turned on. (See the following figure.) From this menu you may access all functions of the analyzer by using the available menu choices. Chapters 4 thorough 19 of this manual describe each main menu item selection, the function of each item, and the general steps necessary to perform each function. The Main Menu banner section has the added ability to display the current state of the database. This is an approximate representation of how much of the analyzer’s memory is currently occupied. Your analyzer may not show all items displayed in the screen below if you do not have a license number for certain functions. Consult your ACES sales representative for optional Viper functions and attaining a license number for them.

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Chapter 4 Propeller Balance (Revision 2, Oct 2012)

“Propeller Balance” is an analyzer function that is accessed from the analyzer’s Main Menu banner screen as shown in the illustration below. Selecting this function from the main menu brings up the “Propeller Balance” banner screen menu (also shown below). Each of the listings on this banner screen menu is an option within the function. Descriptions of each of these options follow, along with the information required to complete the menu screens within the options, and the steps necessary to perform propeller balance function.

4.1.

- Start Job

Selecting “Start Job” from the “Propeller Balance” banner screen allows you to begin a new propeller balance job. When you select this option, one of three screens will appear depending on whether you are: 1) Starting a new job with no setups previously defined in the analyzers memory; 2) Starting a new job with previously defined setups available in the analyzers memory; or 3) Resuming an incomplete job being held in the analyzers memory. If you are starting a new job with no setups previously defined in the analyzer’s memory, the screen will automatically display the Prop Balance Setup banner screen shown below. See section 4.1.1. for step-by-step instructions on completing the Prop Balance Setup.

If you are starting a new job with previously defined setups available in the analyzer’s memory, the screen will automatically display the Select Setup List banner screen similar to

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the one shown below. The actual setup names will be those, which you have entered into your analyzer.

If you are resuming an incomplete job being held in the analyzer’s memory, the opportunity to do so is presented immediately following the “Start Job” selection. The screen displays the message as shown below. If you press the [F1] “Yes” key, the analyzer will return you to the last logical in-progress step of the job. If you press the [F5] “No” key, the analyzer will proceed as described in the two examples above, depending on your circumstances.

4.1.1. - Prop Balance Setup The “Prop Balance Setup” banner screen allows you to define and store a propeller balance Setup. The “Prop Balance Setup” banner screen displays fill-in and selection type fields. The fill-in fields have squared off ends ([ ]). These fields are filled in using inputs from the analyzer keypad. The selection fields have pointed ends (< >). These fields have two or more preset values that are selected by using the [⇒] and [⇐] keys. Navigate between the fields on 4 Propeller Balance – 4-3

this screen using the [⇓] and [⇑] keys. (Refer to Chapter 3, “Using the Model 4040 Viper Analyzer” if you are unfamiliar with using the keypad or inputting data.) Complete the “Prop Balance Setup” screen per the following example. 4.1.1.1. – Propeller Balance Setup Screen To complete the “Prop Balance Setup” banner screen (as shown below), do the following:

4.1.1.1.1.

In the “Name” field, enter a name for this setup using the keypad. (Refer to Chapter 3, “Using the Model 4040 Viper Analyzer” if you are unfamiliar with using the keypad.) The name you choose will aid you in differentiating this setup from other stored setups should you choose to review it at a later time. The name should be one of your choosing which you will be easily recognized and associated with this setup such as “Cessna 150,” “King Air, ” or “T-6 TEXAN II.”

4.1.1.1.2.

Using the [⇓] key, move down to the “Eng HP” field. Enter the rated horsepower of the engine using the keypad. The valid range of values for this field is 0 to 5000.

4.1.1.1.3.

Using the [⇓] key, move to the “Max Baln.Wts” field. Enter the maximum total trim balance weight (in grams) allowed for this installation. If the manufacturer does not specify a maximum weight, refer to the ACES Systems Guide to Propeller Balancing. The valid range of values for this field is 1 to 9999.

4.1.1.1.4.

Move to the “Balance RPM” field using the [⇓] key. Using the keypad, enter the actual propeller RPM at which you intend to balance. If no manufacturer recommendation is available, refer to the ACES Systems Guide to Propeller Balancing included with the Propeller Balance option. A low cruise RPM is usually best. The valid range of values for this field is 50 to 32767.

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4.1.1.1.5.

Using the [⇓] key, move to the “Relative to” field. Select “Tape” or “Sensor” using the [⇒] key. If using predetermined weight locations, select “Tape.” Decide if you wish to measure weight placement phase angles relative to the reflective tape or the vibration sensor as an index point.

4.1.1.1.6.

Move to the “Holes:” filed and select either “Yes” or “No” using the [⇒] key. Yes indicates that the propeller assembly has predetermined locations, or holes where trim balance weights can be added. If you select “Yes” a page for defining the location of each hole will be provided. You may also download setups with these predefined locations from the ACES Systems web site and load the setups into your analyzer. The “No” answer indicates that no predetermined locations are available and that you will be drilling holes for the permanent mounting of the final trim balance weights.

4.1.1.1.7.

Move to the “Vib:” field and use the [⇒] key to choose the vibration engineering units for this balance job. The choices are IPS (inches per second velocity), mm/sec (millimeters per second velocity), cm/sec (centimeters per second velocity), Mils (1000ths of an inch displacement), Microns, and Gs (equivalent gravities).

4.1.1.1.8.

The field to the immediate right of the Vib: filed is unmarked. It is a select field also and is the modifiers to be used with the units of vibration (Vib:). The selections are Peak, Pk-Pk (Peak-to-Peak, may also be called double amplitude), Avg. (Average), and RMS (Route Mean Square).

4.1.1.1.9.

Move to the “FSR” field and use the [⇒] key to select the Full Scale Range for the vibration amplitude you reasonable expect to encounter on this job. For a propeller balance conducted using IPS, a normal selection would be 1. You should make your selection to accommodate the highest vibration as an overload of the analyzer caused by higher values than that selected might delay or lengthen the job.

4.1.1.1.10.

Move down to the “Rotation (#1)” field using the [⇓] key. Using the [⇒] key, Select CW (Clockwise) or CCW (Counter-Clockwise) for the rotation of the propeller as viewed standing Forward of the propeller Looking Aft toward the tail of the airplane (FLA).

4.1.1.1.11.

Using the [⇓] key, move to the “Tach Type” field. Using the [⇒] key, select the type of tachometer you are using. Tach Type selections for this field include: “Optical” - Includes the PhotoTach and LaseTach. This is the only selection that will provide power to the Tach device. “Mag (Lo)” - A magnetic interrupter with an output of 120mV or greater. This selection is used for clean Tach signals with a low noise floor. “Mag (Hi)” - A magnetic interrupter with an output of greater than 3 volts and less than 5 volts. This selection provides isolation from erratic signals containing electrical noise above 120 mV but less than 3 volts. 4 Propeller Balance – 4-5

“Monopole” - A monopole type pickup with an output of 120mV or greater. “Tach Gen” - A one to three pole tachometer generator with an output of 390mV or more. (This type of input is normally used for synchronous vibration surveys and not for a once per rev signal used to calculate phase angles in balancing.) 4.1.1.1.12.

Using the [⇓] key, move to the “Tach Chan” field. Using the [⇒] key, select “TACH 1, TACH 2, TACH 3, or TACH 4” according to the analyzer’s tach input channel(s) you intend to use. The default for single sensor input is TACH 1.

4.1.1.1.13.

Using the [⇓] key, move to the “Tach Pos (FLA)” field. Using the [⇒] key, select the tach position. The tach position is determined by standing Forward of the propeller Looking Aft (FLA) toward the tail of the aircraft. From this viewpoint, determine the approximate clock position (1:00 to 12:00) of the tachometer pickup.

CAUTION Sensors connected to Channel A and Channel B or Channel C and Channel D must be of the same type. Using different sensors during the same job will cause erroneous readings and problems achieving good balance results. 4.1.1.1.14.

Move down to the “Sens Type” field using the [⇓] key. Select the sensor type from the available options using the [⇒] key. If your sensor type is not listed, see the section of this manual entitled “Sensor Setup”.

4.1.1.1.15.

Move to the next field, “Sens Chan” using the [⇓] key. Select sensor channel “A, B, C, or D” according to which of the analyzer’s input channels you intend to use. The default for single-sensor input is Channel A. Use the [⇒] key to make the selection. If you are conducting a two plane balance, the default for the second sensor is Channel B.

4.1.1.1.16.

Using the [⇓] key, move to the “Sens Pos (FLA)” field. Using the [⇒] key, select the vibration sensor position. The sensor position is determined by standing Forward of the propeller Looking Aft (FLA) toward the tail of the aircraft. From this viewpoint, determine the approximate clock position (1:00 to 12:00) of the vibration sensor.

4.1.1.2. - Edit ICF The “Edit ICF” (which corresponds to the [F1] key) selection appears at the bottom left of the “Prop Balance Setup” banner screen. Press the [F1] key if you wish to define the Influence Coefficients for this setup. The following “Edit ICF” banner screen is displayed.

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4.1.1.2.1.

If you do not have ICF information for the balance setup, press the [BACKUP] key. This sets the ICF at the default for the known conditions. The ICF default value is added automatically when the Setup is created. The user may use this key at any time to reset the ICF to default. If an ICF has been calculated by the analyzer and stored from previous runs, the “Samples” field displays the number of samples included in the calculation. (The Samples field is a display-only field and cannot be edited by the user.) When satisfied with the displayed ICF, press [ENTER] to return to the “Prop Balance Setup” banner screen.

4.1.1.3. - Sensor Setup Pressing the [F5] “Sensor” key from the “Prop Balance Setup” banner screen displays the “Sensor Setup” banner screen shown below. The information on this screen should correspond to the sensor you selected for this setup in step 4.1.1.1.14 above.

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4.1.1.3.1.

This is an information-only screen for use in verifying the parameters of the vibration sensor you have chosen. You may not edit or otherwise enter information on this screen. If this sensor does not possess the specifications you require for this setup, you may enter a new sensor in the “Sensor Setup” screen, or choose another sensor from the existing list. Press [BACKUP] or [ENTER] to exit this screen and return to the “Prop Balance Setup” banner screen. When all fields are completed to your satisfaction, press the [ENTER] key to accept the inputs and continue to the “Prop Hole Layout Setup”.

4.1.1.4. – Prop Hole Layout Setup

4.1.1.4.1.

If “Yes” was selected under the “Holes:” entry in step 4.1.1.1.6 the “Prop Hole Layout Setup” banner screen is the next screen displayed. The “Name” field is automatically filled in from the name you entered in the previous “Prop Balance Setup” screen. Complete the fields on the screen by doing the following:

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4.1.1.4.2.

Use the [⇓] key to move to the “No. of Holes” field. Enter the number of holes that correspond to the total number of trim weight mounting locations. The valid range of values for this field is 1 to 36.

4.1.1.4.3.

Move to the “Space” field using the [⇓] key and then use the [⇒] key to select “Even” or “Uneven” from the available selections. Even indicates that all trim weight mounting locations are evenly spaced. The analyzer will automatically calculate the number of degrees between holes in this case. If you select “Uneven,” and then use the [⇓] key to move away from the field, several fields (“Ang” and “No.”) appear at the bottom of the screen. You will complete these fields later in the process at step 4.1.1.4.6.

4.1.1.4.4.

Use the [⇓] key to move to the next field, “Dir (FLA).” Complete this field by using the [⇒] key, select CW for clockwise or CCW for counter-clockwise to indicate the direction of increasing hole numbers as viewed from forward looking aft.

4.1.1.4.5.

Move to the “Max H. Wt” field using the [⇓] key. Using the keypad, enter the maximum allowable weight (in grams) for any single hole. Use the [⇓] key to move to the next field.

4.1.1.4.6.

Complete the next fields differently depending on data you input in step 4.1.1.4.3 above. If you selected “Even” in step 4.1.1.4.3 - The “Enter the Angle of No. 1 Hole” field is displayed. Use the keypad to enter the angle of hole number 1 as viewed from the front of the engine looking aft. To determine this angle, do the following. With mag switches OFF, rotate the propeller to align the tachometer pickup and its triggering device (magnetic interrupter, reflective tape, etc.). With the propeller in this position, use the 12:00 position as the “0” or “360 degrees” (index point) and measure opposite the direction of rotation to the angle of hole number 1. For example, if the #1 hole is at the 3:00 position (simply as viewed on the face of a clock from in front of the engine, disregarding propeller direction of rotation) and the engine rotates counterclockwise, the angle would be 90 degrees. If the #1 hole is at the 3:00 position and the engine rotates clockwise it would be 270 degrees. The measurement to hole # 1 must always be measured opposite the direction of rotation. If you selected “Uneven” in step 4.1.1.4.3 – Multiple angle/hole number fields are displayed. Each hole angle must be defined individually. Using the keypad, complete each field by entering a hole number (“No.”) and its corresponding angular (“Ang”) location as measured opposite the direction of propeller rotation. Use the [⇓] and [⇑] keys to move between these fields. To determine these values, do the following. With mag switches OFF, rotate the propeller to align the tachometer pickup and its triggering device (magnetic interrupter, reflective tape, etc.). With the propeller in this position, use the 12:00 position as the “0” or “360 degrees” (index point) and measure opposite the direction of rotation to the angle of each hole number and record that angle adjacent to the hole number. (See the example “Prop Hole Layout Setup” screen shown at the beginning of the section.) For example, if the number 1 hole is near the 6:00 position, the angle may be

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measured as 174 degrees. On the screen, use the keypad to enter the angle of hole number 1 as “174.” Then, using the [⇓] key to move to the adjacent field (“No.”), input the number “1.” Next, measure to hole number 2. If hole number two is measured as 156 degrees, enter that value and “2” in the adjacent field. Continue this process until all angles for all holes are defined. The measurement must always be opposite the direction of rotation of the propeller. 4.1.1.4.7.

When all fields are complete, press [ENTER] to accept the settings and continue. The analyzer will display the message, “Store this new setup?” If you choose to store this new setup in the analyzer’s memory, press the [F1] key for “Yes,” otherwise press [F2] for “No.”

4.1.2. – Job Identification

4.1.2.1. At this point in the “Propeller Balance” process, you should have completed the following steps: selected “Propeller Balance” from the Main Menu; selected “Start Job;” and completed the “Prop Balance Setup” screen which included editing ICF and sensor setup, or you selected a setup from a list of predefined setups. Depending on whether or not you made use of predetermined hole locations, you may have also defined values for a number of trim weight mounting holes. If these steps have been completed, then the “Job Identification” banner screen will be displayed. Job information is optional but will appear on the job printout if entered and will assist you in identifying this job when stored in memory. Complete the information fields using the keypad. Press [ENTER] to continue. NOTE If a name is not entered on the Job Identification screen, the job will be commonly labeled “Unnamed” in the resume and manage job lists. This will complicate finding a specific job, as multiple jobs are stored. We recommended you enter a name.

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4.1.3. – Engine Information

4.1.3.1. The “Engine Information” banner screen is displayed. This information is optional but will appear on the job printout if entered and will assist you in identifying this job when stored in memory. Complete the information fields using the keypad. When finished, press [ENTER] to continue.

4.1.4. – Connect Sensors

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4.1.4.1. The “Connect Sensors” banner screen will be displayed as shown above. Messages that appear on this screen prompt you to perform the physical installation and connection of the tach and vibration sensors to the input ports you specified in the setup. 4.1.4.2. - Tachometer Setup To install the tachometer, do the following: 1. Install the Phototach at the position specified in the setup. The Phototach should be not less than 4 inches but no greater than 18 inches from the back surface of the target blade. Use speed tape or duct tape to secure the 3x3 base mount to the cowling surface. An angle of approximately 5 degrees from perpendicular to the target blade will produce the best results. 2. Connect the tachometer cable to the Phototach connector. Route the cable away from hot areas and electrical equipment back to the cockpit and attach to the tach channel specified in the setup you are using. Secure the cable along its route with duct tape or tie wraps. 3. Near the bottom of the analyzer screen, ensure that the message, “Tach Power is Off” is displayed and that the Block directly below this statement and corresponding to the [F1] key is labeled “Tach Pwr”. Press the [F1] key once to change the statement at the bottom of the screen to read “Tach Power is On”. This will energize the tach for proper tape alignment. WARNING Insure mag switches are off prior to any movement of the propeller.

4. Rotate the propeller to visually align the Phototach with a point on the backside of the target blade where you intend to place the reflective tape. Clean this area thoroughly to insure adhesion of the tape. 5. Cut a strip of reflective tape (3M Tape, Model 7610 is recommended) approximately 1.5 to 2 inches long. With the tape backing still in place, hold the tape in position on the propeller blade and move the propeller blade back and forth in front of the Phototach beam. NOTE To insure quality reflective action back to the Phototach, use 3M 7610 reflective tape. Use of other reflective tape or devices may result in poor signals back to the Phototach. NOTE If balancing large-diameter or high-speed propellers, refer to Chapter 19, Equipment and Accessory Setup and Troubleshooting for information on reflective tape width requirements for these applications.

6. With an inspection mirror, watch the red LED gate indicator light on the aft end of the Phototach illuminate and extinguish as the tape crosses the beam. This indicates the position of the tape is correct.

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7. Remove the tape backing and attach the reflective tape to the propeller at that location. Be sure to smooth out any wrinkles or bubbles in the tape. Ensure the edges are smoothed and firmly attached. 8. Connect the vibration sensor cable to the sensor connector. Route the cable away from hot areas and electrical equipment back to the cockpit and attach to the sensor channel specified in the setup you are using. Secure the cable along its route with duct tape or tie wraps. NOTE All trim balance weights installed during previous dynamic balance procedures should be removed before proceeding beyond this point. Refer to the ACES Systems’ Guide to Propeller Balancing (included with your Model 4040) for a full list of FAA-approved inspection requirements.

4.1.5. – Start Aircraft When you have completed the physical equipment setup tasks, press [ENTER] on the analyzer to continue with the propeller balance job.

The analyzer will then display the “Start Aircraft” banner screen (shown above). Two information lines are shown on the screen. The first: “Remove all trim weights” and the second: “Perform a FOD check and start engine(s) per flight manual.” Removing previously installed trim balance weights is necessary to prevent stack ups, or attempts to counterbalance installed weights. Follow the instructions in the ACES Systems’ Guide to Propeller Balancing included with your analyzer for inspections prior to balancing. The document is FAA approved and provides guidelines for the selection and installation of balance weights. When balance weights are removed and inspections are complete, “Press [ENTER] to start prop balance”. The [F2] “Swap Job” key allows you to return to the Main Menu without rebooting the analyzer. You can then switch between multiple propeller balance jobs to perform balances on several propellers during a single maintenance run. 4 Propeller Balance – 4-13

4.1.6. - Acquiring Data After starting the aircraft, the “Set Engine Speed” banner screen is displayed. At the top left of the screen, the run number is displayed. Directly below the run number, is the message, “Set eng # x RPM to: xxxx (where xxxx is the balance speed entered in the setup being used.” This is your target RPM for balancing. The next line, “Current RPM: xxxx.” indicates the RPM the propeller is turning currently. Attempt to match the two as closely as possible with throttle/prop lever adjustments. The next line, “Difference: xx” gives the current difference between the Target and the Current RPM. When the target speed and current speed are matched as closely as possible, press [ENTER] to continue. The screen changes to display the “Engine: x Run: x” banner screen. (See the figure below.)

The converging vibration indicator shows the average amplitude. (See Chapter 20, Reading Spectrum and Scales, for information on how to read the data contained on this screen.) The sensor location (Front) is indicated at the top of the text, right side of the screen. The current and average frequency, amplitude, and phase are also displayed along with the percentage of error (Error) in the averaging. When the error is at its lowest point and no longer decreasing, press [ENTER] to stop the data collection process. If you wish to reset the averaging and take new data, press the [F1] “Reset” key.

4.1.7. – Review Job When you are finished acquiring data, the “Review Job” banner screen (shown below) is displayed next. The amplitude and phase (Mag/DEG.) are displayed for each sensor input channel. Data is displayed for only the input channels that were used for the job; others are left blank.

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If you are satisfied with the results of the run and are ready for a solution, press [ENTER] to accept the data and continue. If you want to retake data for this run, press the [F1] “Retake #1” key. This option returns you to the “Set Engine Speed” banner screen (see section 4.1.6 above). An information screen will appear prompting you to “Shut down the engine(s) per manual instructions”. If you are performing a balance on more than one propeller, use the [F2] “Swap Job” key to return to the Main Menu and switch jobs. Press the [F5] “Continue” key to progress to the “Review Job” screen as shown in section 4.1.7.

4.1.8. - Balance Solution The “Balance Solution” banner screen shown below is displayed. The screen is identified at the top left as being “Run: 1”. Vibration amplitude and phase angle are displayed for each

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channel being used (Channel A only in the example screen shown) and a solution for the first run. In this example screen shown below, the “Solution” is “45.1 GMS @ 276°” which means to place 45.1 grams (g) of weight at 276 degrees from the index point. (see Chapter 2, Analyzer Description on how to use the Propeller Protractor to locate the phase angle.)

In the lower portion of the screen you see an information line stating “Remove previous trim weights.” Since all previously installed trim weights were removed prior to the start of the first run; this is only a reminder for Run 1. This same information line in following runs means to remove the trim weights installed on the previous run. In other words, the balance solution and resulting weight installed here after Run 1 may change in Run 2. The weights installed after Run 1 would be removed and new weights added at another location to refine the balance solution. NOTE In subsequent runs, all installed weights from each previous run must be removed. The “remove weight” message will be repeated for every run and solution. Each new solution dictates that the previously applied solution (installed weight) be totally replaced. In some cases this may mean removing and reapplying weight at the same or near the same location. Failure to remove previously installed weight prior to applying the new solution weight will result in failure of the propeller balance function.

The next line of text states “Enter Actual Weight Installed.” In the weight and angle fields directly below this line, enter the exact amount of weight and the angle, as near as possible, where it was installed. If you are unable to install the exact amount of weight in the recommended solution, install a weight as near the suggested solution weight as possible. The important point is whatever the actual amount of weight is, enter it here. If the solution exceeds the single location limits of the propeller or spinner assembly (refer to ACES Systems’ Guide to Propeller Balancing included with your analyzer) you may split the weight across two locations. If you do not wish to split the weights, press [ENTER] to continue and then move to the end of this section, to continue with the instructions at the “Start Aircraft” screen.

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4.1.8.1. – Set Split Weights To use the split weight option, press the [F1] “Split Weight” key from the “Balance Solution” banner screen. The “Set Split Weights” banner screen below is displayed.

The single location solution (in this case 46.1 g @ 16 degrees) is displayed at the top of the screen. The next line states “Enter New Locations.” Use the keypad to complete the next two fields, “Angle 1” and “Angle 2.” Locate the two available weight installation locations (one on each side of the 16-degree location) and enter them in the two fields. Use the [⇓] key to move between the fields. Press [ENTER] to continue. 4.1.8.2. - Record Split Weights The screen displays the “Record Split weights” banner screen like the one shown below.

The “New Solution” is given for the two new angles you specified as available for weight application. Match the new weight solution as near as possible to the recommended solution

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and install it at the new angles. Weigh the test weights carefully and enter the exact amount of weight in the “Actual Weight Installed” fields. If you discover a problem with the split weight locations you specified, press the [F1] “Resplit” and [BACKUP] key and enter the two new angles. When the “Actual Weight Installed” fields are completed, press [ENTER] to continue. The screen will return to the “Balance Solution” banner screen with the combined splitweight solution being displayed for the user. Press [ENTER] to continue. The screen will display the “Start Aircraft” banner screen shown below.

The “Start Aircraft” banner screen indicates the upcoming run number and directs you to “Perform FOD check and start engine(s) per flight manual”. Press [ENTER] to start prop balance.” Then repeat the procedures described above starting with item, 4.1.5 until the level of vibration is at or better than an acceptable level. See the ACES Systems Guide to Propeller Balancing for details of vibration levels and weight installation procedures. NOTE If the engine/propeller assembly is mechanically sound, a normal balance job should take no more than three runs to complete. The analyzer will only allow you to complete 6 runs in attempts to balance. If the balance job is not completed by the sixth run you should suspect possible problems with your technique or mechanical faults with the engine and/or propeller assembly. Mechanical faults may also be indicated by drastic changes in suggested weight or angle from one solution to the next.

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4.2. - Resume Job

Selecting “Resume Job” from the “Propeller Balance” banner screen menu allows you to select a job to resume. Only jobs that are left unfinished will appear in the list. Using the [⇓] key, highlight the job you wish to complete from the list of incomplete jobs, and press [ENTER]. You will be taken to the last step completed in the job process. NOTE If you did not enter information in the optional “Job Identification” fields when starting a job, that job will be stored by the name, “Unnamed”. If several “Unnamed Jobs” are listed, you may wish to review the data for each in order to ensure you are resuming the job you intended. See section 4.3.1 for specific guidelines on the Review function.

4.3. - Manage Jobs

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Selecting “Manage Jobs” from the “Propeller Balance” banner screen menu presents several sub-menu choices to choose from. These choices allow you to “manage” previously completed job data you have stored in the analyzer.

4.3.1. - Review Selecting the “Review” option presents a list of stored jobs on the “Job List” banner screen. You can select one job for on-screen viewing. When viewing is complete, press the [BACKUP] key to exit the screen. The analyzer will then return you to the "Manage Jobs" menu screen to select another function.

4.3.2. - Delete The “Delete” option presents a list of stored jobs on the “Job List” banner screen. From the list, you may select one job for deletion. After making your selection, the “Delete Job” banner screen will appear, asking you to verify your intent to delete the selected job by pressing the [F1] key for “Yes” or the [F5] key for “No.” You may wish to download the job for reference or permanent record prior to deleting. Once deleted, the job cannot be retrieved from the analyzer.

4.3.3. - Delete All The “Delete All” option will delete all currently stored jobs. After selecting this option, the “Delete All Jobs” banner screen will appear, asking you to verify your intent to delete all the jobs by pressing the [F1] key for “Yes” or the [F5] key for “No.” You may wish to download the jobs for reference or permanent record prior to deleting. Once deleted, the jobs cannot be retrieved from the analyzer.

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4.4. - Manage Setups

Selecting “Manage Setups” from the “Propeller Balance” banner screen menu presents several sub-menu choices to choose from. These choices allow you to “manage” setups you have stored previously in the analyzer.

4.4.1. - Edit Selecting the “Edit” function displays the “Setup List” screen. Select the setup you wish to edit. The screen will display the “Propeller Balance Setup” screen. Edit the setup as necessary and press [ENTER] to store and exit the edited setup screen. Refer to section 4.1.1 for detailed instructions on how to complete/edit the fields in the “Propeller Balance Setup” screen.

4.4.2. – New Selecting “New” will allow you to build a new propeller setup. After selecting “New”, the screen will display the fields necessary for building the new setup. Refer to section 4.1.1.

4.4.3. - Delete The “Delete” option presents you with a list of stored setups. From the list, you may select one setup for deletion. If you wish to delete all stored setups, you must delete them individually. After making your selection, you will be asked to verify your intent to delete the selected job by pressing the [F1] key for “Yes,” or the [F5] key for “No.” We highly recommend you download the setup for reference or permanent record prior to deleting them. Once deleted, the setups cannot be retrieved from the analyzer.

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Chapter 5 Main Rotor Track & Balance (Revision 3, Oct 2012)

This section is intended to familiarize you with the various electronic chart forms and setup screens used with the Viper 4040. First by looking at each of the chart forms found in both the main and tail rotor sections, then by using these forms to create an actual setup.

5.1. – Analyzer Chart Forms Just as in the case with polar balance charts, there are two types of analyzer chart “forms” used with the 4040 Viper, and one tracking influence setup screen. The chart forms are also categorized as either “Regular” or “Irregular”. The selection of setup type is made within the chart form itself by using either the [⇒] or [⇐] keys to toggle between “Regular” and “Irregular” in the “Chart Type” field, then pressing the [⇓] key to move to the next field. The remaining fields in the screen will automatically change if necessary. The tracking influence setup screen is separate from the chart forms and allows entry of the amount of adjustment required to move the blade a specified distance. The paragraphs below describe these forms in detail.

5.1.1. – Regular Chart Forms A “Regular” chart is one that has all weight positions spaced equally around the chart, all adjustments are of the same type, and all adjustments carry the same ICF. The next paragraphs detail the process for defining both a main rotor and tail rotor “Regular” chart setup. There are slight differences between the two functions that will be noted in the text.

5.1.1.1. – Regular Main Rotor Chart Setup The main rotor balance chart shown to the right depicts three weight positions, Red, Yellow, and Blue. The move line for each position has been indicated with an arrow, the type of adjustment given below the chart is “Plates”. The ICF is approximately 8 plates per 1.0 IPS. This chart meets all criteria to place it in the “Regular” chart type category; all weight positions have the same ICF and type of adjustment, and all move lines are equally spaced around the chart. Using this chart, follow the example below to properly define a “Regular” main rotor chart setup in the analyzer.

Name: The name of the chart will be automatically inserted from the “Main Rotor Condition Setup” screen and is not editable. Chart Type: Using the [⇒] or [⇐] key, select the chart type. For this example, the chart type is “Regular”. Sweep Only: This field is used when defining a chart that utilizes blade sweep only as a means of adjustment. If the chart you are defining uses only sweep moves, select “YES” using either the [⇐] or [⇒] keys. Otherwise, leave this field set to “NO”. No Adjustment Bld/Pos.: This field is used to designate a main rotor blade as a “no adjustment blade”. This feature is used when the OEM suggests that no adjustments be

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applied to a particular blade during a track and balance job. An optimized solution is provided by the analyzer that requires no adjustments to the designated “No Adjustment Blade”. Max ICF Update: This field is used to limit the learning ability for move-line length. The example above uses 100%. With 100% selected any move that exceeds 100% of the expected length for a given adjustment will be ignored by the analyzer for ICF (Influence Coefficient) updates. Using the keypad, enter the desired parameter to be placed in the setup. R(°) (Rotation in Degrees): This field is used to limit the learning ability for move-line direction. The example uses 45 degrees. With 45 degrees selected, any move line that falls more than 45 degrees outside of the expected vector for a given adjustment will be ignored by the analyzer and will not update the ICF. Using the keypad, enter the desired parameter to be placed in the setup. Adj. Unit: Using the keypad, enter a three-letter designator for the type of adjustment utilized by the chart. In this case, “PLT” has been entered to represent plates. The designator used in this screen will also be used when the analyzer recommends a solution. Adj. / IPS: Using the keypad, enter the influence from the chart. This is the amount of adjustment required to reduce a one IPS (Inch-Per-Second) vibration. The ICF for this example is approximately 8 plates per 1.0 IPS, therefore, 8 has been entered in to the “Adj / IPS” field. Bld/Pos and MoveLine: The lower portion of the screen provides fields for entry of the blade position names and Move Line clock angles. Because this is a “Regular” chart setup, you need only enter the move lines for the first two blade positions; the analyzer will determine the remaining angles. •

Starting with any of the blade positions listed on the chart; enter a name of up to six characters in the first field as shown.

•

Press the [⇓] key and move one field to the right, now enter the angle (in hours) of the move line for this position. If the move line contains an angle in minutes, press the [⇓] key and move to the next field to enter the minutes.

Repeat the name and move line process for the second blade position, then enter the remaining blade position names and this chart is complete. NOTE Blade position names must be entered sequentially in either clockwise or counter clockwise order. It does not matter what direction is chosen.

5.1.2. – Irregular Chart Forms Any polar chart that does not fit the “Regular” category must use the “Irregular” chart form. The next paragraphs detail the setup for both main rotor and tail rotor “Irregular” chart setups.

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5.1.2.1. – Irregular Main Rotor Chart Setup The main rotor balance chart shown to the right presents two different types of adjustments: the addition of weight to target or blank, and sweeping either the target or blank blade aft. The ICF is different for each set of adjustments, 220 grams of weight per 1.0 IPS and 2 points of aft sweep per 1.0 IPS. The move lines for these adjustments are equally spaced, however since the ICF and adjustment types are different, this chart must use the “Irregular” chart form. Using this chart, follow the examples below to properly define an “Irregular” main rotor chart setup in the analyzer.

Name: The name of the chart will be automatically inserted from the “Main Rotor Condition Setup” screen and is not editable. Chart Type: Press either the [⇒] or [⇐] keys to select the chart type. For this example, select “Irregular”. Sweep Only: This field is used when defining a chart that incorporates sweeping of the blades as the only means of adjustment. If the chart you are defining uses only sweep moves, select “YES” using either the [⇒] or [⇐] keys. Otherwise, leave this field set to “NO”. No Adjustment Bld/Pos.: This field is used to select one of the main rotor blades where the OEM suggests that no adjustments be used. An optimized solution is provided by the analyzer that requires no adjustments to the designated “No Adjustment Blade”.

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Max ICF Update: This field is used to restrict the learning criteria for move-line length. The example uses 100%. With 100% selected, any move line over 100% of the expected length for a given adjustment, and the analyzer will not update the ICF. Using the keypad, enter the desired parameter to be placed in the setup. R(°) (Rotation): This field is used to restrict the learning criteria for move line direction. The example uses 45 degrees. With 45 degrees selected, any move line that falls more than 45 degrees outside of the expected vector for a given adjustment, and the analyzer will not update the ICF. Using the keypad, enter the desired parameter to be placed in the setup. BLD/Pos, UNIT, ADJ, IPS, and MoveLn: •

Starting with any of the correction points on the chart, enter up to six characters for the blade position name in the first field. This example will use positions “TARGET”, “T AFT”, “BLANK”, and “B AFT”.

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Press the [⇓] key and move to the “Unit” field, enter a three character abbreviation for the type of correction this position uses. This example will use the abbreviations “GMS” to represent grams and “PTS” to represent points of sweep.

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Press the [⇓] key and move to the next field. Enter the adjustment amount portion of the ICF in the “Adj” field. The two amounts of adjustment in our example are “200.00” grams and “2” points of sweep.

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Press the [⇓] key and enter the amplitude reference for the amount of adjustment just entered. For this example, the ICF for weight is 220 gram per 1.0 IPS, the ICF for sweep is 2 points per 1.0 IPS, and therefore 1.0 is entered in this field.

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Press the [⇓] key to move to the “MoveLn” field and enter the clock angle move line for this point. For the “Add to TARGET” move line, the hour angle is 2, and the minute angle is 30. Perform this for each adjustment point shown on the chart and the setup is complete. The move line for the T AFT position will be 5:30. The move line for the BLANK position will be 8:30. B AFT will have the move line at 11:30. NOTE Blade position names must be entered sequentially in either clockwise or counter clockwise order. It does not matter what direction is chosen.

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5.1.3. – Tracking Influence Setup

The tracking influence setup screen is used to define the type and number of adjustment units used to move a blade 1.0 unit of measure at the condition listed. Conditions: The condition name will be automatically entered and is not editable. Adjustment Name: Using the keypad, enter a three-character identifier for the adjustment type. Example = PCL (Pitch Change Link), SWP (Sweep), WGT (Weight), and TAB (Tab). Unit: Using the keypad, enter a three-character identifier for the unit of adjustment type. Example = FLT (Flat), PTS (Points), GMS (Grams), DEG (Degrees), and THO (Thousandths). Adjustments / in (mm): Enter the number of adjustment units to move the blade 1.0 unit of measure. This will either be requested in Adj/in or Adj/mm depending on the measurement units selected in the initial setup screen. In this example, it will take an adjustment of 6 flats to move the blade tip one inch in ground or hover conditions. Max ICF Update: This field is used to restrict the learning criteria for track adjustments. The example uses 50%. With 50% selected, any movement over 50% of the expected result for a given adjustment, and the analyzer will not update the ICF. Using the keypad, enter the desired parameter to be placed in the setup. No Adjustment Bld/Pos.: This field is used to designate a main rotor blade as a “no adjustment blade.” This feature is used when the OEM suggests that no adjustments be applied to a particular blade during a track and balance job. An optimized solution is provided by the analyzer that requires no adjustments to the designated “No Adjustment Blade”. Tracking Planes: This field is used to designate the number of planes in which the main rotor blades fly. If all blades fly in the same plane, select . If there are two distinct planes for the blade path select .

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Offset: This field will only appear after “Tracking Planes” above is set to 2 and the field is exited. This field is used to define the optimum distance between multiple blade planes. The analyzer will use this distance to properly position the groups of blades. Blades: The blade names will default to those defined previously in the setup. If a change is required, change the blade name to reflect the blades in passing order staring with the blade that is over the nose when the tach and interrupter are aligned. This will be the name used in the track display and when viewing available adjustments. Plane: This field will only appear after “Tracking Planes” above is set to 2 and the field is exited. This field is used to identify how the blades will be grouped. Blades flying in the same plane require identical “Plane” entries. Press [ENTER] to save the setup.

5.2. – Setup Process This section covers the complete setup process in the 4040 Viper for the main rotor balance functions.

5.2.1. – Main Rotor Setup The following paragraphs illustrate each of the screens necessary to define and store an enhanced main rotor setup. 5.2.1.1. – Main Rotor Setup Screen

The first screen to complete is the “Main Rotor Setup” banner screen. As shown in the example below, some fields in this screen have default values that appear automatically. You can use this information if appropriate or input your own specific setup information using the

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keypad. (Refer to Chapter 3, “Using the Model 4040 Viper” if you are unfamiliar with using the keypad.) Follow the directions below to complete the “Main Rotor Setup” screen. 1. In the “Name” field, enter a name for the setup using the keypad. The field will accept up to 20 alphanumeric characters. CAUTION Sensors connected to Channel A, Channel B, Channel C and Channel D must be of the same type. Using different sensors during the same job will cause erroneous readings and problems achieving good balance results.

2. Use the [⇓] key to move to the “Vertical Chan” (Channel) field. Use the [⇒] key to “toggle” between the selections in this field, either “A”, “B”, ”C”, ”D”, “A+B”, or “None”. The value selected for this field determines which analyzer channel will be used to measure and display the vertical vibration. 3. Use the [⇓] key to move to the “Lateral Chan” field. Use the [⇒] key to “toggle” between the selections in this field, either “A”, “B”, “C”, “D”, “A-B”, or “None.” The value selected for this field determines which analyzer channel will be used to measure and display the lateral vibration. 4. Move to the “Sensor” field using the [⇓] key. Use the [⇒] key to toggle between the options and select a sensor. If the sensor you are using does not appear as an optional selection, you must input a new sensor setup into the analyzer’s memory. (See Chapter 18 of the Model 4040 Analyzer User Manual, Section titled “Setup Sensors” for instructions on how to perform this function.) 5. Move to the “Tach Type” field by pressing the [⇓] key. The selection in the “Tach Type” field identifies which tachometer sensor you are using as a once-per-revolution source. For main rotors, this will most often be “Mag (Hi).” Use the [⇒] key to make the selection. The choices are “Mag (Hi)”, “Monopole”, “Tach Gen”, “Dbl Intr”, “Optical”, and “Mag (Lo)”. 6. Press the [⇓] key to move to the “Tach Chan” field. Use the [⇒] key to select and identify which analyzer tachometer input port you are using to acquire tachometer data. Available channels are 1, 2, 3, or 4. 7. Press the [⇓] key to move to the “Number of Weight Positions” field. Using the [⇒] key, select the total number of lateral balance weight positions as determined from the lateral balance chart. The maximum number of positions equals 6. 8. Move to the “Blades” field pressing the [⇓] key. Using the [⇒] key, select the number of blades of the main rotor system you are balancing. The maximum number of blades equals 6. 9. Use the [⇓] key to move to the “Relative to” field. This selection will determine the reference blade for tracking displays. Selecting “AVG” will present rotor blade positions relative to the average of all blades. Selecting a specific blade number will present all other blade positions relative to the blade number selected. (For more information on tracking, refer to Chapter 16 of the Model 4040 Analyzer User Manual.)

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10. Move to the “RPM” field using [⇓] key. Using the keypad, enter the approximate maximum expected RPM of the rotor system. 11. Press the [⇓] key and move to the “Trk Units”. Use the [⇒] key to select the desired unit of measure to be used by the analyzer when presenting tracking data. Selectable options are either inches or millimeters. (For more information on tracking, refer to Chapter 16 of the Model 4040 Analyzer User Manual.) 12. Using the [⇓] key, move to the first field in the grouping of “Conditions”. The fields allow you to define up to six different conditions under which to measure and store data. Each condition name may be a maximum of six characters long and should represent a flight regime at which you wish to record data. Directly to the right of each condition name box is a toggle selection for the type of measurement desired for that specific condition. In each of the measurement type fields, use the [⇒] key to select from the following: •

“Both” = measurement and storage of both vibration and track for the listed condition

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“Vib” = measurement and storage of vibration only for the listed condition

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“Trk” = measurement and storage of track only for the listed condition

When all conditions and measurement types desired have been input to your satisfaction, press [ENTER] to continue. 5.2.1.2. – Tracking Setup Screen English

Metric

The “Tracking Setup” screen appears. The purpose of this screen is to allow the user to input the relevant dimensions of the rotor being balanced. This information will be required to obtain accurate measurements. Additional, device specific, instructions can be found in either the Model 550 TraXTM Operational Supplement (ACES P/N 75-900-4043) or the Model 540/540-2 Operational Supplement (ACES P/N 75-900-2021). 1. In the “Rotor Diameter” block, use the keypad to enter a number between 1 and 999999 to include a decimal point.

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2. Press the [⇓] key to proceed to the unit label field. This is the unit of measure used to identify the diameter described in the above block. The available choices are: “ft”, “in”, “mm”, or “m”. Use the [⇒] key to select the appropriate unit. This field is independent of the other unit fields required in the setup. 3. Use the [⇓] key to move to the “Lead/Lag Units” block. This will define the units that the lead/lag measurements are displayed in. Available choices are “in” and “mm”. Use the [⇒] key to select the appropriate unit. 4. Use the [⇓] key to move to the “Blade 1 Offset” block. This will define the angular distance between the Tach event and the passage of the first blade over the tracking device. Use the keypad to enter a number between 30 and 90 degrees. 5. Use the [⇓] key to move to the “In. from Mast CL” block. This will define the linear distance, as measured in the same plane as the tracker is mounted, from the tracker to the extended centerline of the mast. This value will always be in inches regardless of any other units used in the setup. Use the keypad to enter a value between 1 and 999 to include a decimal point. 6. Use the [⇓] key to move to the “Trkr Inclination” block. This field will record the angular relationship between the horizon and the centerline of the tracking device as aimed at the main rotor blades. Use the keypad to enter a number between 30 and 90 degrees. 5.2.1.3. Main Rotor Condition Setup Screen

The “Main Rotor Conds. Setup” screen appears. The purpose of this screen is to allow the user to enter an “ID” number for each polar chart or tracking influence to be used by the analyzer when determining if a solution is required. •

To the left of the screen is a column of fields containing the conditions as entered in the main rotor setup screen. The names are automatically entered and are non-editable.

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To the right of each condition name is a chart “ID” field for each measurement type. If a “0” is entered in an “ID” field, the measurement obtained will be for reference only and will not be used as a basis for correction. If a number is entered in an “ID” field, the setup will require an electronic chart be defined and will result in corrections being given for that measurement vs. condition. If the same “ID” number is given to more than one condition for the same measurement type, the data for each of the conditions will be averaged together and a solution presented for the average. Different adjustment types (for example, PCL and TAB) for the same measurement type (i.e. vertical vibration), would require different “ID” numbers for the conditions applicable to each adjustment type.

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The “Limit” fields allow input of a maximum acceptable vibe (for vertical and lateral measurements) and maximum acceptable total track split (when using a tracking influence vs. blade position for corrections). Simply enter the value you wish to use. If the measurements recorded during a job are above this value, the analyzer will present corrections, if the measurements are below, the analyzer will not give an adjustment.

Looking at the example main rotor conditions setup screen above, three charts will be used, two vertical and one lateral. One tracking influence definition will also need to be created. The first chart is for vertical measurements at hover only. The second chart is for the averaged vertical measurements from both FLT 80 and FLT 120. The last chart is for the average lateral measurement from both Ground and Hover. The tracking influence will use track readings from Hover measurements. No other measurements will be used to produce corrections for this setup. Both vertical and lateral vibrations must be 0.20 IPS or greater for the analyzer to present solutions. Track splits must be 0.25 inches or greater for the analyzer to present a solution. For more “Main Rotor Conditions Setup” screen examples, see paragraphs 5.2.1.3.1, and 5.2.1.3.2. When you have completed the conditions setup screen, press [ENTER] to accept and continue. Proceed to paragraph 5.2.1.4. for the next main rotor setup screen. 5.2.1.3.1. – Conditions Setup Screen, Example 2

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In the example main rotor condition setup screen above, only one vertical chart ID, one lateral chart ID, and one tracking adjustment ID have been entered. Based on the ID numbers entered, all of the vertical measurements for Hover, FLT 80, and FLT 120 will be averaged and the solution based on this average. The lateral measurement for both Ground and Hover will also be averaged, with the lateral solution based on this average. Finally, a tracking adjustment based on the recorded track split on the ground will be presented. This type of setup would be used with a ship that requires a pitch change link adjustment on ground based on visual track and a trim tab adjustment based on the vertical vibration in flight. 5.2.1.3.2. – Conditions Setup Screen, Example 3

The last example shows one lateral chart and two track adjustment ID entries. The lateral measurements for both Ground and Hover will be averaged, with the solution based on this average. The recorded track split for Ground and Hover will be averaged with one solution based on this average. The recorded track split for FLT 80 and FLT 120 will also be averaged with a second solution based on this average. This is an example of a setup for use on an aircraft that requires pitch change link adjustment for ground and hover visual track, then trim tab adjustment based on visual track in forward flight.

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5.2.1.4. – Main Rotor Adjustment Symbol and Solution Logic Setup Screen

The “M/R Adjustment Symbol Setup” screen appears as shown. This screen is used to establish the direction of move for a positive adjustment as determined by the charts. For example, if the selection of “Sweep (AFT)” is made, when the analyzer gives an adjustment for blade sweep to move a blade “4 flats”, the actual movement of the blade is 4 flats aft. A movement of this same blade forward would be a negative move (-4.0 flats). Look at the polar charts you are using to determine the primary direction of move according to the chart. Use the [⇑] or [⇓] keys to select the field and the [⇐] or [⇒] key to select the option for each of the movement types. •

Weight: Weight adjustments should always be entered as the addition of weight.

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Sweep: Select “FWD” or “AFT” for the direction of blade movement if adjusting lateral balance using sweep in accordance with a polar chart. If the aircraft does not utilize blade sweep for lateral balance, this field is not applicable.

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Blade: Select “UP” or “DOWN” for the direction of blade movement if adjusting pitch change links in accordance with a polar chart.

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Tab: Select “UP” or “DOWN” for the direction of blade movement if adjusting trim tabs in accordance with a polar chart.

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Soln: The two solution options are “Max” and “All”. When solving for “Max”, the analyzer will present the solution for the highest vibration reading attained for the vertical and lateral sensors. When solving for “All”, the analyzer will present all of the available solutions for vertical, lateral and track readings.

When completed, press [ENTER]. 5.2.1.5. – Chart Definition The final step in the setup process is to define the electronic chart forms as described in section 5.1, Analyzer Chart Forms. Vertical chart(s) will be defined first, followed by the Revision 3, Oct 2012

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lateral chart(s), then any track adjustment influences required. When all charts have been completed, press [ENTER] to save the setup and return to the “Main Rotor Manage Setups” menu. Follow paragraphs 5.2.1.6 through 5.2.1.6.7 for a complete example of a typical main rotor setup. 5.2.1.6. – Main Rotor Setup Example This setup example is applicable to a helicopter type that utilizes pitch change link adjustments to correct for vertical vibration in a hover, weight and blade sweep adjustments for lateral vibration in a hover, and blade trim tab adjustments for vertical vibrations in forward flight regimes. The polar charts used for this example are illustrated below.

Rotor diameter: 37.0 Feet. Lead/lag units are read in inches. Rotor speed: 385 RPM/

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5.2.1.6.1. – Main Rotor Setup Screen

1. The name of the setup has been labeled as “EXAMPLE 1”. 2. Vertical vibration will be measured on channel “A”. 3. Lateral vibration will be measured on channel “B”. 4. The type of vibration sensor chosen for this setup is the “991D-1”. 5. The type of tachometer source for this setup is the “Mag(Hi)”. 6. The tachometer channel for this setup is channel “1”. 7. Looking at the lateral balance chart presented in paragraph 5.2.1.6, four weight positions have been identified, Target – Blank sweep and Target – Blank weight. 8. The main rotor is a two bladed system. 9. Tracking will be displayed relative to blade number “1”. 10. Rotor speed is 385 RPM. 11. Track measurements will be displayed in “inches”. 12. Four conditions have been entered for this job, “GROUND”, “HOVER”, “FLT80”, and “FLT120”. Both track and vibration will be measured and recorded for this setup. Press [ENTER] to proceed to the next screen.

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5.2.1.6.2. – Tracking Setup Screen

1. Enter “37.00” in the first block using the keypad. 2. Select “ft” for units of rotor diameter. 3. Select “in” for the display units of lead/lag data. 5.2.1.6.3. – Main Rotor Conditions Setup

Use the sample polar charts in section 5.2.1.6. In the “Main Rotor Conditions Setup” screen above, two vertical charts and one lateral chart have been identified. The first vertical chart, ID number “1”, will be used for a vertical measurement in hover only, while the second vertical chart, ID number “2”, is for the average vertical measurement of both “FLT 80” and “FLT120”. One lateral chart has been identified for the lateral measurement in “Hover” only. The vibration limit for both the vertical and lateral measurements has been set at 0.20 IPS. This main rotor setup will not use the tracking information measured by the analyzer for any corrections; it will be for user reference only.

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When completed, press [ENTER] to continue. 5.2.1.6.4. – Main Rotor Adjustment Symbol and Solution Logic Setup

In the “Main Rotor Adjustment Symbol and Solution Logic” setup screen above, the positive numeric value in a solution screen has been identified as the addition of weight, sweeping a blade aft, moving a blade upwards using either pitch change links or tabs. The solution logic has been set to “MAX” and will present the solution related to the highest vibration readings attained for the vertical and lateral sensors. Press [ENTER] to continue. 5.2.1.6.5. – “Vertical: Hover” Chart Definition

The “Vertical: HOVER” chart setup screen appears first. Use the vertical vibration chart in paragraph 5.2.1.6, to complete the steps below and properly define this chart.

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1. The name of the chart, “Vert: HOVER”, has been automatically entered from the “Main Rotor Conditions Setup” screen and is non-editable. 2. The chart type is “Regular”. 3. This chart uses no sweep adjustments, and is therefore left as “No”. 4. No Adjustment Blade/Pos. is left as “None”. 5. Max ICF Update is “50”%. 6. Rotation is “45” degrees. 7. The type of adjustment applied in accordance with this chart is pitch change link in flats; therefore “FLT” has been entered. 8. The influence co-efficient for the pitch change links is “5.0” flats per 1.0 IPS vibration. 9. The Bld/Pos names entered from the chart are “TARGET” and “BLANK”. 10. The “MoveLine” for moving the “TARGET” blade up is “12:45”. 11. The “MoveLine” for moving the “BLANK” blade up is “6:45”. When completed, press [ENTER] to continued. 5.2.1.6.6. – “Vertical: FLT 80 – FLT120” Chart Definition, Example 1

The “Vertical: FLT 80 – FLT120” chart setup screen appears next. Use the vertical vibration chart in paragraph 5.2.1.6, to complete the steps below and properly define this chart. 1. The name of the chart, “Vert: FLT 80 – FLT120”, has been automatically entered from the “Main Rotor Conditions Setup” screen and is non-editable. 2. The chart type is “Regular”. 3. This chart uses no sweep adjustments, and is therefore left as “No”. 4. No Adjustment Blade/Pos. is left as “None”.

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5. Max ICF Update is “50”%. 6. Rotation is “45” degrees. 7. The type of adjustment applied in accordance with this chart is trim tab in degrees; therefore “DEG” has been entered. 8. The influence co-efficient for trim tab adjustment is “10.0” degrees per 1.0 IPS vibration. 9. The Bld/Pos names entered from the chart are “TARGET” and “BLANK”. 10. The “MoveLine” for moving the “TARGET” blade up is “12:45”. 11. The “MoveLine” for moving the “BLANK” blade up is “6:45”. When completed, press [ENTER] to continued. 5.2.1.6.7. – Lateral Hover Chart

The last chart defined will be “Lateral: HOVER”. Use the lateral vibration chart in paragraph 5.2.1.6, to complete the steps below and properly define this chart. 1. The name has been automatically entered as “Lat: HOVER” from the “Main Rotor Conditions Setup” screen and is non-editable. 2. The type of chart is “Irregular”. 3. Although this chart does utilize a sweep adjustment for balancing, it is not the only type of adjustment used and therefore requires this entry to be left set as “No”. 4. No Adjustment Blade/Pos. is left as “None”. 5. Max ICF Update is “50”%. 6. Rotation is “45” degrees. 7. The first Bld/Pos name entered is “TARGET”, utilizing an adjustment unit of “GMS” weight. The influence co-efficient for this point is “200.00” grams adjustment per “1.0” IPS vibration. The Move line for this position is “8:30”.

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8. The second Bld/Pos name entered is “T AFT”, utilizing an adjustment unit of “PTS”. The influence co-efficient for this point is “2.00” points adjustment per “1.0” IPS vibration. The Move line for this position is “11:30”. 9. The third Bld/Pos name entered is “BLANK”, utilizing an adjustment unit of “GMS” weight. The influence co-efficient for this point is “200.00” grams adjustment per “1.0” IPS vibration. The Move line for this position is “2:30”. 10. The last Bld/Pos name entered is “B AFT”, utilizing an adjustment unit of “PTS”. The influence co-efficient for this point is “2.00” points adjustment per “1.0” IPS vibration. The Move line for this position is “5:30”. When completed, press [ENTER] to save and exit this setup.

5.3. – Main Rotor Balance Process

The following paragraphs present the main rotor track and balance process and its associated screens and are intended to familiarize the user with the data acquisition and correction capabilities of the 4040 Viper.

Prior to starting a new main rotor track and balance job, you must first select the “Main Rotor Track & Balance” option from the main menu. Do this by highlighting the “Main Rotor Track & Balance” option from the “Main Menu” screen using the [⇓] key and pressing [ENTER].

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5.3.1. – Starting a New Job

Selecting “Start Job” from the “Main Rotor Track & Balance” banner screen allows you to begin a main rotor balance job. When you select this option, one of three screens will appear next depending on whether you are using the main rotor function for the first time, have previously defined main rotor setups, or have a previously started job stored in the analyzer. •

If you are using the analyzer for the first time, the “Main Rotor Setup” banner screen will appear allowing you to define a new main rotor setup to use. Refer to paragraph 5.2.1 “Main Rotor Setup” for detailed instructions on defining a setup.

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If you have previously saved setups stored in the analyzer’s memory, a screen displaying the list of setups will be displayed. You can then select a setup from this list to use for the job. Proceed to paragraph 5.3.2 “Setup List”

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If another job was already in progress but not completed, the “Incomplete Job” banner screen will be displayed and the analyzer will present a message prompting you to verify that you wish to finish the incomplete job or begin a new job. The screen will display the message; “The last job performed is incomplete. Do you want to RESUME work on it?” If you wish to return to the unfinished job, press the [F1] “Yes” key and you will be returned to the point where the in-progress job was stopped and allowed to complete it. If you wish to continue with starting a new job, press the [F5] “No” key and the screen will then display the “Setup List”. Proceed to paragraph 5.3.2.

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5.3.2. – Setup List

The setup list presents the stored main rotor setups in analyzer memory. Select the setup you wish to use by highlighting the name of the setup using the [⇓] key and pressing [ENTER]. If the setup you need is not present, press the [F1] “New” key to proceed to the “Main Rotor Setup” screen to define a new setup. The [F4] key can be used to copy an existing setup and rename or change parameters.

5.3.3. – Job Identification

The “Job Identification” banner screen appears next allowing entry of the customer name, ACFT registration, and total time. This information is optional, but it is suggested that at least a customer name be entered, as it will aid in identifying the job for future use.

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If the analyzer has been used previously, a list of customer names will have been stored and are accessed by pressing the [F1] “Names” key. A name can then be selected from this list for use with this job. When finished, press [ENTER].

5.3.4. – Tracking Selections

The “Tracking Selections” screen is displayed, allowing you to choose a tracking device for use with the job. This screen will always be presented at the start of a new job to allow selection of a tracking device or when resuming a job to ensure the device has not been changed. •

The tracking device field is a toggle selection of either “TraX”, “Tracker” or “Strobe.” Use the [⇒] or [⇐] keys to select the tracking device being used.

If you select “TraX” or “Tracker,” press the [⇓] key and move to the lower portion of the screen to input the following: •

Using the keypad, enter the number of revolutions for which you will acquire track data. The minimum entry is 20 and the maximum is 99, however, it is highly suggested that you use no less than 30 for the number of rotations to measure track. This will result in greater accuracy from the tracker.

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Using the keypad, enter the distance, in inches, from the tracker’s location (usually the cockpit) to the blade tips at 12:00 with the interrupter over the magnetic pickup, or reflective tape in front of the Phototach.

Additional, device specific, instructions can be found in either the Model 550 TraXTM Operational Supplement (ACES P/N 75-900-4043) or the Model 540/540-2 Operational Supplement (ACES P/N 75-900-2021).

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When finished, press [ENTER].

5.3.5. – Connect Sensors

The “Connect Sensors” banner screen will be displayed next. Messages that appear on this screen prompt you to perform the physical installation and connection of the tachometer and vibration sensors to the input channels you specified in the applicable setup. •

You must use the vibration sensor installation locations as specified by the applicable polar charts. The orientation of the sensor is key to the accuracy of the chart, if the sensor is installed in a direction other than that specified, the phase (clock) angles will be incorrect and solutions will not be accurate.

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If you are using a magnetic pickup for the speed sensor, install and set the gap as directed in the applicable maintenance manual or polar chart.

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It is permitted to use the Phototach for the main rotor one per revolution source. If using a Phototach as the tachometer, refer to paragraph 5.3.5.1 “Optical Tachometer Setup”.

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Also at this time, install any ship’s power and strobe cables as needed.

When completed, press [ENTER]. 5.3.5.1. – Optical Tachometer Setup (Optional) To install the optical tachometer, do the following: •

If not specifically provided by an ACES Systems Application Note or manufacturer’s directions, locate a position that allows the Phototach to be installed not more than 18 inches away or closer than 4 inches from a rotating main rotor component. This component will be used to install the reflective tape to serve as the once-per-revolution

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tachometer source for the analyzer. Connect and route the tachometer cable from the Phototach to the analyzer. NOTE If possible, the location of the Phototach should allow for the reflective tape to trigger it when the main rotor is in the reference position as specified by the balance chart. This will provide a direct correlation of the clock angles produced by the analyzer and the charts. If this is not possible, the clock positions on the chart will have to be rotated based on the vibration results from the first applied correction.

•

While still in the “Connect Sensors” banner screen, a message is presented near the bottom that reads “Tach Power is Off”. The Block directly below this statement and corresponding to the [F1] key, is labeled “Tach Pwr.” Pressing the [F1] “Tach Pwr” key will power the Tach. Turning the tachometer power on is not required to start the balance job; this step is only accomplished to verify the proper operation of the Phototach.

•

Rotate the main rotor until the target object is aligned with the Phototach. Clean this area thoroughly to insure adhesion of the tape.

•

Cut a strip reflective tape (3M Tape, Model 7610) approximately 1.5 to 2 inches long. With the tape backing still in place, hold the tape in position on the target object, then verify the red LED “Gate Light” indicator light on the back end of the Phototach is illuminated. This indicates the position of the tape is correct.

•

Remove the tape backing and attach reflective tape at that location. Be sure to smooth out any wrinkles or bubbles in the tape. Insure the edges are smoothed and attached.

Once the above steps are completed and good “Gate Light” signal is present, press [ENTER] to proceed with the job.

5.3.6. – Start Aircraft

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The analyzer will now direct the user to “Perform FOD check and start aircraft per flight manual”, refer to the aircraft’s flight manual for all aircraft starting and operational instructions. This screen allows you to view the current main rotor RPM. When the aircraft has been started and RPM is stable, press [ENTER] to continue. The [F2] “Swap Job” key allows you to return to the Main Menu without rebooting the analyzer. This allows you to quickly and easily switch between various jobs.

5.3.7. – Select Aircraft Condition

The “Select Condition” screen appears listing the conditions that were defined in the setup; each preceded by a set of brackets. To measure a condition, highlight it using the [⇓] key and press [ENTER]. If a condition has already been measured, an “X” will be inserted between the brackets. You may re-measure a condition if desired, however all data previously measured for that condition will be over-written and subsequently lost. •

When all desired conditions have been measured, pressing the [F1] “End Run” key will terminate the current run and direct you to shut down the aircraft. Go to paragraph 5.3.10.

If during the current run, the [F2] “Adjust” key becomes visible, the analyzer has collected enough information to present a solution. The solution presented will depend on the conditions measured and the charts defined in the setup. For example, in our sample setup paragraph 5.2.1.6.3, we defined only two charts for use with the aircraft in a hover: •

Vertical balance and Lateral balance. In the example screen above, only hover measurements have been acquired. Therefore the only solutions the analyzer could present would have to be for either vertical balance or lateral balance.

•

The process for measuring and recording track data is covered in the measurement screens, it must be done from the “Review Data” screen as shown in paragraph 5.3.9.

When all desired conditions have been measured, press the [F1] key to end the current run.

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5.3.8. – Data Acquisition

Upon selecting to acquire a measurement, the data acquisition screen appears. The screen banner will contain the run number as well as the condition being measured. Within the screen, the analyzer will present the “Current” and “Average” RPM, IPS level, and Phase (Clock) angle readings. The averaged measurement will be used when calculating solutions. There is also an error value indication associated with the averaged measurement. NOTE The error value will typically lower rapidly when the amplitude of vibration is high. When the amplitude reaches a lower level (Approx. < 0.05 IPS) the error value may remain high. This is a normal response and is not cause for alarm.

•

Press the [F1] “Reset” key to restart the measurement and averaging process at any time. This may be performed as a means of validating the quality of a measurement. If, after the reset key is pressed, the average measurement does not return to approximately the same value shown before, the quality of the measurement may be questionable. If this occurs, repeat the averaging process and try it again until the measurement values are similar both before and after resetting.

When the error reaches its lowest level, press [ENTER] to stop the acquisition process.

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5.3.9. – Review Data

The “Review Data” screen will now appear presenting the vibration data for the current run and condition. This screen also offers a chance to retake the measurement by pressing the [F1] “Retake” key. Pressing this key returns you to the data acquisition screen, paragraph 5.3.8. If you wish to measure and record track for this run and condition, press the [F5] “Track” key. Proceed to paragraph 5.3.9.1. When you have finished reviewing the data, press [ENTER] to return to the “Select Conditions” screen in order to acquire more measurements or to end the run. See paragraph 5.3.7 “Select Aircraft Condition”. 5.3.9.1. – Track Measurement NOTE The steps below will only be required when using the Model 540/540-2 Optical Tracker. TM When using the Model 550 TraX it will not be necessary to aim the unit each time TM data is collected. After the TraX is installed, data acquisition should be automatic TM when required. See the TraX Operational Supplement (550-OM-01, ACES P/N 75-900TM 4043) for details on operating the TraX .

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If you select [F5] to measure track, a screen will appear prompting you to “Aim and Fire Tracker”. At this point, the tracker is energized and ready to use. Verify the presence of a solid amber light at the bottom of the LED aiming lights. If present, raise the tracker into the rotor disk and align until the green LED’s illuminate. Press and release the trigger once while holding the tracker with the green LED’s illuminated. The amber LED should now pulsate. When the amber LED is completely extinguished the tracker has measured the desired number of revolutions as entered at the start of the job. 5.3.9.2. – Check Track – Results

A screen will appear presenting the track data just acquired. This data will be shown in both graphical and numerical format. The sample data above was taken relative to blade one, the “TARGET” blade. You can see that the TARGET blade is shown lagging 0.04 inches and the BLANK blade is shown leading 0.04 inches. You will notice that the track of the TARGET blade zero and the BLANK blade is shown to be 0.75 inches high. The lower portion of the screen shows the number of valid data packets the tracker sent to the analyzer.

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NOTE If the number of data packets gathered is less than 75 % of the total rotations defined in paragraph 5.3.4, select the [F5] “Track” option upon returning to the review data screen as described in paragraph 5.3.9.

When you have finished reviewing the track, press [ENTER] to return to the “Review Data” screen.

5.3.10. – Shut Down Engines

When you have chosen to end the current run, the analyzer will prompt you to shutdown the aircraft. You can use the [F2] “Swap Job” key to return to the Main Menu without rebooting the analyzer or [F5] “Continue” key to move to step 5.3.11.

5.3.11. – Review Prior Run(s) Data

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The “Review Prior Run(s) Data” screen appears as shown. The data will be displayed in the order of the current run and first condition measured. From this first screen, press the [⇓] key to proceed to the next condition measured for the current run. Press the [⇑] key to return to the previous condition. If the current run is number two or greater, pressing the [⇐] key will move to the same condition as on the previous run. Press the [⇒] key to return to the current run. Always observe the run number and condition name at top of the screen to identify the data you are viewing. When you have completed reviewing the data, press [ENTER] to continue to the solution screens.

5.3.12. – Solution Screens The number and type of solutions presented will depend upon the data gathered and the limits that were set for each of the measurement types in the “Conditions Setup” screen when the setup was defined. Solutions will be presented in the following order: Track, Lateral, and then Vertical, as shown below. Choose the solution for the current run, highlight it with the cursor and press [ENTER] to view the actual solution. Typically, starting with the first suggestion and applying corrections until this exceedance is under the defined limit before proceeding to the next solution will be the best course of action.

The analyzer will present all of the solutions that are possible from the data gathered for the current run. This means that it is possible for the analyzer to give two adjustments that would affect the other adversely. The user will ultimately be responsible for determining which adjustments to make and which to discard. For instance, in the following sample screens, the analyzer will recommend solutions for both the pitch change links and the main rotor blade trim tabs for the same run. If you were to make both of these adjustments, chances are, this would over-correct causing counteradjustments on the next run. Most likely in this case, and depending on the amount of PCL

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adjustment, the trim tab adjustment would be skipped and only the pitch change link adjustment would be made. As stated earlier, the solutions presented by the analyzer are based on the charts defined in the setup and the measurements acquired for the current run. These influences will be updated each time the analyzer is used. For the updates to be accurate, you must enter exactly the adjustments performed, or skipped. If the analyzer presents a solution and you choose not to apply it on the current run, you are required to zero out the adjustment entries in the recording screen for that particular adjustment. If you believe that the current ICFs are correct and the impact of one adjustment on another will be minimal, it is possible to make multiple adjustments during a single run by pressing the [F1] “All Adj” key. 5.3.12.1. – Example Solution Screen #1

For our sample job, the first adjustment given is for a vertical measurement at hover. The adjustment type to be applied is “FLT” or flats of a pitch change link. The line at the bottom of the screen serves as a reminder that a positive adjustment is intended to move the blade up. For this measurement, the analyzer’s recommended adjustment is to raise the Target blade by 4.00 flats. This solution has been automatically entered in the appropriate “Installed” field. If you are able to make this adjustment exactly as entered, all that is necessary to continue is pressing the [ENTER] key. If an adjustment is made other than raising the Target blade 4.00 flats, you must enter this in the appropriate “Installed” field using the keypad. •

Pressing the [F1] “Inst=Sugg” key will return any “Installed” field that has been edited to the original values presented by the analyzer.

•

Pressing the [F2] “Inst=None” key will delete all “Installed” field entries. This function is used when a particular adjustment is to be skipped on the current run.

•

Pressing the [F5] “Quit Job” key will exit the current job and store it as complete. Warning Using the [F5] “Quit Job” function will close the job and not allow resuming at a later

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time. If you wish to stop the job temporarily, press the “Main Menu” key or simply turn the analyzer off.

When you have finished entering the adjustments performed, press [ENTER] to continue to the next screen. 5.3.12.2. – Example Solution Screen #2

The second solution the analyzer gave for our sample job is for the average vertical measurement from flight at 80 knots and flight at 120 knots. The adjustment type for this chart is degrees of trim tab. For the current run, if you chose to make the pitch link adjustment as recommended in the previous screen, you would most likely skip the trim tab adjustment. Do this by pressing the [F2] “Inst=None” key and then [ENTER]. 5.3.12.3. – Example Solution Screen #3

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The last correction given for our sample job is for the lateral ground measurement. The solution type for this adjustment is grams of weight or points of blade sweep. The solution presented for this screen is to add 200.00 grams to the target blade. NOTE The analyzer will attempt to give solutions that “resolve to zero” in all cases. This may nullify the ability to make some adjustments with any degree of accuracy. If this occurs, it is the user’s responsibility to adjust the amount either up or down to achieve a quantifiable adjustment. Remember that the analyzer will update the influence coefficient between every run based on the vibration results from the previous adjustment.

When the last solution screen has been updated, pressing [ENTER] will take you to the “Start Aircraft” screen for the next run.

5.4. – Main Rotor Manage Data Functions The main rotor “Review Job” function presents chart information, correction history, and influence co-efficient for the job. The following paragraphs will describe these new screens and how to navigate through them to review this information.

5.4.1. – Main Rotor Review Job

Upon selecting to review a job, the “Review Job” screen will appear as shown above. The run number and condition name are displayed at the top of the screen along with the vibration and track measurements acquired for the current run and condition listed. •

To review different conditions within the same run, press either the [⇑] or [⇓] key.

•

To review data for a different run, press either the [⇐] or [⇒] key.

•

To view adjustments made for the current run, press the [F1] “ViewAdj” key. See paragraph 5.4.2.

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5.4.2. – View Main Rotor Track and Balance

The “View Main Rotor Track and Balance” screen appears as shown above. This screen presents both the suggested and installed adjustments for the run number and chart name displayed. •

Press either the [⇑] or [⇓] keys to view different chart types for the same run.

•

Press the [⇐] or [⇒] key to change the current run.

•

Press the [F1] “ViewMeas” key to return to the “Review Job” screen as shown in paragraph 5.4.1.

•

Press the [F2] “View Chart” key to view the polar chart influence information for the job as shown in paragraph 5.4.3.

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5.4.3. – View Main Rotor Chart

The “View M/R Chart” screen gives the chart name, chart type, default magnitude of adjustment, name and adjustment ratio of each blade position. •

Pressing the [⇑] or [⇓] keys will toggle between multiple chart types if more than one is defined for the setup.

•

Press the [F1] key to “ViewMeas” and return to paragraph 5.4.1.

•

Press the [F2] key to “ViewAdj” and return to paragraph 5.4.2.

•

Press the [F5] key to view the “ICF” changes recorded during the job as shown in paragraph 5.4.4.

When completed reviewing, press [ENTER] to return to the manage data menu.

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5.4.4. – View Main Rotor Chart ICFs

The “View M/R Chart ICFs” screen shows how the influence coefficient magnitude and rotation was changed as a result of the correction made on each run. Because the analyzer continues to learn between runs, it is very important to ensure accurate data entry for the actual correction made during each run. •

Press [ENTER] to return to the “Review Job” screen explained in paragraph 5.4.1.

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Chapter 6 Tail Rotor Balance (Revision 3, Oct 2012)

This section is intended to familiarize you with the various electronic chart forms and setup screens used with the 4040 Viper. First by looking at each of the chart forms found in the tail rotor section, then by using these forms to create an actual setup.

6.1. – Analyzer Chart Forms Just as in the case with polar balance charts, there are two types of analyzer chart “forms” used with the 4040 Viper. The chart forms are also categorized as either “Regular” or “Irregular”. The selection of setup type is made within the chart form itself by using either the [⇒] or [⇐] keys to toggle between “Regular” and “Irregular” in the “Chart Type” field, then pressing the [⇓] key to move to the next field. The remaining fields in the screen will automatically change if necessary. The paragraphs below describe these forms in detail.

6.1.1. – Regular Chart Forms A “Regular” chart is one that has all weight positions spaced equally around the chart, all adjustments are of the same type, and all adjustments carry the same ICF. The next paragraph details the process for defining a tail rotor “Regular” chart setup.

6.1.1.1. - Regular Tail Rotor Chart Setup The tail rotor balance chart shown to the right depicts six adjustment points. Each adjustment point has been circled to ease identification and differentiate them from the clock hours. The move line for each adjustment point has been indicated with an arrow, and the ICF is labeled at the bottom of the chart as being 12 grams per 1.0 IPS. This chart meets all criteria to place it in the “Regular” chart type category, all weight positions have the same ICF and type of adjustment, and all move lines are equally spaced around the chart. Using this chart, follow the examples below to properly define a “Regular” tail rotor chart setup in the analyzer. ICF = 12.0 Grams / 1.0 IPS

Name: The name of the chart will be automatically inserted from the “Tail Rotor Setup Screen” name field and is not editable. Chart Type: Use [⇒] or [⇐] key to select the chart type. For this example, the type is “Regular”. No. WtPos: Enter the number of weight positions used. You can input up to 20 positions if needed. This chart uses “6”. Grams / IPS: Enter the grams per IPS influence for the tail rotor. In this case the entry is “12.00” grams per 1.0 IPS. The ICF amount entered must always be for 1.0 IPS vibration. 6-2 - Tail Rotor Balance 6

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Additionally, the tail rotor balance function assumes the adjustment will always be weight in grams. If the chart uses an adjustment type such as the number of washers per IPS, simply enter this number and overlook the label of grams. WtPos, Add @: The lower portion of the screen provides fields for entry of the “WtPos” names and “Add @” (move line) clock angles. Since this is a “Regular” chart setup, you will only have to enter the move lines for the first two weight positions; the analyzer will determine the rest. •

Starting with any of the weight positions, enter a name, up to six characters, in the first field as shown.

•

Next, press the [⇓] key to move one field to the right; enter the angle (in hours) of the move line for this position. If the move line contains an angle in minutes, press the [⇓] key again to move to the next field and enter the minutes.

Repeat the name and move line process for the second weight position, then enter the rest of the weight position names and this chart is completed. NOTE Weight position names must be entered sequentially in either clockwise or counter clockwise order. It does not matter what direction is chosen.

6.1.2. – Irregular Chart Forms 6.1.2.1. – Irregular Tail Rotor Chart Setup The tail rotor balance chart shown to the right represents four adjustment points, all of which utilize the addition of weight as a correction type. However, the ICF is different for two of the points. Target and Blank have an ICF of 10 grams per 1.0 IPS where “A” and “B” have an ICF of 33 grams per 1.0 IPS. The clock angle move lines are not equally spaced around the chart therefore it must use the “Irregular” chart form in the analyzer. Using this chart, follow the examples below to properly define an “Irregular” tail rotor chart setup in the analyzer.

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Name: The name of the chart will be automatically inserted from the main setup screen for a tail rotor job. Chart Type: Select “Irregular” as the chart type. No. of WtPos: Enter the number of weight positions used as indicated by the polar chart, in this case 4. You can input from 2 to 13 positions as needed. After pressing the [⇓] key to exit the field, the value entered in this field will change the remainder of the screen to allow input of each weight position’s ICF. Wt/Pos, Grams, IPS, Add @: •

Starting with any of the correction points on the chart. Enter the weight position name in the first field up to six characters. “TARGET” is the first weight position name in our example.

•

Press the [⇓] key and move to the next field. Enter the amount of adjustment portion of the ICF under “Grams”. This example uses “10.00” grams.

•

Press the [⇓] key and enter the amplitude reference for the amount of adjustment just entered. For this example, enter “1.0” IPS

Press the [⇓] key to move to the “Add @” field. Enter the clock angle move line for this point. For the “TARGET” weight position the move line is “6:00”. Perform this for each adjustment point shown on the chart and the setup is complete. Note: Weight position names must be entered sequentially in either clockwise or counter clockwise order. It does not matter what direction is chosen. 6-4 - Tail Rotor Balance 6

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6.2. – Tail Rotor Setup The following paragraphs illustrate each of the screens necessary to define and store a tail rotor setup.

6.2.1. – Tail Rotor Setup Screen Use the following screen capture and polar chart to follow the steps below to complete the tail rotor setup screen for “Example 1” as shown below.

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1. In the “Name” field, enter a name for the setup using the keypad. 2. Press [⇓] to move to the “Sensor Channel” field. Use the [⇒] key to select the vibration sensor channel for this setup. 3. Press [⇓] to move to the “Sensor” field and select a sensor type to be used with this setup by pressing the [⇒] key. 4. Move to the “Tach Channel” field by pressing the [⇓] key. Select the tachometer channel to measure using the [⇒] key. 5. Press the [⇓] key to move to the “Tach Type” field. Select the appropriate type of tachometer using the [⇒] key. 6. Press the [⇓] key to move to the “Tach Position” field. Using the [⇒] key, select the tachometer position in hours at which the photocell beam strikes the reflective tape during rotation of the tail rotor. Use the statements below to determine which viewing perspective to use. If using a Strobe polar chart for this setup enter the location in clock angle (1-12) looking from the side the strobe would be used to acquire phase. If using a Photocell polar chart for this setup, and the location of the photocell is as specified on the balance chart, enter “12”. 7. Press [⇓] to move to the “Balancing RPM” field. Using the keypad, enter the tail rotor RPM balance speed for the setup. This speed is only a reference used at the start of the job. If during the job, a different tail rotor speed is used, subsequent runs will also call for the adjusted RPM. 8. Move to the “Direction of Rotation” field by pressing the [⇓] key. Use the [⇒] key to select the direction of rotation for the tail rotor. Use the statements below to determine which viewing perspective to use. If using a Strobe polar chart for this setup, enter the direction of rotation as viewed from the side on which the strobe would have been used to acquire phase. If using a Photocell polar chart for this setup, enter the direction of rotation as viewed from the photocell’s position. 9. Press the [⇓] key to move to the “Number of Blades” field. Using the keypad, enter the number of blades on the tail rotor. The maximum number of blades is 20. 10. Press the [⇓] key to move to the “Conditions” field. Using the [⇐] and [⇒] keys, enter the number of conditions. The maximum number of conditions is 3.

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11. Press the [⇓] key to proceed to the “Maximum Balance Weight” field. If there is a published maximum amount of weight that may be used for balancing the tail rotor, you may enter it in this block. This is the total amount of balance weight allowable, not the limit of each balance position. If the Installed Weights for a single run is more than the maximum allowed, the user will encounter a warning screen to notify him that the maximum weight limit is being exceeded. When finished with the main setup screen, press [ENTER].

6.2.2. – Tail Rotor Chart Setup

The “Tail Rotor Chart Setup” screen appears next. Using the tail rotor polar chart found in paragraph 6.2.1 titled “Tail Rotor Setup Screen”; fill in the appropriate information as follows: 1. The name for the chart, “EXAMPLE 1”, has already been inserted from the first setup screen. 2. Press the [⇓] key and select the chart type by pressing the [⇒] key. The type of chart for this example is “Irregular”. 3. Press the [⇓] key and enter the number of weight positions using the keypad. This example uses 4 weight positions. 4. Press the [⇓] key and enter the first weight position name as “TARGET”. Using the [⇓] key to change fields, enter the influence co-efficient for this location as “0.60” grams adjustment per “1.0” IPS vibration, and the move line of “5:45” using the keypad.

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5. Press the [⇓] key and enter the second weight position name of “A”. Using the [⇓] key to change fields, enter the influence co-efficient for this location as “5.0” grams adjustment per “1.0” IPS vibration, and the move line of “10:00” using the keypad. 6. Press the [⇓] key and enter the third weight position name of “BLANK”. Using the [⇓] key to change fields, enter the influence co-efficient for this location as “0.60” grams adjustment per “1.0” IPS vibration, and the move line of “11:45” using the keypad. 7. Press the [⇓] key and enter the fourth weight position name of “B”. Using the [⇓] key to change fields, enter the influence co-efficient for this location as “5.0” grams adjustment per “1.0” IPS vibration, and the move line of “4:00” using the keypad. When completed, press [ENTER] to save the setup.

6.3. – Multiple Condition Setups The following paragraphs will describe the process for building multiple condition setups for tail rotor balance. Multiple condition setups are used for aircraft that require balancing at more than one speed and may have more than one balance chart. Follow the steps below to complete the tail rotor setup screen for “Multiple Example” as shown.

6.3.1. – Tail Rotor Setup Screen

1. In the “Name” field, enter a name for the setup using the keypad.

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2. Press [⇓] to move to the “Sensor Channel” field. Use the [⇒] key to select the vibration sensor channel for this setup. 3. Press [⇓] to move to the “Sensor” field and select a sensor type to be used with this setup by pressing the [⇒] key. 4. Move to the “Tach Channel” field by pressing the [⇓] key. Select the tachometer channel to measure using the [⇒] key. 5. Press the [⇓] key to move to the “Tach Type” field. Select the appropriate type of tachometer using the [⇒] key. 6. Press the [⇓] key to move to the “Tach Position” field. Using the [⇒] key, select the tachometer position in hours at which the photocell beam strikes the reflective tape during rotation of the tail rotor. Use the statements below to determine which viewing perspective to use. If using a Strobe polar chart for this setup enter the location in clock angle (1-12) looking from the side the strobe would be used to acquire phase. If using a Photocell polar chart for this setup, and the location of the photocell is as specified on the balance chart, enter “12”. 7. Press [⇓] to move to the “Balancing RPM” field. Using the keypad, enter the tail rotor RPM balance speed for the setup. This speed is only a reference used at the start of the job. If during the job, a different tail rotor speed is used, subsequent runs will also call for the adjusted RPM. 8. Move to the “Direction of Rotation” field by pressing the [⇓] key. Use the [⇒] key to select the direction of rotation for the tail rotor. Use the statements below to determine which viewing perspective to use. If using a Strobe polar chart for this setup, enter the direction of rotation as viewed from the side on which the strobe would have been used to acquire phase. If using a Photocell polar chart for this setup, enter the direction of rotation as viewed from the photocell’s position. 9. Press the [⇓] key top move to the “Number of Blades” field. Using the keypad, enter the number of blades on the tail rotor. The maximum number of blades is 20. 10. Press the [⇓] key top move to the “Conditions” field. Using the keypad, enter the desired number of conditions required for balancing. The maximum number of conditions is 3. 11. Press the [⇓] key to proceed to the “Maximum Balance Weight” field. If there is a published maximum amount of weight that may be used for balancing the tail rotor, you may enter it in this block. This is the total amount of balance weight allowable, not the Revision 3, Oct 2012

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limit of each balance position. If the Installed Weights for a single run is more than the maximum allowed, the user will encounter a warning screen to notify him that the maximum weight limit is being exceeded. When finished with the main setup screen, press [ENTER].

6.3.2. – Tail Rotor Condition Setup Screen

1. The name for the first condition will be labeled “1”. Use the keypad to change to the desired condition name. 2. Press the [⇓] key and assign the chart ID. 3. Press the [⇓] key to move to the name field for the second condition. 4. Press the [⇓] key to assign the next chart ID. If the tail rotor requires different charts as shown above, the ID’s will be 1 and 2. If all conditions use the same chart all of the ID numbers will be 1. 5. Continue assigning names and chart IDs until all conditions are defined. 6. Press the [⇓] key and if there is more than one chart ID specified the Soln: toggle field will appear. The three choices are “All”, “Max”, and “LSQ” (Least Mean Square). If “All” is selected the analyzer will present a solution for each of the charts. If “Max” is selected the analyzer will present a single solution for the condition that recorded the highest vibration reading. If “LSQ” is selected the analyzer will present a solution that will lower vibration levels at all conditions. Press the [ENTER] key to continue.

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6.3.3. -First Condition Tail Rotor Chart Setup Screen

80% Balance Chart 1.0 " "IPS

100

12 1

.8

+Target

.9

11

.7 .6

50

2

.5

10

.4 .3

3 .3

.4

.5

.6

.7

.8

.9

1.0 "IPS"

8

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50 +C

5

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The “Tail Rotor Chart Setup” screen for the first condition (80%) appears next. Using the tail rotor polar chart above, fill in the appropriate information as follows: 1. The name for the chart, “80%”, has already been inserted from the “Tail Rotor Condition Setup” screen. 2. Press the [⇓] key and select the chart type by pressing the [⇒] key. The type of chart for this example is “Regular”. 3. Press the [⇓] key and enter the number of weight positions using the keypad. This example uses 4 weight positions.

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4. Press the [⇓] key to enter the grams per IPS influence for the tail rotor. This example uses “100.00” grams. 5. Press the [⇓] key and enter the first weight position name as “TARGET”. 6. Press the [⇓] key and enter the “Add @” move line for weight placement on the “TARGET” blade as “12:00”. 7. Press the [⇓] key and enter the second weight position name of “A”. 8. Press the [⇓] key and enter the “Add @” move line for weight placement on the “A” blade as “3:00”. 9. Press the [⇓] key and enter the next blade name as “B”. 10. Press the [⇓] key and enter the last blade name as “C”. Press [ENTER] to continue to the next chart.

6.3.4. – Second Condition Tail Rotor Chart Setup Screen The “Tail Rotor Chart Setup” screen for the second condition (100%) appears next. Using the tail rotor polar chart, fill in the appropriate information as follows:

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100% Balance Chart 1.0 " "IPS

1

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11

100

12

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+A

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50

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3 .3

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50 +B

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100

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1.0 "IPS "

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+C

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50

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0

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100 + Target

1. The name for the chart, “100%”, has already been inserted from the “Tail Rotor Condition Setup” screen 2. Press the [⇓] key and select the chart type by pressing the [⇒] key. The type of chart for this example is “Regular”. 3. Press the [⇓] key and enter the number of weight positions using the keypad. This example uses 4 weight positions. 4. Press the [⇓] key to enter the grams per IPS influence for the tail rotor. This example uses “100.00” grams. 5. Press the [⇓] key and enter the first weight position name as “TARGET”. 6. Press the [⇓] key and enter the “Add @” move line for weight placement on the “TARGET” blade as “3:00”. 7. Press the [⇓] key and enter the second weight position name of “A”. 8. Press the [⇓] key and enter the “Add @” move line for weight placement on the “A” blade as “12:00”. 9. Press the [⇓] key and enter the next blade name as “B”. 10. Press the [⇓] key and enter the last blade name as “C”. Press [ENTER] to continue to the next chart, if necessary. Revision 3, Oct 2012

6 Tail Rotor Balance – 6-13

6.4. – Tail Rotor Balance Process

The following paragraphs present the tail rotor balance process and its associated screens. It is intended to familiarize the user with the data acquisition and correction capabilities of the Viper 4040. Prior to starting a new tail rotor balance job, you must first select the “Tail Rotor Balance” option from the main menu by using the [⇓] key and press [ENTER].

6.4.1. – Starting a New Job

Selecting “Start Job” from the “Tail Rotor Balance” banner screen allows you to begin a tail rotor balance job. When you select this option, one of three screens will appear next

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depending on whether you are using the tail rotor function for the first time, have previously defined tail rotor setups, or have a previously started job stored in the analyzer. •

If you are using the analyzer for the first time, the “Tail Rotor Setup” banner screen will appear allowing you to define a new tail rotor setup to use. Refer to paragraph 6.2 “Tail Rotor Setup” for detailed instructions on defining a setup.

•

If you have previously saved setups stored in the analyzer’s memory, a screen displaying the list of setups will be displayed. You can then select a setup from this list to use for the job. Proceed to paragraph 6.4.2 “Setup List”.

•

If another job was already in progress but not completed, the “Incomplete Job” banner screen will be displayed and the analyzer will present a message prompting you to verify that you wish to finish the incomplete job or begin a new job. The screen will display the message; “The last job performed is incomplete. Do you want to RESUME work on it?” If you wish to return to the unfinished job, press the [F1] “Yes” key and you will be returned to the point where the in-progress job was stopped and allowed to complete it. If you wish to continue with starting a new job, press the [F5] “No” key, and the screen will then display the “Setup List” for selection of a setup to use for the new job. Proceed to paragraph 6.4.2 “Setup List”.

6.4.2. – Setup List

The setup list presents the stored tail rotor setups in analyzer memory. Select the setup you wish to use by highlighting the name of the setup using the [⇓] key and pressing [ENTER]. If the setup you need is not present, press the [F1] “New” key to proceed to the “Tail Rotor Setup” screen as outlined in paragraph 6.2. If a similar setup is in the list, you can use the [F4] key to “Copy” this setup, change the setup name, and make the desired changes.

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6.4.3. - Job Identification

The “Job Identification” banner screen appears next allowing entry of the customer name, A/C registration, and A/C total time. This information is optional, but it is suggested that at least a customer name be entered, as it will aid in identifying the job for future use. If the analyzer has been used previously, a list of customer names will have been stored and are accessed by pressing the [F1] “Names” key. A name can then be selected from this list for use with the new job. When finished, press [ENTER].

6.4.4. – Connect Sensors

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The “Connect Sensors” banner screen will be displayed next. Messages that appear on this screen prompt you to perform the physical installation and connection of the tachometer and vibration sensors to the input ports you specified in the applicable setup. •

You must use the vibration sensor installation location as specified by the applicable polar chart. The orientation of the sensor is key to the accuracy of the chart, if the sensor is installed in a direction other than that specified, the phase (clock) angle will be incorrect and any solution will not be accurate.

Tach Power need not be “ON” before leaving this screen. The option simply exists for installing and checking alignment of the reflective tape and PhotoTach. When completed, press [ENTER].

6.4.5. – Start Aircraft

The “Start Aircraft” screen appears. The current run number is displayed at the top of the screen, followed by both the current and desired speed in RPM. The differential speed is also displayed. The [F2] “Swap Job” key can be used to return directly to the Main Menu without rebooting the analyzer. When the current speed matches the desired speed, press [ENTER] to begin acquiring the measurement.

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6.4.6. – Select Tail Rotor Condition Screen

The “Select Tail Rotor Condition” screen allows the user to select which condition he would like to take balance readings from. This screen will only appear in “Multiple Condition” balance runs. In a single condition run, the next screen to appear is the “Data Acquisition” screen, proceed to paragraph 6.4.7. Use the [⇓] key to highlight the proper condition and press [ENTER] to begin gathering data for that condition.

6.4.7. – Data Acquisition

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The data acquisition screen will appear next, displaying the current and averaged rotor speed, vibration amplitude (IPS), and phase angle (in clock format). There will also be a numeric error indication associated with the averaged measurement. The numeric error value will typically lower rapidly when the amplitude of vibration is high. The top line of this screen can display three different status messages. The messages are: “Waiting for Data” This message is displayed until in-range RPM, IPS, and Phase Angle readings are recorded by the analyzer. The only way to exit the screen while this message is displayed is to use the [BACKUP] key. “Acquiring Data” This message is displayed during data acquisition. As long as the data remains in-range, the analyzer will add each new sample to the running average. The only way to exit the screen while this message is displayed is to use the [BACKUP] key. “Complete! Press ENTER” This message will appear when a minimum number of consistent samples have been collected. Allow the unit to collect data as long as the error continues to decrease. This will insure you have the most accurate data possible. Use the [ENTER] key to exit this screen and store the reading. The text below the “Current” heading indicates the RPM, IPS, and Phase Angle from the latest collect vibration sample. These values will change as the individual readings are collected. The RPM will be the currently recorded speed value. For Run 1 the “RPM” heading itself will blink “HIGH” or “LOW” if the current RPM is more than +/- 200 RPM from the RPM defined in a Fan/Turbine Balance setup. For Run 2, the HIGH/LOW warning will appear if the value is +/- 50 RPM from the value recorded during Run 1. NOTE: When the amplitude reaches a lower level (Approx. < 0.05 IPS) the numeric error may remain high. This is a normal response and is not cause for alarm.

•

Pressing the [F1] “Reset” key will restart the data acquisition process. This may be performed as a means of validating the quality of a measurement. If, after the “Reset” key is pressed, the average measurement does not return to approximately the same value shown before, the quality of the measurement may be questionable. If this occurs, repeat the averaging process and try it again until the measurement values are similar both before and after resetting.

•

When the error has reached its lowest point, press [ENTER] to stop acquisition and continue the job.

•

If performing a tail rotor balance job consisting of more than one condition, the “Select Aircraft Condition” screen will appear. Select the condition desired and press [ENTER]. When data has been collected at all of the conditions, the condition boxes will have “X’s” showing that data has been collected.

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•

After data has been collected press the [F1] End Run.

6.4.8. - Shut Down Engines

A screen directing you to shut down the engine(s) will appear next. You can use the [F2] “Swap Job” key to return directly to the Main Menu without rebooting the analyzer. Shut down and press [F5] “Continue” to proceed.

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6.4.9. – Review Prior Run(s) Data

The “Review Prior Run(s) Data” screen appears. This will allow you to review the data just acquired as well as all prior run data (if any has been taken). •

If you wish to re-acquire the current run data, press the [F1] “Retake #1” key. If the setup has more than one condition, press the [F2] “Next Cond” key to view the data for the second condition.

When finished reviewing, press [ENTER] to continue to the solution process.

6.4.10. – Tail Rotor Suggested/Installed Weights Screen

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The “T/R Suggested / Installed Weights” screen appears displaying the suggested adjustments and providing for input of the actual changes made to the tail rotor prior to the next run. It is extremely important that these changes are entered, as they will be used to update the influence co-efficient for the next run. Use the keypad to enter changes. If weight is removed from a location, use the negative symbol [-] when entering the adjustment performed. •

Pressing the [F1] “Suggested” key will return any “Installed” field that has been edited to the original values presented by the analyzer.

•

Pressing the [F2] “None” key will delete all “Installed” entries. This function is used when an adjustment is to be skipped on the current run.

•

Pressing the [F3] “Re-Solve” key will allow you to find an alternate solution. This may be used when weight is already attached to the tail rotor or the suggested weights are smaller than the minimum hole weight. See below for instructions on using the “ReSolve” feature.

•

Pressing the [F5] “Quit Job” key will exit the current job and store it as complete.

Warning Using the [F5] “Quit Job” function will close the job and not allow you the resume option at a later time. If you wish to pause the job temporarily, press the “Main Menu” key or simply turn the analyzer off. You may then use the “Resume” function to complete the job.

When you have finished entering the adjustments performed, press [ENTER] to continue to the next run.

6.4.11. - Tail Rotor Re-Solve Feature The [F3] “Re-Solve” key will allow you to find an alternate solution. This may be used when weight is already attached to the tail rotor or the suggested weights are smaller than the minimum hole weight. For instance, in the example below, the attaching nut and bolt weigh 3.9 grams. This is larger than either of the suggested weights. In this case, press the [F3] “Re-Solve” key and follow the instructions below. Using the keypad, record the actual weight(s) installed between runs and their location. If you choose to remove weight from an opposite or alternate position, enter the negative adjustment. Do this by moving the highlight to the appropriate field, press the [SPACE+/-] key to produce a (-). Using the screen below as an example, the suggested weight installation is to add 2.5 Grams to the #6 weight hole location and to add 2.8 Grams to the #7 weight hole location. This is shown on the top line of the screen, directly below “Run 1 Suggestion:” In the example below, the closest matching weight combination was to add 2.5 Grams to the #6 weight hole location and to add 3.0 Grams to the #7 weight hole location. This change was made on the tail rotor and entered into the analyzer adjacent to the appropriate weight 6-22 - Tail Rotor Balance 6

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hole locations under the “Enter Installed Wts” portion of the screen. This adjustment will only be possible if there is already attaching hardware in holes # 6 and #7. If this is not the case continue below.

In the example above, the suggested weight is smaller than the minimum weight; a bolt and nut, which are required to attach hardware (attach hdw). The weight of this hardware must be included in the final weight installation. In this case, press the [F3] “Re-Solve” key to find an alternate solution. The screen below will appear. In the “Min Hole Wt (inc attach hdw):” line, enter the value of the attaching hardware. In the example below, the attaching nut and bolt weigh 3.9 grams. To re-solve the solution simply compensating for the minimum hole weight, press [ENTER] to display the new solution. If there are existing weights on the tail rotor continue below to obtain the solution optimized for both the weight removal and the minimum hole weight requirements.

The example below shows the procedure for removing any weights already installed on the tail rotor. After entering the required minimum hole weight, press the [⇓] key to move to the next field. Weigh any weights that are currently installed on the tail rotor. In the example below there were 4.5 grams in the #3 weight hole and 3.9 grams in the #7 hole. These

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weights are removed to leave the tail rotor free of weight. Press the [SPACE+/-] key once to enter the negative sign before the removed weight value. When all weights have been weighed, removed from the tail rotor and entered into the appropriated field, press the [ENTER] key to re-solve the balance solution.

Now, the solution presented on the top half of the “T/R Suggested/Installed Weights” screen below “Run 1 Suggestion:” will be the minimum weight required in the minimum number of holes allowing for the attaching hardware. These weights may not be in adjacent holes. This is necessary to provide the weight “influence” at the optimum location on the tail rotor. Every attempt should be made to match the suggested weight value. If it is not possible to match the suggestion exactly, match the weight as closely as possible. Enter the values actually placed on the tail rotor in the table at the bottom of the screen, under “Enter Installed Weights”. Use the [⇓] [⇑] key to move from field to field.

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6.5. – Tail Rotor Manage Data Functions The tail rotor “Review Job” function also now presents chart information, correction history, and influence co-efficient for each job. The following paragraphs will describe the new screens and the navigation steps to review this information.

6.5.1. – View Tail Rotor Balance

After selecting to review a job, the “View T/R Balance” screen appears showing the run number, RPM at which the data was acquired, amplitude and clock angle of the vibration, and suggested, as well as the installed, corrections to the rotor. To view a different run number, press the [⇒] or [⇐] keys. To view the chart information for the job, press the [F1] “Chart” key and refer to paragraph 6.5.2.

6.5.2. View Tail Rotor Chart The “View T/R Chart” screen consists of multiple parts; the first shows the chart name, chart type, default grams per inch influence, name and adjustment ratio of each blade position (below top). The second gives the influence co-efficient and phase angle rotation changes for each run (below bottom). Any additional charts will have similar screens to view. Pressing [F5] “Continue” will progress through all available screens for all conditions. When returned to the “View T/R Balance” screen, paragraph 6.5.1, press [ENTER] to return to the “Manage Data” screen.

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Chapter 7 Fan/Turbine Balance and Fan Blade Optimizer (Revision 3.02, Oct 2012) “Fan/Turbine Balance” is an analyzer function that is accessed from the analyzer’s Main Menu banner screen as shown in the illustration below. Selecting this function from the main menu brings up the “Jobs and Setups” banner screen menu (also shown below). Each of the listings on this banner screen menu is an option within the function. Descriptions of each of these options follow, along with the information required to complete the menu screens within the options, and the steps necessary to perform the fan balance function.

7.1. 7.1.1.

– Fan/Turbine Balance Selecting “Start Job” from the “Jobs and Setups” banner screen allows you to begin a new fan trim balance job. When you select this option, one of three screens will appear depending on whether you are: 1) Starting a new job with no fan setups previously defined in the analyzers memory; 2) Starting a new job with previously

defined fan setups available in the analyzers memory; or 3) Resuming an incomplete fan job being held in the analyzer’s memory.

7.1.2.

Setup List. If you are starting a new job with previously defined setups available in the analyzer’s memory, the screen will automatically display the Select Setup List banner screen similar to the one shown below. The actual setup names will be those which you have entered into your analyzer.

7.1.3.

Fan/Turbine Balance Setup Screen. If you are starting a new job with no setups previously defined in the analyzer’s memory, the screen will automatically display the Fan/Turbine Balance Setup banner screen shown below. See paragraph 7.1.6 for step-by-step instructions on completing the Fan/Turbine Balance Setup.

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7.1.4.

Incomplete Job. If you are resuming an incomplete job being held in the analyzer’s memory, the opportunity to do so is presented immediately following the “Start Job” selection. The screen displays the message as shown below. If you press the [F1] “Yes” key, the analyzer will return you to the last logical in-progress step of the job. If you press the [F5] “No” key, the analyzer will proceed as described in the two examples above, depending on your circumstances.

7.1.5.

Fan/Turbine Balance Setup. The “Fan/Turbine Balance Setup” banner screen allows you to define and store a Fan/Turbine Balance Setup. The “Fan/Turbine Balance Setup” banner screen displays fill-in and selection fields. The fill-in fields have squared off ends ([ ]). These fields are filled in using inputs from the analyzer keypad. The selection fields have pointed ends (). These fields have two or more preset values that are selected by using the [⇒] and [⇐] keys. Navigate between the fields on this screen using the [⇓] and [⇑] keys. (Refer to Chapter 3, “Using the Model 4040 Viper Analyzer” if you are unfamiliar with using the keypad or inputting data.)

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Complete the “Fan/Turbine Balance Setup” screen per the following example. 7.1.6.

Complete the Fan/Turbine Balance Setup. To complete the “Fan/Turbine Balance Setup” banner screen (as shown below), do the following:

7.1.6.1.

In the “Name” field, enter a name for this setup using the keypad. (Refer to Chapter 3, “Using the Model 4040 Viper Analyzer” if you are unfamiliar with using the keypad.) The name you choose will aid you in differentiating this setup from other stored setups should you choose to use or review it at a later time. The name should be one of your choosing which will be easily recognized and associated with this setup such as “Citation 10,” “Lear 45, ” or “CF34-3A”.

7.1.6.2.

Using the [⇓] key, move down to the “Eng Rotation” field. Use the [⇒] to select the direction of engine rotation. The choices in this field are CW for clockwise or CCW for counter clockwise.

7.1.6.3.

Using the [⇓] key, move to the “Viewed From:” field. This field is used to define the Engine Rotation perspective. The two available perspectives are (Forward Looking Aft) and (Aft Looking Forward). The perspective is determined by standing in front of the engine and noting the direction the fan rotates as viewed looking back into the intake. The perspective is determined by noting the direction the fan/turbine rotates as viewed from behind the fan/turbine looking forward out of the intake.

7.1.6.4.

Using the [⇓] key, move to the “Num Baln Planes” field. Use the [⇒] key to select the total number of rotational balance planes on this engine type.

7.1.6.5.

Using the [⇓] key, move to the “Num Optional Planes” field. Use the [⇒] key to select the total number of optional rotational balance planes on this engine type. An optional plane is usually one which you may move to and continue balancing when attempts to balance on the primary balance plane do not yield the desired results.

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7.1.6.6.

Using the [⇓] key, move to the “Balance Wt Type:” field. The balance weight type is a description of the balance weights for this application. Use the right arrow key to select from Actual, Class, or Both. Class weights are balance weights designed specifically for use with the engine. Class weights usually have a part number for the set and a designation for each weight in the set. Weights are fixed values for each individually designated weight. Actual means the weights are not designed specifically for the engine, such as standard AN washers or slug weights. The weights are designated as units of measure (grams or ounces) in the solution offered by the analyzer rather than a specific class weight by name.

7.1.6.7.

Using the [⇓] key, move to the “Num Class Wt Sets” field. Use the [⇒] key to select the total number of class weight sets available for use on this engine. If you choose a number here, be prepared to define each class weight on the next screen.

7.1.6.8.

Use the [⇓] key to move to the “Label Detail Wts:” field. Detail weights are those weights that are installed at the factory and cannot be removed. If these weights occupy positions normally used for trim balancing, you may label those occupied positions so that the balance solution will be calculated disregarding those locations. In addition, if the engine has holes that are typically unusable for trim balancing, bolts used to attach the spinner for example; this setting can define those holes as unusable also. The choices here include “No”, “Job”, and “Setup”. With the selection set to “Job” you have the opportunity to define these holes at the start of each job. This selection is better suited for engines where the number of unusable holes changes on each engine. If the detail weight holes are in fixed locations, you can define these locations by selecting “Setup”. They would be saved in the setup and you would not have to indicate them at the start of each job. Storing the detail weight locations in the setup may also keep you from having to unnecessarily define the hole layout as “Uneven” in step 7.1.8.15 below.

7.1.6.9.

Use the [⇓] key to move to the “Baln Weight Unit:” field. Use the [⇒] key to select “g” for grams or “oz” for ounces. You will use this unit of measurement to define your class weight set. If using Actual Weights, this defines the units of measure in which the balance solution will be presented.

7.1.6.10. Move to the “Num Sens / Eng:” field using the [⇓] key. Select the number of sensors you will use on each engine by using the [⇒] key to scroll between the selections. This selection will define total number of sensors being used on each engine for the balance job. 7.1.6.11. Move to the “Num Baln Speeds” field using the [⇓] key. Use the [⇒] key to select the number of actual speeds (1 to 9) or Sel. In Job. The “Sel in Job” selection in this field will allow you to choose the number of balance speeds as well as the actual speeds themselves in the job. If you always use the same number of speeds and the same speeds to balance this engine, you should select that number of balance speeds here. If the number of speeds can vary with each job using this setup, select the option of “Sel in Job”. 7.1.6.12. Move to the “Slow Roll RPM” field by using the [⇓] key and use the numeric keys to enter a Slow Roll RPM for this balance job. If no entry is required, leave this field at 0. A Slow Roll RPM may be required when using proximity probes. With these probes you may encounter a phenomenon known as runout. Runout occurs as 7 Fan Balance – 7-5

a result of the physical properties of some shafts. The Slow Roll RPM is used to identify what the actual signal is, and then these measured values are subtracted from all subsequent vibration measurements. 7.1.6.13. Move to the “Min Baln RPM:” (minimum balancing speed) field by using the [⇓] key. Enter the minimum speed, in RPM, that may be used for this balance setup. 7.1.6.14. Move to the “Actual RPM @ 100%” field by using the [⇓] key. Use the numeric keypad to enter the actual RPM of the fan or turbine being balanced at 100% of its allowable speed. 7.1.6.15. Move to the “Vibe Unit:” field by using the [⇓] key. Using the [⇒] key, select the engineering units used for this balance setup. Refer to the LMM if you are not familiar with the vibe unit used for this application. 7.1.6.16. Using the [⇓] key, move to the “Modifier” field. Using the [⇒] key, select the modifier used for this balance setup. Refer to the LMM for verification of required engineering units and modifier to be used for this application. The Vib (engineering) Unit and Modifier are used in conjunction with one another to express a value as in “Mils Pk-Pk, gs RMS, or IPS Peak”. Refer to the LMM if you are not familiar with the modifier used for this application. 7.1.6.17. Use the [⇓] key to move to the “Solution Iterations:”. The Solution Iterations field is used for varying the weights for the least squares. 1 means take the straight LSQ solution (minimize RMS vib), more than one means adjust the weighting to minimize worst case vib. Solution Iterations only appears when the “Num Baln Planes” in paragraph 7.1.6.4 above is greater than 1. When all fields are completed as required, press [ENTER] to proceed. 7.1.6.18. If you selected a number of balance speeds in paragraph 7.1.6.11 above, the “Fan/Turbine Balance Speeds” banner screen will be displayed. If you selected “Select in Job”, go to paragraph 7.1.7. The number of speeds (Num Baln Speeds:) line will display the number entered in step 7.1.6.11. 7.1.6.19. If multiple sensors were defined in paragraph 7.1.6.10 above the “All Sensors Use the Same RPM;” line will be present. If the same engine RPM settings will be used for all balance measurements, select “Yes”. The analyzer will use the RPM settings shown under “All Sensors” on the top example below. Setting this entry to “No” will cause the labels to change to “Sens 1” and “Sens 2” as shown in the bottom example below. Enter values for the speed settings for the first sensor in the first column and the speed settings for the second sensor in the second column. 7.1.6.20. Press the [⇓] key to move the cursor to the “Balance Relative to Defined Peak Speed?” field. The field will be highlighted and defaulted to the “No” answer as illustrated in the first screen below. With the “No” answer displayed, the entered speeds are not relative to the highest peak vibration. In this case, press the [⇓] key to move to the “Enter Speeds As N% or Defined RPM” field and enter the speed(s) determined from the fan survey or LMM. You may enter the speed(s) as an actual RPM or %.

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If the speeds are to be entered based on a vibration survey and relative to the highest peak encountered, use the [⇒] key to toggle the answer to “Yes” in the “Entered RPM Relative to Peak:” field. Press the [⇓] key and a new field “Peak Speed:” will appear as shown in the second screen below. Use the keypad to enter the speed at which the highest amplitude peak occurred in the fan survey. Press the [⇓] key to move to the “Enter Speeds As N% or Defined RPM” field and enter the variance in speed relative to the Peak Speed entered. For instance, if the Peak speed was entered as “90” indicating 90% RPM, you might enter three speeds in the bottom example screen below as “-1”, “0”, and “1” to indicate speeds of 89, 90, and 91 % respectively. 7.1.6.21. Use the [⇓] key to move to the toggle field at the bottom of the screen. This field gives you the option to use the Actual Speeds acquired during the first run as the target speeds for all subsequent runs OR use the speeds defined on this screen as the target for ALL runs. Use the [⇒] key to make your selection. When all fields are completed and set per your requirements, press [ENTER] to accept and continue.

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7.1.7.

Define Class Weights. The “Define Class Wts” banner screen (if class weight is selected in item 7.1.6.6) will be displayed. To define a class weight set, do the following:

7.1.7.1.

In the “Set ID” field, use the keypad to enter a name or part number for the class weight set you are about to define. The Set ID should be one that is recognizable and commonly used by everyone who will be using this setup to balance.

7.1.7.2.

Use the [⇓] key to move to the “MaxErr:” field. Use the numeric keypad to enter a number that will be used to determine the maximum amount of error between the suggested solution and the available class weight placement combination. The lower this number, the closer the two solutions will match, but the longer it may take to generate a solution during the solution process.

7.1.7.3.

Use the [⇓] key to move to the “Num Wts:” (number of weights) field. Use the numeric keypad to enter a number corresponding to the total number of different weights in this class weight set.

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7.1.7.4.

Use the [⇓] key to move to the “Placement” field. Use the [⇒] key to select from “Continuous” or “Spread”. Selecting “Continuous” will tell the analyzer to match the suggested solution as closely as possible while keeping the installed weights in consecutive positions. Selecting “Spread” will allow the analyzer to insert empty weight positions between weights, as needed, in an attempt to match the suggested solution.

7.1.7.5.

Use the [⇓] key to move to the “Add/Remove” field. The only selection in this field is “Remove then Add”. You cannot edit this selection at this time.

7.1.7.6.

Use the [⇓] key to move to the “Name” field. Use the keypad to enter a name or part number to identify each weight in the class weight set.

7.1.7.7.

Use the [⇓] key to move to the “Wt” (weight) field. This field defines the exact weight of the individual class weights in the adjacent “Name” field. The unit of measure is that which you defined in item 7.1.6.9 above. Note that just above the Name, Wt, and Span fields, is the statement “The min wt must be a base wt”. This means that the smallest defined class weight in this table must be a base weight. A base weight is one that may be used to occupy a position when an actual balance weight is not required. It may also be the smallest available weight in the class weight set or have a weight value of 0. Normally, if this weight is required to occupy each location not containing a trim balance weight, its weight value should be 0.

7.1.7.8.

Use the [⇓] key to move to the “Span” field. This field defines the number of positions or weight mounting locations that will be occupied by this class weight.

7.1.7.9.

Complete a Name, Wt, and Span field for each of the available fields until the chart is filled. If you find that you have specified too few or too many class weights, use the [⇓] key to place the cursor in the “Num Wts:” field and adjust the number accordingly. The number of available fields will be changed per this input. If you have specified more than one class weight set for this setup in item 7.1.6.7 above, another Define Class weight screen will be displayed, such as the two screens below, when you press [ENTER] to store the current screen and continue. Repeat section 7.1.7.1 through 7.1.7.9 for each additional class weight set. If you have specified only one class weight set for this setup, press [ENTER] and go to item 7.1.8.

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7.1.8.

Balance Plane Information Setup. To complete the “Balance Plane Information” setup screen(s), as shown below, do the following:

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7.1.8.1.

In the “Plane:” field, use the [⇒] key to select the identifying number for the first balance plane information. You will complete one of these information screens for each balance plane as defined in item 7.1.6.4 or 7.1.6.5 above. If you defined only one balance plane, you will only complete one balance information screen.

7.1.8.2.

Use the [⇓] key to move to the “Posn Type:” field. This field will define the terminology used to refer to the weight locations throughout the balance job. The choices in this field are , or . After you exit this field the remaining references will change to the selected term. Consequently, the fields described in these instructions are identified generically as “Position”. Your screen will display the actual term you selected in this field.

7.1.8.3.

Use the [⇓] key to move to the “Num Positions:” (number of weight positions) field. Use the numeric keypad to enter a number equal to the total number of positions where balance weights may be attached for this balance plane only.

7.1.8.4.

Use the [⇓] key to move to the “Num Usable:” field. Use the numeric keypad to enter a number that will define the maximum number of positions that can be used for installing weight on a single run.

7.1.8.5.

Use the [⇓] key to move to the “Detail Reduce Usable?” This field will let you define whether the detail weight holes reduce the number of holes usable for trim balance. In some cases, the “Num Usable” holes, paragraph 7.1.8.4 above, may be reduced by the presence of detail weights. In this case, enter “Yes” and the analyzer will reduce the number of available trim balance holes by the number of holes occupied by detail weights. If this field is set to “No”, the analyzer will not reduce the number of available trim balance holes by the number of holes already occupied by detail weights. For example, with this field set to “Yes”, if there are 15 Usable holes and 4 are already filled with detail weights, the analyzer will only place trim balance weights in 11 additional holes. With this field set to “No” the analyzer will be able to place trim weight in all 15 Usable holes for a total of 19 holes on the spinner.

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7.1.8.6.

Use the [⇓] key to move to the “RivetWt:” field. Use the numeric keypad to enter a value for the weight in grams or ounces (as defined in item 7.1.6.9 above) of any attaching hardware used to secure the balance weight to the balance plane.

7.1.8.7.

Use the [⇓] key to move to the “Radius” field. This field will only appear if an optional balance plane is identified in paragraph 7.1.6.5 above. Use the numeric keypad to enter a value defining the radius of the weight locations on this balance plane.

7.1.8.8.

Use the [⇓] key to move to the “Spacing:” field. Use the [⇒] key to select “Even” or “Uneven”. Your selection is based on the equal or unequal spacing between all positions. An Even setting is used when each individual position is spaced the same relative to all adjacent positions. The Even selections will automatically assign an angle to each position number based the other information you provide in this screen. Any unequal spacing of even a single position dictates that you use the Uneven setting. If using the Uneven setting, an additional screen displaying a table will be displayed when you leave this screen. You must define each position angle and its sequential number on the next screen as shown in paragraph 7.1.8.15.

7.1.8.9.

Use the [⇓] key to move to the “Position Num Dir:” (position numbering direction) field. Use the [⇒] key to select either CW for clockwise or CCW for counter clockwise. The direction is based on the order of ascending value or increasing numbers.

7.1.8.10. Pressing the [⇓] key will move the cursor to the “from” field to the right of the “Position Num Dir:” field. Use the [⇒] key to select the perspective used to view the direction of the position numbering. The two available perspectives are (Forward Looking Aft) and (Aft Looking Forward). The perspective is determined by standing in front of the engine and noting the direction the position numbers increase as viewed looking back into the intake. The perspective is determined by noting the direction the position numbers increase as viewed from behind the fan/turbine looking forward out of the intake. 7.1.8.11. Use the [⇓] key to move to the “MaxWt/Position” (maximum weight per position) field. Enter a numeric value to define the maximum total number of grams or ounces (as defined in item 7.1.6.9 above) allowed for installation at any one individual position. 7.1.8.12. Use the [⇓] key to move to the “MaxWt/Plane" (maximum weight for this balance plane) field. Enter a numeric value to define the maximum total number of grams or ounces (as defined in item 7.1.6.9 above) allowed for installation on this balance plane. This is the total of all weight at all individual positions on this plane. 7.1.8.13. Use the [⇓] key to move to the “Wt Set:” (weight set) field. If you defined only one weight set in section 7.1.6.7 above, that weight set name will appear in this field and your only possible choice. If you defined more than one weight set, use the [⇒] key to select one of the previously defined sets.

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NOTE If more than one set of class weights is available for this balance plane, you must select, and use ONLY one of the class weight sets for the balance plane. DO NOT MIX CLASS WEIGHTS.

7.1.8.14. Use the [⇓] key to move to the “Trial Wt” field. Use the numeric keypad to enter a weight in grams or ounces (as defined in item 7.1.6.9 above) for the analyzer to use as a trial weight in the first balance run. This trial weight will only be used if an Influence Coefficient is not stored in the setup. 7.1.8.15. If you selected “Even” position spacing in paragraph 7.1.8.8 above, use the [⇓] key to move to the “Angle of #1 Posn” field. Use the keypad to enter the angular location of the first weight position as viewed from the perspective selected in paragraph 7.1.6.9 above. Determine the angle by rotating the fan to align the tachometer pickup and its triggering device (magnetic interrupter, reflective tape, etc.). With the fan in this position, use the 12:00 position as the “0” or “360 degrees” (index point) and measure opposite the direction of rotation to the angle of position number 1. For example, if the #1 hole is at the 3:00 position (simply as viewed on the face of a clock from the perspective selected in paragraph 7.1.6.9 above) and the engine rotates counterclockwise, the angle would be 90 degrees. If the #1 hole is at the 3:00 position and the engine rotates clockwise it would be 270 degrees. The measurement to position # 1 must always be measured opposite the direction of rotation. If the angle of position #1 is unknown, enter “0”. After entering the angle of the #1 position, press [ENTER] to continue.

If you selected “Uneven” in step 7.1.8.8 above, the “Angle of #1 Posn:” field will not be displayed, but when you press [ENTER] the multiple angle/position number fields are displayed as shown in the example above. Each position angle must be defined individually. Using the keypad, complete each field by entering a position number (“No.”) and its corresponding angular (“Ang”) location as measured opposite the direction of fan rotation as viewed from the perspective selected in paragraph 7.1.8.10 above. Use the [⇓] and [⇑] keys to move between these fields. To determine these values, do the following. Rotate the fan to align the tachometer

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pickup and its triggering device (magnetic interrupter, reflective tape, etc.). With the fan in this position, use the 12:00 position as the “0” or “360 degrees” (index point) and measure opposite the direction of rotation to the angle of each position number and record that angle adjacent to the position number. For example, if the number 1 position is near the 6:00 position, the angle may be measured as 174 degrees. On the screen, use the keypad to enter the angle of position number 1 as “174.” Then, using the [⇓] key to move to the adjacent field (“No.”), input the number “1.” Next, measure to position number 2. If position number two is measured as 156 degrees, enter that value and “2” in the adjacent field. Continue this process until all angles for all positions are defined. The measurement must always be opposite the direction of rotation of the fan maintaining the perspective selected in paragraph 7.1.8.10 above. Continue entering Balance Plane Information for all planes described in paragraph(s) 7.1.6.4 and 7.1.6.5 above. 7.1.9.

Complete the “Label Detail Wt Holes” screen as follows:

7.1.9.1.

If you selected to label the detail weights in the Setup in paragraph 7.1.6.8 above the next screen to appear will be the Label Detail Wt Holes screen. Use the [⇓] key to move from hole number to hole number. When the cursor highlights a hole number that is currently occupied by a detail weight, use the [⇒] key to toggle between the hole number and an . The X symbolizes that a Detail Weight is located in this hole and it is not available for trim balancing.

7.1.10.

Complete the “Sensor Information” screen as follows:

7.1.10.1. In the Eng ID: (engine identification) use the numeric keypad to enter the number of the engine. Press the [⇓] key to move to the next field. 7.1.10.2. Use the [⇒] to select the Tach Chan (tachometer channel) you will use for this job. Be sure the channel you select here is the channel you actually connect the tachometer-input signal to when setting up the equipment. Press the [⇓] key to move to the next field. 7-14 – Fan Balance 7

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7.1.10.3. Use the [⇒] key to select the “Tach Type:” The analyzer will process the signal of several tooth types, Shifted Tooth - Shfd Tth, High Tooth - Hi Tth, Low Tooth - Lo Tth, Missing Tooth - Mssg Tth, Adjustable Shifted Tooth - AjSh Tth, as well as tachometer generators and optical sensors. Optical sensors include the Phototach and Lasetach. If “AjSh Tth” is selected the additional “Delta(%):” field will appear after Tach Pos (FLA). See paragraph 7.1.10.5 below for more on this setting. Press the [⇓] key to move to the next field. 7.1.10.4. Use the [⇒] to select “Tach Pos (FLA):” (Tachometer position, from Forward Looking Aft). This is the clock position where the tachometer triggers during the fan rotation as viewed from forward of the engine looking aft into the intake. The selections are in whole hours from 1 to 12. If you are unsure of the location of the tach trigger event, use the [⇒] key to select “UNK”. Press the [⇓] key to move to the next field. 7.1.10.5. Use the keypad to enter a value in the “Delta(%):” field. This value will be the amount that the shifted tooth detection is shifted. Valid entries are from 1.0% through 16% in signal shift. 7.1.10.6. Use the [⇒] key to select the “Full Scale Vibration”. This should be the highest amplitude of vibration you would reasonably expect to see during a typical balance job. This value should be enough above the maximum allowable vibration for the engine so that any amplitude in excess of that limit can be readily seen. Use the [⇓] key to move to the next field. 7.1.10.7. Use the [⇒] key to select the “Sensor Type” you will use for this balance. If the sensor you intend to use is not among those listed, see Chapter 18, Miscellaneous Items, paragraph 18.1.2 on setting up a new sensor. Use the [⇓] key to move to the next field. 7.1.10.8. Use the [⇒] key to select the “Ch” (Channel A, B, C, or D) where you will connect the sensor input from the vibration sensor in this same row. Use the [⇓] key to move to the next field.

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7.1.10.9. Use the keypad to enter a name in the “Desc” field. The name should reflect the source, location, or other common attribute of this sensor input. Some suggestions are FRONT, REAR, VERT, HORIZ, or FFV, FFH. Use the [⇓] key to move to the next field. 7.1.10.10. In the “Pos” field, use the [⇒] key to select the clock position of the sensor on the engine as viewed from forward of the engine looking into the intake. Use the [⇓] key to move to the next field. 7.1.10.11. Use the keypad to enter a value in the “Targ” field. The value will define the point where the analyzer provides a suggestion to terminate the balance job. When all fields are complete, press ENTER to accept and continue. 7.1.11.

The “Define Fan/Turbine Balance ICFs” screen is shown below. This screen will only appear if an Influence Coefficient has not already been defined in the setup or if the setup is using “Select in Job” for the number of balance speeds. Use the [⇒] to toggle the YES / NO answer field to indicate if you wish to use the same influence coefficient for all planes. If using a single balance plane, this option will not be presented. Use the [⇒] to toggle the YES / NO answer field to indicate if you wish to use the same influence coefficient for all speeds. If using a single speed balance, this option will not be presented. Use the [⇓] key to move to the next field. Enter an established or calculated influence for this setup from the keypad. In the “(Balance weight units)/(Vib units)” field, enter the units of weight, grams or ounces as designated in the setup, required to reduce one engineering unit of vibration to the lowest possible level. In the “Deg” field, enter the phase correction in degrees. If you have selected multiple planes or sensors, repeat these steps for the next screens. When all fields are complete per your requirements, press [ENTER] to accept and continue.

7.1.12.

Job Identification Screen. The Job Identification screen will be displayed where you may enter the optional information of Name, A/C Registration and AC/Total Time. Complete each field as necessary using the analyzer keypad. If Names have previously been entered in this analyzer, you may optionally press the [F1]

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“Names” key and select a name from the stored list of names. When all fields are complete per your requirements, press [ENTER] to accept and continue.

7.1.13.

Engine Information. The Engine Information screen will be displayed where you may enter the optional information of Position, Engine S/N, Type, TSO, TSN, and Cyc. Complete each field as necessary using the analyzer keypad. If Serial Nos have previously been entered in this analyzer, you may optionally press the [F1] “Serial Nos” key and select a serial number from the stored list of serial numbers. When all fields are complete per your requirements, press [ENTER] to accept and continue.

7.1.14.

If you selected to label detail weights in the Job in paragraph 7.1.6.8 above, the “Label Detail Wt Holes” screen will appear. Use the [⇓] key to move from hole number to hole number. When the cursor highlights a hole number that is currently occupied by a detail weight, use the [⇒] key to toggle between the hole number and an . The X symbolizes that a Detail Weight is located in this hole and it is not available for trim balancing. 7 Fan Balance – 7-17

7.1.15.

Fan/Turbine Balance Equipment Setup. The Fan/Turbine Balance Equipment Setup banner screen, shown below, will be displayed. Install the speed sensor, vibration sensor, and cables as indicated. Near the center of the screen, the information message “Tach power is off” will be displayed. This indicates that power to the optical tachometer is currently not available to check alignment with the reflective target. If you wish to do the alignment at this point, press the [F1] “Tach Pwr” key to provide power to the optical tachometer being used. When all installations and connections are made, and tachometer checks completed as necessary, press [ENTER] to accept settings and exit this screen.

NOTE The option to turn tach power on or off using the [F1] function key is for tachometer alignment only and will not affect the tachometer’s operational condition. Regardless of selection, once this screen is exited power WILL be supplied to an Optical Tachometer.

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7.1.16.

The Tach Power may also be checked from the Main Menu option “Test Tach Power” as shown below. Highlight the “Test Tach Power” item and press [ENTER] to access the “Tach Power” screen.

7.1.16.1. Each function key on the “Tach Power” screen corresponds to a Tach channel. By pressing the corresponding function key, power will be routed to that tach channel for testing or alignment purposes. Only one tach channel can be powered at a time. The powered tach will be identified following the “Tach Power:” statement. To turn off power to any tach channel press [F5] “Off”. Exit the “Tach Power” screen by pressing [ENTER] or [BACKUP]. Tach power will automatically be turned off to all channels when the screen is exited.

7.1.17. Start Aircraft. The “Start Aircraft” banner screen, shown below, will be displayed with several informational messages. The Run number indicates which run of the balance job is currently being collected. The second line states “Perform FOD check, start engine(s) per flight manual and set engine(s) to idle.” Before starting the engine, make sure all previously installed trim balance jobs have been removed. 7 Fan Balance – 7-19

On some engines, there may be detail or factory installed weights, which must not be removed. Check the LMM prior to removing weights if you are not familiar with this engine and the balancing procedures. Start the engine using normal procedures and allow the engine to warm up to normal operating temperatures. When warm up is complete, allow the engine to stabilize at speed, make any minor adjustments as necessary, then press [ENTER] to continue. Use the [F2] “Swap Job” key to return directly to the Main Menu without rebooting the analyzer. Use the [F3] “+/- Pol.” key to reverse the polarity of the Tach Signal. If the Current RPM is erratic at a stable engine speed, press this key in an attempt to stabilize the reading. This option may be necessary when some of the Tooth settings; Shfd Tth, Hi Tth, Lo Tth, Mssg Tth, AjSh Tth; are selected on some engines.

7.1.18. The analyzer will display the “Set Engine Speed” screen. Use the on-screen indications of engine RPM and Percent to set the current RPM to match the desired RPM. When the desired RPM is reached press the [ENTER] key to progress to the next screen. The Set Engine Speed screen will be repeated as many times as the number of balance speeds selected in paragraph 7.1.6.11 above.

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7.1.19. A data acquisition screen similar to the one shown below will be displayed. If you are unfamiliar with reading this screen, see Chapter 20 of this manual, “Reading Spectrum and Scales”. Allow the analyzer to average the acquired data until the indications are stable. The term STABLE is used here to indicate that the Average indications are not widely fluctuating and that the Error indication is as low as possible and not increasing. Press [F1] “Reset”, to clear the averaged data to this point and begin the averaging process anew or press [ENTER] to stop the acquisition and proceed. The top line of this screen can display three different status messages. The messages are: “Waiting for Data” This message is displayed until in-range RPM, IPS, and Phase Angle readings are recorded by the analyzer. The only way to exit the screen while this message is displayed is to use the [BACKUP] key. “Acquiring Data” This message is displayed during data acquisition. As long as the data remains in-range, the analyzer will add each new sample to the running average. The only way to exit the screen while this message is displayed is to use the [BACKUP] key. “Complete! Press ENTER” This message will appear when a minimum number of consistent samples have been collected. Allow the unit to collect data as long as the error continues to decrease. This will insure you have the most accurate data possible. Use the [ENTER] key to exit this screen and store the reading. The text below the “Current” heading indicates the RPM, IPS, and Phase Angle from the latest collect vibration sample. These values will change as the individual readings are collected. The RPM will be the currently recorded speed value. For Run 1 the “RPM” heading itself will blink “HIGH” or “LOW” if the current RPM is more than +/- 200 RPM from the RPM defined in a Fan/Turbine Balance setup. For Run 2, the HIGH/LOW warning will appear if the value is +/- 50 RPM from the value recorded during Run 1. Use the [F1] “Reset” key as a way to validate the measurement or to reset the average. Use the [F3] “+/- Pol.” key to reverse the polarity of the Tach Signal. If the Current RPM is erratic at a stable engine speed, press this key in an attempt to stabilize the reading. This option may be necessary when some of the Tooth settings; Shfd Tth, Hi Tth, Lo Tth, Mssg Tth, AjSh Tth; are selected on some engines. NOTE While collecting data, if the amplitude is high, the Error number will decrease toward and possible to 0.00 very rapidly. This indicates the numbers of errors in the indication are averaged out. As the amplitude is decreased in the balancing process on subsequent runs, the Error indication may not drop as rapidly and will most likely not reach a 0.00 reading because the amplitude is so low. In lower amplitude situations, watch for the Error indication to be stable as an indication of acceptable data rather than waiting for it to decrease further.

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7.1.20. Shut Down Engines. The screen will display the message “Shut Down engine(s) per flight manual instructions”. Press [F2] “Swap Job” to return directly to the Main Menu without rebooting the analyzer. Press the [F5] “Continue” key to acknowledge the message and shut down the engine(s).

7.1.21. Review Prior Run(s) Data. The Review Prior Run(s) Data screen, shown below, will be displayed showing the RPM, Vib (amplitude) and Deg (phase angle) collected on all runs up to this point. Pressing the [⇐] or [⇒] keys will allow you to navigate through the readings from all runs of the current job. Use the text on the first line to determine the run number. While viewing the current run, the currently active RPM field will have its color scheme inverted. Use the [⇓] and [⇑] keys to move the highlighted field. To re-take measurements for the current speed, press the [F1] “RetakeOne” key. To retake readings for all speeds, use the [F2] “RetakeAll” key. Press [ENTER] to accept the current measurements and continue.

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7.1.22. The Fan/Turbine Suggested /Installed Wts screen will be displayed. If this is the first suggested weight screen, the weights will be test weights unless an established influence was entered in the setup. Notice at the top of the screen that the message “Remove Old Wts” is shown. All previously installed weights must be removed EACH TIME a new solution is installed. This means that weights installed on the previous run of a balance job must be removed completely before a new solution is installed. The example screen below shows the suggested installation of class weights. Identified in the Name: Plane # line as 4096T45PXX (this will be the name of the default class weight set as specified in paragraph 7.1.8.13 above). The left column, with a heading of “Posn”, shows the suggested position (or preferred term selected in paragraph 7.1.8.2 above) for each class weight. To change the position, use the [⇓] [⇑] keys to move from field to field. When the correct field is highlighted, use the [⇒] [⇐] keys to change the value in that field. The center column, with a heading of “Suggest” is the Class Weight suggested for that Position. The right column, with a heading of “Install”, is the entry for the actual Class Weight installed in a particular Position. To change the Class Weight installed for each Position, use the [⇓] and [⇑] keys to move from field to field. When the correct field is highlighted, use the [⇒] and [⇐] keys to change the value in that field. In this case, the P01 weights are null weights that occupy positions when no balance weight is suggested for the position. Near the bottom of the screen, you will see the Total: “Soln =”, and the “Inst =”. The Soln field shows you the exact solution required to balance the plane. The Inst field shows you the total you indicated you have installed up to this point. If you do not agree with the Inst, review the screen again and change weights as necessary. If you have installed the exact weights and locations suggested, you need only press [ENTER] to continue. You may press the [F1] “Function2” key, to view an additional list of function keys. If you choose to install no weights, you may indicate this by pressing the [F2] “Inst=None” key. This will return all “Installed” values to the null or “0” weight. If you do not have a complete set of class weights, press the [F3] “Edit Weight” key and go to paragraph 7.1.22.1 below for complete instructions. If you press the [F4] “Positions” key you will be taken to a second screen that shows the remaining hole locations and suggested weights. Complete the second screen exactly as you would the first screen. If you want to stop and exit this job without the option to resume at a later

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time, press the [F5] “Quit Job” and the job will be terminated. When all fields are completed per your requirements, press [ENTER] to accept and continue.

7.1.22.1. The “Edit Class Wt Set” screen is used to tell the analyzer that certain members of the class weight set are not available. Use the [⇑] or [⇓] keys to move from weight to weight. When you reach a weight that is not available, use the [⇒] and [⇐] keys to place an -X- in the field replacing the class weight number. Class weights marked with an X will no longer be used to calculate weight Suggestions.

7.1.23. If you pressed the [F1] “Function2” key in paragraph 7.1.22 above, the list of function keys will change to the display shown in the example below. You can return the values in the “Installed” column to their original suggested values by pressing the [F2] “Inst=Sugg” key. This will return all “Installed” values to the values listed under the center “Suggest” column. If you do not have a complete set of class weights, press the [F3] “Edit Weight” key and go to paragraph 7.1.22.1 above for complete instructions. If you press the [F4] “Graph” key you will be taken to a picture of the disc as viewed from the perspective chosen in paragraph 7-24 – Fan Balance 7

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7.1.8.10 above. This will help you place the weights in the correct position/hole/blade location. If you want to stop and exit this job without the option to resume at a later time, press the [F5] Quit Job and the job will be terminated. When all fields are completed per your requirements, press [ENTER] to accept and continue.

7.1.24. Start Aircraft. The screen will again display the Start Aircraft banner screen and indicate a new Run number. From this point, repeat steps 7.1.17 to 7.1.23 until the vibration amplitude is reduced to an acceptable level or below the target amplitude entered in the setup.

7.1.25. When the vibration levels have been reduced to a satisfactory level, press the [F5] “Quit Job” key to complete the job and store any pertinent information back into the setup. If the job went well, the Influence Coefficient (ICF) stored in the setup will be updated. If certain criteria were not met indicating a good job, you will see the message below telling you why the ICF could not be updated.

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7.2.

Fan Blade Optimizer The Fan Blade Optimizer is an accessory program that is activated with the licensing of the Fan/Turbine Balance option in the analyzer. Fan Blade optimizer allows you to remove a single blade from a fan disk then enter the weight moment information for the new blade and all other blades currently installed on the disk. The program will shuffle the entire set and display a new placement location for each blade in the set to attain the best possible balance through weight distribution. This negates the necessity for changing matched pairs of blades when one of the blades is not damaged and still serviceable. The program is not limited by the number of new blades that can be combined with the remaining serviceable blades in a set. To use the Fan Blade Optimizer, proceed as follows:

7.2.1.

Start Job: From the Fan Blade Optimizer Jobs, use the [⇑] or [⇓] keys as necessary to select “Start Job” and press [ENTER].

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7.2.2.

Select Setup List. If a Blade Optimizer setup has previously been entered for the engine model you are currently working, you may select it from the Select, Setup List as illustrated in the screen sample below and proceed to step 7.2.4. If your engine model is not listed, press the [F1] “New” key and proceed to step 7.2.3. If no setups were previously entered, the analyzer will open a new setup screen. If this is the case, go to step 7.2.3 below.

7.2.3.

In the Fan Blade Optimizer Setup screen, shown below, use the [⇓] key to move from field to field and complete the screen as follows

7.2.3.1.

In the Name: field, use the analyzer keypad to enter a name for this setup. The engine model is usually a good choice for this name.

7.2.3.2.

In the Number of Blades: field, use the analyzer keypad to enter the total number of blades on the disk. The field will accept values from 5 to 99.

7 Fan Balance – 7-27

7.2.3.3.

In the Blade Num Style: Use the [⇒] key to select the numbering style you would prefer to use for this setup. The choices are , which will allow up to 26 blades, or which will allow up to 99 blades in a set. This numbering style is how you will identify each blade in the set for weight and later for location placement.

7.2.3.4.

In the Units of Measure: field, use the keypad to enter the units of measure you wish to use for the blades, such as Inch Grams.

7.2.3.5.

In the Max Total Error: field, use the analyzer keypad to enter the maximum total error for the assembly AFTER the blades have been reshuffled. If you do not know the maximum allowable error, enter 0.1 which is generally acceptable for all assemblies. This error is used as the target for the reshuffle and keys the analyzer to continue calculations until this limit is either met, or cannot be achieved.

When all fields are complete as necessary, press [ENTER] to accept your settings and continue.

7.2.4.

The Job Identification screen, shown below will be displayed. Use the [⇓] key to move from field to field. Use the analyzer keypad to enter a Name, and optional Aircraft (A/C) Registration and Aircraft Total Time. If Names have previously been entered in this analyzer, you may optionally press the [F1] “Names” key and select a name from the stored list of names. When all fields are complete as necessary, press [ENTER] to accept your settings and continue.

7-28 – Fan Balance 7

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7.2.5.

The Engine Information screen, shown below will be displayed. This is a generic form used for various analyzer features. Use the [⇒] key to select the Position for the engine (1, 2, 3, or 4). Enter the optional Engine Serial Number (S/N), Type, Time Since Overhaul (TSO) and Time Since New (TSN) as required. When the cursor is in the S/N field, you may alternately press the [F1] “Serial Nos” key to select from a list of previously entered serial numbers. When all fields are complete as necessary, press [ENTER] to accept your settings and continue.

7.2.6.

The Fan Blade Optimizer Job screen, shown below will be displayed. Notice that there are two columns, one for the Blade identifier (A-Z or B1 – B99) and one for the Weight. There are a number of rows equal to the total number of blades in the set as identified earlier in paragraph 7.2.3.2 above. The Weight column will display all zeros (0.00). Use the [⇑] and [⇓] key to move from field to field in the Weight column. Use the analyzer keypad to enter a value for the selected measurement type corresponding to the identified blade number. When all values are entered, recheck to insure accurate entries for each blade. When you are

7 Fan Balance – 7-29

satisfied that all entries are correct, press [ENTER] to accept your entries and continue.

7.2.7.

A momentary screen reading “Stand-by, Optimizing” will be displayed along with a progression bar. When the progression bar is completely darkened, the process will be complete (about 30 seconds to one minute) and the Fan Blade Optimizer Result screen, shown below, will be displayed. This is the screen that displays the optimal blade placement for each blade in the set to achieve the best weight distribution and balance. There are now three columns shown on screen, the Order, Bld (Blade number), and Wt (Weight). The Order is the order of placement; the blade number is the identifying number of the blade which should be placed in the corresponding position shown in the Order column. At the bottom of the screen you will see the Total Error for the new placement. If you notice that any of the weights shown is not correct, or if you wish to replace one of the blades with a new blade and its new weight, press the [F1] “Edit Wt” key. The screen will revert to that shown in paragraph 7.2.6 above. Go to that paragraph and repeat the process as directed. Otherwise, when placement is complete, you may press [ENTER] to exit the screen and turn the analyzer off. A record of the job will be stored in the analyzer for later reference if required. NOTE

The screen below is for illustration purposes only and does not reflect accurate values for an actual Blade Optimizer Job.

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7.2.8.

Once the blade placement is complete, a vibration survey should be completed to insure the balance is acceptable. If the balance is not acceptable, proceed to the Fan/Turbine Balance section of this chapter.

7 Fan Balance – 7-31

Chapter 8 TFE731 Performance (Revision 3, Oct 2012) TFE731 Performance EMS is the function that makes the Viper the controller for the ACES1752B, and 1754 JEDA units. The 1750 and 1752 JEDA will collect performance data on all TFE731 engine models not equipped with N1 DEEC computers and currently requires the use of the 17XX series analyzer acting as a controller. The 1752B will collect performance data on all TFE731 engine models regardless of the engine computer type and the 1754 will collect performance data only from TFE731 engine models with N1 DEEC computers. The 1752B and 1754 JEDA models can be controlled with either a 17XX analyzer or the 4040 Viper. The TFE731 Performance EMS function is used exclusively with the model 1752B Mini JEDA and 1754 Micro JEDA models. The EMS function is included as part of the 4040 Viper Main Menu. The EMS function cannot be intermixed as controller for 1750 and 1752 JEDA equipment and will not perform as described here. If you are not sure what performance equipment and accessories you currently have, contact ACES Systems. To conduct a performance run using EMS, refer to section 8.1 below.

8.1. TFE731 Performance EMS 8.1.1.

Necessary Equipment. In order to use the EMS function of the Viper 4040 analyzer you must first have the EMS function active on your analyzer. There is no charge for the EMS function to be activated on the analyzer. If “TFE731 Performance - EMS” does not appear on your main menu screen, contact ACES Systems for information on how to activate this function. In addition to the EMS function being active, you must have the necessary data logger (Jet Engine Data Acquisition, or JEDA) plus accessories required for the TFE731 engine model that you intend to conduct the performance calibration run on. The following is a list and short explanation of each.

**Falcon 900EX, Falcon 50 (center engine)

10-320-0287 10-320-0273

Lear 45

10-320-0288

**Falcon 900EX, Falcon 50 (side engines)

10-320-0331

Falcon 50 (Pre-Aegis Installation)

10-320-0275

*Falcon 900EX / Galaxy

uJEDA to 8002-60 / -62 only N1 DEEC Comm

10-320-0274

Air Filter

PT 2

PO

J2

N1 DEEC

To Eng.

DEEC HARNESS

For N2 DEEC and 8002-60\62 N1 DEEC equipped engines

J1

Generic uJEDA N1 DEEC Comm

To Engine

10-320-0267

P O

PO

J2

N2 DEEC

PT 2

EEC

PT 2

10-320-0239

J1

Function Seletct

J2

N1 DEEC

8002-60 \ -62

J1

EEC HARNESS

10-320-0238

J1 J2 PT 2

DEEC HARNESS

To Engine

10-320-0239

Sta. 3.0 Temp Cable

10-320-0243

Sta. 2.35 Temp Cable

10-320-0242

2.35 Press Cable

10-320-0241

To Engine

uJEDA/1700 COMM

10-320-0258 DB25

(Optional) 2.35 Press Transducer

RS232/ RS422 Converter

75-210-0058

10-100-0356

3.0 Press Cable

2.35 PRES

FLOW

3.0 TEMP

ECC/ DEEC

10-320-0241 0%

(Optional) 3.0 Press Transducer

10-100-0357

DB25

FUEL 2.35 TEMP

100 %

BATTERY LEVEL 3.0 PRES

10-320-0310

FUEL

DEEC COMM

TEMP

COMM

TEMP

RS422 JEDA COMM-TO-4040

AMB Press Cable ON

10-320-0262 AMB PRES

OFF POWER

AMB

(Optional) AMB Press Transdcer

A

1

B

2

10-100-0355

COMM

3

C

4

D

Model 4040

ACES SYSTEMS

AMB Temp Cable

10-320-0232

2.35 & 3.0 Pressure Hoses

10-100-0349

ON OF / F

MAI MEN N U

AMB Temp Probe

10-100-0214

**SN 88 and higher only *SN 87 and lower only

B A C K U P

1752B JEDA with 4040 Viper Analyzer Equipment Setup

8-2 – TFE731 Performance 8

F 1

F 2

F 3

F 4

PRINT

1 ABC

2 DE F 5 MNO

3 GHI

HELP

4 JK L 7 8 STU VWX . @% #

0 ()?

6 PQ R 9 YZ* SPACE +/-

F 5

CLEAR

E N T E R

Viper 4040 User Manual

8.1.1.1. Datalogger (JEDA): There are two possible selections for the JEDA unit required. 1.) The Model 1752 Mini JEDA is a compact designed data logger, which enables you to collect data from any TFE731 engine model, regardless of the computer type (EEC, N2 DEEC, or N1 DEEC) and 2.) The Model 1754 Micro JEDA is a super compact designed data logger that enables you to collect data from only TFE731 engine models equipped with N1 DEEC computers. 8.1.1.2. ACES AvTrend Software: ACES AvTrend is the companion software provided with the purchase of the Viper 4040 analyzer. AvTrend allows you to dump and store all Jobs completed with your Viper 4040 to your computer. This includes TFE731 performance calibration runs. AvTrend directs the logger files to the MEDRA Logger Directory where it is stored until the data is reduced by MEDRA. 8.1.1.3. RS232-to-RS422 Communications Cable: This is the communications cable that enables the Viper 4040 to control the JEDA unit via a serial communications link. The communications cable between the Viper 4040 and the JEDA unit includes a RS232-to-RS422 converter and is approximately 70 feet long to accommodate all known airframe applications. The RS232-to-RS422 converter is attached in line at the Viper 4040 end of the cable to the DB25 connector. The converter connects directly to the DB25 end of the Serial Comm cable, which is included with the Viper 4040 analyzer. The Serial Comm cable then connects to the analyzer via a 6 pin MS connector and the AUX COMM port 8.1.1.4. EEC, N2 DEEC, and N1 DEEC Comm Cable(s): The EMS software will accommodate all TFE731 engine types. The EEC harness is connected to the engine EEC computer and to the JEDA unit. The connection at the computer also passes the signals through to the engine normally except for the T5 connection, which is opened by the JEDA unit. For this reason, the EEC or DEEC harness must never be attached independently to the engine computer (that is without also being connected to the JEDA unit) to prevent torching and overheating during engine start. The N2 DEEC harness is used in the same fashion as the EEC harness. Both the EEC and DEEC harness are the only cables required to be connected to EEC and N2 DEEC computers to collect the calibration data. There are several N1 DEEC Comm cables available as of this writing. You may expect that others will become available as new airframe/engine combinations are designed and as older N2 DEEC equipped engines are upgraded to the newer N1 DEEC computers. The Standard N1 DEEC Comm cable is a generic design that connects directly to the J2 connection of the N1 computer, where possible. Engine/airframe specific cables are necessary for access to the computer where other means of communicating with the computer are not available. There are specific designs for the Falcon 900EX, Falcon 50 (Side and Center Engine), Lear 45, ASTRA SPX/Galaxy, and for the 8002-60 and

8 TFE731 Performance – 8-3

8002-62 N1computers. When collecting data from either the 8002-60 or 8002-62 computers, you must also use the N2 DEEC harness cable (10-3200239) in conjunction with the –60/-62 N1 DEEC comm cable, 10-320-0274. The two cables are necessary to: 1) control the computer ( -60/-62 N1 DEEC Comm Cable) and 2) to facilitate a faster acquisition speed (N2 DEEC breakout cable) from these older design N1 Computers. 8.1.1.5. Ambient Temperature Probe and Cable: The EMS software design dictates that you must have an ambient temperature sensor and connecting cable installed for all EMS performance runs. The ambient temperature sensor is placed in a shaded area near the engine and secured to prevent ingestion into the engine or damage due to movement caused by jet blast or wind. The cable then connects the sensor to the JEDA unit. 8.1.1.6. Optional sensors and cables: Optional Sensors include the Station 3.0 Temperature cable, the Station 2.35 Temperature cable, the Station 2.35, and 3.0 pressure sensors and connecting cables and the pressure hoses to connect the Station 2.35 and Station 3.0 pressure sensors to the engine. The Ambient Pressure sensor and cable are also optional but recommended for data quality. 8.1.2.

Analyzer Operation

8.1.2.1.

Turn the analyzer ON by pressing the ON/OFF key.

8.1.2.2.

From the Main Menu, shown below, use the [UP ARROW] or [DOWN ARROW] key to select “TFE731 Performance – EMS” and press [ENTER].

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Viper 4040 User Manual

8.1.2.3.

From the EMS Menu, select “Start EMS Job” and press [ENTER].

8.1.2.4.

The analyzer will perform a communications check with the JEDA unit and the aircraft computer. If an error is encountered, the information screen below will be displayed. Check all cable connections and attempt to start the job again. Press the [F5] “Continue” key to acknowledge the warning and continue.

8.1.2.5.

The Aircraft Select screen will be displayed. Use the [RIGHT ARROW] key to scroll through the list of available aircraft. When the name of the aircraft on which you are conducting the calibration run appears, press [ENTER] to accept and continue.

8 TFE731 Performance – 8-5

8.1.2.6.

The Engine Select screen will be displayed. Use the [RIGHT ARROW] key to scroll through the list of available engine models. The list is restricted to those engine models that may be installed on the aircraft model selected in the Aircraft Selection screen above. Double check the engine model as an error in this selection can make significant differences in the reduced data. If the engine model installed on the selected aircraft is NOT AVAILABLE from the list, contact ACES Systems at the number listed in front of this manual. When you are ready to continue, press [ENTER] to accept your selection.

8.1.2.7.

The Nozzle Select screen will be displayed. Use the [RIGHT ARROW] key to scroll through the list of available Nozzles that may be installed on the engine model and aircraft selected in paragraphs 8.1.2.7 and 8.1.2.8 above. Press [ENTER] to accept your selection and continue.

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8.1.2.8.

The Performance Calibration Setup screen, shown below, will be displayed. Complete this screen as follows:

Customer Name:

Use the analyzer keypad to enter a customer name. Press the [DOWN ARROW] key to move to the next field.

Aircraft S/N:

Use the analyzer keypad to enter the aircraft registration or serial number as required. Press the [DOWN ARROW] key to move to the next field.

Fuel Spec Gravity:

If you are using a fuel flow meter, use the analyzer keypad to enter the Specific Gravity of the fuel at 60 degrees F (15.6 degrees C). NOTE: If you are not using a fuel flow meter, this entry is not required. Press the [DOWN ARROW] key to move to the next field.

Fuel LHV(BTU/lbm): If you are using a fuel flow meter, use the analyzer keypad to enter the Fuel Lower Heating Value. If you are not using a fuel flow meter, this entry is not required. Press the [DOWN ARROW] key to move to the next field. Temp Disp Units:

Use the [RIGHT ARROW] key to toggle the desired temperature display units between degrees C or degrees F. Press the [DOWN ARROW] key to move to the next field.

N1 Delta (rpm):

Use the numeric keypad to enter the N1 Delta RPM. This is the allowable N1 speed drift from a stable speed, before the data logger will detect and store an invalid sample. The default is 100. If wind conditions dictate, this value may be set as high as 300 RPM, however; data quality may be questionable if taken in such extreme conditions as to require a 300 RPM delta. Press the [DOWN ARROW] key to continue.

8 TFE731 Performance – 8-7

Calib. Reason:

Use the [RIGHT ARROW] key to scroll through the available selections for Calibration Reason. When the Reason you are conducting the calibration run is displayed, press the [DOWN ARROW] key to move to the next field.

Engine Hours:

Use the analyzer’s numeric keypad to enter the total Engine Hours. Press the [DOWN ARROW] key to move to the next field.

Engine Cycles:

Use the analyzer’s numeric keypad to enter the total Engine Cycles. Review all fields on this page for correct entry then press [ENTER] to accept your selections and entries and continue.

8.1.2.9.

If the selected engine is APR equipped, the following information page will be displayed. The message varies according to the aircraft selected above. If APR equipped and aircraft is a Hawker with N1 DEEC 9020-3 or 9010-8000, the message “PRIOR TO START APR MUST BE TURNED OFF…” is given. If the selected aircraft is not a Hawker, the message “PRIOR TO START APR MUST BE ARMED AND ON.” is given. Press the [F5] “Continue” key to acknowledge this information message and continue.

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Viper 4040 User Manual

8.1.2.10.

If the engine you are running is EEC or N2 DEEC equipped, the information message below will be displayed. Press [F1] “Yes” to conduct the bleed valve check or no to continue without conducting the check. NOTE: If the engine is N1 DEEC equipped, this message will not be seen as the Bleed Valve Check is not an option with N1 DEEC equipped engines. This is a limitation of the N1 DEEC design.

8.1.2.11.

The information screen below will be displayed. Allow the engine to warm up to normal operating conditions. When normal operating conditions are attained, press the [F5] “Continue” key.

8 TFE731 Performance – 8-9

8.1.2.12.

If the engine is N1 DEEC equipped, the WARNING message below will be displayed. The message indicates that the computer is not in the certified, factory default mode. If power to the analyzer is lost for any reason, the N1 DEEC control will not automatically return to its default, certified mode. In order to return the N1 DEEC computer to the default mode, you must cycle the N1 DEEC power switch any time power to the analyzer is lost during a calibration run. Press the [F5] key to acknowledge and continue.

8.1.2.13.

The information screen below will be displayed. The OAT (outside air temperature) will be displayed on the screen. Use this temperature to calculate N1 for the day with the aircraft performance data. When the power setting is calculated, advance the power lever to N1 for the day. When the ITT is stable at N1 for the day, press [ENTER] to continue.

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Viper 4040 User Manual

8.1.2.14.

The information screen below will be displayed if you are running an N1 DEEC equipped engine. The message is to inform you that all power adjustment will be made automatically by the Viper 4040 analyzer. While you do not need to adjust power for the calibration run, you still have the ability to reduce the engine power using the PLA if necessary, such as in an emergency or because of airfield traffic. If power is reduced, the analyzer will afford you the opportunely to continue the run without returning to the beginning of the run. Press [F5] to acknowledge and continue.

8.1.2.15.

The STABILIZATION screen, shown below, will be displayed. This screen will be displayed while the engine is in the stabilization mode and will automatically advance to the acquisition mode when the engine is thermodynamically stable. The length of time this screen is displayed will vary according to the quality of the data being collected. Note the P/Set: 1 indicates this is the first of the five power point settings.

8 TFE731 Performance – 8-11

When the analyzer switches to the Acquisition mode, the header at the top of the screen will indicate “Acquisition” and the data quality indications, ACCEPTABLE, QUESTIONABLE and UNRELIABLE will be shown to the right of the P/Set indication. The normal time required for acquiring each point is one minute. If data quality dictates, the scan period may be extended until the required number of acceptable data samples is acquired.

When acceptable data is acquired, the screen will automatically display the review screen shown below. As indicated at the bottom of the screen, use the [LEFT ARROW] and [RIGHT ARROW] keys to select data points. Press the [BACKUP] key to retake this power set point or press [ENTER] to accept this data and continue.

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Viper 4040 User Manual

8.1.2.16.

The Cockpit Readings screen, as shown in the example below, will be displayed. The fields immediately to the right of the N1, N2 and ITT names will be blank. Use the analyzer keypad to enter the values as indicated by the cockpit instruments. Use the [UP ARROW] or [DOWN ARROW] key to move between fields. When all fields are complete, press the [ENTER] key to accept and continue. The screen will then return to the acquisition screen shown above in 8.1.2.15 with the P/Set indicating the next sequential point number. The process then repeats for each of the five points until all data is collected.

8.1.3.

Information Screens

8.1.3.1.

During data collection, you may encounter one or more of the screens shown below. Each screen is displayed if certain events occur. The first of these is “Do you wish to abort the performance calibration?” You will encounter this screen if the PLA is moved during the data acquisition phase; the PLA potentiometer is producing noise levels above the pre-set allowable level. In either case, there are

8 TFE731 Performance – 8-13

two possible answers “Yes” or “No” that may be selected by pressing either the [F1] or [F5] key, respectively.

8.1.3.2.

The Information screen below, “Reduce PLA slowly until the engine slows below N2 = XX.X%” indicates that you have either selected the [F1] “Yes” answer from the screen above, or you have completed data acquisition and terminating the job. This screen directs actions that are required in order to return normal control to the N1 DEEC computer. As indicated, the PLA must be reduced to a point equal to or less than an N2 indication of 92.4%. When the required speed is attained, press [ENTER] to continue the process.

8.1.3.3.

The screen below will be displayed as a last action to be completed for returning control of the engine to the N1 DEEC computer and the operator. As indicated, cycle the N1 DEEC power to complete the procedure. Press the [F5] “Continue” key to acknowledge and continue.

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Viper 4040 User Manual

8.1.3.4.

The information screen below confirms that control of the engine has been returned to the N1 DEEC computer and the operator.

8.1.3.5.

The information screen below will be displayed each time the Viper 4040 is adjusting power for the next point. As stated in the message, you should not attempt to press any keys during this process. You should also not move the PLA, activate or deactivate any aircraft systems that would change the power setting of the engine. This screen is active only when conducting calibration runs on N1 DEEC equipped engines.

8 TFE731 Performance – 8-15

8.1.3.6.

The information screen below will be displayed following the collection of data from the fifth point of a calibration run. A minimum of five points are required, however, the analyzer will allow you to acquire an additional seven points if you so desire. If you answer “YES” to the screen below, you must then define the parameters of the additional points and manually make power adjustment for the additional points, even when the engine computer is an N1 DEEC.

8.1.3.7.

The information screen below will follow the screen above in paragraph 8.1.3.6 if you answer “Yes” in that screen. In this case, move the PLA to the desired power point and press the [F5] key to continue collecting data.

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Viper 4040 User Manual

8.1.4.

Getting the latest software. As modifications, additions, and changes are made to the EMS program, the Application running in your analyzer will change. To check the currency of your application software, contact ACES Systems or visit our web site at http://www.acessystems.com/applications.htm and look for the Viper 4040. You may download the latest application at this location. The site is updated during the first week of each month. The application software can also be delivered to you via E-mail or on CD in special cases.

8 TFE731 Performance – 8-17

Chapter 9 Vibration Spectrum Survey (Revision 3.01, Oct 2012) “Vibration Spectrum Survey” is an analyzer function that is accessed from the analyzer’s Main Menu banner screen as shown in the illustration below. Selecting this function from the main menu brings up the “Vibration Spectrum Survey Jobs” banner screen menu (also shown below). Each of the listings on this banner screen menu is an option within the “Vibration Spectrum Survey” function. Descriptions of each of these options follow, along with the information required to complete the menu screens within the options, and the steps necessary to perform the vibration spectrum surveys function.

The Vibration Spectrum Survey option allows the user to rapidly complete and store vibration surveys using the “Spectra Setup” feature (described in section 9.1.1 below). With the setup feature you may complete surveys on several different components without manually entering the setup data between surveys. Each job is unique and very quick.

9.1. - Start Job Selecting “Start Job” from the “Vibration Spectrum Survey Jobs” banner screen allows you to begin a vibration spectrum survey. When you select this option, one of two screens will appear next depending on whether you are starting a job from scratch or an incomplete job still exists in the analyzer’s memory.

If you have previously saved setups in the analyzer’s memory, a screen with the list of setups, as shown below, will be displayed. If no setups are stored, or if you choose “New” by pressing the [F1] key from the Setup List screen, the analyzer will display the “Spectra Setup” banner screen. If you select a setup from the list, the analyzer will proceed to the “Job Identification” banner screen described in section 9.1.2. Instructions for completing the “Spectra Setup” banner screen appear in the following Section, 9.1.1.

9-2 – Vibration Spectrum Surveys 9

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If another job was in progress but was not completed, the “Incomplete Job” banner screen will be displayed to inform you of this. This screen will also display a message prompting you to verify that you want to complete the in-progress job or that you want to ignore it and begin a completely new job. This verification prevents you from accidentally erasing data from an in-progress job. The screen will display the message “The last job performed is incomplete. Do you want to RESUME work on it?”

You must then choose a “Yes” or “No” answer by pressing the corresponding [F1] key, for “Yes,” or the [F5] key, for “No.” The “Yes” answer will return you to the point where the inprogress job was stopped and allow you to complete it. If you choose the “No” answer, the screen will then display the “Spectra Setup” banner screen so you can program a new setup or if you have previously-saved setups stored in the analyzer’s memory, a screen displaying the list of setups will be displayed. You can then select a setup from this list. If you select from the list, you proceed to the “Job Identification” banner screen described in section 9.1.2. Instructions for completing the “Spectra Setup” banner screen appear in the following Section, 9.1.1.

9 Vibration Spectrum Surveys – 9-3

NOTE The analyzer will store Setups as long as available memory remains. If you are attempting to store a survey that will exceed the analyzer’s memory capacity, the analyzer will display a message saying “You must delete an item before adding a new one.” Press the [BACKUP] key and select “Manage Setups” to delete the Setup of your choosing.

9.1.1. - Spectra Setup The “Spectra Setup” banner screen allows you to define and store a vibration spectrum survey job. As shown in the figure below, some fields in this screen have default values that appear automatically. You can use this information if appropriate or input your specific setup information using the keypad. (Refer to Chapter 3, “Using the Viper 4040 Analyzer” if you are unfamiliar with using the keypad.) The analyzer will display the “Spectra Setup” banner with default values as those shown in the figure below.

9.1.1.1.

Spectra Setup

9.1.1.1.1.

In the Name: field, use the keypad to enter a name for the vibration spectra survey job. (Refer to Chapter 3, “Using the Viper 4040 Analyzer” if you are unfamiliar with using the keypad.) The “Name” should be one of your choosing which you will easily recognize and associate with this job. The airframe or engine name such as “AS350” or “TFE731-2” is best to use when naming a Setup.

9.1.1.1.2.

Use the [⇓] key to move to the frequency units (RPM or Hz) field. Determine if the required frequency units are revolutions per minute (RPM) or cycles per second (Hz), then use the [⇒] key to “toggle” between the two selections in this field.

9.1.1.1.3.

Use the [⇓] key to move to the Minimum Frequency and Maximum Frequency fields. These fields are unnamed, are located immediately to the right of the

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frequency units filed, and are separated by the word “to”.Using the keypad, enter the minimum frequency value, then press [⇒] key and enter the and maximum frequency value according to the requirements for the job. For instance, if the frequency of interest is 300 Hz, choose a minimum and maximum frequency that will place the 300 Hz in the center of the range. The minimum could be 250 Hz and the maximum 350 Hz for example. Be sure to set the min and max frequencies wide enough to encompass all turning speeds you wish to capture. The maximum frequency may be set as high as 30000 Hz (1,800,000 RPM). You should also consider other factors such as Harmonics. If you want multiples of the fundamental frequency included in the frequency range, determine to what extent that need is (1X, 2X, 3X, and so on) then extend the frequency range to include it. For example, 300Hz is the frequency of interest, the fundamental frequency. If you want 3X harmonics included in the frequency range you must multiply the fundamental frequency (300 Hz) X the harmonic range (3X) and arrive at an upper range of 900 Hz. 9.1.1.1.4.

Move to the “Resolution” field using the [⇓] key. Complete the field by setting the resolution as required at 100, 200, 400, 800, 1600, 3200, or 6400 lines by pressing the [⇒] key until the desired resolution is displayed. Unless you are attempting to separate two frequencies that are within close proximity to one another, the default 400 lines should more than suffice for general analysis. Higher resolutions will provide a much sharper image of the specified frequency band, but also require more time and more memory for acquisition.

9.1.1.1.5.

Move to the “Average Type” field using the [⇓] key. Select the “Average Type” by scrolling between the available choices using the [⇒] key. The three available options are “Normal, Expon.” and “Peak Hold”. Normal averaging displays a running average of the last specified number of blocks of data. All blocks are weighed equally in normal averaging. Peak Hold averaging plots the highest or worst case amplitude for all frequencies and holds that value on the display until a higher value is acquired. The displayed amplitude will not decrease thus the term “peak hold.” A peak hold survey will continue to collect data until you stop acquisition by pressing the [ENTER] key. Expon. will show the changes in amplitude as they occur allowing you to view the data in real time. The analyzer collects data until you stop the data collection by pressing the [ENTER] key. Consult your aircraft’s equipment maintenance manual for specific requirements of a vibration survey or for analysis guidelines.

9.1.1.1.6.

Use the [⇓] key to move to the “Blocks” field. Using the keypad, enter the number of data blocks you wish to be used in the calculations. The default is 4. The valid range is 0 to 999. Remember that a higher numbers of blocks, while providing more reliable data, also require more time to acquire and memory to store. The default of 4 is sufficient for most applications. This means that four blocks of data will be acquired before the averaging process is executed. The analyzer then acquires four more blocks and the process repeats until data acquisition is terminated.

9.1.1.1.7.

Use the [⇓] key to move to the “Units” field in the Channel A: row (or rows corresponding to the input channel you will use.). The “Units” field determines the engineering units in which the amplitude or “Y” axis (amplitude) of the

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spectra will be displayed. Consult your equipment maintenance manual for specific requirements of a vibration survey or for analysis guidelines. Use the [⇒] key to select IPS (Inches Per Second), mm/sec (millimeters per second), cm/sec (centimeters per second), Mils (1/1000th of an inch), Microns (1/1000000th of a meter), g’s (equivalent gravities of acceleration), mbars (microbars), Pascals, Volts, cm/s/s (centimeters per second per second) or db. 9.1.1.1.8.

Move to the “Mod” (Modifier) field using the [⇓] key. “Modifier” means unit Modifiers relevant to the (Vibration) engineering units you selected in step 9.1.1.1.7 above. Use the [⇒] key to select either Peak, Pk - Pk (Peak to Peak, also called Double Amplitude), Avg. (Average) or RMS (Root Mean Square). Consult the appropriate equipment maintenance manual for specific requirements of a vibration survey or for analysis guidelines.

9.1.1.1.9.

Use the [⇓] key to move to the “MaxValue” field. Toggle between the selections by using [⇒] key. The full scale indicates the maximum amplitude you reasonably expect to acquire or the maximum amplitude of interest. You should choose an amplitude value that will adequately display the full amplitude of any specified limit. If you do not expect amplitudes in excess of what would normally be experienced for the equipment application, set this field as low as possible while still allowing sufficient space to display the maximum limitations as stated above.

NOTE Encountered amplitudes above this setting may cause the analyzer to overload. It is best to set the “Full Scale Vibration” higher than needed as opposed to lower than needed for this reason. The overload does not cause a fatal error. You can recover from the overload by pressing the [MAIN MENU] key and starting the process again from the beginning. However, avoiding an overload will save you time in the process.

The available selections are: 0.01, 0.02, 0.05, .10, .20, .50, 1.00, 2.00, 5.00, 10.00, 20.00, 50, and 100. This scale refers to the number of engineering units of vibration amplitude specified in step 9.1.1.1.7 above. Repeat steps 9.1.1.1.7 thru 9.1.1.1.9 for each channel being used to acquire vibration data for this survey. NOTE See the Chapter 19, Equipment and Accessory Setup and Troubleshooting, for additional information on installing accessory equipment such as vibration sensors and tachometers.

9.1.1.1.10.

Use the [⇓] key to move to the “Sensor” field for the Channel A: row. Select a sensor from the available sensor list by using [⇒] key. A “None” selection indicates that you do not intend to use the channel. You MUST select at least one sensor for any channel. You may use different sensor types for each individual channel. The analyzer will process the incoming signal and display the vibration in the units and modifiers specified in 9.1.1.1.7and 9.1.1.1.9 above. If you are using an accelerometer for the sensor and have the Units set to mils (displacement), you will require an external integrator for signal processing. Call ACES Systems for more information.

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9.1.1.1.11.

Use the [⇓] key to move to move to the “Desc” (description) field. If the Sensor field contains a sensor selection, use the keypad to enter a description for the sensor such as FRONT, REAR, or a clock position (12:00 for instance). The Desc fields are optional .The available field length is 7 characters. Use the keypad to make an entry in these fields. Repeat steps 9.1.1.1.10 and 9.1.1.1.11 for each channel being used for this survey. Press the [⇓] key repeatedly to skip over the unused Sensor and Desc fields.

9.1.1.2. – Edit Conditions The “Edit Conds” or Edit Conditions, (which corresponds to the [F1] key) selection appears at the bottom left of the “Spectra Setup” banner screen. Press the [F1] key if you wish to define conditions for the survey. Defining conditions for the survey allows you to acquire data in each job for the same optional conditions. If you choose this option, the following “Spectra Conditions” banner screen is displayed.

To input conditions, do the following: 9.1.1.2.1.

Use the [⇑], [⇓], [⇒], and [⇐] keys to navigate the screen and input conditions’ using the keypad.

9.1.1.2.2.

In the “Condition” column, use the analyzer keypad to enter a descriptive name for up to fifteen conditions. You may define up to fifteen individual conditions for which you optionally collect and store data. When defined, these conditions are stored with the setup and are accessed when the setup is selected from the START JOB function

9.1.1.2.3.

When the conditions are completed per your requirements, press [ENTER] to accept and return to the “Spectra Setup” screen.

9.1.1.3. – Speeds Press the [F2] “Speeds” key from the Spectra Setup screen shown above in paragraph 9.1.1. The Speeds option allows you to measure several types of speed inputs for synchronizing 9 Vibration Spectrum Surveys – 9-7

with the vibration input or to provide an entry field for reference where no actual speed input is available. This allows you to view amplitude, in the selected engineering units, relative to the speed of the machine or component being monitored. To complete the Speed option, do the following: 9.1.1.3.1.

Use the [⇑] and [⇓] to move from field to field on this screen and the [⇒] and [⇐] keys to navigate within the field. Make field entries in the fields using the keypad.

9.1.1.3.2.

The column of numbers to the left side of the fields represents the four speed input channels, TACH 1, 2, 3, and 4. In the “Measure” field, use the [⇒], and [⇐] keys to select the type of input. The available selections are: NONE (where no speed input or reference is used), PULSE S-H (Pulse, Single ended – High), Volts S (volts – single ended), PULSE D – H (Pulse Differential – High), Volts D (Volts Differential), PULSE S – L (Pulse, Single ended – Low), PULSE D – L (Pulse Differential – Low), and ENTRY (A user entered speed reference).

9.1.1.3.3.

The “DESC” column is the descriptive name for the tachometer input such as N1, N2, Fan, or HPT. Enter up to five alphanumeric characters in this field. The description should be one that all users of this setup are familiar with and easily understand.

9.1.1.3.4.

The “OFF/100%” column is used when the VOLTS selection is made in the “Measure” column described above. This field is used to enter the offset if measuring a DC voltage or the frequency at 100% of component speed if measuring frequency in Hertz (Hz). Use the keypad to enter the value in the OFF/100% field.

9.1.1.3.5.

In the “FACTOR” column, enter the multiplier for the DC voltage or Hertz to attain the actual component speed. If measuring a voltage, the speed in RPM is equal to OFF + voltage x Factor. If using a Pulse (RPM) input, the RPM is equal to Hertz x Factor. The analyzer assumes the input to be relative to Hz (cycles per second) so that an input of one pulse per revolution (one-per-rev) would

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require a FACTOR of 60 (1 (pulse per-rev) X 60 Hz) to equal Revolutions per minute (RPM). Enter the factor using the keypad. 9.1.1.3.6.

Repeat steps 9.1.1.3.2 through 9.1.1.3.5 for each of the channels required. When all fields are completed per your requirements, press the [ENTER] key to return to the Spectra Setup screen.

9.1.1.4. – Limits Press the [F3] “Limits” key from the Spectra Setup screen shown above in paragraph 9.1.1. The Limits option allows you to enter the limits relative to the speed, or frequency (X coordinate of the spectra) which will place a limit line directly on the spectral plot for quick reference of compliance with operating limits of the machine or component being monitored. To complete the Limits option, do the following:

9.1.1.4.1.

After pressing the [F3] “Limits” key from the Spectra Setup screen, the five function key values will change to those shown in the example screen above. Press the key corresponding to the channel for which you wish to enter limits, [F1] for Channel A, [F2] for Channel B, [F3] for Channel C, [F4] for Channel D, or you may exit back to the Spectra Setup by pressing the [F5] “Back” key. When you select a Channel the Edit Limits for Channel X screen, shown below will be displayed.

9.1.1.4.2.

In the “Edit Limits for Channel X:” screen, use the [⇑] and [⇓] keys to move from field to field and the [⇒] and [⇐] keys to select options or move the cursor within each field. Use the keypad to enter a beginning limit frequency in the “F-low” field. Use the keypad to enter an ending limit frequency in the “Fhigh” field. Select the unit multiplier for the reference frequency in the “Unit” field and finally enter the actual limit, in numbers of engineering units of amplitude, in the “Limit” field. You may then copy the specified limits to all other input channels by pressing the [F1] “CopyToAll” key or to any other individual channel by pressing the corresponding “F” key for “CopyToX”. When all limits are set, press [ENTER] to accept and continue. The second

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screen below illustrates an example of how the limit line is actually depicted on the analyzer screen. Press [ENTER] from the Spectra Setup screen to finish and save the setup.

9.1.2. - Job Identification The next screen displayed is the “Job Identification” banner screen shown in the following illustration. At this point you may turn the analyzer off or continue with the job. All information on this screen is optional; however we highly recommend you fill in as much information as possible to ease the task of storage and retrieval of surveys from AvTrend and the analyzer’s memory. If you have other names stored, you may press the [F1] key to select from a list of stored names, which will then be entered into the “Name” field. Enter information as desired in each of the fields using the analyzer keypad. When all fields are completed as desired, press [ENTER] to continue.

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9.1.3. – Engine Information The “Engine Information” banner screen, shown below, will be displayed. Use the [⇒] key to select a position number for the engine being surveyed. A serial number (“S/N”), “Type” “TSO” (time since new), and “TSN” (time since new) field is available for both an engine and a propeller so that stored surveys can be traced by either component of the powertrain system, where applicable. All fields are optional but we highly recommend you fill in as much information as possible for ease of use in trending, recall, and storage. Navigate (move) between the fields using the [⇓] and [⇑] keys. When all fields are filled as required, press [ENTER] to continue.

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9.1.4. – Microphone Calibration If you have selected to gather data using a microphone, the “Start Engine” screen shown below will appear before data collection. You MUST calibrate the microphone before every use. Differences in temperature and pressure will affect the microphone readings if it is not properly calibrated. Follow the steps below to properly calibrate the microphone.

9.1.4.1. Press the [F4] “Calib” to display a list of all channels which are currently configured to collect data with a microphone similar to the example below. Select the first channel and press [ENTER]. Continue the process for all applicable channels.

9.1.4.2. The analyzer will display the current calibration settings. Press [F1] “Change” to change the current settings.

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9.1.4.3. Enter the Reference Level, typically in decibels (db), and the Reference Frequency, in Hertz (Hz), as found on the calibrator. Plug the microphone into the correct size adapter in the top of the calibrator. Turn the calibrator on and press [ENTER] on the analyzer. NOTE The minimum and maximum Reference Frequency range, displayed below the “Ref. Frequency” cell, is dynamic. If the displayed range does not include the frequency found on the calibrator, you will have to expand the frequency range defined in the setup. See paragraph 9.1.1.1.3 above.

9.1.4.4. After a brief period the analyzer will display the Measurement Level and the Adjustment that will be applied to the measurement. You can change the adjustment by pressing [F1] “Change” and following the above steps again.

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9.1.4.5. As the channels are calibrated, an X will fill the brackets ([X]) indicating that data has been collected. When all channels are calibrated, press [BACKUP] to exit the calibration process and return to the “Start Engine” screen for the current job. Data collection from this point on is no different than with any other vibration sensor.

9.1.4.6. As a way to verify the microphone settings, simply take sample data. Keep the microphone plugged into the calibrator and view the results. The vibration peak should be displayed within the tolerance of the microphone.

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9.1.5. – Select Aircraft Condition The “Select Aircraft Condition” banner screen is displayed. The conditions are those defined in the “Edit Conditions” screen (see section 9.1.1.2 above). Use the [⇑] or [⇓] keys to select the condition you wish to collect. When your choice is highlighted, press [ENTER] to begin collecting data.

9.1.6. – Start Component Start the component you are checking (engine, generator, gearbox, etc.). When the component reaches the desired or normal operating conditions (speed, temp, pressures, etc.), press the [ENTER] key to begin acquiring data. NOTE When the spectra is displayed on screen, you may press the [⇒] key to produce a NORMAL CURSOR immediately at the highest displayed amplitude frequency. The [⇑] or [⇓] keys may also be used immediately to EXPAND or SHRINK the Y scale.

9.1.7. - Collecting Data When the spectra is displayed, you will also see four function boxes at the bottom of the screen (see following figure) corresponding to the position of the [F1], [F2], and [F5] keys directly below them. The boxes read “Options,” “Pause,” “Overall” and “Restart.”

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Once any of these “F” key options are selected, both the screen and the corresponding “F” key functions change. With each selection, the “F” keys offer different options (e.g., Expand, Shrink, X scale) for viewing the spectra. The “F” key functions for viewing spectra are described in the following steps. 9.1.7.1. Pressing the [F1] “Options” key will change the [F1], [F2], [F3], [F4], and [F5] boxes to read “Cursor,” “X scale,” “Y scale,” “View,” and “Cancel” respectively as shown in the figure below.

9.1.7.2. Pressing the [F1] “Cursor” key will change the [F1], [F2], [F3], and [F5] boxes to read “Normal,” “Harmonic,” “None,” and “Cancel” respectively. The functions of the “F” keys will continue to change as the screens change. 9.1.7.3. Pressing the [F1] “Normal” key will produce a normal cursor on the screen accompanied by an X and Y scale value readout box in the upper right corner of each displayed spectra (see the following figure). These X and Y values are relative

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to the current position of the cursor only. The cursor can be moved along the X (horizontal) axis of the spectra by pressing the [⇐] or [⇒] keys. Hold down the key for large and rapid incremental changes. The value of the X-axis (frequency) and Yaxis (amplitude) will be displayed for the current position of the cursor. Incremental values are determined by the number of lines of resolution specified in the setup screen. 9.1.7.4. Pressing the [F2] “Harmonic” key will produce multiple harmonic cursors according to the specified frequency range. When this key is pressed, cursors will appear to the right of the fundamental frequency identified by the leftmost cursor. For example, if the fundamental frequency is 300 Hz cursors will be placed at 2X (600 Hz) 3X (900 Hz) 4x (1200 Hz) and so on until the upper frequency limit of the screen is met. When the primary cursor (for the fundamental frequency) is moved, the multiple harmonic cursors will automatically follow the movement and position themselves at the new multiple of the fundamental frequency. To remove the harmonic cursors, repeat steps 9.1.7.1 to 9.1.7.2 above. At step 9.1.7.3, press either the [F1] “Normal” or [F5] “None” key and the harmonic cursor will be replaced by your selection. 9.1.7.5. Pressing the [F5] “None” key will remove either a normal or harmonic cursor if currently displayed on screen. The four boxes above the [F1], [F2], [F4] and [F5] keys will return to “Options,” “Pause,” “Overall” and “Restart” respectively. If no cursor is displayed when pressing this key, only the box nomenclature will change.

9.1.7.6. Pressing the [F2] “X scale” key will change the [F1], [F2], [F3] and [F5] boxes to read “Expand,” “Default,” “Shrink,” and “Cancel” respectively as shown in the following figure.

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9.1.7.7. Pressing the [F1] “Expand” key will expand the X scale of the spectra, in effect enlarging the viewing area. You might think of this function as a “Zoom Out” feature. The center of the Expanded view will be the position of the cursor prior to pressing the [F1] key. If the view is already at the maximum range of the specified X scale range, no scaling change will occur. However, the cursor will be displayed and the X, Y, and “Ovr” (Overall) values will be shown in the upper right corner of the screen. The [F1], [F2], [F4] and [F5] boxes will return to the format described in step 9.1.7.5 above. If you wish to Expand the X scale even further, retrace the steps from that point as described in the text. 9.1.7.8. Pressing the [F2] “Default” key will return the X scale and Y scale to the values specified in the setup. This is a quick and easy way to return all expanded and shrunken scales to that default value without the necessity of numerous keystrokes. If the X and Y scales are already at the setup values when the [F2] Default key is pressed, the four function boxes will return to “Options,” “Pause,” “Overall” and “Restart”. No other changes will occur. 9.1.7.9. Pressing the [F3] “Shrink” key will lower the X scale of the spectra, in effect shrinking the viewing area. You might think of this function as a “Zoom In” feature. If the view is already at the minimum of the specified X scale range, no scaling change will occur. However, the cursor will be displayed and the X, Y, and “Ovr” (Overall) values will be shown in the upper right corner of the screen. The [F1], [F2], [F4] and [F5] boxes will return to the format described in step 9.1.7.5 above. If you wish to Shrink the X scale even further, retrace the steps from that point as described in the text. 9.1.7.10. Pressing the [F5] “Cancel” key will cancel the selection and return the “F” keys to the format described in step 9.1.7.5 above. 9.1.7.11. Pressing the [F3] “Y scale” key in step 9.1.7.6 above changes the [F1], [F2], [F3] and [F5] boxes to read “Expand,” “Default,” “Shrink,” and “Cancel” respectively (see step 9.1.7.7 above).

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9.1.7.12. Pressing the [F1] “Expand” key will expand the Y scale of the spectra, in effect enlarging the viewing area. You might think of this function as a “Zoom Out” feature. If the view is already at the maximum range of the specified Y scale range, no scaling change will occur. However, the cursor will be displayed and the X, Y, and Ovr: (Overall) values will be shown in the upper right corner of the screen. The [F1], [F2], [F4] and [F5] boxes will return to the format described in step 9.1.7.5 above. If you wish to Expand the Y scale even further, retrace the steps from that point as described in the text. 9.1.7.13. Pressing the [F2] “Default” key will return the X scale and Y scale to the values specified in the setup. This is a quick and easy way to return all expanded and shrunken scales to that default value without the necessity of numerous keystrokes. If the X and Y scales are already at the setup values when the [F2] Default key is pressed, the four function boxes will return to “Options,” “Pause,” “Overall” and “Restart.” No other changes will occur. 9.1.7.14. Pressing the [F3] “Shrink” key will lower the Y scale of the spectra, in effect shrinking the viewing area. You might think of this function as a “Zoom In” feature. If the view is already at the minimum of the specified Y scale range, no scaling change will occur. However, the cursor will be displayed and the X, Y, and “Ovr” (Overall) values will be shown in the upper right corner of the screen. The [F1], [F2], [F4] and [F5] boxes will return to the format described in step 9.1.7.5 above. If you wish to shrink the Y scale even further, retrace the steps from that point as described in the text. 9.1.7.15. Pressing the [F5] “Cancel” key will cancel the selection and return the “F” keys to the format described in step 9.1.7.5 above. 9.1.7.16. Pressing the [F4] “View” key in step 9.1.7.1 above will allow you to “zoom” in to view a spectral plot from a single channel. The function keys will change to list the “Description” assigned to each vibration channel. Press the key below the name of the channel you want to view. Press [F4] “View” again then select [F5] “All” to return to the display showing all of the active vibration channels.

9.1.8. - Storing Data When you press [ENTER] to store the spectral plot from any screen as described in section you will be presented with the screen shown below. On this screen you can decide to “Store the data?” by pressing the [F1] “Yes” key. If you wish to retake the data for any reason, press the [F5] “No” key and you will be returned to the “Select Aircraft Condition” screen.

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The “Select Aircraft Condition” banner screen is again displayed as shown in the following figure. Notice that the condition for which you just collected and stored data now has an “X” immediately to the left of the defined condition. This alerts the user that data has been collected and stored for this condition. This does not preclude you from selecting and acquiring new data for this condition. However, if you choose to store the data, the previously stored data will be written over and may not be recovered.

At this point you may select a new condition and repeat this procedure starting from section 9.1.4 until all required data is collected. When the last data point is collected the analyzer will display the screen shown below. Press [F5] “Continue” to terminate the job.

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It is also possible to quit the job without data being taken for all defined conditions by pressing the [F5] “Quit Job” key. You will not be able to resume this job at this point. You will be returned to the Vibration Spectrum Survey banner screen where you may Start a new job.

9.2. - Resume Job

When you select “Resume Job” from the “Vibration Spectrum Surveys” banner screen menu, the “Incomplete Jobs” banner screen will be displayed. Incomplete jobs are listed by name, preceded by an asterisk. Select the job you wish to complete and the analyzer will return you to the point where the in-progress job was stopped, allowing you to complete it.

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9.3. - Manage Jobs Selecting “Manage Jobs” from the “Vibration Spectrum Surveys” banner screen menu presents several sub-menu choices to choose from. These choices allow you to “manage” previously completed job data you have stored in the analyzer.

9.3.1. - Review Selecting the “Review” option presents a list of stored jobs on the “Job List” banner screen. You can select one job for on-screen viewing. When viewing is complete, press the [BACKUP] or [ENTER] key to exit the screen.

9.3.2. - Delete The “Delete” option presents a list of stored jobs on the “Job List” banner screen. From the list, you may select one job for deletion. After making your selection, the “Delete Job” banner screen will appear, asking you to verify your intent to delete the selected job by pressing the [F1] key for “Yes” or the [F5] key for “No.” You may wish to transfer the data to AvTrend for reference or permanent record prior to deleting. Once deleted, the job cannot be retrieved from the analyzer.

9.3.3. - Delete All The “Delete All” option will delete all currently stored jobs. After selecting this option, the “Delete All Job” banner screen will appear, asking you to verify your intent to delete all the jobs by pressing the [F1] key for “Yes” or the [F5] key for “No.” You may wish to transfer the data to AvTrend for reference or permanent record prior to deleting. Once deleted, the jobs cannot be retrieved from the analyzer.

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9.4. - Manage Setups

Selecting “Manage Setups” from the “Vibration Spectrum Surveys” banner screen menu presents several sub-menu choices to choose from. These choices allow you to “manage” job setups you have stored previously in the analyzer.

9.4.1. - Edit Selecting the “Edit” function displays the “Setup List” screen. Select the setup you wish to edit. The screen will display the “Spectra Setup” screen. Edit the setup as necessary and press [ENTER] to store and exit the edited setup screen. DO NOT use the BACKUP key to exit the screen following changes made in the setup with the Edit mode. You must use the [ENTER] key to progress to the end of the setup for the changes to be permanent.

9.4.2. – New If you select “New,” the “Spectra Setup” screen is displayed. See section 9.1.1 for instructions on how to proceed from this point.

9.4.3. - Delete The “Delete” option presents you with a list of stored setups. From the list, you may select one setup for deletion. If you wish to delete all stored setups, you must delete them individually. After making your selection, you will be asked to verify your intent to delete the selected job by pressing the [F1] key for “Yes,” or the [F5] key for “No.” We highly recommend you download the setup(s) for reference or permanent record prior to deleting them. Once deleted, the setups cannot be retrieved from the analyzer. If the setup is locked, indicated by a small padlock icon to the left of the setup name, the setup can still be deleted but not edited. Setups can only be locked as a function of AvTrend.

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Chapter 10 Overall Vibration Surveys (Revision 3.01, Oct 2012)

“Overall Vibration Surveys” is an analyzer function that is accessed from the analyzer’s Main Menu banner screen as shown in the illustration below. Selecting this function from the main menu brings up the “Overall Vibration Surveys” banner screen menu. Each of the listings on this banner screen menu is an option within the “Overall Vibration Surveys” function. Descriptions of each of these options follow, along with the information required to complete the menu screens within the options, and the steps necessary to perform the overall vibration surveys function.

The Overall Vibration Survey option allows the user to rapidly complete and store overall vibration surveys using the “Overall Vibration Setup” feature (described in section 10.1.1 below). With the setup feature you may complete surveys on several different components without manually entering the setup data between surveys. Each job is unique and very quick.

10.1. - Start Job Selecting “Start Job” from the “Overall Vibration Surveys” banner screen allows you to begin an overall vibration survey. When you select this option, one of two screens will appear next depending on whether you are starting a job from scratch or an incomplete job still exists in the analyzer’s memory.

If you have previously saved setups in the analyzer’s memory, a screen displaying the list of setups, as shown below, will be displayed. If no setups are stored, or if you choose “New” by pressing the [F1] key from the Setup List screen, the analyzer will display the “Overall Vibration Setup” banner screen. If you select from the list, you proceed to the “Job Identification” banner screen described in section 10.1.2. Instructions for completing the “Overall Vibration Setup” banner screen appear in the following Section, 10.1.1.

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If another job was in progress but was not completed, the “Incomplete Job” banner screen will be displayed to inform you of this. The analyzer will then display a message prompting you to verify that you want to complete the in-progress job or that you want to ignore it and begin a completely new job. This verification prevents you from accidentally erasing data from an in-progress job. The screen will display the message “The last job performed is incomplete. Do you want to RESUME work on it?”

You must then choose a “Yes” or “No” answer by pressing the corresponding [F1] key, for “Yes”, or the [F5] key, for “No.” The “Yes” answer will return you to the point where the inprogress job was stopped and allow you to complete it. If you choose the “No” answer, the screen will then display the “Overall Vibration Setup” banner screen so you can program a new job setup or if you have previously-saved setups stored in the analyzer’s memory, a screen displaying the list of setups will be displayed. You can then select a setup from this list. If you select from the list, you proceed to the “Job Identification” banner screen described in section 10.1.2. Instructions for completing the “Overall Vibration Setup” banner screen appear in the following Section, 10.1.1.

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NOTE The analyzer will store Setups as long as available memory remains. If you are attempting to store a survey that will exceed the analyzer’s memory capacity, the analyzer will display a message saying “You must delete an item before adding a new one.” Press the [BACKUP] key and select “Manage Setups” to delete the Setup of your choosing. It is advisable to transfer setups to AvTrend for storage and, when necessary, retrieval.

10.1.1. – Overall Vibration Setup The “Overall Vibration Setup” banner screen allows you to define and store an overall vibration survey job. As shown in the figure below, some fields in this screen have default values that appear automatically. You can use this information if appropriate or input your own specific setup information using the keypad. (Refer to Chapter 3, “Using the Viper 4040 Analyzer” if you are unfamiliar with using the keypad.) The analyzer will display the “Overall Vibration Setup” banner with default values or values entered from the previous job such as those shown in the figure below.

10.1.1.1.

To complete the “Overall Vibration Setup” banner screen, do the following

10.1.1.1.1.

In the “Name:” field, use the analyzer keypad to enter a name for the overall vibration survey setup. (Refer to Chapter 3, “Using the Viper 4040 Analyzer” if you are unfamiliar with using the keypad.) The name should be one of your choosing which you will easily recognize and associate with this setup. The airframe or engine name such as “AS350 or TFE731-2” is best to use when naming a Setup.

10.1.1.1.2.

Use the [⇓] key to move to the frequency units field. Determine if the required frequency units are revolutions per minute (RPM) or cycles per second (Hz), then use the [⇒] key to “toggle” between the two selections in this field.

10.1.1.1.3.

Using the [⇓] key, move to the Minimum Frequency and Maximum Frequency field. (These are the two unmarked fields immediately to the right of the

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frequency units filed and separated by the word “to”.) Using the keypad, enter the minimum and maximum frequency values according to the requirements for the job. For instance, if the frequency of interest is 300 Hz, choose a minimum and maximum frequency that will place the 300 Hz in the center of the range. The minimum could be 250 Hz and the maximum 350 Hz for example. You should also consider other factors such as Harmonics. If you want multiples of the fundamental frequency included in the frequency range, determine to what extent that need is (1X, 2X, 3X, and so on) then extend the frequency range to include it. For example, 300Hz is the frequency of interest, the fundamental frequency. If you want 3X harmonics included in the frequency range you must multiply the fundamental frequency (300 Hz) X the harmonic range (3X) and arrive at an upper range of 900 Hz. After you have entered the appropriate minimum and maximum frequency values, use the [⇓] to move to the next field. 10.1.1.1.4.

The “Units” field determines the engineering units in which the amplitude or “Y” axis (amplitude) of the spectra will be displayed. Consult your equipment maintenance manual for specific requirements of a vibration survey or for analysis guidelines. Use the [⇒] key to select g’s (equivalent gravities of acceleration), IPS (Inches Per Second), mm/sec (millimeters per second), cm/sec (centimeters per second), Mils (1/1000th of an inch), Microns (1/1000000th of a meter), or m/s/s (meters per second per second) or cm/s/s (centimeters per second per second). Use the [⇓] key to move to the next field.

10.1.1.1.5.

The “Mod” field is an abbreviation for the unit Modifiers relevant to the engineering units specified in step 10.1.1.1.4 above. Use the [⇒] key to select either Peak, Pk - Pk (Peak to Peak, also called Double Amplitude), Avg. (Average) or RMS (Root Mean Square). Consult the appropriate equipment maintenance manual for specific requirements of an overall vibration survey or for analysis guidelines. Use the [⇓] key to move to the next field.

10.1.1.1.6.

In the “MaxValue” field, toggle between the possible selections by using the [⇒] key. This value indicates the maximum amplitude you expect to acquire or the maximum amplitude of interest. You should choose an amplitude that will adequately display the full amplitude of any specified limit. If you do not expect amplitudes in excess of what would normally be experienced for the equipment application, set this field as low as possible while still allowing sufficient space to display the maximum limitations as stated above. Repeat steps 10.1.1.1.4 through 10.1.1.1.6 for all the channels you are planning to use during the survey. Then press the [⇓] key to move to the “Sensor” field.

10.1.1.1.7.

Select a “Sensor” from the available sensor list by using [⇒] key. A “None” selection indicates that you do not intend to use the channel and the “Desc” (description) field will be skipped. If the Sensor field contains a sensor selection, use the [⇓] key to move to the “Desc” fields.

10.1.1.1.8.

The “Desc” fields are optional fields that are not required to be filled in to use the Overall Vibration Survey function; however, this information will aid you

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in differentiating the reading on one channel from another. The Channel A, B, C, and D descriptions likewise should be a description of your choosing which you and your co-workers easily understand, such as “Lateral,” “Vertical,” or “No. 1 Gen” and “No. 2 Gen”. All other fields are not optional and must be selected or filled in. NOTE Encountered amplitudes above this setting may cause the analyzer to overload. An overload will result in spurious harmonics and may cause unusual termination of the job. It is best to set the “Full Scale Vibration” higher than needed as opposed to lower than needed for this reason. The overload does not cause a fatal error. You can recover from the overload by pressing the [MAIN MENU] key and starting the process again from the beginning. However, avoiding an overload will save you time in the process.

The available selections are: 0.01, 0.02, 0.05, .10, .20, .50, 1.00, 2.00, 5.00, 10.00, 20.00, 50. and 100. This scale refers to the number of engineering units of vibration amplitude specified in step 10.1.1.1.4 above. NOTE See the Chapter 15, Equipment and Accessory Setup and Troubleshooting, for additional information on installing accessory equipment such as vibration sensors and tachometers.

10.1.1.2. – Conditions The “Conds” (which corresponds to the [F1] key) selection appears at the bottom left of the “Overall Vibration Setup” banner screen. Press the [F1] key if you wish to define conditions for the survey. If you choose this option, the following “Conditions” banner screen is displayed.

To input conditions, do the following:

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10.1.1.2.1. Use the [⇑] and [⇓] to move from field to field on this screen and the [⇒] and [⇐] keys to navigate within the field or toggle between selections. Make field entries in the fields using the keypad. 10.1.1.2.2. In the “Condition” column, use the analyzer keypad to enter a descriptive name for up to fifteen conditions. You may define up to fifteen individual points at which you collect and optionally store data. When defined, these conditions are stored with the setup and are accessed when the setup is selected. 10.1.1.2.3. When the conditions are completed per your requirements, press [ENTER] to accept and exit back to the “Overall Vibration Setup” screen. 10.1.1.3. – Speeds The “Speeds” (which corresponds to the [F2] key) selection appears at the bottom, second from the left, of the “Overall Vibration Setup” screen. Press the [F2] key if you wish to define speeds for the survey. If you choose this option, the following “Speed Inputs Setup” banner screen is displayed. There are four rows, 1, 2, 3, and 4 indicating the tachometer input channel. There are four columns, Measure, DESC, OFF/100%, and Factor. These inputs are described below.

To define the Speed Inputs Setup, do the following: 10.1.1.3.1.

Use the [⇑] and [⇓] to move from field to field on this screen and the [⇒] and [⇐] keys to navigate within the field or toggle between selections. Make field entries in the fields using the keypad.

10.1.1.3.2.

In the “Measure” column, use the [⇒], and [⇐] keys to select from Pulse S-H, Volts S, Pulse D-H, Volts D, Pulse S-L, Pulse D-L, or None indicating the tachometer input type for the corresponding tachometer input channel 1 through 4. “None” is selected when the corresponding tach channel is not being used.

10.1.1.3.3.

In the “DESC” (description) column, enter a description for the corresponding tachometer input channel. The description should be a name commonly

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understood by all users of this setup. Use the analyzer keypad to input the description. For instance, if the input is in Hertz (cycles per second), the description might be Hz1. If the input is in a raw voltage, the input description might be DC2 indicating a Direct Current input on Channel 2. You might also choose common terminology such as N1, N2, Fan, etc. 10.1.1.3.4.

In the “OFF/100%” column you should enter the DC OFFSET when measuring a DC voltage, if known. If you are measuring a Hertz input enter the expected Hz @ 100% speed.

10.1.1.3.5.

In the “FACTOR” column, enter the multiplier for the voltage or frequency to result in a 100% speed reading for the component being measured. The resultant speed indication is based on either OFFSET + VOLTS x FACTOR, or Hz x FACTOR.

10.1.1.3.6.

When all fields are completed per your requirements, press ENTER. The screen will return to the “Overall Vibration Setup” banner screen. Press ENTER again.

10.1.2. - Job Identification The next screen displayed is the “Job Identification” banner screen shown in the following illustration. All information on this screen is optional; however we highly recommend you fill in as much information as possible to ease the task of storage and retrieval of surveys. If you have entered names into the analyzer previously, you may press the [F1] key to select from a list of stored customer names, which will then be entered into the “Name” field. When all fields are completed as desired, press [ENTER] to continue.

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10.1.3. – Engine Information The “Engine Information” banner screen is displayed as shown below. A serial number (“S/N”) and “Type” field are available for both an engine and a propeller so that stored surveys can be traced by either component of the powertrain system. All fields are optional but we highly recommend you fill in as much information as possible for ease of use in trending, recall, and storage. Navigate (move) between the fields using the [⇓] and [⇑] keys. All fields are entered from the keypad with the exception of the “Pos” (Position) field, which is a selection field. The position indicates the position on the airplane of the engine, propeller or subcomponent. Using the [⇒] key, select positions from 1 through 4. The “TSO” and “TSN” fields for “Time Since New” and “Time Since Overhaul” are optional fields. When all fields are filled as required, press [ENTER] to continue.

10.1.4. – Select Aircraft Condition The “Select Aircraft Condition” banner screen is displayed. The conditions are those defined in the “Edit Conditions” screen (see section 10.1.1.2). Use the [⇑] or [⇓] keys to select the condition you wish to collect. When your choice is highlighted, press [ENTER] to begin collecting data.

10.1.5. – Start Component Start the component you are checking (engine, generator, gearbox, etc.). When the component reaches the desired operating condition (speed, temp, etc.), press the [ENTER] key to begin acquiring data. NOTE When the spectra is displayed on screen, you may press the [⇑] or [⇓] keys to produce

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a NORMAL CURSOR immediately at the highest displayed amplitude frequency. The [⇐] and [⇒] keys may also be used immediately to EXPAND or SHRINK the Y scale.

10.1.6. - Collecting Data When the data screen is displayed, you will also see one function box at the bottom of the screen (see following figure) corresponding to the position of the [F5] key. The box reads “Reset.”

Pressing the “[F5]” key will delete the collected data, zero out the affected fields and begin anew. As shown in the screen above, the analyzer will report the total number of Samples taken and the engineering Units of vibration plus the modifier for those samples. Lower on the screen, there are two columns corresponding to the “Current” input measurements and the “Maximum” which is the highest amplitude reading from the number of Samples taken. There will be a number of rows corresponding to the number of input channels specified in the Setup for this job.

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10.2. - Resume Job

When you select “Resume Job” from the “Overall Vibration Surveys” banner screen menu, the “Incomplete Jobs” banner screen will be displayed. Incomplete jobs are listed by name, preceded by an asterisk. Select the job you wish to complete and the analyzer will return you to the point where the in-progress job was stopped, allowing you to complete it.

10.3. - Manage Jobs Selecting “Manage Jobs” from the “Overall Vibration Surveys” banner screen menu presents several sub-menu choices to choose from. These choices allow you to “manage” previously completed job data you have stored in the analyzer.

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10.3.1. - Review Selecting the “Review” option presents a list of stored jobs on the “Job List” banner screen. You can select one job for on-screen viewing. When viewing is complete, press the [BACKUP] or [ENTER] key to exit the screen.

10.3.2. - Delete The “Delete” option presents a list of stored jobs on the “Job List” banner screen. From the list, you may select one job for deletion. After making your selection, the “Delete Job” banner screen will appear, asking you to verify your intent to delete the selected job by pressing the [F1] key for “Yes” or the [F5] key for “No.” You may wish to download the job for reference or permanent record prior to deleting. Once deleted, the job cannot be retrieved from the analyzer.

10.3.3. - Delete All The “Delete All” option will delete all currently stored jobs. After selecting this option, the “Delete All Job” banner screen will appear, asking you to verify your intent to delete all the jobs by pressing the [F1] key for “Yes” or the [F5] key for “No.” You may wish to download the jobs for reference or permanent record prior to deleting. Once deleted, the jobs cannot be retrieved from the analyzer.

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10.4. - Manage Setups

Selecting “Manage Setups” from the “Overall Vibration Surveys” banner screen menu presents several sub-menu choices to choose from. These choices allow you to “manage” job setups you have stored previously in the analyzer.

10.4.1. - Edit Selecting the “Edit” function displays the “Setup List” screen. Select the setup you wish to edit. The screen will display the “Spectra Setup” screen. Edit the setup as necessary and press [ENTER] to store and exit the edited setup screen.

10.4.2. – New If you select “New,” the “Overall Vibration Setup” screen is displayed. See section 10.1.1 for instructions on how to proceed from this point.

10.4.3. - Delete The “Delete” option presents you with a list of stored setups. From the list, you may select one setup for deletion. If you wish to delete all stored setups, you must delete them individually. After making your selection, you will be asked to verify your intent to delete the selected job by pressing the [F1] key for “Yes,” or the [F5] key for “No.” We highly recommend you download the setup(s) to your PC for reference or permanent record prior to deleting them. Once deleted, the setups cannot be retrieved from the analyzer.

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Chapter 11 Transient Vibration Survey (Revision 3, Oct 2012) “Transient Vibration Survey” is an analyzer function that is accessed from the analyzer’s Main Menu banner screen as shown in the illustration below. Selecting this function from the main menu brings up the “Transient Vibration Survey Jobs” banner screen menu. Each of the listings on this banner screen menu is an option within the “Transient Vibration Survey” function. Descriptions of each of these options follow, along with the information required to complete the menu screens within the options, and the steps necessary to perform the transient vibration survey function.

The Transient Vibration Survey option allows the user to rapidly complete and store a transient vibration survey using the “Setup” feature (described in section 11.1.1 below). With the setup feature you may complete surveys on several different components without manually entering the setup data between surveys. Each job is unique and very quick.

11.1.

- Start Job

Selecting “Start Job” from the “Transient Vibration Survey Jobs” banner screen allows you to begin a transient vibration survey. When you select this option, one of two screens will appear next depending on whether you are starting a job from scratch or whether an incomplete job still exists in the analyzer’s memory.

If you have previously saved setups in the analyzer’s memory, a screen displaying the list of setups, as shown below, will be displayed. If no setups are stored, or if you choose “New” by pressing the [F1] key from the Setup List screen, the analyzer will display the “Transient Survey Setup” banner screen. If you select from the list, you proceed to the “Job Identification” banner screen described in section 11.1.2. Instructions for completing the “Transient Survey Setup” banner screen appear in the following Section, 11.1.1.

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If another job was in progress but was not completed, the “Incomplete Job” banner screen will be displayed to inform you of this. The analyzer will then display a message prompting you to verify that you want to complete the in-progress job or that you want to ignore it and begin a completely new job. This verification prevents you from accidentally erasing data from an in-progress job. The screen will display the message “The last job performed is incomplete. Do you want to RESUME work on it?”

You must then choose a “Yes” or “No” answer by pressing the corresponding [F1] key, for “Yes,” or the [F5] key, for “No.” The “Yes” answer will return you to the point where the inprogress job was stopped and allow you to complete it. If you choose the “No” answer, the screen will then display the “Transient Survey Setup” banner screen so you can program a new job setup or if you have previously-saved setups stored in the analyzer’s memory, a screen displaying the list of setups will be displayed. You can then select a setup from this list. If you select from the list, you proceed to the “Job Identification” banner screen described in section 11.1.2. Instructions for completing the “Transient Survey Setup” banner screen appear in the following Section, 11.1.1.

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NOTE The analyzer will store Setups as long as available memory remains. If you are attempting to store a survey that will exceed the analyzer’s memory capacity, the analyzer will display a message saying “You must delete an item before adding a new one.” Press the [BACKUP] key and select “Manage Setups” to delete the Setup of your choosing. It is advisable to transfer setups to AvTrend for storage and, when necessary, retrieval.

11.1.1. – Transient Survey Setup The “Transient Survey Setup” banner screen allows you to define and store a transient vibration survey setup. As shown in the figure below, some fields in this screen have default values that appear automatically. You can use this information if appropriate or input your own specific setup information using the keypad. (Refer to Chapter 3, “Using the Viper 4040 Analyzer” if you are unfamiliar with using the keypad.) The analyzer will display the “Transient Survey Setup” banner with default values or values entered from the previous job such as those shown in the figure below.

To complete the “Transient Survey Setup” banner screen, do the following: 1. Using the keypad, enter a name for the transient vibration survey setup. (Refer to Chapter 3, “Using the Viper 4040 Analyzer” if you are unfamiliar with using the keypad.) 2. Using the [⇓] key, move to the frequency unit field which is defaulted to “RPM”. The two selections are RPM and Hz. Determine if the display frequency units are to be in revolutions per minute (RPM) or cycles per second (Hz), then use the [⇒] key to “toggle” between the two selections in this field. If the frequency unit you desire is not currently in the field, press the [⇒] key to toggle between the two choices until your unit is shown in the field. 3. Use the [⇓] key to move to the minimum frequency field, immediately to the right of the frequency units field. Use the analyzer keypad to enter the minimum frequency of interest for this survey relative to the frequency units selected in step 2 above. If you 11-4 – Transient Vibration Surveys 11

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desire a high pass frequency, such as 40 Hz, the minimum frequency field should reflect this as the minimum frequency of interest. 4. Use the [⇓] key to move to the maximum frequency field, immediately to the right of the word “to” and the minimum frequency field. Use the analyzer keypad to enter the highest frequency of interest for this survey relative to the frequency units selected in step 2 above. You should also consider other factors such as Harmonics. If you want multiples of the fundamental frequency included in the frequency range, determine to what extent that need is (1X, 2X, 3X, and so on) then extend the frequency range to include it. For example, 300Hz is the frequency of interest, the fundamental frequency. If you want 3X harmonics included in the frequency range you must multiply the fundamental frequency (300 Hz) X the harmonic range (3X) and arrive at an upper range of 900 Hz. 5. Use the [⇓] key to move to the “Resolution:” field. Resolution is the number of lines of resolution for the spectra display. Press the [⇒] key to increase the number of lines up to 6400. Normally 400 to 800 lines are sufficient for spectra. Higher resolutions may be used when separation of two frequencies of very close proximity is required. 6. Use the [⇓] key to move to the “Display” field. Use the [⇒] key to select the Display type. Your selection in this field will determine how the initial data is displayed on the analyzer screen during acquisition. A selection of “Overall” will provide a numeric value reading while a selection of “Spectra” will display a full spectral graph of the acquired data. Either selection will cause the analyzer to begin recording data as soon as the data acquisition process begins. It should be noted that a setting of “Overall” in this field will provide faster data updates and a higher accuracy due to the lower demand on the digital signal processors for this type of display. The display can be toggled between the two during the job. See Section 11.1.7 for instructions on switching between the two display modes. The data can then be review or played back after recorded in full spectral or waterfall modes. The selection of “Overall w/Record” or “Spectra w/Record” allows the user to begin the data acquisition process, view the data and confirm the values then select the point at which data will begin to get recorded. 7. Use the [⇓] key to move to the “Every” field. Enter a sample rate in numbers of samples per millisecond. The sample rate determines how often the analyzer acquires the data. A setting of “0” tells the analyzer to update as rapidly as possible for existing conditions. A setting 1000 tells the analyzer to sample once every second. If you are acquiring a “start up” survey, where the engine acceleration is automatic and very rapid, you may wish to set the rate at shorter intervals, 50 or 20 for instance. If you can control the acceleration or deceleration of the engine (or component being checked) you may wish to set the rate at longer intervals, 200 or 500 for instance. 8. Use the [⇓] key to move to the “Define related tachs?” field. This field will allow you to define correlations between vibration channels and tach signals. The default field value is which correlates all vibration channels with all tach inputs. By selecting , using the [⇒] key, additional Tach selection fields will appear to the right of the “Max” fields in the upper set of “Channel” definition rows. See step 12 below for information about filling in additional fields that will appear as a result of your selection. 9. Use the [⇓] key to move to the “Units” column of the “Channel A:” row. Select an engineering unit from the available list by using [⇒] key. A selection of “None” in the

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field indicates there will be no input to the Channel (A, B, C, or D) adjacent to the field where the word “None” appears. Your selection determines the engineering units in which the vibration spectra will be displayed. Each channel is independent of the other three so that the type of unit can vary between channels. For example, you may select IPS in channel A for velocity, gs in channel B for acceleration, Mils in channel C for displacement, and db in Channel D for acoustics. Any selection, other than “None” will automatically provide additional selection fields in the “Mod” and “MaxValue” columns. 10. Use the [⇓] key to move to the “Mod” field. The “Mod” field determines the modifier that will be applied to the engineering units of the spectra. Consult your equipment maintenance manual for specific requirements of a vibration survey or for analysis guidelines. Use the [⇒] key to select the modifier, such as Peak, Peak-to-Peak (Pk-Pk), RMS or Average. Consult the appropriate equipment maintenance manual for specific requirements of an overall vibration survey or for analysis guidelines. 11. Move to the “MaxValue” field using the [⇓] key. “MaxValue” means the Maximum Amplitude value, relative to the engineering units selected in step 9 above, you expect to see in this job. Use the [⇒] key to select a maximum value above, but not less than the value you expect to see. 12. Use the [⇓] key to move to the “Tach x” field as appropriate. When the “Define related tachs?” field in step 8 above is set to “Yes” and the field is exited, the “Tach x” portion of the Channel line will become visible. Use the [⇓] key to move from field to field even though the fields are arranged horizontally. Once a field is highlighted, use the [⇒] key to select (display a dot in the box) or deselect (erase a dot in the box) the Tach input you would like to correlate with the vibration channel described by this line line. NOTE Encountered amplitudes above this setting may cause the analyzer to overload. An overload will result in spurious harmonics and may cause unusual termination of the job. It is best to set the “Full Scale Vibration” higher than needed as opposed to lower than needed for this reason. The overload does not cause a fatal error. You may recover from the overload by pressing the [MAIN MENU] key and starting the process again from the beginning. However, avoiding an overload will save time in the process.

13. Repeat steps 9 through 12 above for each of the four channels per your requirements. 14. Move to the “Sensor” column in the Channel A: row by using the [⇓] key. Use the [⇒] key to select the sensor you will use for this channel. If the sensor you are using is not in the selection list, you must enter the sensor setup. See Chapter 18 for entering a sensor setup. 15. Move to the “Desc” (description) column in the Channel A: row by using the [⇓] key. Use the analyzer keypad to enter a six character description for the channel such as “#1 Eng”, or “Fan”. 16. Repeat steps 14 and 15 for each of the four channels per your requirements.

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11.1.1.1. – Config The “Config” (which corresponds to the [F1] key) selection appears at the bottom left of the “Transient Survey Setup” banner screen. Press the [F1] key if you wish to define Conditions, Speeds, and Parameters for the survey. If you choose this option by pressing the [F1] “Config” key, the Transient Survey Setup banner screen does not change, however, the definitions for the function keys at the bottom of the screen will change as shown in the example below.

The “Conds” (conditions) key, which corresponds to the [F1] key, will display the Conditions screen as shown in the example below.

To input conditions, do the following: 1.

Use the [⇑] and [⇓] keys to navigate the screen and input data from the keypad or select conditions’ using the [⇒], and [⇐] keys.

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2.

In the “Condition” column, use the analyzer keypad to enter a descriptive name for up to fifteen conditions. You may define up to fifteen individual points at which you collect and optionally store data. When defined, these conditions are stored with the setup and are accessed when the setup is selected and set into motion. 3.

In the Spectrum Column, select from NONE, PEAK HOLD, AVERAGE, WATERFALL, or TIME per your requirements. Note The WATERFALL option must be selected to utilize the playback feature of the analyzer and AvTrend.

4.

In the “Max. Time” column, enter the maximum amount of time, in seconds, that you wish to automatically collect and stop data collection for that condition. This option is used as both a time and memory management tool. It also allows the analyzer a specific time block to collect data at the specified condition. Following data acquisition for the specified amount of time, data collection will terminate allowing you to proceed to the next condition. A setting of “0” will allow the analyzer to acquire data until terminated by the user pressing [ENTER].

5.

When all conditions are completed per your requirements, press [ENTER] to accept and exit back to the “Transient Survey Setup” screen.

11.1.1.2. – Speeds The “Speeds” (which corresponds to the [F2] key) selection appears at the bottom, second from the left, of the “Transient Survey Setup” banner screen. Press the [F2] key if you wish to define speed inputs for the survey. If you choose this option, the following “Speed Inputs Setup” banner screen is displayed. There are two sets of fields with four rows each, 1, 2, 3, and 4 indicating the four tachometer input channels. There are seven columns, Measure, DESC, OFF/100%, Factor, Plot Min, Plot Max, and Plot Div. These inputs are described below.

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To define Speed inputs, do the following: 1.

Use the [⇑] and [⇓] keys to navigate the screen and input or select data using the keypad or the [⇒], and [⇐] keys respectively.

2.

In the “Measure” column, use the [⇒] or [⇐] key to select from Pulse S-H, Volts S, Pulse D-H, Volts D, Pulse S-L, Pulse D-L, or None indicating the tachometer input type for the tachometer input channel indicated. NONE is selected when the corresponding tach channel is not being used. Pulse is used when there is a pulse input such as a Phototach, Lasetach or magnetic pickup. This pulse input may be, but is not necessarily a once-per-rev pulse. The preference is actually a multi-pulse per revolution input. The D or S in the selection depicts either single ended (S) or differential (D) while the H or L depicts a setting of high gain (H) or low gain (L) as required.

3.

The “DESC” column is the descriptive name for the tachometer input such as “N1, N2, Fan, or Turbine. Enter up to five alphanumeric characters in this field. The description should be one that all users of this setup are familiar with and easily understand.

4.

The “OFF/100%” column is used when the VOLTS selection is made in the “Measure” column described in item 2 above. This field is used to enter the offset if measuring a DC voltage if measuring the frequency in Hertz (Hz) or the frequency at 100% of component speed. Use the keypad to enter the value in the OFF/100% field.

5.

In the “FACTOR” column, enter the multiplier for Volts or Hertz to attain the actual component speed. If measuring a voltage, the speed is equal to OFF + voltage x Factor. If using a Pulse input, the RPM is equal to Hertz x Factor. The analyzer assumes the input to be relative to Hz (cycles per second) so that an input of one pulse per revolution (oneper-rev) would require a FACTOR of 60 (1 per-rev X 60 Hz assumed) to equal Revolutions per minute (RPM). Enter the factor using the keypad. For multiple pulses per revolution, divide 60 (Hz) by the number of pulses to display RPM.

6.

When viewing Plots, you should know the minimum and maximum speeds of interest. When you arrive at that speed range, use the keypad to enter the “Plot Min”, or minimum speed of interest in this column.

7.

For the “Plot Max” you should, likewise, determine the speed range of interest and enter the maximum speed of that range in this column using the keypad.

8.

The “Plot Div” determines the intervals or divisions of speed indication on the plots across the full speed range. For instance, if you intend to view the plot in a range of 1000 to 2000 RPM and wish it to be in divisions of 500 RPM, enter “2” in this column using the keypad. That is, the upper range (2000) minus the lower range (1000) divided by increments of 500 RPM = 2 divisions. The valid range for the field is 1 to 10. An entry of 1 will show NO incremental divisions of the X scale.

9.

Press ENTER to return to the Transient Survey Setup screen.

11.1.1.3. – Parms The “Parms”, or Parameters, (which corresponds to the [F3] key) selection appears at the bottom center of the “Transient Survey Setup” banner screen. Press the [F3] key if you wish 11 Transient Vibration Surveys – 11-9

to define data collection parameters for the survey. If you choose this option, the following “Transient Parameters Setup” banner screen is displayed.

To input information into the Transient Vibration Parameters screen, do the following. 1.

Use the [⇑] and [⇓] keys to navigate the screen and input or select data using the keypad or the [⇒] and [⇐] keys respectively.

2.

In the “Description” column, use the keypad to input a description of the individual component you will track with a speed input. The description should be one that is familiar and easily understood to all users of this setup. In the example above, we have used N1and N2 for the number 1 and number 2 spools respectively. You might use terms such as FAN, INPUT SHAFT, or COMPRESSOR.

3.

In the “Type” column, use the [⇒] and [⇐] keys to select “PWR” for displaying the value of total energy within the specified bandwidth you specify in the “F(lower)” and “F(upper)” columns. Select “MAX” to display the maximum single amplitude peak within the specified frequency bandwidth.

4.

Use the keypad to enter the lowest frequency of interest, (F) lower. This is the component speed x this factor and defines the lowest frequency variance where you will monitor the component speed.

5.

Use the keypad to enter the highest frequency of interest, (F) upper. This is the component speed x this factor and defines the highest frequency variance where you will monitor the component speed.

6.

In the “Speed” column, use the [⇒] and [⇐] keys to select “xRPM, xHz, xCS1, xCS2, xCS3, or xCS4. CS is an abbreviation for “Calculated Speed” The xCS1 through xCS4 selections will base the limit on a dynamic speed reference calculated per your specifications in the Speed Inputs Setup screen above in section 11.1.1.2.

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7.

When fields are completed for all Parameters, press ENTER to return to the Transient Survey Setup screen.

11.1.1.4. – Plots The “Plots” (which corresponds to the [F4] key) selection appears at the bottom, second from the right function keys of the “Transient Survey Setup” banner screen. Press the [F4] key if you wish to define plots for display of the collected survey data. If you choose this option, the following “Transient Plot Setup” banner will be displayed.

1.

The Parameters column is a display of the available parameters for plotting. These are based on your specifications in other screens of the Transient Survey Setup.

2.

Use the [⇑] and [⇓] keys to navigate the screen and use the [⇒] and [⇐] keys to toggle the answer field between “Yes” and “No”. All fields default to No on initial opening of the screen.

3.

If you wish to plot a transient survey, toggle the answer field to “Yes” under the column of choice. In the example above, you may choose to plot the OVERALL, and N1 vs. Time and/or vs. Calculated Speed (xCS) inputs. A “No” answer in any field will indicate that you do not wish to plot that parameter.

4.

Press ENTER to return to the Transient Survey Setup screen. 11.1.1.5. – Limits The “Limits” (which corresponds to the [F5] key) selection appears at the far right bottom of the “Transient Survey Setup” banner screen. Press the [F5] key if you wish to define limits. When limits are defined in this page, a limit line will be plotted on the survey screen as a quick reference. If you choose this option, the following Transient Survey Setup screen will be displayed. Note that he only difference from the main Transient Survey Setup screen and this screen is in the function key, [F1] through [F5] selections.

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11.1.1.5.1. – L:Parms

The “L:Parms”, or Limit :Parameters, (which corresponds to the [F1] key) selection appears at the bottom left of the Transient Survey Setup screen after selection [F5] “Limits” from the main Transient Survey Setup screen. Press the [F1] key if you wish to define Parameter Limits for the transient survey plots. Use the [⇓] key to move from field to field and enter a limit value using the analyzer keypad. When all desired limits are defined, press ENTER to accept your settings and return to the Transient Survey Setup screen.

11.1.1.5.2. – L:Spec

The “L:Spec”, or Limit: Spectra, (which corresponds to the [F2] key) selection appears at the bottom, second from the left of the Transient Survey Setup screen after selection of [F5] “Limits” from the main Transient Survey Setup screen. Press the [F2] key if you wish to define Spectra Limits for the transient survey plots.

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To define spectra limits, do the following: 1.

Choose the spectrum for which you wish to define limits, A-Limits, B-Limits, CLimits, or D-Limits from the corresponding function key at the bottom of the screen. The letters A, B, C, and D are in reference to the input channel of the analyzer.

2.

Use the [⇑] and [⇓] keys to navigate the screen and input or select units using the keypad or the [⇒] and [⇐] keys respectively.

3.

The “Edit Limits for Channel X” banner screen, where X represents the input channel letter A, B, C, or D, shown above, will be displayed.

4.

Use the keypad to enter the lower frequency (F – low) in the 1) row. Move to the next column (F – high) and again use the keypad to enter the upper frequency limit in the 1) row.

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5.

Move to the next column (Unit) and use the [⇒] and [⇐] keys to select the frequency unit. This selection will determine the frequency unit where lines will be drawn on the spectra relative to the x (frequency) axis specified in item 3 above.

6.

Move to the “Limit” column and enter the amplitude limit for the bandwidth specified in F-low and F-high of the same row. This limit will be displayed as a horizontal line relative to the engineering units specified on the Transient Survey Setup screen in the “Vibration:” field. When all desired limits are set, press [ENTER] to accept your settings and exit the screen.

11.1.2. - Job Identification The next screen displayed is the “Job Identification” banner screen shown in the following illustration. All information on this screen is optional; however we highly recommend you fill in as much information as possible to ease the task of storage and retrieval of surveys. If you have other customer information stored, you may press the [F1] key to select from a list of stored customer names, which will then be entered into the “Name” field. When all fields are completed as desired, press [ENTER] to continue.

11.1.3. – Engine Information The “Engine Information” banner screen is displayed as shown below. Serial number (“S/N”) and “Type” fields are available for both an engine and a propeller so that stored surveys can be traced by either component of the powertrain system. All fields are optional but we highly recommend you fill in as much information as possible for ease of use in trending, recall, and storage. Navigate (move) between the fields using the [⇓] and [⇑] keys. All fields are entered from the keypad with the exception of the “Pos” (Position) field, which is a selection field. The position indicates the position on the airplane of the engine, propeller or subcomponent. Using the [⇒] key, select positions from 1 through 4. The “TSO” and “TSN” fields for

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“Time Since New” and “Time Since Overhaul” are optional fields. When all fields are filled as required, press [ENTER] to continue.

11.1.4. – Start Engine Start the engine (or component) you are checking (generator, gearbox, etc.). When the component reaches normal operating conditions (speed, temp, etc.), press the [ENTER] key to begin acquiring data. You can use the [F2] “Swap Job” key to return directly to the Main Menu without rebooting the analyzer.

11.1.5. – Microphone Calibration If you have selected to gather data using a microphone, the “Start Engine” screen shown below will appear before data collection. You MUST calibrate the microphone before every

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use. Differences in temperature and pressure will affect the microphone readings if it is not properly calibrated. Follow the steps below to properly calibrate the microphone.

1.

Press the [F4] “Calib” to display a list of all channels which are currently configured to collect data with a microphone similar to the example below. Select the first channel and press [ENTER]. Continue the process for all applicable channels.

2. The analyzer will display the current calibration settings. Press [F1] “Change” to change the current settings.

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3. Enter the Reference Level, typically in decibels (db), and the Reference Frequency, in Hertz (Hz), as found on the calibrator. Plug the microphone into the correct size adapter in the top of the calibrator. Turn the calibrator on and press [ENTER] on the analyzer. NOTE The minimum and maximum Reference Frequency range, displayed below the “Ref. Frequency” cell, is dynamic. If the displayed range does not include the frequency found on the calibrator, you will have to expand the frequency range defined in the setup. See paragraphs 3 and 4 above.

4. After a brief period the analyzer will display the Measurement Level and the Adjustment that will be applied to the measurement. You can change the adjustment by pressing [F1] “Change” and following the above steps again.

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5. As the channels are calibrated, an X will fill the brackets ([X]) indicating that data has been collected. When all channels are calibrated, press [BACKUP] to exit the calibration process and return to the “Start Engine” screen for the current job. Data collection from this point on is no different than with any other vibration sensor.

6. As a way to verify the microphone settings, simply take sample data. Keep the microphone plugged into the calibrator and view the results. The vibration peak should be displayed within the tolerance of the microphone.

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11.1.6. – Select Aircraft Condition The “Select Aircraft Condition” banner screen is displayed. The conditions are those defined in the “Edit Conditions” screen (see section 11.1.1.1). Use the [⇑] or [⇓] keys to select the condition you wish to collect. When your choice is highlighted, press [ENTER] to begin collecting data.

11.1.7. – Collecting Data If the display type was selected as “Spectra” in step 6 of paragraph 11.1.1 above, the spectra is displayed, you will also see three function boxes at the bottom of the screen (see following figure) corresponding to the position of the [F1], [F4], and [F5] keys directly below them. The boxes read “Options,” “Overall” and “Event”.

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Once any of these “F” key options are selected, both the screen and the corresponding “F” key functions change. With each selection, the “F” keys offer different options (e.g., Expand, Shrink, X scale) for viewing the spectra. The “F” key functions for viewing spectra are described in the following steps. 1.

Pressing the [F1] “Options” key will change the [F1], [F2], [F3], [F4] and [F5] boxes to read “Cursor”, “X Scale”, and “Y Scale”, “View” and “Cancel” respectively as shown in the figure below.

2.

Pressing the [F1] “Cursor” key will change the [F1], [F2], [F3] and [F5] boxes to read “Normal,” “Harmonic,” “None” and “Cancel” respectively. The functions of the “F” keys will continue to change as the screens change.

3.

Pressing the [F1] “Normal” key will produce a normal cursor on the screen accompanied by an X and Y scale value readout box in the upper right corner of each displayed spectra (see the following figure). These X and Y values are relative to the current position of the cursor only. The cursor can be moved along the X (horizontal) axis of the spectra by pressing the [⇐] or [⇒] keys. Hold down the key for large and rapid incremental changes. The value of the X-axis (frequency) and Y-axis (amplitude) will be displayed for the current position of the cursor. Incremental values are determined by the number of lines of resolution specified in the setup screen.

4.

Pressing the [F2] “Harmonic” key will produce multiple harmonic cursors according to the specified frequency range. When this key is pressed, cursors will appear to the right of the fundamental frequency identified by the leftmost cursor. For example, if the fundamental frequency is 300 Hz cursors will be placed at 2X (600 Hz) 3X (900 Hz) 4x (1200 Hz) and so on until the upper frequency limit of the screen is met. When the primary cursor (for the fundamental frequency) is moved, the multiple harmonic cursors will automatically follow the movement and position themselves at the new multiple of the fundamental frequency. To remove the harmonic cursors, repeat steps 1 and 2 above. At step 3, press either the [F1] “Normal” or [F3] “None” key and the multiple cursors will be replaced by your selection.

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5.

Pressing the [F3] “None” key will remove either a normal or harmonic cursor if currently displayed on screen. The three boxes above the [F1], [F4] and [F5] keys will return to “Options,” “Overall” and “Event” respectively. If no cursor is displayed when pressing this key, only the box nomenclature will change.

6.

Pressing the [F2] “X scale” key will change the [F1], [F2], [F3], and [F5] boxes to read “Expand,” “Default,” “Shrink” and “Cancel” respectively as shown in the following figure.

7.

Pressing the [F1] “Expand” key will expand the X scale of the spectra, in effect enlarging the viewing area. You might think of this function as a “Zoom Out” feature. The center of the Expanded view will be the position of the cursor prior to pressing the [F1] key. If the view is already at the maximum range of the specified X scale range, no scaling change will occur. However, the cursor will be displayed and the X, Y, and “Ovr” (Overall) values will be shown in the upper right corner of the screen. The [F1], [F2] and [F5] boxes will return to the format described in step 5

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above. If you wish to Expand the X scale even further, retrace the steps from that point as described in the text. 8.

Pressing the [F2] “Default” key will return the X scale to the values specified in the setup. This is a quick and easy way to return all expanded and shrunken scales to that default value without the necessity of numerous keystrokes. If the X scale is already at the setup values when the [F2] Default key is pressed, the three function boxes will return to “Options,” “Overall” and “Event”. No other changes will occur.

9.

Pressing the [F3] “Shrink” key will lower the X scale of the spectra, in effect shrinking the viewing area. You might think of this function as a “Zoom In” feature. If the view is already at the minimum of the specified X scale range, no scaling change will occur. However, the cursor will be displayed and the X, Y, and “Ovr” (Overall) values will be shown in the upper right corner of the screen. The [F1], [F4] and [F5] boxes will return to the format described in step 5 above. If you wish to Shrink the X scale even further, retrace the steps from that point as described in the text.

10.

Pressing the [F3] “Y scale” key changes the [F1], [F2], [F3], and [F5] boxes to read “Expand,” “Default,” “Shrink” and “Cancel” respectively (see above).

11.

Pressing the [F1] “Expand” key will expand the Y scale of the spectra, in effect enlarging the viewing area. You might think of this function as a “Zoom Out” feature. If the view is already at the maximum range of the specified Y scale range, no scaling change will occur. However, the cursor will be displayed and the X, Y, and Ovr: (Overall) values will be shown in the upper right corner of the screen. The [F1], [F4] and [F5] boxes will return to the format described in step 5 above. If you wish to Expand the Y scale even further, retrace the steps from that point as described in the text.

12.

Pressing the [F2] “Default” key will return the Y scale to the values specified in the setup. This is a quick and easy way to return all expanded and shrunken scales to that default value without the necessity of numerous keystrokes. If the Y scale is already at the setup values when the [F2] Default key is pressed, the three function boxes will return to “Options,” “Overall,” and “Event.” No other changes will occur.

13.

Pressing the [F3] “Shrink” key will lower the Y scale of the spectra, in effect shrinking the viewing area. You might think of this function as a “Zoom In” feature. If the view is already at the minimum of the specified Y scale range, no scaling change will occur. However, the cursor will be displayed and the X, Y, and “Ovr” (Overall) values will be shown in the upper right corner of the screen. The [F1], [F4] and [F5] boxes will return to the format described in step 5 above. If you wish to shrink the Y scale even further, retrace the steps from that point as described in the text.

14.

Pressing the [F4] “View” key will display another sub menu. The [F1], [F2], [F3], [F4] keys will be identified by the descriptions assigned in Section 11.1.1 step 15 above. The [F5] key will be labeled “All”. Pressing the “F” key below the name of the channel will enlarge the display of that plot to the full size of the screen. The other plots will continue to gather data they will just be hidden from view. Pressing

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[F1] “Options”, [F3] “View”, and [F5] “All” will return all available plots to the screen. The “F” keys will return to “Options”, “Spectra”, and “Event”. 15.

Pressing [F4] “Overall” will cause the screen to change from the spectra plot to the overall display as shown below. You can change back to the spectra plot by pressing [F4] “Spectra”.

16.

Pressing [F5] “Event” from the initial function key display will store a marker in the job indicating the time the “Event” key was pressed. Multiple tags will be incremented sequentially as Event 1, Event 2, and so on. The tag will help you identify the point in time during the run when the “Event” key was pressed during the “Review Job” process or in AvTrend.

11.1.8. - Storing Data Anytime the spectrum is displayed on screen you may press [ENTER] to terminate data acquisition. The analyzer then displays the screen shown below.

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The “Select Aircraft Condition” banner screen is again displayed as shown in the following figure. Notice that the condition for which you just collected and stored data now has an “X” immediately to the left of the defined condition. This alerts the user that data has been collected and stored for this condition. This does not preclude you from selecting and acquiring new data for this condition. However, if you choose to store the data, the previously stored data will be written over and may not be recovered.

At this point you may select a new condition and repeat procedures starting from section 11.1.5 until all required data are collected. If you would like to exit the job with the ability to resume it later, you can press the [F1] “End Run” key. This will cause the following screen to be displayed. From this screen, you can use the [F2] “Swap Job” key to return to the Main Menu without rebooting the analyzer. This will leave the job incomplete and suspended in the analyzer’s memory. If you are finished collecting data, shut down the engine(s) per the manual instructions and use the [F5] “Continue” key to mark the job complete and store it to memory.

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From the “Select Condition” screen, to quit the job and return to the “Transient Vibration Surveys” banner screen, press [F5] for “Quit Job.”

11.2. - Resume Job

When you select “Resume Job” from the “Transient Vibration Survey Jobs” banner screen menu, the “Incomplete Jobs” banner screen will be displayed. Incomplete jobs are listed by name, preceded by an asterisk. Select the job you wish to complete and the analyzer will return you to the point where the in-progress job was stopped, allowing you to complete it. If no in-progress jobs are available to resume, an information screen with that message will be displayed.

11.3. - Manage Jobs Selecting “Manage Jobs” from the “Transient Vibration Survey Jobs” banner screen menu presents several sub-menu choices to choose from. These choices allow you to “manage” previously completed job data you have stored in the analyzer.

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11.3.1. - Review Selecting the “Review” option presents a list of stored jobs on the “Job List” banner screen. You can select one job for on-screen viewing. When viewing is complete, press the [BACKUP] or [ENTER] key to exit the screen.

11.3.2. - Delete The “Delete” option presents a list of stored jobs on the “Job List” banner screen. From the list, you may select one job for deletion. After making your selection, the “Delete Job” banner screen will appear, asking you to verify your intent to delete the selected job by pressing the [F1] key for “Yes” or the [F5] key for “No.” You may wish to download the job for reference or permanent record prior to deleting. Once deleted, the job cannot be retrieved from the analyzer.

11.3.3. - Delete All The “Delete All” option will delete all currently stored jobs. After selecting this option, the “Delete All Job” banner screen will appear, asking you to verify your intent to delete all the jobs by pressing the [F1] key for “Yes” or the [F5] key for “No.” You may wish to download the jobs for reference or permanent record prior to deleting. Once deleted, the jobs cannot be retrieved from the analyzer.

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11.4. - Manage Setups

Selecting “Manage Setups” from the “Transient Vibration Survey Jobs” banner screen menu presents several sub-menu choices to choose from. These choices allow you to “manage” job setups you have stored previously in the analyzer.

11.4.1. - Edit Selecting the “Edit” function displays the “Setup List” screen. Select the setup you wish to edit. The screen will display the “Spectra Setup” screen. Edit the setup as necessary using steps 11.1.1 through 11.1.1.5 above as a guide and press [ENTER] to store and exit the edited setup screen. NOTE When the EDIT mode is being used, you must press the [ENTER] key until the screen again displays the TRANSIENT VIBRATION SURVEY JOBS banner screen, shown above, for the edited information to be stored. Using the [BACKUP] key to return to the menu will exit the edit function without storing the new information.

11.4.2. – New If you select “New,” the “Spectra Setup” screen is displayed. See section 11.1.1 for instructions on how to proceed from this point.

11.4.3. – Delete The “Delete” option presents you with a list of stored setups. From the list, you may select one setup for deletion. If you wish to delete all stored setups, you must delete them individually. After making your selection, you will be asked to verify your intent to delete the

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selected job by pressing the [F1] key for “Yes,” or the [F5] key for “No.” We highly recommend you download the setup(s) for reference or permanent record prior to deleting them. Once deleted, the setups cannot be retrieved from the analyzer.

11.4.4. - Select Setup for Remote Job

The “Select Setup for Remote Job” option allows you to select the name of a transient survey setup to use for a REMOTE transient job. You must select the name of a specific setup from the “Name:” toggle field, as shown below. The next line allows you to select the method the analyzer will use to start the job. The choices are “Automatically” or “Pilot Trigger”. Automatically tells the analyzer to start the job as soon as it is turned on. Pilot Trigger is an ACES option that allows the job to be started from a remote location, the Pilot’s station for example. To help the analyzer properly manage internal memory, you should also enter a time (in seconds) of a typical data acquisition. Valid time entries are between 20 and 999 seconds.

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Chapter 12 Monitor Spectrum (Revision 3, Oct 2012) “Monitor Spectrum” is an analyzer function that is accessed from the analyzer’s Main Menu banner screen. A description of this function follows, along with the information required to complete the menu screens within the function, and the steps necessary to perform the function. The “Monitor Spectrum” function allows the user to rapidly set up the analyzer to acquire vibration data for troubleshooting, verification of repair, comparison of similar components or “snap shot” recording of pre- or post-maintenance conditions.

12.1 Spectra Setup 12.1.1. Select “Monitor Spectrum” from the Main Menu banner screen. 12.1.1.1. The analyzer will display the “Spectra Setup” banner screen shown in the illustration below. Complete the fields as follows:

12.1.1.2.

Determine if the required frequency units are revolutions per minute (RPM) or cycles per second (Hz). Press the [⇒] key to toggle between the frequency unit selections in the field.

12.1.1.3.

Use the [⇓] key to move down to the next field. Using the keypad, enter the determined minimum frequency in the “Min Frequency” field. This is the first field directly to the right of the frequency units (RPM or Hz) field. Determine the minimum and maximum frequency requirements. For instance, if the frequency of interest is 300 Hz, you might choose a minimum and maximum frequency that will place the 300 Hz in the center of the range. The minimum might then be 250 Hz and the maximum 350 Hz for instance. You might also consider other factors such as Harmonics. If you want multiples of the fundamental frequency included in the frequency range, determine to what extent that need is (1X, 2X, 3X and so on) then extend the frequency range to include it. For example, 300Hz is the frequency of interest, the fundamental frequency. If you want 3X harmonics included in the frequency range you must multiply the fundamental frequency (300 Hz) X the harmonic range (3X) and arrive at an upper range of 900 Hz.

12.1.1.4.

Use the [⇓] key to move down to the next field. Using the keypad, enter the determined maximum frequency in the “Max Frequency” field. This is the first field directly to the right of the word “to” which separates the Min and Max frequency fields.

12.1.1.5.

Use the [⇓] key to move down to the next field. Set the Resolution as required at 100, 200, 400, 800, 1600, 3200 or 6400 lines by pressing the [⇒] key to scroll through the selections until the desired resolution is displayed. Unless you are attempting to separate two frequencies that are within close proximity to one another, 100 or 200 lines should suffice for general analysis. Higher resolutions will provide a much sharper image of the specified frequency band but also require more time and memory for acquisition [⇒] key and should only be used when genuinely needed.

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12.1.1.6.

Use the [⇓] key to move to the “Average Type” field. Select the average type by scrolling through the selections in the field using the [⇒] key until your selection is displayed. There are three available options, “Expon”. “Normal” and “Peak Hold”. If you select “Expon” the screen will constantly update both the amplitude and frequency. The screen will have a dynamic appearance and change as the input condition changes. The analyzer will continue to collect data until stopped by pressing [ENTER] or the acquisition time selected in Conditions for the current running condition expires. If you select “Normal” the analyzer will acquire only the total number of blocks specified in step 12.1.1.7 below, then automatically stop data acquisition, average the collected blocks and plot them on screen. If you select “Peak Hold” the analyzer will plot and hold the highest amplitude received on screen. These values will not decrease once plotted, but will increase if amplitude of higher value is acquired. The analyzer will continue to collect data until stopped by pressing [ENTER]. Consult the appropriate equipment maintenance manual for specific requirements of a vibration survey or for analysis guidelines.

12.1.1.7.

Use the [⇓] key to move to the “Blocks in Avg.” field. Enter the number of data blocks you wish to be used in the calculations. This is the total number of samples taken, and then averaged before being plotted on the screen. The default is four. The valid range is 0 to 999. Remember that higher numbers of averaging, while providing more reliable data, also require more time. The default of 4 is sufficient for most applications.

12.1.1.8.

Use the [⇓] key to move to the “Units” column of the Channel A row. The “Units” field determines the engineering units in which the amplitude, or “Y” axis, of the spectra will be displayed. Consult the appropriate equipment maintenance manual for specific requirements of a vibration survey or for analysis guidelines. Use the [⇐] or [⇒] keys to scroll through the selections in this field. The available selections are: G’s (equivalent gravities), IPS (Inches Per Second), mm/sec (millimeters per second), cm/sec (centimeters per second), Mils (1/1000th of an inch), Microns (1/1000000th of a meter), ubars (Millibars), Pascals, Volts, m/s/s (meters per second per second), cm/s/s (centimeters per second per second, db (decibels), Special and None. NOTE

Selecting Mils in this block will not allow you to select any accelerometer input in step 12.1.1.12 below. If an accelerometer is being used, you must also use an external converter to convert the actual input to the analyzer to velocity (IPS) input.

12.1.1.9.

Use the [⇓] key to move to the “Mod” (Modifier) field. This is Modifiers relevant to the engineering units specified in step 12.1.1.8, above. Use the [⇐] or [⇒] keys to toggle through the available selections in the field which are: Peak, Pk-Pk (Peak to Peak), Avg. (Average), and RMS (Root Mean Square). Consult the appropriate equipment maintenance manual for specific requirements of a vibration survey or for analysis guidelines.

12.1.1.10.

Use the [⇓] key to move to the “MaxValue” field. The “MaxValue” field is a toggle selection field. Use the [⇐] or [⇒] keys to toggle through the available selections for the field. The available selections are: 0.01, 0.02, 0.05, 0.10, 0.20,

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0.50, 1.00, 2.00, 5.00, 10.0, 20.0, 50.0, 60.0, 70.0, 80.0, 90.0, 100, 110, 120, 130, 140, 150, 200, 500, 1000, 2000 and 5000. This scale refers to the number of engineering units of vibration amplitude specified in the previous field. The full scale indicates the maximum vibration amplitude you expect to acquire or the maximum amplitude of interest. Choose the amplitude that will adequately display the full amplitude of any specified limits as a minimum. If you do not expect amplitudes in excess of what would normally be experienced for the equipment application, set this field as low as possible while still allowing sufficient space to display the maximum limitations as stated above. NOTE Amplitudes encountered above the setting in this field may cause the analyzer to overload. It is best to set the Full Scale Vibration higher than needed as opposed to lower than needed so the overload does not cause a fatal error. You can recover from the overload by pressing the [Main Menu] key and starting the process again from the beginning. However, avoiding an overload will save you time in the process.

12.1.1.11.

Repeat steps 12.1.1.8 through 12.1.1.10 for all channels you intend to use for this job.

12.1.1.12.

Use the [⇓] key to move to the “Sensor” column for “Channel A” row. Scroll through the choices in this field using the [⇐] or [⇒] keys. The available choices are dependent on the number of sensors you have programmed into your analyzer. (See chapter 18 Miscellaneous Items, for sensor setups.)

12.1.1.13.

Use the [⇓] key to move to the “Channel “Desc” column for “Channel A” row. You define this optional field. The field will accept any alphanumeric characters entered from the keypad. This field is used as a description for the individual channel such as “Lat” and “Vert” or “GBox” and “Core.”

12.1.1.14.

Repeat steps 12.1.1.12 through 12.1.1.13 for each of the channels you intend to use for this job.

12.1.2. Speeds 12.1.2.1.

Press the [F2] “Speeds” key from the Spectra Setup screen shown above in paragraph 12.1.1.1. The Speeds option allows you to measure several types of speed inputs for synchronizing with the vibration input or to provide an entry field for reference where no actual speed input is available. This allows you to view amplitude, in the selected engineering units, relative to the speed of the machine or component being monitored.

12.1.2.2.

The column of numbers to the left side of the fields represents the four speed input channels, TACH 1, 2, 3, and 4. In the “Measure” field, use the [⇒], and [⇐] keys to select the type of input. The available selections are: NONE (where no speed input or reference is used), PULSE S-H (Pulse, Single ended – High), Volts S (volts – single ended), PULSE D–H (Pulse Differential – High), Volts D (Volts Differential), PULSE S – L (Pulse, Single ended – Low), PULSE D – L (Pulse Differential – Low), and ENTERY (A user entered speed reference).

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NOTE Where selections vary between an “S” and a “D” suffix are necessary, the selection is dependent on whether the input is single ended (S) or differential (D). Where selections between an “L” and an “H” suffix are necessary, the selection is dependent on whether the required gain for the incoming signal is Low (L) or High (H). Generally a signal below 1 volt peak will require you to use the High gain (H) selection and inputs of over one volt Peak will require you to use the Low gain (L) selection.

12.1.2.3.

The “DESC” column is the descriptive name for the tachometer input such as “N1, N2, Fan, or Turbine. Enter up to five alphanumeric characters in this field using the analyzer keypad.

12.1.2.4.

The “OFF/100%” column is used when the VOLTS selection is made in the “Measure” column described in paragraph 12.1.2.2 above. This field is used to enter the offset if measuring a DC voltage, or the frequency at 100% of component speed if measuring frequency in Hertz (Hz). Use the keypad to enter the value in the OFF/100% field.

12.1.2.5.

In the “FACTOR” column, enter the multiplier for the DC voltage or Hertz to attain the actual component speed. If measuring a voltage, the speed is equal to OFF + voltage x Factor. If using a Pulse input, the RPM is equal to Hertz x Factor. The analyzer assumes the input to be relative to Hz (cycles per second) so that an input of one pulse per revolution (one-per-rev) would require a FACTOR of 60 (1 per-rev X 60 Hz assumed) to equal Revolutions per minute (RPM). Enter the factor using the keypad.

12.1.2.6.

Repeat the steps from paragraph 12.1.2.2 through 12.1.2.5 for each of the four channels you intend to use for this job the/or press [ENTER] to accept your settings and exit back to the Spectra Setup screen.

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12.1.3. Monitor 12.1.3.1.

Install the sensors and cables required for the task.

12.1.3.2.

Start the component you are checking (engine, generator, etc.). When the component is at normal operating condition (speed, temp, etc.) press the [ENTER] key to begin acquiring data. When monitoring is complete, press [ENTER] again to stop data collection.

NOTE When the spectrum is displayed on screen, press the [⇐] or [⇒] key to produce a NORMAL CURSOR immediately at the frequency where the highest amplitude is displayed. The keys may also be used to immediately EXPAND [⇑] or SHRINK [⇓] the Y scale.

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Chapter 13 Monitor Magnitude & Clock (Revision 1, Aug 2007)

“Monitor Magnitude and Clock” is an analyzer function that is accessed from the analyzer’s Main Menu banner screen. A description of this function follows, along with the information required to complete the menu screens within the function, and the steps necessary to perform the function.

The “Monitor Magnitude and Clock” function provides for rapid acquisition of a clock angle and amplitude reading without defining and saving a setup. This function allows for no storage of readings for future review. It is not recommended that you use this function for the acquisition of measurements from tail rotors or other items that have a balance chart that utilizes a strobe light for phase (clock) angles. Measurements acquired with this function will not be accurate for use in these applications. To balance these applications, use the “Tail Rotor Balance” selection from the Main Menu. To use the “Monitor Magnitude and Clock” function, do the following:

1. From the Main Menu banner screen, select “Monitor Magnitude and Clock.” The “Monitor Magnitude and Clock” banner screen appears as shown in the figure below.

2. Use the [⇒] key to toggle between the selections in the “Tach Input” field. Toggle between selections using the [⇒] keys to select the tachometer-input channel to be monitored. 3. Move down to the “Tach Type” field by using the [⇓] key. Use the [⇒] key to select the tachometer type you are using for the once-per-revolution input into the analyzer. 4. Use the [⇓] key to move to the “Vibration” field. The “Vibration” field determines the engineering units in which the amplitude, or “Y” axis, of the spectra will be displayed. Consult the appropriate equipment maintenance manual for specific requirements of a vibration survey or for analysis guidelines. Use the [⇐] or [⇒] keys to scroll through the selections in this field. The available selections are: IPS (Inches Per Second), mm/sec (millimeters per second), cm/sec (centimeters per second), Mils (1/1000th of an inch), Microns (1/1000000th of a meter), M/S/S (millimeters per second squared), C/S/S (centimeters per second squared), and G’s (equivalent gravities). 5. Use the [⇓] key to move to the “Modifier” field. “Mod” is short for unit Modifiers relevant to the engineering units specified in step 4, above. Use the [⇐] or [⇒] keys to toggle through the available selections in the field which are: Peak, Pk-Pk (Peak to Peak), Avg. (Average), and RMS (Root Mean Square). Consult the appropriate equipment maintenance manual for specific requirements of a vibration survey or for analysis guidelines. 6. Use the [⇒] key to toggle between the selections in the “Display 1” field to select the output of “Display 1.” The available selections are: “A,” “B,” “C,” “D,” “A+B,” and “AB.” 7. Use the [⇓] key to move down to the “Description” field. Enter a name from the keypad in the description field. (Refer to Chapter 3, “Using the VIPER” if you are unfamiliar with using the keypad.) The description field is optional.

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8. Use the [⇓] key to move down to the “Description” field. Enter a name from the keypad in the description field. The description field is optional. If you are only measuring one channel, leave this field blank. 9. Use the [⇓] key to move to the “Full Scale Vibration” field. The “Full Scale Vibration” field is a toggle selection field. Use the [⇐] or [⇒] keys to toggle through the available selections for the field. The available selections are: 0.01, 0.02, 0.05, 0.10, 0.20, 0.50, 1.00, 2.00, 5.00, 10.0, 20.0, 50.0, 60.0, 70.0, 80.0, 90.0, 100, 110, 120, 130, 140, 150, 200, 500, 1000, 2000 and 5000. This scale refers to the number of engineering units of vibration amplitude specified in the previous field. The full scale indicates the maximum vibration amplitude you expect to acquire or the maximum amplitude of interest. Choose the amplitude that will adequately display the full amplitude of any specified limits as a minimum. If you do not expect amplitudes in excess of what would normally be experienced for the equipment application, set this field as low as possible while still allowing sufficient space to display the maximum limitations as stated above. NOTE Amplitudes encountered above the setting in this field may cause the analyzer to overload. It is best to set the Full Scale Vibration higher than needed as opposed to lower than needed so the overload does not cause a fatal error. You can recover from the overload by pressing the [Main Menu] key and starting the process again from the beginning. However, avoiding an overload will save you time in the process.

10. Use the [⇓] key to move down to the “Sensor” field. Select a sensor type by using the [⇒] key to toggle between selections. 11. Once all fields are filled press the [ENTER] key to begin acquiring vibration data. See Chapter 20, “Reading Spectrum and Scales” for a detailed explanation of the information contained on the acquisition screen. 12. When finished acquiring vibration data, press the [ENTER] key to stop.

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Chapter 14 Monitor Magnitude and Phase (Revision 1, Aug 2007)

“Monitor Magnitude and Phase” is an analyzer function that is accessed from the analyzer’s Main Menu banner screen. A description of this function follows, along with the information required to complete the menu screens within the function, and the steps necessary to perform the function. The “Monitor Magnitude and Phase” function provides for rapid acquisition of a phase angle and amplitude reading without defining and saving a setup. This function allows for no storage of readings for future review. To use the “Monitor Magnitude and Phase” function, do the following: 1. From the Main Menu banner screen, select “Monitor Magnitude and Phase.” The “Monitor Magnitude and Phase” banner screen appears as shown in the figure below.

2. Use the [⇒] key to toggle between the selections in the “Tach Channel” field. Toggle between selections using the [⇒] keys to select the tachometer-input channel to be monitored.

3. Move down to the “Tach Type” field by using the [⇓] key. Use the [⇒] key to select the tachometer type you are using for the once-per-revolution input into the analyzer.

4. Use the [⇓] key to move to the “Vibration” field. The “Vibration” field determines the engineering units in which the amplitude, or “Y” axis, of the spectra will be displayed. Consult the appropriate equipment maintenance manual for specific requirements of a vibration survey or for analysis guidelines. Use the [⇐] or [⇒] keys to scroll through the selections in this field. The available selections are: IPS (Inches Per Second), mm/sec (millimeters per second), cm/sec (centimeters per second), Mils (1/1000th of an inch), Microns (1/1000000th of a meter), M/S/S (millimeters per second squared), C/S/S (centimeters per second squared), and G’s (equivalent gravities). 5. Use the [⇓] key to move to the “Modifier” field. Use the [⇐] or [⇒] keys to toggle through the available selections in the field which are: Peak, Pk-Pk (Peak to Peak), Avg. (Average), and RMS (Root Mean Square). Consult the appropriate equipment maintenance manual for specific requirements of a vibration survey or for analysis guidelines. 6. Use the [⇓] key to move to the “Input” field. Use the [⇒] key to toggle between the selections in the “Input” field to select the output of “Input” field. The available selections are: “A,” “B,” “C,” “D,” “A+B,” and “A-B.” 7. Use the [⇓] key to move down to the “Description” field. Enter a name from the keypad in the description field. (Refer to Chapter 3, “Using the VIPER” if you are unfamiliar with using the keypad.) The description field is optional. 8. Use the [⇓] key to move to the “Full Scale Vibration” field. The “Full Scale Vibration” field is a toggle selection field. Use the [⇐] or [⇒] keys to toggle through the available selections for the field. The available selections are: 0.01, 0.02, 0.05, 0.10, 0.20, 0.50, 1.00, 2.00, 5.00, 10.0, 20.0, 50.0, 60.0, 70.0, 80.0, 90.0, 100, 110, 120, 130, 140, 150, 200, 500, 1000, 2000 and 5000. This scale refers to the number of engineering units of vibration amplitude specified in the Vibration field in step 4 above. The full scale indicates the maximum vibration amplitude you expect to acquire or the maximum amplitude of interest. Choose the amplitude that will adequately display the full 14-2 – Monitor Magnitude and Phase 14

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amplitude of any specified limits as a minimum. If you do not expect amplitudes in excess of what would normally be experienced for the equipment application, set this field as low as possible while still allowing sufficient space to display the maximum limitations as stated above. NOTE Amplitudes encountered above the setting in this field may cause the analyzer to overload. It is best to set the Full Scale Vibration higher than needed as opposed to lower than needed so the overload does not cause a fatal error. You can recover from the overload by pressing the [Main Menu] key and starting the process again from the beginning. However, avoiding an overload will save you time in the process.

9. Use the [⇓] key to move down to the “Sensor” field. Select a sensor type by using the [⇒] key to toggle between selections. 10. Once all fields are filled press the [ENTER] key to begin acquiring vibration data. See Chapter 20, “Reading Spectrum and Scales” for a detailed explanation of the information contained on the acquisition screen. 11. When finished acquiring vibration data, press the [ENTER] key to stop.

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Chapter 15 Monitor Overall (Revision 2, Aug 2007) “Monitor Overall” vibration is an analyzer function that is accessed from the analyzer’s Main Menu banner screen. A description of this function follows, along with the information required to complete the menu screens within the function, and the steps necessary to perform the function.

“Monitor Overall” vibration” allows the user to monitor the overall vibration condition of a system or component in a digital numeric display only and will not produce a spectral view. This function also provides the means to monitor under one set of criteria then quickly change those criteria and return to the monitor mode. As with all “monitor” functions of the analyzer, there are no provisions for storing, reviewing, or printing the monitored data. 15.1.1.

Overall Vibration Setup

15.1.1.1. Select “Monitor Overall” from the Main Menu banner screen. 15.1.1.2. The analyzer will display the “Overall Vibration Setup” banner screen shown in the illustration below.

15.1.1.3. Enter a name for the job in the optional “Name” field if desired using the keypad. (Refer to Chapter 3, “Using the Model 4040 Analyzer” if you are unfamiliar with using the keypad. Use the [⇓] key to move down to the next field. 15.1.1.4. Use the [⇓] key to move to the “RPM/Hz” field. Determine if the required frequency units are revolutions per minute (RPM) or cycles per second (Hz). Press the [⇒] key to toggle between the frequency unit selections in the field. Use the [⇓] key to move down to the next field. 15.1.1.5. Determine the minimum and maximum frequency requirements. For instance, if the frequency of interest is 300 Hz, you might choose a minimum and maximum frequency that will place the 300 Hz in the center of the range. The minimum might then be 250 Hz and the maximum 350 Hz for instance. You might also consider other factors such as Harmonics. If you want multiples of the fundamental frequency included in the frequency range, determine to what extent that need is (1X, 2X, 3X and so on) then extend the frequency range to include it. For example, 300Hz is the frequency of interest, the fundamental frequency. If you want 3X harmonics included in the frequency range you must multiply the fundamental frequency (300 Hz) X the harmonic range (3X) and arrive at an upper range of 900 Hz. 15.1.1.6. Using the keypad, enter the determined minimum frequency in the “Min Frequency” field. This is the first field directly to the right of the frequency units (RPM or Hz) field. Use the [⇓] key to move down to the next field. 15.1.1.7. Using the keypad, enter the determined maximum frequency in the “Max Frequency” field. This is the first field directly to the right of the word “to” which separates the Min and Max frequency fields. Use the [⇓] key to move down to the next field. 15.1.1.8. Use the [⇓] key to move to the “Units” column of the Channel A row. The “Units” field determines the engineering units in which the amplitude, or “Y” axis, of the spectra will be displayed. Consult the appropriate equipment maintenance manual

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for specific requirements of a vibration survey or for analysis guidelines. Use the [⇐] or [⇒] keys to scroll through the selections in this field. The available selections are: G’s (equivalent gravities), IPS (Inches Per Second), mm/sec (millimeters per second), cm/sec (centimeters per second), Mils (1/1000th of an inch), Microns (1/1000000th of a meter), ubars (Millibars), Pascals, Volts, m/s/s (meters per second per second), cm/s/s (centimeters per second per second, db (decibels), Special and None. NOTE Selecting Mils in this block will not allow you to select any accelerometer input in step 15.1.1.12 below. If an accelerometer is being used, you must also use an external converter to convert the actual input to the analyzer to velocity (IPS) input.

15.1.1.9. Use the [⇓] key to move to the “Mod” (Modifier) field. This is Modifiers relevant to the engineering units specified in step 15.1.1.8, above. Use the [⇐] or [⇒] keys to toggle through the available selections in the field which are: Peak, Pk-Pk (Peak to Peak), Avg. (Average), and RMS (Root Mean Square). Consult the appropriate equipment maintenance manual for specific requirements of a vibration survey or for analysis guidelines. 15.1.1.10. Use the [⇓] key to move to the “MaxValue” field. The “MaxValue” field is a toggle selection field. Use the [⇐] or [⇒] keys to toggle through the available selections for the field. The available selections are 0.01, 0.02, 0.05, 0.10, 0.20, 0.50, 1.00, 2.00, 5.00, 10.0, 20.0, 50.0, 60.0, 70.0, 80.0, 90.0, 100, 110, 120, 130, 140, 150, 200, 500, 1000, 2000 and 5000. This scale refers to the number of engineering units of vibration amplitude specified in the Units field. The full scale indicates the maximum vibration amplitude you expect to acquire or the maximum amplitude of interest. Choose the amplitude that will adequately display the full amplitude of any specified limits as a minimum. If you do not expect amplitudes in excess of what would normally be experienced for the equipment application, set this field as low as possible while still allowing sufficient space to display the maximum limitations as stated above. NOTE Amplitudes encountered above the setting in this field may cause the analyzer to overload. It is best to set the Full Scale Vibration higher than needed as opposed to lower than needed so the overload does not cause a fatal error. You can recover from the overload by pressing the [Main Menu] key and starting the process again from the beginning. However, avoiding an overload will save you time in the process.

15.1.1.11. Repeat steps 15.1.1.8 through 15.1.1.10 for all channels you intend to use for this job. 15.1.1.12. Use the [⇓] key to move to the “Sensor” column for Channel A row. Scroll through the choices in this field using the [⇐] or [⇒] keys. The available choices are dependent on the number of sensors you have programmed into your analyzer. (See chapter 18 “Miscellaneous Items”, for sensor setups.) 15.1.1.13. Use the [⇓] key to move to the “Channel “Desc” column for Channel A row. You define this optional field. The field will accept any alphanumeric characters entered

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from the keypad. This field is used as a description for the individual channel such as “Lat” and “Vert” or “Gearbox” and “Core.” 15.1.1.14. Repeat steps 15.1.1.12 through 15.1.1.13 for each of the channels you intend to use for this job. 15.1.2. Speeds 15.1.2.1. Press the [F2] “Speeds” key from the Overall Vibration Setup screen shown above in paragraph 15.1.1.2. The Speeds option allows you to measure several types of speed inputs for synchronizing with the vibration input or to provide an entry field for reference where no actual speed input is available. This allows you to view amplitude, in the selected engineering units, relative to the speed of the machine or component being monitored.

15.1.2.2. The column of numbers to the left side of the fields represents the four speed input channels, TACH 1, 2, 3, and 4. In the “Measure” field, use the [⇒], and [⇐] keys to select the type of input. The available selections are: NONE (where no speed input or reference is used), PULSE S-H (Pulse, Single ended – High), Volts S (volts – single ended), PULSE D–H (Pulse Differential – High), Volts D (Volts Differential), PULSE S – L (Pulse, Single ended – Low), PULSE D – L (Pulse Differential – Low), and ENTERY (A user entered speed reference). NOTE Where selections vary between an “S” and a “D” suffix are necessary, the selection is dependent on whether the input is single ended (S) or differential (D). Where selections between an “L” and an “H” suffix are necessary, the selection is dependent on whether the required gain for the incoming signal is Low (L) or High (H). Generally a signal below 1 volt peak will require you to use the High gain (H) selection and inputs of over one volt Peak will require you to use the Low gain (L) selection.

15.1.2.3. The “DESC” column is the descriptive name for the tachometer input such as “N1, N2, Fan, or Turbine. Enter up to five alphanumeric characters in this field using the analyzer keypad.

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15.1.2.4. The “OFF/100%” column is used when the VOLTS selection is made in the “Measure” column described in paragraph 15.1.2.2 above. This field is used to enter the offset if measuring a DC voltage, or the frequency at 100% of component speed if measuring frequency in Hertz (Hz). Use the keypad to enter the value in the OFF/100% field. 15.1.2.5. In the “FACTOR” column, enter the multiplier for the DC voltage or Hertz to attain the actual component speed. If measuring a voltage, the speed is equal to OFF + voltage x Factor. If using a Pulse input, the RPM is equal to Hertz x Factor. The analyzer assumes the input to be relative to Hz (cycles per second) so that an input of one pulse per revolution (one-per-rev) would require a FACTOR of 60 (1 per-rev X 60 Hz assumed) to equal Revolutions per minute (RPM). Enter the factor using the keypad. 15.1.2.6. Repeat the steps from paragraph 15.1.2.2 through 15.1.2.5 for each of the four channels you intend to use for this job the/or press [ENTER] to accept your settings and exit back to the Overall Vibration Setup screen. 15.1.3.

Monitor

15.1.3.1. Install the sensors and cables required for the task. 15.1.3.2. Start the component you are checking (engine, generator, etc.). When the component is at normal operating condition (speed, temp, etc.) press the [ENTER] key to begin acquiring data. When monitoring is complete, press [ENTER] again to stop data collection.

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Chapter 16 Check Track (Revision 3, Oct 2012)

“Check Track” is an analyzer function that is accessed from the analyzer’s Main Menu banner screen. A description of this function follows, along with the information required to complete the menu screens within the function, and the steps necessary to perform the function.

The “Check Track” option is provided for quick track observations. This function allows for no data storage for later recall and review of data as do the other rotor-related functions of the analyzer. The “Check Track” function can be performed using either an industry-standard strobe for visual blade tracking or the ACES Systems’ Model 550 TraXTM, or Model 540 Series Optical Trackers. Before using the “Check Track” function on the analyzer, you must first install physical equipment such as cables and sensors. To setup equipment, do the following:

1. Place the analyzer in the location it will be used. Install and connect the one-per-rev source to the TACH channel of choice. (You must use a single pickup or optical tach for the once-per-rev signal.) 2. Connect the integrated cable of the Model 550 TraXTM directly to the “AUX/COM” input port located on the top end of the analyzer. If using the Model 540-2, connect the tracker to the analyzer’s “AUX/COM” input port located on the top end of the analyzer. If using a strobe light, connect the strobe interface cable to the analyzer’s “STROBE” input port. Connect the strobe to the interface. Set the strobe to the slave mode or turn the internal oscillator off. Connect the interface to the ship’s 28-volt power source. If aircraft power is 12V you must transform it to 28V to use the strobe with the analyzer. Install tip targets or place reflective tape on the blade tips per manufacturer's directions. NOTE Using the strobe may cause the “ON/OFF” function of the analyzer to be disabled. If you cannot turn the analyzer off using the [ON/OFF] key, disconnect the strobe, then turn the analyzer off.

After all equipment is installed, return to the analyzer. Then, to use the “Check Track function” on the analyzer, do the following: NOTE The Track Device selection will determine the fields necessary for that device. Not all fields are required for every device and therefore some fields may be omitted from the display.

1. Select “Check Track” from the Main Menu banner screen. The “Check Blade Track” banner screen appears as shown in the figure below.

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2. Use the [⇒] key to toggle between the two selections in the “Track Device” field, “TraX”, “Strobe” or “Tracker”. As shown in the figures above, the lower portion of the “Check Blade Track” banner screen then changes depending on the type of track device you selected. 3. Use the [⇓] key to move down to the “Tach Type” field. Using the [⇒] key, toggle between the available selections to select the tach type you are using to generate the once-per-rev signal. 4. Use the [⇓] key to move to the “Tach Channel” field. Using the [⇒] key, toggle between the available selections to select the tach channel you connected your tachometer to. 5. Use the [⇓] key to move down to the “No. of Blades” field. Using the [⇒] key, select the number of blades on the rotor you are checking. 6. Use the [⇓] key to move down to the “Relative to Blade” field. This selection will determine the reference blade for tracking displays. Selecting “AVG” will present rotor blade positions relative to the average of all blades. Selecting a specific blade number will present all other blade positions relative to the blade number selected. Use the [⇒] key to select the reference blade. 7. Move to the “Track Units” field using the [⇓] key. Select the track units from either inches or mm by using the [⇒] key to toggle between the available selections. This will set the scale for the track-recording screen. 8. Use the [⇓] key to move down to the “Blade RPM” field. Use the keypad to enter the expected main rotor RPM. 9. From the “Blade RPM” field, use the [⇓] key to move down to the “No. of Rotations” field. The field will accept numbers between 20 and 99. It is strongly recommended to use 30 rotations under normal conditions. The number of rotations may need to be increased as light conditions decrease. This will give the analyzer enough data to provide accurate track results. Using the keypad, enter the number of rotations you wish to use

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when acquiring blade data. (Refer to Chapter 3, “Using the VIPER” if you are unfamiliar with using the keypad.) NOTE The “Inches to Tip” field will ALWAYS be defined in inches. This field is independent of any units defined elsewhere in the configuration.

10. Use the [⇓] key to move down to the “Inches To Blade Tip” field. Using the keypad, enter the distance, in inches, between the point where the tracker will be used, to the blade tip in the location where the interrupter is over the magnetic pickup. (Or the reflective tape in front of the PhotoTach when used as the one-per-revolution source.) 11. Use the [⇓] key to move down to the “Rotor Diameter” field. Enter the diameter of the Main Rotor into this field using the analyzer’s keypad. (Refer to the Model 550 TraXTM operational supplement, P/N 75-900-4043 for additional details as necessary.) 12. Use the [⇓] key to move down to the unlabeled units field. Use the [⇒] key to select the measurement units you would like to use for the Main Rotor Diameter ONLY. Track elevation, lead/lag units, and adjustment units are all set in separate locations. (Refer to the Model 550 TraXTM operational supplement, P/N 75-900-4043 for additional details as necessary.) 13. Use the [⇓] key to move down to the “Lead/Lag Units” field. Use the [⇒] key to select the measurement units you would like to use for the Lead/Lag ONLY. Track elevation, rotor diameter, and adjustment units are all set in separate locations. (Refer to the Model 550 TraXTM operational supplement, P/N 75-900-4043 for additional details as necessary.) 14. Use the [⇓] key to move down to the “Blade 1 Offset” field. Use the analyzer’s keypad to enter a number between (-)180 and 180 indicating the angular distance from the location of the TraXTM to the location of the Target Blade at the time of the Tach event. (Refer to the Model 550 TraXTM operational supplement, P/N 75-900-4043 for additional details as necessary.) 15. Use the [⇓] key to move down to the “In. from Mast CL” field. Use this field to enter the distance between the centerline of the mast and the mounted location of the TraX. This is the linear distance measured in the same plane as the TraX is mounted. Valid entries are from 1 inch to 999 inches. (Refer to the Model 550 TraXTM operational supplement, P/N 75-900-4043 for additional details as necessary.) 16. Use the [⇓] key to move down to the “Trkr Inclination” field. Use the Inclinometer to measure the installed angle and enter it in this field. Valid entries are from 30 thru 90 degrees. (Refer to the Model 550 TraXTM operational supplement, P/N 75-900-4043 for additional details as necessary.) 17. When all fields are completed to your satisfaction, press [ENTER]. 18. The process, after setting up the tracking parameters, changes depending on the type of tracking device you are using.

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If using the TraXTM - When you press [ENTER] to accept the configuration above, the TraXTM will automatically begin taking data. As long as the Tach and Ready lights continue to flash, the unit is actively collecting data. When the Tach and Ready lights extinguish, the “Check Track – Results” screen will appear as shown in the sample above. The “Check Track -Results” screen presents the blade-tip-path information in both a graphical and a numeric format. The final percentage display on the “Data Gathered” line at the bottom of the screen is an indicator of the quality of data. The higher the percentage, the better the data quality. When finished, press the [BACKUP] key to exit back to the Main Menu banner screen. You may retake the track data by simply selecting the “Check Track” function again from the Main Menu banner screen and performing Steps 1 - 17 again.

If using a strobe - When the screen shown above appears, aim the strobe and press the trigger to fire. The targets will appear as a stacked image. By using the [F3] key you can spread the targets out from each other. Each time you press the [F3] key the targets

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separate further. To return the targets to the stacked position, press the [F1] “Reset” key. To rotate the group of targets to another position for ease of viewing, press the [F2] “Rotate” key. When finished, press the [ENTER] key to exit back to the Main Menu banner screen.

If using the Model 540-2 Optical Tracker - After arming the tracker by pressing [ENTER], a message to “Aim and Fire Tracker” appears on the screen (shown above). Aim the tracker and press the trigger to begin acquiring data. When acquisition is finished, the “Check Track Results” banner screen (shown in the following figure) appears.

The “Check Track -Results” screen presents the blade-tip-path information in both a graphical and a numeric format. Leading results will be displayed numerically as positive numbers and the blade icons will be to the left of the reference line. Track results will display high blades as positive numbers and the blade icon will be above the “0” reference line. The “Data Gathered” line at the bottom of the screen is an indicator of

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the quality of data. The higher the number of gathered data packets, the better the data quality. If the number is below 75% of the number defined in the “No. of Rotations” line above, you may retake the track data by pressing [BACKUP], selecting the “Check Track” function again from the Main Menu banner screen and performing steps 1- 17 again.

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Chapter 17 Transfer Data with PC (Revision 1, Aug 2007)

“Transfer Data with PC” is accessed from the analyzer’s Main Menu banner screen. A description of each of the functions follows, along with the information required to complete the menu screens within the function, and the steps necessary to perform the functions.

The “Transfer Data With PC via RS-232” menu selection is used in conjunction with ACES Systems’ AvTrend Silver software program. This software program is included with the purchase of the Model 4040 Viper Analyzer. See the AvTrend program help files or user manual for further information on using AvTrend. The “Transfer, Send Application” function of AvTrend provides a link between your PC and the analyzer so you can upgrade the analyzer software version without having to send the analyzer back to the factory. Upgrade files can be emailed to you upon request, but are normally downloaded from the ACES Systems web site www.acessystems.com. Check the web site to determine if you have the latest software version. AvTrend also enables you to upload jobs and setups to your PC. The data can be reviewed, trended and stored in AvTrend. Setups can be built in AvTrend Silver and then transferred to the Viper via a communication cable. As the setup is used in the analyzer, the stored influence coefficient is updated with the completion of each balance job. That influence is

transferred to the PC when data is downloaded. When the setup is transferred back to the analyzer, the updated influence remains with it. Setups can also be downloaded directly from the ACES Systems web site at www.acessystems.com, then uploaded to the analyzer A user manual as well as help files accompanies the AvTrend software program. Refer to those sources for detailed operating instructions.

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Chapter 18 Miscellaneous Items (Revision 3.01, Oct 2012)

18.1. Miscellaneous Items

The “Miscellaneous Items” banner menu screen contains several menu items, three of which are used for identification of the analyzer. The other items are user-accessible and editable items. All are described in the following sections.

18.1.1.

- Setup Sensors

The “Setup Sensors” option allows you to preprogram information about all the vibration sensors you own or use. Once all sensors are preprogrammed, they can be recalled and selected from an option list during a balance/analysis procedure, saving time during the procedure by eliminating the need to reinput sensor data. The “Setup Sensors” option also allows you to add, edit, and delete sensors from the analyzer’s memory. When the “Edit” function is selected, the screen changes to the “Select” banner screen.

On this screen you may choose to “Edit” the information for any of the listed sensors that are unlocked simply by selecting that sensor from the list. The screen will then change to the 18-2 – Miscellaneous Items 18 2012

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“Sensor Setup” screen and show the complete information currently in memory for the selected sensor.

18.1.1.1. – Add or Edit Sensor Names for some industry-standard sensors have already been preloaded into the analyzer at the factory and appear with a small padlock to the left of the name. The default sensor list cannot be edited or deleted. If your sensor name appears in the preprogrammed list, you may not need to proceed further. If your sensor name does not appear, then you must select “Edit” to add a new sensor name and specifications. To preprogram a sensor in the analyzer’s memory, you will need the following sensor specifications which should be available from the data sheet supplied with your sensor. 1. The sensor’s model or name that will be familiar to you and other users. 2. The sensor’s amplitude units sometimes called EU or engineering units. This will be expressed in one of the following formats: g’s (for equivalent gravities), IPS (Inches Per Second), mm/sec (millimeters per second), cm/sec (centimeters per second), mils (1000th of an inch), microns (1,000,000th of a meter), ubars, Pascals, Volts, m/s/s (meters per second per second), cm/s/s (centimeters per second per second), db (decibels), or Special. 3. The sensor’s sensitivity. This is normally expressed in mV per engineering unit, as described above. For instance, if using the model 991D –1 accelerometer, its engineering unit is in gs and it produces 20 mV for every g of force exerted on it, therefore its sensitivity is 20 mV/g. To add a sensor or to edit the specifications for an already programmed unlocked sensor, do the following: 1. Select “Miscellaneous Items” from the Main Menu banner screen.

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2. Select “Setup Sensors” from the “Miscellaneous Items” banner screen menu. 3. Select “Edit” from the “Manage Sensors” banner screen menu. NOTE To edit an existing unlocked sensor in the list, select it at this point, and proceed with step 5. For adding a new sensor, go to step 4. Preset sensors cannot be edited, only those entered by the user.

4. Press the [F1] key, which corresponds, to the function key window labeled “New” at the bottom of the screen. 5. The Sensor Setup screen shown below will be displayed. Toggle between the fields using the [⇑] or [⇓] key.

6. Enter a name for the sensor in the “Name:” field, using the keypad. The field will accept up to twenty, alphanumeric characters. 7. The “Amplitude Units:” field is a toggle selection field. Use the [⇐] or [⇒] key to toggle between the selections until the appropriate units are displayed. The choices are gs; (for equivalent gravities), IPS (Inches Per Second), mm/sec (millimeters per second), cm/sec (centimeters per second), mils (1000th of an inch), microns (1,000,000th of a meter), ubars (µbars, 0.1 Pascal), Pascals (100,000 bars), Volts, m/s/s (meters per second per second), cm/s/s (centimeters per second per second), db (decibels) or Special (custom configuration). 8. The “Probe Sensitivity” field is a numeric data field. It is used to enter the millivolt (mV) output of the sensor. This information can be found on the Sensor’s Specification Sheet from the manufacturer. Valid entries are from 0.001 to 3000.0 mV. 9. The “Reverse Polarity” is a toggle selection field. The two selections are “Yes” and “No”. This is a special function that will only apply to a very few sensors available. The selection should be toggled to “No” for the majority of cases. The ACES 991V sensor

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uses the reverse polarity and is set to “Yes”. If you do not know the polarity requirements of the sensor, call ACES Systems and ask for Customer Support. 10. The “Input Type:” is a toggle selection field. The two selections are “Single Ended” and “Differential”. This information is obtained directly from the Sensor’s Specification Sheet, Single Ended being the most common. If you do not know the polarity requirements of the sensor, call ACES Systems and ask for Customer Support. 11. When all fields are completed as required, press [ENTER] to accept your settings and exit the screen. 18.1.1.2. - Delete Sensor Delete is a selection available on the “Manage Sensors” banner screen menu. Select Delete from the “Manage Sensors” banner screen menu. Next select a sensor to delete from the list that appears. Only unlocked sensors will appear in this list. The analyzer will display a message that asks “Are you sure?” Press [F1] to confirm “Yes,” press [F5] for “No” and to return to the “Manage Setups” screen.

18.1.2.

- Set Date and Time

The “Set Date and Time” selection allows you to set the desired date and time in the analyzer. These settings are entered directly using the analyzer keypad.

To set the date and time, do the following:

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1. Select “Miscellaneous Items” from the Main Menu banner screen. 2. Select “Set Date /Time” from the “Miscellaneous Items” banner screen menu. 3. Enter the time in a 24-hour format as follows in the “Time” field. Hour - Valid range is 1 through 24, followed by a “.” (Decimal) Minute - Valid range is 0 through 59, followed by a “.” (Decimal) Seconds - Valid range is 0 through 60 4. Use the [⇓] to move to the “Date Format” field. You may specify the date format you wish to use by using the [⇒] key to toggle the selection to the format you wish to use. Available formats are: MM/DD/YYYY, DD/MM/YYYY and YYYY/MM/DD, where YYYY = Year, MM = Month and DD = Day. 5. Use the [⇓] key to move to the “Month” field and enter the month. Valid range is 01 through 12. 6. Use the [⇓] key to move to the “Day” field and enter the say. Valid range is 01 through 31. 7. Use the [⇓] key to move to the “Year” field and enter the Year. Valid range is 1998 through 9999. Press [ENTER] to accept the entries and exit the screen.

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18.1.3.

– Set Power-Off Timeout

To set the Power-Off Timeout, do the following: 1. Select “Miscellaneous Items” from the Main Menu banner screen and press [ENTER]. 2. Select “Set Power-Off Timeout” from the Miscellaneous Items banner screen menu and press [ENTER]. The “Set Power-Off Timeout” screen will appear as shown below.

3. Use the [⇒] key to select “Yes” or “No” to answer the question “Enable power-off timeout?”. Use the [⇓] key to exit the field. 4. Exiting the above field with “Yes” selected will cause the “Timeout length (minutes)” line to appear. Select a number of minutes between 5 and 60; this is the length of time the analyzer power will remain on before automatically shutting off. Press [ENTER] to exit this screen and return to the “Miscellaneous Items” menu. Revision 3.01, Oct 2012

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18.1.4.

– Set Job Count Limit

You can limit the number of jobs the analyzer will store for each type of job. For example, if you institute a 10-job limit, the analyzer will store a maximum of 10 propeller balance jobs, 10 Main Rotor Balance Jobs, 10 Vibration Survey Jobs, 10 Transient Vibration Survey jobs, etc. all at the same time. To enable or disable this feature select “Set Job Count Limit” from the Miscellaneous Items menu and press [ENTER]. Then, from the “Job Count Limit” screen set “Enable job count Limit?” to “Yes” to enable and “No” to disable. If you have enabled this feature you will be able to select the number of jobs the analyzer retains. Valid entries in the “Max jobs of each type:” field are integers between 10 and 50.

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18.1.5.

– Check Battery

The “Check Battery” function allows the user to check the remaining battery life prior to beginning a job. The current state of the battery is presented in a percentage of full charge remaining. This check is for planning purposes only but should give you sufficient information to determine f you have enough battery capacity remaining to conduct a normal job. A fully charged, new battery should normally supply constant power to the analyzer using two vibration sensors and one optical tachometer for approximately 10 hours. This time will vary dependent on the number of sensors and tachometers and their power requirements. Therefore, for planning purposes, an indication of 50% should be sufficient charge remaining for 5 hours of operation. To check the battery life, do the following: 1. Select “Miscellaneous Items” from the Main Menu banner screen. 2. Select “Check Battery” from the “Miscellaneous Items” banner screen menu. 3. The analyzer will display the percentage of full battery charge remaining. NOTE We recommend the battery be charged on a regular schedule and that a job not be started with less than 50% of full charge remaining. See “Chapter 2, Analyzer Description” for instructions on charging the battery.

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18.1.6.

- Analyzer Information

The “Analyzer Information” banner screen contains information about the analyzer and its owner. The information is entered into each individual analyzer at the factory at the time of purchase.

This information is significant for two reasons. If your analyzer is ever stolen or lost, it can easily be identified by the information contained on this screen. The information cannot be deleted or altered and remains intact regardless of the availability of power to the analyzer. Also, if the analyzer is used in a business, this information can is used as advertisement and future reference to your customers as each printout contains a header based on the information from this screen. The analyzer information can only be entered or changed by technicians at the ACES Systems facility. Check to insure all information on this screen is correct. If changes are required, contact ACES Systems at the phone number listed at the front of this manual. 18-10 – Miscellaneous Items 18 2012

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To access the “Analyzer Information” banner screen, do the following: 1. Select “Miscellaneous Items” from the Main Menu banner screen. Select “Analyzer Information” from the “Miscellaneous Items” banner screen menu. In addition to owner information, this screen displays the following information: Serial # - The serial number of the analyzer. License: - The license number determines which Main Menu items are accessible to this analyzer. The license number is specific to the serial number of the analyzer and can only be issued by ACES Systems. Prior Seq - Indicates whether you have purchased a limited-use license. ROM Ver – Indicates the version of Read Only Memory currently installed in your analyzer. This may also be referred to as the “BOOT ROM.” ROM Date: - Indicates the date of the currently installed ROM Version. APP Ver – Indicates the version of the currently installed application software running in your analyzer (The application version is upgraded by you, the user via ACES Systems’ WinFlash Software.). APP Date – Indicates the date of the currently installed application software. Calibration Date: - Indicated the date and time that the last calibration was performed on the analyzer. This date and time can only be changed by ACES Systems personnel. Available Working Memory: - Indicates an approximate value of memory available to the analyzer for storing setups and jobs. At the bottom of the screen, the [F2] key correlates to “License” on the screen. By pressing the [F2] key you will be taken to the “License Edit” screen shown below. You will enter the license number, typically found inside the lid of the analyzer, into the analyzer from this screen. Use the [⇓] key to move from field to field. When all fields are filled in, press [ENTER] to store the new configuration. When the analyzer is turned [OFF] then back [ON], any new menu items will become visible.

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18.1.7.

– Database Information

The “Database Information” selection will produce the “Database Information” banner screen. The screen is divided into two sections to accurately reflect the status of the two memory areas found in the Model 4040 Viper. The top half of the screen displays information about the “RAM Database”. This database stores most of the information recorded during Propeller Balance, Fan/Turbine Balance, Main and Tail Rotor Balance, and Vibration Survey Jobs. The total number of objects stored and read successfully will be displayed. The total free memory (in bytes) and the total amount of stored data (in bytes) will be displayed. The “Last Modified” date and time will be listed as the last line of the RAM Database section. The bottom portion of the screen displays the amount of “Transient Storage” that is currently full. This data comes from the Transient Vibration Survey function and may fill at a different rate than the data stored in the RAM Database. When the Full indication approaches 100% 18-12 – Miscellaneous Items 18 2012

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Full, you must delete some of the Transient Vibration Survey Jobs to allow for proper data storage. In either case, the RAM Database or the Transient Storage, you will be prompted during the job or before the job if enough memory is not available to store the current job. This is an information (read only) screen and its contents cannot be altered by the user from within this screen. Press the [F5] “Continue” key or the [BACKUP] key to exit this screen.

18.1.8.

– Erase Entire Database

The Erase Entire Database menu item is a fast method of removing all stored data, setups, and jobs that currently reside in the analyzer’s memory. After selecting this option and pressing the Enter key, the analyzer will show a message asking you to verify that this is what you intend to do. Pressing the [F1] “Yes” key or the [F5] “No” key verifies your intent.

18.1.9.

– USB Information

The USB Information key has no function even though USB transfers are possible.

18.1.10. – Erase Orphaned Transient Spectra The Erase Orphaned Transient Spectra function checks the flash file system (FFS) for any spectra that belong to any transient vibration survey that no longer exists. The transient vibration survey may have been intentionally erased or deleted by several available options in the analyzer. For instance, if a transient survey in the RAM database becomes corrupt the analyzer will detect this during the next boot and present an information screen to notify you of the corrupt data. It will then provide the option to delete all corrupt data by pressing a function key. The Revision 3.01, Oct 2012 13

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software process that rebuilds the RAM database following the deletion of the corrupt data doesn't know what kind of corrupt object was deleted, because that information, being corrupt, is unreliable. As a result, any spectra taken for that job get left behind in the flash file system (FFS), where they occupy memory space, but are not accessible or useful in any way. Orphaned Spectra should be a rare occurrence. This function is made available to correct memory problems that may exist during those occasions. There is no need to run this function routinely unless memory errors occur and you are asked to run it during a troubleshooting exercise with a customer support representative of ACES. If you do not use the Transient Vibration Survey feature, this menu item is not a usable feature.

18.1.11. – Bus Test The Bus Test feature of the Miscellaneous Items menu is a troubleshooting tool for boot related errors. There is no reason to run this test unless you are experiencing numerous boot errors or you do it as directed by an ACES support representative in the course of troubleshooting.

18.1.12. – EMS Comm Test This feature will allow you to perform an EMS communications test to test your cable connections with the 1752B JEDA equipment. Specific diagnostic messages will help you troubleshoot connectivity issues.

18.1.13. – Show Welcome Screen This option will display the welcome screen giving you a quick method to access the Boot and App versions of the analyzer operating software. Press [ENTER] to leave the welcome screen and return to the “Miscellaneous Items” menu.

18.1.14. – Enable Memory Leak Tests This function is made available to troubleshoot memory problems that may exist during usage. There is no need to run this function routinely unless memory errors occur and you are asked to run it during a troubleshooting exercise with a customer support representative of ACES.

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Chapter 19 Equipment and Accessory Setup and Troubleshooting (Revision 3, Aug 2007)

The information in this chapter is provided to assist you in avoiding some of the common pitfalls associated with setting up and using the various accessories, cables and sensors required for performing routine balance or vibration survey jobs with the Viper 4040.

19.1. - Battery Charger and Battery The following troubleshooting paragraphs apply only to the Nickel Cadmium (NiCd) battery installed as original equipment in analyzers having a 01xxx serial number. CAUTION The charger is built for indoor use only. Don’t expose the charger to the elements. WARNING Power requirements must be determined on an individual basis. Operating the Viper with the battery charger connected can affect the accuracy of the acquired readings. The analyzer was not intended to be operated during the charging process.

Always replace the cap on the “BATT CHG” port of the analyzer. The unprotected pins may short out on surrounding material and cause damage to the analyzer or battery. Battery Specifications The Viper 4040 battery pack is a custom built 12V NiCd pack. The specifications of the battery pack are: ♦ Nominal 12V pack voltage. ♦ Fully charged voltage 14V. ♦ 3000mAh nominal capacity

♦ The custom pack is composed of 10 size C 1.2V cells. BATTERY LIFE/DISCHARGE When the battery pack is fully charged, the battery voltage is approximately 14V, which is considered above the 100% charge level. When the analyzer is used, the battery voltage will quickly drop (within the first 20-30 minutes of use) to 12.4V, which is approximately 60% indicated charge level. At that point the voltage will stabilize near 12.3V to 12.2V, with a slight decrease with use, until the full capacity is reached, at which point the voltage will drop VERY quickly. When the battery voltage reaches the 8% charge level, which is 11.8V, the battery voltage is beginning to decrease VERY rapidly. This is a standard discharge characteristic of ALL NiCd batteries. A typical discharge curve is presented below to illustrate this behavior.

Typical Battery Discharge Curve (C/5 Rate)

15 14

Battery Voltage (V)

13 12 11 10 9 8 7 6 0

50

100

150

200

250

300

Operating Time (minutes)

Under typical usage conditions, using two channels, an optical tachometer and the backlight ON, the analyzer should maintain an operational charge for approximately 4.5 hours. If the backlight is turned off or otherwise not used, this time increases to near 7 hours.

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CHARGING The most important guideline for charging is that no charger should be left connected to the analyzer for an indefinite amount of time. The charger can safely be used overnight (12-14 hours), but leaving it connected for longer periods can lead to overcharging, over heating, and reduced capacity effects. A good rule of thumb is to charge only when needed and then for overnight time periods. If you practice this method, the battery pack should last 5 years. If the charger is connected indefinitely (for days until the unit is needed), the battery pack will probably be damaged and require replacement after only 6 months. The reason for this is that the charger uses a constant-voltage charge technique and is not true “trickle-charger”. The charger does reach a quasi trickle-charge state, which is a slow charge, but the battery eventually reaches a point where it cannot accept any additional charge. At that point, heat buildup and electrolyte breakdown begins resulting in permanent and irreversible damage to the battery pack. Some common charging problems are leaving the battery connected to the charger for too long of a time period (overcharging) and repeated shallow cycling of the battery (memory effect). Both of these charging problems result in reduced battery capacity, but in most cases are reversible problems. OVERCHARGING If the battery is left on the charger for an extended period of time, overcharging can occur. This occurs when either the charge rate exceeds the ability of the battery pack to recombine oxygen gas and limit pressure buildup or when it generates more heat than the battery can safely dissipate. Overcharging can damage the battery and SIGNIFICANTLY reduce the capacity. Some studies suggest a capacity of up to 30%! This effectively reduces the typical 4.5hrs of battery life to a little over 3 hours. Overcharging is a REVERSIBLE problem, in that a few full charge and discharge cycles will restore normal voltage and expected capacity. This means that the analyzer should be used, or setup on a desk in a measurement mode, until the battery is drained and the unit shuts itself off. The charger should then be connected for 1214 hours and then disconnected. The unit should then be used or run again until the battery is completely drained. Full discharge of the battery does not have to be standard operating procedure (done every time the unit is used), but should be done periodically to keep the battery pack properly “conditioned” to obtain the full capacity. VOLTAGE DEPRESSION/MEMORY EFFECT Voltage depression or “Memory Effect” is a common complaint about NiCd batteries. If a battery is short cycled repetitively, partially discharged and then recharged the voltage and delivered capacity will gradually decrease. If the battery is then fully

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discharged, the discharge voltage is reduced compared to the original full discharge. This basically means that the original 4 hours of life, now reaches the re-charge/cutoff voltage after 3.5 hours. This makes the battery appear to “remember” the lower capacity of the shallow discharge. This phenomenon is REVERSIBLE. The battery can be restored to full capacity with a few full discharge-charge-reconditioning cycles as described above in the OVERCHARGING section. The “memory” problem is typically induced when the battery charged following short usage periods of one-to-two hours. When this cycle is repeated several times, the process effectively conditions the battery to react at 40-50% charge range as if it were the effective full capacity. Subsequent use of the unit results in the voltage reaching the shutoff level much sooner. TYPICAL USE The battery pack will perform best when it is used in full charge/full discharge cycles. This means connecting the analyzer to the charger for 10-14 hours, then disconnecting it and using the analyzer until the battery capacity is 0% indicated charge. Since this is not a typical use pattern, the customer should ensure that periodic complete discharges are performed. You may discharge the unit by simply turning it on, turning on the backlight and allowing it to sit until it shuts off automatically. This will keep the battery pack conditioned and prolong life and capacity. NOTE You must set the Power-Off Timeout option to “NO” in order to discharge the battery using this method. See Chapter 18, “MISCELLANEOUS ITEMS” in this manual for making this setting.

TROUBLESHOOTING If you experience problems with battery life, make sure that everyone who uses the analyzer understands the procedures for caring for battery care. If the overcharging and memory effects are not severe and electrolyte damage has not occurred, you may be able to recover full battery functions by performing several full discharge/charge cycles. Use the following steps: 1. Setup a Transient or Monitor Overall job to measure all 4 analog and all 4 tach inputs and turn the backlight on (there does not have to be an actual inputs on any of the channels). 2. Leave the unit running on a desktop or bench until the unit turns itself off.

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NOTE You must set the Power-Off Timeout option to “NO” in order to discharge the battery using this method. See chapter 18, “MISCELLANEOUS ITEMS” in this manual for making this setting.

3. Connect the unit to the charger for NO MORE than 14 hours. 4. Repeat the above steps at least once, ideally 2 times to fully cycle the battery. If this process does not restore full battery capacity, the batter pack has been damaged and must be replaced.

TIPS/SUMMARY ♦ Ensure you have and are using the proper charger. ♦ Non ACES Supplied chargers are not recommended due operational limits and possible damage that may be incurred. ♦ The analyzer will drop rapidly from 100% charge to around 70% and stabilize there with a much slower rate of decrease over the rest of the discharge cycle. Don’t be alarmed by the initial sudden drop in the % charge indication. ♦ If the use of the backlight is not necessary, battery life can be greatly extended (up to 2.5 hours in a typical configuration) if it is left in the OFF position. ♦ No charger should be left connected to the unit for more than an overnight charge period (12-14 hours). ♦ Periodic full discharge/charge cycles will properly “condition’ the battery and maintain full life and capacity. ♦ Partial discharges followed by full charges should be avoided, if possible, to prevent a “memory” effect. ♦ Overcharging and memory effects can often be resolved/repaired by completing several (2 or 3) full discharge/recharge cycles. If the problem is not resolved using these cycles, the battery has been damaged and must be replaced.

19.2. - Cables Cables can be damaged if pinched in doors and windows. Always check for pinches, cuts, and abrasions prior to using the cable. Discard, replace or repair cables as necessary if damage is discovered. Exercise care when making connections. Bent or damaged pins may cause problems with normal operation. Check all connectors for evidence of damage. An optional automatic cable check device is available from ACES Systems. Route cables away from all hot areas and electrical equipment. If the cable is used while it is lying on the ground, you may experience radio interference. Secure the cable to the aircraft

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19 Equipment and Accessory Setup and Troubleshooting – 19-5

fuselage (off the ground) with duct tape to correct this interference. Duct tape or wire ties are excellent for securing the cables.

19.3 - LASETACH WARNING Never look directly into the laser aperture. Damage to the eye can occur.

Don’t use the LASETACH when the weather conditions include precipitation. A single drop of water on the aperture lens can dissipate or block the laser beam. When humidity and temperature conditions meet certain levels, fog may develop in the intake of the some jet engines due to the low pressure being produced there by engine operation. If this occurs, the fog may be dense enough to effectively block the laser beam from reaching the reflective target. Under these circumstances, you may have to incorporate an alternate tachometer source or wait for conditions to become more favorable. Never use any reflective target tape other than that recommended in the manual (3M Tape, Model 7610 or ACES Systems’ P/N 10-400-0176). The incorrect type of reflective tape can render the LASETACH ineffective in high-speed applications. An angle of 5 to 10 degrees from the perpendicular of the LASETACH/reflective tape is best. If the shape of the laser beam becomes oblong or egg shaped, this may indicate a scratched or damaged lens. If this is associated with erratic or unstable tachometer readings, return the Lasetach to ACES Systems for repair.

19.4. - Phototach The Phototach is very rugged. It is water resistant, but water on the lens may render it ineffective. Always check the lens for cleanliness and to be sure it is free of damage such as cracks and scratches. The optimum range of the Phototach is 12 to 18 inches. It may work at closer or more distant ranges, although it may not be as reliable. In some high-speed applications, the amount of tape passing through the Phototach beam may need to be increased to insure a good trigger. If the indicated speed (in the analyzer function) becomes erratic or unstable at higher speeds, increase the length (or width as the case may be) of tape so that the tape remains in the beam for a longer period of time during each rotation. See paragraph 19.6.1 below for more details.

19.5. – Propeller Protractor The protractor is made of hard plastic. If folded or crimped it will bend and remain bent. To straighten it, lay it on a flat surface and heat it with a hair dryer on a high setting. Discontinue the heat and leave the protractor in its flat position on the level surface to cool.

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19.6. - Reflective Tape (3M Tape, Type 7610) Always thoroughly clean the area where the tape is to be applied. Using scissors or some other cutting tool, round off corners of the tape and be sure all edges are pressed down. Rounded corners help to prevent tape from peeling up during use. Remove any bubbles in the tape by pressing them toward the edge of the tape to prevent “lifting” due to the airfoil effect during high speed runs. If used on a very high speed application, you may use a very thin coat of super glue or clear nail polish on the edges of the tape to prevent the tape from peeling back due to the force of high velocity air along the edges of the tape.

19.6.1. - Reflective Tape Width Requirements If problems are experienced using the Phototach (this does not apply to the Lasetach) while balancing high-speed props with the reflective tape further out on the blade, refer to the following chart for tape placement adjustments. 1. First, measure the distance from the center of the propeller shaft to the location you intend to place the reflective tape. 2. In the chart below, select from the RPM column the first speed greater than the speed at which you intend to balance. 3. From this RPM number, proceed across the chart to the right until you come to the first number larger than the distance measured in Step 1 above. 4. From this point, follow the column up to the top to the minimum tape width required for your application. As an example, use the following parameters: the distance from the propeller shaft to the intended tape location measures 25 inches and the balance speed is 2300 RPM. Select 2400 from the RPM column since this is the first speed greater than your intended balance speed of 2300. From this number, follow the row across to 26.5, which is the first number higher than your intended tape location of 25 inches. From 26.5 follow the column straight up to the top--2 inches. This is the width of tape required for accurate readings at the intended distance and RPM level. (If your reflective tape is only 1-inch wide, place two 1-inch strips of tape side by side to create 2 inches.)

RPM 1000 1200 1400 1600 1800 2000 2200 2400 2600 2800

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1” 31.8 26.5 22.7 19.9 17.7 15.9 14.5 13.3 12.2 11.4

Minimum Tape Required 2” 3” 63.7 95.5 53.1 79.6 45.5 68.2 39.8 59.7 35.4 53.1 31.8 47.7 28.9 43.4 26.5 39.8 24.5 36.7 22.7 34.1

4” 127.3 106.1 90.9 79.6 70.7 63.7 57.9 53.1 49 42.4

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19.7 - Vibration Sensor Do not drop the sensor. Although built for rugged use, most accelerometers and velocity sensors are susceptible to internal damage when dropped, especially on hard surfaces such as concrete ramps. Do not mount a sensor on a hot section of the engine until you are certain it will withstand the maximum amount of head being generated in that area. A sensor must be designed for high temperature use to be used in this type of environment. The extreme heat may permanently damage the sensor. There are no repair capabilities for most modern sensors. When connecting cables to the sensor, make sure the cable is not forced against the cowling at the point where it is connected to the sensor. This condition may introduce resonant vibrations, generated by the cowling, into the sensor via the cable and connector. This induced vibration will complicate or render the balance/vibration survey invalid. Be sure to include your sensor with the analyzer when returning it in for calibration. The sensor will also be checked as part of the calibration procedure.

19.8. – Optical Tachometer See Section 19.3 LASETACH or Section 19.4 PhotoTach for tips that also apply to optical tachometers.

19.9. Reinitializing the Analyzer With the analyzer turned [OFF], push and hold the [5] key. While holding the [5] key down, turn the analyzer on by momentarily pushing the [ON/OFF] key. After the analyzer screen appears, you may release the [5] key and allow the analyzer to continue with the boot process. This may correct some malfunctions associated with corrupt data in the analyzer. After the boot up process is complete, you will see a message on the screen asking “You performed a hard reset. Do you also want to wipe out all information (setups, jobs, etc.) in the database?” You must select either YES by pressing the [F1] key, or NO by pressing the [F5] key at this point to continue. Typically you should select [F5] NO. If any corrupt data is detected in the database, the analyzer will automatically delete it and provide an information message on screen to indicate this. If the corrupt data was in a setup, you may have to reenter the setup or reload it from a setup file using AvTrend. Start a new job with the analyzer to insure the problem has been rectified. If this procedure fails to correct the encountered problem, call ACES Support.

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19.10. – Troubleshooting Ground Loop Issues If ground loop problems are suspected, the offending connection can usually be tracked down by disconnecting analyzer connections one at a time to see if the problem goes away. Non-ACES cables may induce ground loops if shields/grounds are terminated incorrectly. Shields should be terminated at ONE END OF THE CABLE ONLY! Terminating shields at 2 locations will induce ground loops and noise into the system. Case-grounded sensors should be avoided as they connect sensor case to the engine and/or aircraft ground, which may be at several VOLTS different ground potential than analyzer ground. If case grounded sensors must be used, they should be used with an isolating mounting pad. Differential input configuration should be used for most tach/speed connections. This provides a non-ground referenced sensing point that is very high impedance, effectively isolating the analyzer from the tach/speed source (such as a mag pickup or coil, etc). Single-ended input configuration should typically be used for most vibration sensor inputs. Single-ended is required to provide a good ground reference/return for the analog signal. Some sensors are differential, but external ACES charge amplifiers convert the sensor output differential charge to single-ended (ground-referenced) voltage.

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Chapter 20 Reading Spectrum and Scales (Revision 2, Oct 2012)

The information in this chapter is provided to assist you in reading the graphical displays of the various types of data that can be acquired using the Viper 4040 Analyzer.

20.1 - Reading the X and Y Plotted Vibration Spectrum

A graphic spectrum display allows the user to investigate all aspects of a rotating component related to vibration. In the figure above, the primary indicators are the plotted peaks that represent component vibrations. The scale of the “X” axis, along the lower horizontal edge, displays the frequency of interest in Hertz (Hz), which is cycles per second, or in Revolutions per minute (RPM), as shown in the figure. The frequency scale is a means of locating a component operating at a known number of cycles per second (Hz) or minute (RPM).

The scale of the “Y” axis, along the left vertical edge, displays the amplitude or strength of the component’s expended energy in the specified engineering units which in the figure above are presented as IPS, or Inches Per Second, of movement.

20.2 - Reading the Converging Vibration Indicator and Scale.

The converging vibration indicator and scale, as shown in the illustration above, appears in several instances when using the analyzer. The Propeller Balance, Rotor Track and Balance, Fan Trim Balance, and IPS and Clock functions all use the converging vibration scale. The scale is graduated along the right vertical side of the indicator from 0 at the bottom to the upper end of the scale which is determined by the FSR setting. The vertical indicator bar which begins at the bottom and continues upward in the center of the window indicates the current average amplitude by its upper end, relative to the adjacent scale. A thin horizontal line (see arrow 2 in the figure above) indicates the latest collected (non-averaged) amplitude. The lower error bar (see arrow 1 in the figure above) and the upper error bar (see arrow 3 in the figure above) will converge on the average indicator as errors are averaged out of the indication. Also notice that to the right of the indicator, the Error is reported as a numeric value. The value is an indication of the quality of the collected data to this point. When amplitudes are high, this error will average down to, or near 0.00 very quickly. As the amplitude is decreased due to the balancing process, the percent value will be slower to average down toward 0.00. This is not a fault or defect in the analyzer, but only an indication of the averaged data quality relative to the current vibration being produced by the component. When collecting data with this indicator displayed, you should continue taking data until the upper and lower error bars converge on the average indicator. The reported error will also continue to decrease as the bars converge. Allow the unit to collect data as long as the error continues to decrease. This will insure you have the most accurate data possible. Remember that the percent error will be slower to reduce as the balance is improved. If you believe wind

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gust, aircraft movement or other external influences have caused the indications to be corrupted, press the [F1] key for “Reset.” This will clear the averaged data and begin a new averaging. When satisfied that the data is acceptable, press [ENTER] to stop the data collection and accept the averaging. Use the [F3] “+/- Pol.” key to reverse the polarity of the Tach Signal. If the Current RPM is erratic at a stable engine speed, press this key in an attempt to stabilize the reading. This option may be necessary when some of the Tooth settings; Shfd Tth, Hi Tth, Lo Tth, Mssg Tth, AjSh Tth; are selected on some engines. The top line of this screen can display three different status messages. The messages are: “Waiting for Data” This message is displayed until in-range RPM, IPS, and Phase Angle readings are recorded by the analyzer. The only way to exit the screen while this message is displayed is to use the [BACKUP] key. “Acquiring Data” This message is displayed during data acquisition. As long as the data remains in-range, the analyzer will add each new sample to the running average. The only way to exit the screen while this message is displayed is to use the [BACKUP] key. “Complete! Press ENTER” This message will appear when a minimum number of consistent samples have been collected. Allow the unit to collect data as long as the error continues to decrease. This will insure you have the most accurate data possible. Use the [ENTER] key to exit this screen and store the reading. The text below the “Current” heading indicates the RPM, IPS, and Phase Angle from the latest collect vibration sample. These values will change as the individual readings are collected. The RPM will be the currently recorded speed value. For Run 1 the “RPM” heading itself will blink “HIGH” or “LOW” if the current RPM is more than +/- 200 RPM from the RPM defined in a Propeller Balance setup. For Run 1 in Main Rotor Track and Balance or Tail Rotor Balance, the HIGH/LOW warning will appear if the value is +/- 50% of the RPM value defined in the setup. For Run 2, the HIGH/LOW warning will appear if the value is +/- 50 RPM from the value recorded during Run 1.

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Chapter 21 Printing (Revision 3, Oct 2012)

The Model 4040 Viper Analyzer does not allow printing directly from the analyzer. To print jobs, download to AvTrend and print them using AvTrend. This provides much more flexibility and detail. Specific instructions can be found in the AvTrend Silver User’s Manual, ACES P/N 75-900-4042.

Chapter 22 Specifications Viper 4040 (Revision 3, Oct 2012) ACCURACY

Vibration Amplitude +/-5%, 0-190 IPS with 20 mV per IPS sensor Frequency Range 0 -30K Hz per channel Tachometer Inputs +/- 0.01%, 150-32,000 RPM Phase resolution of 1 degree with accuracy of +/- 3 degrees repeatable to 1 degree.

MICROPROCESSORS

5

MEMORY

32 MB

POWER SUPPLY

Type Rechargeable Nickel Cadmium (NiCd) Battery OR Rechargeable Nickel Metal Hydride (NiMH) Battery Operation Time Approximately 8 Hours – NiCd Approximately 10 Hours - NiMH Voltage 12 V DC Battery or 14-28 V DC ships power Charging Time Fast charge approximately 4 hours, Trickle charge 10-12 hours

PHYSICAL

Height Width Depth Weight Operating Temperature

9.75" 10.5" 5" ~7.5 lbs. 0 to +50 C

AC INPUT

The data acquisition system is capable of measuring AC values to +/- 1.55 volts.

UNCONDITIONED TACHOMETER INPUT

Tachometer signal processing electronics are capable of adjusting the fullscale input range to handle any available sensor for measuring speed. Adjustment of the tachometer conditioning electronics is performed automatically and requires no user intervention. The tachometer circuitry can detect speeds up to 32,000 RPM. The tachometer circuitry can detect input voltages up to 30 Volts Peak.

SENSOR TYPES

The analyzer will accept any vibration signal input (acceleration, velocity, or displacement.) The input is then displayed as collected or integrated to any other vibration unit. The vibration input will accept any voltage - generating sensor (must have external charge converter when in charge mode) and will supply power to the sensor when required.

ANALYSIS RANGE

Anti-aliasing filters are used with a Fast Fourier Transform (FFT) to accurately transform data from the time to the frequency domain. The analyzer will perform FFT resolutions of 100,200,400,800, 1600, 3200, and 6400 lines.