PS3006 e

M-DLPS3006 ELECTRICAL CALIBRATION SCHEDULE SPECIFICATION ISSUE RECORD Spec Issue Amendment Approval Issue Date 1 2 3 4 Page No.
5 6 7 8 9 10
Page Issue Status

This document is the property of Messier-Dowty Ltd. and cannot be reproduced or communicated without prior authorization of Messier-Dowty Ltd.
1 2
JWL JWL
28/1/2002 29/5/03
1 2
1 2
1 2
1 2
1 2
1 2
1 2
1 2
1 2
1 2
FOR REFERENCE ONLY WHEN PRINTED UNLESS OTHERWISE SPECIFIED Check revision level prior to use for possible updates 1
This specification may be implemented at once, but it must be implemented by: 29 June 2003. Reason for change: 1. 2. Reflects requirements of Airbus UK audit and ongoing refinement of procedures or new equipemnt. All references to Messier-Dowty Limited specifications are prefixed M-DL, not all of these specifications have been reissued with a M-DL prefix yet. Please ensure you are working to specifications issued to you by Messier-Dowty Limited, see S40M-DL for latest issues.
Compiled by Approved by Agreed by Issuing Authority
See master for signature See master for signature See master for signature See master for signature
D Bevan Principal Electrical Engineer J Lindley Senior Chief Engineer Quality T Hobbs Engineering Services
COPIES OF THIS SPECIFICATION MAY BE OBTAINED FROM ENGINEERING SERVICES, MESSIER-DOWTY LIMITED
THIS DOCUMENT IS THE PROPERTY OF MESSIER-DOWTY LIMITED AND MAY NOT BE COPIED OR DISCLOSED TO THIRD PARTIESITHOUT AUTHORISATION.
M-DLPS3006 Page 1 Issue 2
SPECIFICATION ISSUE RECORD Spec Issue 11 12 13 14 15 16 17 Page No. 18 19 20 21 22 23 24 25
Page Issue Status 1 2

1 2
1 2
1 2
1 2
1 2
1 2
1 2
1 2
1 2
1 2
1 2
1 2
1 2
1 2
1 2
SPECIFICATION ISSUE RECORD Spec Issue Page No. 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40
Page Issue Status 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2
SPECIFICATION ISSUE RECORD Spec Issue 41 42 43 44 45 46 47 Page No. 48 49 50 51 52 53
Page Issue Status 1 2

1 2
1 2
1 2
1 2
1 2
1 2
1 2
1 2
1 2
1 2
1 2 2 2
SPECIFICATION ISSUE RECORD Spec Issue Page Issue Status Page No.
CONTENTS ELECTRICAL CALIBRATION SCHEDULE ..................................................................................................6 1. Purpose. ..................................................................................................................................................6 2. Associated Specifications. ........................................................................................................................6 3. Referenced Documents............................................................................................................................6 4. Metrological Confirmation Systems...........................................................................................................6 A. The following section is taken from the applicable International Calibration Standards and serves to illustrate the philosophy behind this specification document..........................................................................6 A. Scope ......................................................................................................................6 B. Definition ......................................................................................................................6 C. Confirmation System ......................................................................................................................6 D. Checking Measurement Standard .........................................................................................................7 E. Auditing of the system ......................................................................................................................7 F. Planning for Measuring Service or Standards........................................................................................7 G. Intervals of Confirmation ......................................................................................................................8 H. Variation in Applicable Standards..........................................................................................................8 5. Instruments and Equipment......................................................................................................................8 A. Instrument Ranges. ......................................................................................................................8 B. Purchase Control of Electrical Equipment..............................................................................................9 6. Scope ......................................................................................................................................................9 A. Calibration Facilities ......................................................................................................................9 7. Intervals ...................................................................................................................................................9 A. Recall Notification Procedure ................................................................................................................9 B. Calibration Periods ....................................................................................................................10 C. Failed Calibrations ....................................................................................................................10 D. Periodicity of Repaired or Adjusted Instrument Calibrations.................................................................11 8. Standards and equipment.......................................................................................................................11 A. Standards Traceability ....................................................................................................................11 9. General. .................................................................................................................................................11 A. Test Room Temperature during Calibration Procedures. .....................................................................11 B. Batteries ....................................................................................................................13 10. Warning .................................................................................................................................................13 A. Dangerous Voltages. ....................................................................................................................13 B. Qualified Personnel. ....................................................................................................................13 C. De-energising. ....................................................................................................................13 11. Instrument Calibration Methods ..............................................................................................................13 A. DC Voltmeters ....................................................................................................................13 B. DC Voltmeters (PC Controlled Analogue Input Card)...........................................................................13 C. DC Ammeters (Up To 10 Amperes).....................................................................................................14 D. DC Ammeters (Above 10 Amperes) ....................................................................................................14 E. DC Current Shunts ....................................................................................................................14 F. DC Current Shunts ....................................................................................................................15 G. AC Voltmeters ....................................................................................................................15 H. AC Ammeters (Up To 10 Amperes).....................................................................................................15 I. AC Ammeters (Above 10 Amperes) ....................................................................................................16 J. Current Transformers..........................................................................................................................16 K. Frequency Meters Digital and Electronic Types ................................................................................17 L. Oscilloscopes ....................................................................................................................17 M. Wattmeters ....................................................................................................................17 N. Resistance Meters and Wheatstone Bridges .......................................................................................18 O. Kelvin Bridges and Bonding Testers....................................................................................................18 P. Insulation Testers ....................................................................................................................18 Q. Oscillographs and Recorders ..............................................................................................................19 12. Transducers and sensor calibration methods..........................................................................................20 A. Transducers and Sensor Types ..........................................................................................................20 B. Personal Computer Driven Calibration ................................................................................................20 C. Pressure Transducers ....................................................................................................................21
D. Temperature ....................................................................................................................21 E. Temperature Indicators, Monitors and Recorders................................................................................23 F. Flowmeters ....................................................................................................................24 G. Flow Indicators ....................................................................................................................24 H. Load Cells ....................................................................................................................24 I. Torque Meters ....................................................................................................................................25 J. Accelerometers...................................................................................................................................26 K. Displacement Transducers..................................................................................................................26 L. Speed Transducers ....................................................................................................................27 13. Multifunction and Range Meter...............................................................................................................28 A. Analogue or Digital Multimeters...........................................................................................................28 14. System Calibration .................................................................................................................................29 A. System Calibration definition...............................................................................................................29 B. Direct Transducer System Calibration .................................................................................................29 C. Simulated Transducer System Calibration...........................................................................................29 D. General ....................................................................................................................29 15. Cable Insulation Stripping Tools. ............................................................................................................30 A. Calibration Procedure ....................................................................................................................30 B. Precautions ....................................................................................................................31 C. Cable/Wire Strip Inspection Samples ..................................................................................................31 D. Suggested Basic Stripping Methods....................................................................................................31 16. Connection Crimping Tools. ...................................................................................................................34 A. Calibration Procedure ....................................................................................................................34 B. Calibration Method ....................................................................................................................34 C. Crimp Tool Calibration Method Exemptions.........................................................................................34 17. Soldering Irons and Stations...................................................................................................................50 A. Calibration Procedure ....................................................................................................................50 B. Calibration Method ....................................................................................................................50 C. Precautions ....................................................................................................................51 18. Hot Air and Infra Red Tools. ...................................................................................................................51 A. Calibration Procedure ....................................................................................................................51 B. Calibration Method ....................................................................................................................52 C. Precautions ....................................................................................................................53 Table 1..........................................................................................................................................................33 Table 2..........................................................................................................................................................37 Table 3..........................................................................................................................................................38 Table 4..........................................................................................................................................................39 Figure 1 ........................................................................................................................................................31 Figure 2 ........................................................................................................................................................31 Figure 3 ........................................................................................................................................................32 Figure 4 ........................................................................................................................................................36
M-DLPS3006 ELECTRICAL CALIBRATION SCHEDULE 1. Purpose. The purpose of this document is to form a Electrical Calibration Control Procedure for Messier-Dowty Gloucester.
2. Associated Specifications. A. BS 89 Direct Acting Indicating Analogue Electrical Measuring Instruments and their Accessories.
B. BS 5 G 178 C. SR 1359 D. E. F. G. MIL-STD-45662A BS EN 30012-1 BS 5781 ISO 10012-1
Crimped Joints for Aircraft Electrical Cables and Wires. Obsolete Replaced By This Document. Calibration Systems Requirements.

Quality Assurance Requirements for Measuring Equipment.
H. M-DLPS902 I. IPC/WHMA-A-620
Assembly and Test Requirements for Crimped Connectors for Aircraft. Requirements and Acceptance for Cable and Wire Harness Assemblies.
3. Referenced Documents A. MANP 3.3.303 B. AQAP 6 4. Metrological Confirmation Systems. A. The following section is taken from the applicable International Calibration Standards and serves to illustrate the philosophy behind this specification document. A. Scope (1) This document contains the Quality Assurance requirements for a Messier-Dowty Limited Standard to ensure that measurements are made with the intended accuracy. (2) It is applicable to measuring equipment used in the demonstration of compliance with a specification. B. Definition (1) Metrological confirmation is a set of operations required to ensure that an item of measuring equipment is in a state of compliance with the requirements for its intended use. C. Confirmation System (1) Messier-Dowty Limited shall establish and maintain an effective documented system for the managing, confirmation and use of measuring equipment, including measurement standards, used to demonstrate compliance with specified requirements. This system shall be designed to ensure that all such measuring equipment performs as intended. The system shall provide for the prevention of errors outside the specified limits of permissible error, by prompt detection of deficiencies and by timely action for their correction.
(2) The confirmation system shall take full account of all relevant data, including that available from any statistical process control system operated by or for Messier-Dowty Limited. (3) For each item of measuring equipment, Messier-Dowty Limited shall designate a competent member of staff as authorised officer to ensure that confirmations are carried out in accordance with the system and that the equipment is in a satisfactory condition. (4) If any or all of the confirmation, including calibration, is replaced or supplemented by services from outside sources, Messier-Dowty Limited shall ensure that these outside sources also comply with the requirements of ISO 10012 to the extent necessary to ensure compliance with the requirements.
(5) For a commercial device the manufacturers claimed performance is usually taken as the criterion of satisfactory performance and accuracy. It is sometimes necessary to modify the manufacturers claim, or where no claimed performance is available, criteria for satisfactory performance may have to be determined from experience. (6) The use of appropriate statistical methods for analysing the results of previous or preceding calibrations, for assessing the results of calibrations of several similar items of measuring equipment and for predicting cumulative uncertainties is recommended. D. Checking Measurement Standard (1) As guidance, a check that a measuring instrument continues to measure correctly is obtained by the use of a checking measurement standard, applied to the instrument by the user. (2) This will demonstrate if, at the value or values checked and under the conditions of the check, the instrument is still functioning correctly. The checking measurement standard itself needs to be calibrated and confirmed and, in order that the results obtained by its use can with confidence be attributed to the instrument and not to changes in the checking measurement standard, it usually has to be simple and robust. (3) The use of a checking measurement standard is in no way a substitute for regular calibration and confirmation of the instrument, but its use may prevent the use of an instrument which, within the interval between two formal confirmations, ceases to conform to specification. E. Auditing of the system (1) Messier-Dowty Ltd. shall carry out, or arrange to be carried out, periodic and systematic quality auditing of the confirmation system in order to ensure its continuing effective implementation and compliance with the requirements (of ISO 10012). (2) Based on this the system shall be reviewed and modified as necessary. (3) Plans and procedures for the Quality Audit and review shall be documented. The conduct of the Quality Audit and review and any subsequent corrective actions shall be recorded. F. Planning for Measuring Service or Standards (1) Messier-Dowty Ltd. shall review the relevant technical requirements before commencing work on products or services, and shall ensure that the measuring equipment (including measurement standards) needed for the performance of the work are available and are of the accuracy, stability, range and resolution appropriate for the intended application.
G. Intervals of Confirmation (1) Periods of calibration are subjects covered in detail in the standards, these are ISO 10012 section 4.11 and Appendix A, and MIL-STD-45662 section 5.4. Some key points are: (a) Measurement and Test Equipment shall be calibrated at periodic intervals established and maintained to assure acceptable accuracy and reliability. (b) Intervals shall be shortened or lengthened if necessary, to ensure continued accuracy, depending on the results of preceding calibrations.
(c) The intervals of confirmation shall not be lengthened unless the results of calibrations at preceding confirmations provide definite indications that such action will not adversely effect confidence in the accuracy of the measuring equipment. (d) The user shall establish a recall system for the mandatory recall of the Measurement and Test Equipment and measurement standards to assure timely recalibrations, removing it from service, thereby precluding use of an instrument beyond its calibration date. (e) The recall system may include provisions for the temporary extension of the calibration due date for limited periods of time under certain specific conditions, such as the completion of a test in progress. H. Variation in Applicable Standards (1) Interpretation of the Standards for Calibration should note that differences occur between these Standards. Where work is being carried out on different projects, the applied system should take into account the worst case restrictions in order that this Company Standard is applicable to all Customers. 5. Instruments and Equipment A. Instrument Ranges. The following ranges of instruments are covered by the procedures in this schedule.
DC Voltmeters (Analogue and digital types) DC Voltmeters (PC controlled analogue input card) DC Ammeters (Analogue and digital types) AC Voltmeters (Analogue and digital types) AC Ammeters (Analogue and digital types) Frequency Meters (Analogue and digital types) Oscilloscopes Wattmeters Resistance Meters and Bridges (Analogue and digital types) Insulation Testers Oscillographs and Recorders Transducers and Sensors Multimeters
Soldering Irons Hot Air Guns
B. Purchase Control of Electrical Equipment. (1) All electrical equipment purchase from within Messier-Dowty Ltd shall be approved by Engineering (Electrical) as fit for purpose. 6. Scope A. Calibration Facilities
(1) Any calibration of instruments or equipment not covered by categories mentioned in para 5, or by the requirements of this schedule shall be calibrated by qualified engineers to the manufacturers procedures. See also para 4.C.(5). (2) If, after investigation, it is established that the instruments or equipment can be calibrated in the Electrical Calibration Laboratory, then this will be carried out by qualified personnel and full calibration certification issued to the Inspection department. (3) If, however, after investigation, it is established that instrument or equipment cannot be calibrated in the Electrical Calibration Laboratory due to complexity or the requirement for specialised equipment, the following procedure will apply. (f) The instrument or equipment in question will be calibrated externally by approved subcontractors. In these circumstances the sub-contractor offering calibration must be an approved calibration house and must be traceable to National Standards. A full certification of calibration must be issued in all cases for the Electrical Calibration Laboratory records. (4) The initial, and continuing, approval of sub-contractor calibration facilities is the ultimate responsibility of the Quality Assurance Department. The Electrical Calibration Laboratory assists the Quality Assurance Department in this activity by providing initial information, advice and assistance as required necessary. (5) Test rigs which use computer based equipment and recorders will be calibrated by qualified engineers and full certification of calibration will be issued in all cases to the Electrical Calibration Laboratory. 7. Intervals A. Recall Notification Procedure (1) In order to comply with the requirements of para 4.G.(d) the following method of recalling equipment for calibration shall be used. (2) Two (2) weeks before the calibration due date a high priority e-mail or internal memo shall be sent as a reminder to the department head. (3) On the re-calibration date a letter will be sent stating that the addressed department has equipment in use requiring calibration and unless quarantined and returned for calibration, visibility of the infringement will be escalated. Results taken with the offending equipment will be considered invalid following issue of in this letter.
(4) The escalation will be as follows: (a) One (1) week overdue the manager will receive an overdue letter. (b) Two (2) weeks overdue the relevant Director will receive an overdue letter. (c) Three (3) weeks overdue the Quality Director or suitable equivalent will receive an overdue letter. B. Calibration Periods (1) In the absence of any other specific instruction the following calibration shall apply to all instruments encompassed in this schedule: Panel mounted or portable electromagnetic instruments. Resistance bridges, meggers, insulation testers. Panel mounted digital and other electronic equipment. Transducers and Sensors not covered by the above Soldering Irons and Hot Air Guns 3 months 6 months 12 months 12 months 12 months
(2) The above interval periods may be varied for any particular instrument at the discretion of the Electrical Calibration Laboratory in the light of previous calibration records and the requirements of para 4.G, Intervals of Confirmation and recommendations of para 4.C.(6). (3) Any deviations from these periods must be clearly identified on the calibration certificate and record card for the instrument concerned along with the written authority for the deviation. C. Failed Calibrations (1) In the event of a failed Electrical Calibration the instrument should be assessed as to whether it is to be repaired or scrapped. (2) Un-repairable Failed Calibration Equipment: (a) A report shall be prepared with details of the failed instrument calibration, this shall then be sent with an Unfit Equipment Report (form M-DG 0082) to the instrument owner and copied to the Quality Department. (b) The Quality Department and the Instrument owner must then analyse the past data and assess the effects of the failed instrument on the process or processes monitored by the instrument, ensuring the appropriate actions are taken. (3) Repaired or Adjusted Failed Calibration Equipment. (a) When it is deemed possible and economical to repair or adjust an instrument that has failed calibration, the following procedure shall be followed: (b) A report shall be prepared with details of the failed instrument before and after repair or adjustments, this shall then be sent with an Unfit Equipment Report (form M-DG 0082) to the instrument owner and copied to the Quality Department.
(c) The Quality Department and the Instrument owner must then analyse the past data and assess the effects of the failed instrument on the process or processes monitored by the instrument, ensuring the appropriate actions are taken. (d) After an instrument has been repaired or adjusted this will affect the Periodicity of that instrument. D. Periodicity of Repaired or Adjusted Instrument Calibrations. (1) The periodicity of repaired or adjusted instruments following a failure will be adjusted to check the validity of results and monitor the behaviour of that instrument.
(2) The periods will change to: (a) Four (4) calibrations of three (3) months. (b) Two (2) calibrations of six (6) months. (c) Annually. (3) Should the periodicity of the particular instrument be less than any of the above the least will take precedence. 8. Standards and equipment A. Standards Traceability (1) The procedures in this schedule are based on the use of transfer standard calibrated equipment. (2) All standard instruments shall carry a certificate of calibration traceable to national standards in accordance with AQAP-6 and Messier-Dowty Limited document MANP 3.3.303. (3) The certificate of calibration for the standard instruments shall be renewed every 12 months. 9. General. A. Test Room Temperature during Calibration Procedures. The test room temperature shall be maintained at a value between 18 C and 28 C during all calibration procedures.
(1) Equipment shall not be subjected to humidities greater than 85%. (2) All electronic instruments being calibrated or used as standards shall be allowed to "warm up" for a time duration after switch on specified in instruction manuals for each particular instrument. If there is no specified time duration after switch on stated or known then not less than 10 minutes "warm up" shall be allowed. (3) For all calibrated instruments a record sheet must be made and must include the following: (a) Instrument type. (b) Instrument type number and serial number.
(c) Calibration number. (d) Range. (e) Frequency range. (f) Instrument accuracy. (g) Calibration interval. (h) Date of calibration. (i) Date of next calibration.
(j) History and any other relevant details. (4) It may not be possible to calibrate a piece of equipment throughout its specified range. Should this be the case the attached label and record sheet shall clearly indicate the restriction. (5) Records of all readings taken at each calibration are to be recorded and kept for at least five years. (6) During calibration all analogue or scale type meters shall be mounted in the same plane as on their respective rig or location (i.e. vertical, horizontal etc.). (7) All meters shall be zeroed before commencing the calibration and thereafter the zeroing adjustment shall remain unaltered. Any zero adjustment must be recorded on the record sheet. (8) Calibration points shall be taken at each major division on the scale from zero upwards with a minimum of five points taken. At each calibration point the meter shall be gently tapped in order to reveal any tendency of the needle to stick. Meters, which do stick, should be rectified before proceeding with the calibration. (9) On the satisfactory completion of the calibration procedure a label shall be attached. This label shall give the following details: (10) An inspectors signature of stamp and the date when the next calibration is due. (11) In addition to the label each instrument shall be issued with an inspection number and a calibration certificate. See also para 9.A.(4). (12) Occasionally circumstances arise which prevent the equipment being calibrated or tested in accordance with its Calibration Schedule. In this situation alternative procedures, agreed to by a Qualified Engineer, may be used until the situation is normal. These circumstances shall require a covering memo. (13) Where the calibration error exceeds that specified on the record sheet the instrument shall be removed from service, rejected for investigation and corrective action taken or the instrument replaced. (14) Since the procedures in this schedule may entail removing meters or instruments from their rigs and transporting them to the Electrical Calibration Facility, it is essential that a suitable means of transport is provided. It is desirable on all rigs concerned that provision is made for the easy removal of instruments and transducers.
(15) In cases where the removal of instruments proves difficult provisions must be made for easy access in order to calibrate the instruments and transducers in their respective rigs. This may be carried out using transfer standard equipment previously calibrated in the Electrical Calibration Facility. B. Batteries (1) Before calibration of portable battery powered instrumentation with rechargeable batteries the equipment shall be charged at the manufacturers recommended current and for the recommended time duration. (2) Before calibration of portable battery powered instrumentation, all non-rechargeable batteries shall be replaced with fresh cells. 10. Warning A. Dangerous Voltages. The voltages used for some of these calibration procedures can be dangerous. Also, dangerous voltages are present on test rigs so care must be taken when removing or calibrating instruments and transducers.
B. Qualified Personnel. Only qualified or suitably trained personnel shall operate these procedures.
C. De-energising. It is essential that all instruments and transducers are de-energised before connecting or disconnecting as damage to personnel or instruments may occur.
11. Instrument Calibration Methods The following methods apply to both analogue and digital instruments.
A. DC Voltmeters (1) The meter under test shall be connected to a suitable standard calibrator. The selected calibrator shall be set to produce DC volts. Using the instruction manual of the respective calibrator, measure the accuracy of the meter under test at each major division or convenient interval taking a minimum of five readings. (2) If the error at any point exceeds the appropriate limit specified on the record sheet then investigation will be undertaken and corrective action shall be taken. (3) All readings and results shall be recorded. B. DC Voltmeters (PC Controlled Analogue Input Card) (1) The PC controlled Analogue Input Card shall be correctly installed within the relevant PC, powered up and initialised to accept and display DC input signals. (2) The Analogue Input Card may have more than one input channel, each shall be calibrated individually, in turn.
(3) The Channel under test shall be connected to a suitable standard calibrator. The selected calibrator shall be set to produce DC volts. Using the instruction manual of the respective calibrator, measure the accuracy of the PC Controlled Analogue Input Card Channel under test at each major division or convenient interval taking a minimum of five readings. (4) If the PC Controlled Analogue Input Card has a bipolar input, both polarities shall be calibrated at each major division or convenient interval taking a minimum of five readings, or eleven in total including zero. (5) If the error at any point exceeds the appropriate limit specified on the record sheet then investigation will be undertaken and corrective action shall be taken.
(6) All readings and results shall be recorded. C. DC Ammeters (Up To 10 Amperes) (1) The meter under test shall be connected to a suitable standard calibrator. Set the calibrator selected to produce DC current and with the use of the instruction manual of the respective calibrator, measure the accuracy of the meter under test at each major division or convenient interval taking a minimum of five readings. (2) If the error at any point exceeds the appropriate limit specified on the record sheet then investigation will be undertaken and corrective action shall be taken. (3) All readings and results shall be recorded. D. DC Ammeters (Above 10 Amperes) (1) This class of meter almost universally consists of a millivoltmeter connected across a main current shunt. (2) Therefore, the actual instrument is calibrated as on an appropriate range millivoltmeter by the procedure of paragraph (DC Voltmeters) taking into account the relevant millivolt/amperes scaling factor of the meter/shunt combination under test. (3) Some panel type ammeters having a very low internal resistance cannot be calibrated on MessierDowty Limited standard calibrators due to their high current consumption. These meters can easily be recognised because it is impossible to obtain full-scale deflection of the meter under test on this range. (4) Such meters shall be fitted with an appropriately valued, calibrated current shunt (up to 10 amperes) and then calibrated using a suitable standard calibrator. Set the selected calibrator to produce DC current and calibrate meter under test as a DC ammeter (up to 10 amperes) taking into account the scaling factor of the shunt and meter concerned. A minimum of five readings shall be taken. (5) If the error at any point exceeds the appropriate limit specified on the record sheet then investigation will be undertaken and corrective action shall be taken. (6) All readings and results shall be recorded. E. DC Current Shunts (1) (Up to 10 Amperes)
(2) The full-scale current rating and output voltage of the shunt under test shall be determined before proceeding with calibration. (3) Connect the shunt under test to a suitably calibrated standard calibrator and the output of the shunt to a calibrated standard DC voltmeter. Set the calibrator to produce DC current and with the use of the instruction manuals of the respective calibrator and DC voltmeter, measure the output voltage of the shunt under test throughout its predetermined range taking a minimum of five readings. (4) If the error at any point exceeds the appropriate limit specified on the record sheet then investigation will be undertaken and corrective action shall be taken.
(5) All readings and results are to be recorded. F. DC Current Shunts (1) (Above 10 Amperes) (a) The full-scale current and output voltage of the shunt under test shall be determined before proceeding with calibration. From these pre-determined values, calculate the ratio between voltage and current and record value. (b) Connect the shunt under test to a suitably calibrated standard calibrator and DC voltmeter. Set the calibrator to produce a DC current of 10 amperes. With the use of the instruction manuals of the respective calibrator and voltmeter, measure the output voltage at a DC current of 10 amperes. (c) From the measured values obtained, calculate the ratio between voltage and current and record value. (d) If there is an error between pre-determined calculated ratio and measured calculated ratio greater than that specified on the record sheet, then investigation will be undertaken and corrective action shall be taken. (e) All readings and results are to be recorded. G. AC Voltmeters (1) The meter shall be connected to a suitable standard calibrator. The calibrator shall be set to produce AC volts and the procedure mentioned in this paragraph is to be carried out at the frequencies stated on the instrument record sheet. Use the instruction manual of the respective calibrator to measure the accuracy of the meter under test at each major division or convenient intervals taking a minimum of five readings. (2) If the error at any point exceeds the appropriate limits specified on the record sheet then investigation will be undertaken and corrective action shall be taken. (3) All readings and results are to be recorded. H. AC Ammeters (Up To 10 Amperes) (1) The meter shall be connected to a suitable standard calibrator. The calibrator shall be set to produce AC current and the procedure mentioned in this paragraph is to be carried out at frequencies stated on the instrument record sheet. With the use of the standard calibrators instruction manual, measure the accuracy of the meter under test at each major division or convenient intervals taking a minimum of five readings. (2) If the error at any point exceeds the appropriate limits specified on the record sheet then investigation will be undertaken and corrective action shall be taken.
(3) All readings and results are to be recorded. I. AC Ammeters (Above 10 Amperes) (1) This class of meter almost universally consists of a meter connected across the secondary of a current transformer. (2) The full scale current of the meter under test shall be determined before proceeding. (3) The procedure mentioned in this paragraph is to be carried out at frequencies stated on the record sheet.
(4) The meter is therefore calibrated using a suitable standard calibrator set to produce AC current. Taking into account the scaling ratio of the meter under test, use calibrator's instruction manual to measure the accuracy of the meter under test at each major division or convenient interval taking a minimum of five readings. (5) If the error at any point exceeds the appropriate limits specified on record sheet then investigation will be undertaken and corrective action shall be taken. (6) All readings and results are to be recorded. J. Current Transformers (1) First ascertain the turns ratio and maximum rated current of the transformer. (2) Depending on the AC current source available, pass a number of turns of suitable wire through the transformer under test so creating a "primary". (3) Connect the "primary" to a suitable AC standard calibrator source and a calibrated AC ammeter connected in series. (4) Connect the secondary or output of transformer to a suitable standard AC ammeter. (5) The calibrator shall be set to produce AC current and the procedure mentioned in this paragraph is to be carried out at frequencies stated on the record sheet. With the aid of the calibrator's instruction manual, measure the accuracy of the transformer ratio at convenient intervals (minimum of five readings) ensuring limits of current output are not exceeded. (6) The Transformer ratio is given by: (a) Primary Current divided by Secondary Current multiplied by Number of primary turns. e.g. a 50:1 current transformer with two turns on its primary with 1 ampere flowing into its primary, giving 0.04 Amps as its secondary current.
1 / 0.04 * 2 = 50
Hence the ratio is 50:1
(b) If the error exceeds the appropriate limits specified on the record sheet then investigation will be undertaken and corrective action shall be taken. (c) All readings and results are to be recorded.
K. Frequency Meters Digital and Electronic Types (1) Connect input of instrument under test to the output of a convenient oscillator. Monitor this signal with a standard frequency counter. (2) Before proceeding it is necessary to ensure that the output amplitude is sufficient for the instrument under test to function properly. (3) Vary oscillator frequency over desired range. Compare the readings of the instrument under test to those of standard counter at convenient intervals over specified range taking a minimum of five readings. (Note: ignore any frequency graduations on the oscillator.)
(4) In the case of instruments with more than one pre-set time base setting, repeat the procedure stated in para 11.K.(3) taking into account the appropriate frequency scaling factor for each time base control position. (5) For digital counters with "dial-up" variable time base facility, the time base settings and display digits will be checked as follows. (6) Set output of oscillator to produce 1 kHz. (7) Set the time base "dial-up" function to 10,000. The counter will indicate the same value as the time base setting. (8) Set the time base "dial-up" function to 111,111. The counter display will indicate the same as the time base setting. (9) Increment each time base "dial-up" function to next number. The counter display will indicate the same as the time base setting. (10)Repeat para 11.K.(8) for all values of time base "dial-up" function. The counter display will indicate the same as the time base setting. (11)All readings and results are to be recorded. (12)If any errors at any point exceed the appropriate limits specified on the record sheet then investigation will be undertaken and corrective action shall be taken. L. Oscilloscopes (1) Most oscilloscopes are used as indicators or monitors and not for accurate measurement. Therefore, an annual functional check shall be made against a known calibrated source to check whether the scope is functioning to the manufacturer's specification. (2) For oscilloscopes that are used for direct measurement, the oscilloscope must be calibrated using the standard calibration equipment by referring to the instruction manual of oscilloscope under test, i.e. ensuring that checks are made to input attenuator and time base settings etc. (3) If any errors at any point exceed the appropriate limits specified on the record sheet then investigation will be undertaken and corrective action shall be taken. (4) All readings and results are to be recorded.
M. Wattmeters (1) Single Phase Instruments (a) Single-phase instruments can be calibrated by using RFL standard calibrators and phase unit. (b) Connect the wattmeter, RFL standard calibrators and phase unit as shown in the instruction manuals. With the use of the instruction manuals, measure the accuracy of the wattmeter under test at each major division or convenient interval taking a minimum of five readings.
(c) If the error at any point exceeds the appropriate limit specified on the record sheet then investigation will be undertaken and corrective action shall be taken. (d) All readings and results are to be recorded. (2) Three Phase Instruments (a) Three phase instruments will only be checked by qualified engineers. (b) Three phase units will be checked against two calibrated wattmeters connected in the "Two Wattmeter Method" of measuring power which will be carried out in situ with the unit under test.
(c) Any deviations in limits specified on the record sheet then investigation will be undertaken and corrective action shall be taken. (d) All results and readings are to be recorded. N. Resistance Meters and Wheatstone Bridges (1) Check readings of meter or bridge against standard resistors obtainable from suitable standard calibrator set to produce resistance. Compare readings at convenient intervals taking a minimum of five readings. (2) For resistance values not covered by standards in calibrator, use separate standard precision resistances. NOTE: When comparing values below 1 ohm, appropriate precautions shall be taken to compensate for the resistance of leads between the instrument under test and the standard precision resistances. (3) If the error at any point exceeds the appropriate limits specified on the record sheet then investigation will be undertaken and corrective action shall be taken. (4) All readings and results are to be recorded. O. Kelvin Bridges and Bonding Testers Repeat procedures stated in para 11.N. Resistance Meters and Wheatstone Bridges.
P. Insulation Testers (1) Meggers (a) Connect instrument under test in parallel with the standard electrostatic voltmeter and suitable high ohmic value calibrated resistors. NOTE: The high ohmic value of calibrated resistors chosen will depend on the range of the instrument under test and ensuring that a minimum of five readings throughout the range shall be achieved. (b) Compare readings on instrument under test with those of calibrated high ohmic value resistors and measure the output voltage produced in each case. (c) For meggers having a multi-voltage range facility then repeat paras 11.P.(1)(a) and 11.P.(1)(b) for all ranges. (d) If the error at any point exceeds the appropriate limits specified on the record sheet then investigation will be undertaken and corrective action shall be taken. (2) Insulation Testers (a) Connect output leads of instrument under test to the standard electrostatic voltmeter. Advance voltage control of instrument under test and compare its voltmeter readings with the electrostatic voltmeter readings taking a minimum of five readings.
(b) In the case of insulation testers incorporating a leakage current indication, this meter can be separately checked to the procedure of para 11.H. (On most testers of this type it is possible to make the calibrator connections to the leakage current meter in situ. Consult the relevant wiring diagram). (c) If the procedure mentioned in para 11.P.(2).(b) proves complex, then connect high ohmic value, calibrated resistors to the output of the instrument under test and repeat procedure mentioned in para 11.P.(2)(a) and record the readings on the leakage current indicator. (d) Calculate the value of theoretical current obtained from readings on voltmeter and calibrated resistors and compare with readings obtained on leakage current meter.
(e) If the error at any point exceeds the appropriate limits specified on the record sheet then investigation will be undertaken and corrective action shall be taken. (f) All readings and results are to be recorded. Q. Oscillographs and Recorders (1) Time Axis (a) The following procedure checks the recorder paper speed and/or internal time marker. Any necessary amplitude calibrations are carried out as part of the pre-test procedure with the associated input signal. (b) Connect any convenient oscillator to any one of the input channels of the instrument under test. Monitor this input with a calibrated digital frequency counter and adjust oscillator frequency to a convenient multiple of time marker or paper speed. (c) Adjust oscillator output to produce a convenient amplitude on recorder and take a recording to include at least ten cycles of time markers on major paper graduations. (d) Compare number of cycles of recorded waveform with the number of time markers (or paper graduations) to determine accuracy. (e) For instruments not incorporating internal time markers repeat previous sub-paragraphs at other preselected paper speeds. (f) This calibration procedure shall be carried out at 12 monthly intervals. (2) Frequency Response (a) The following procedure checks the frequency response of galvanometers and/or pens used in these types of instruments. (b) Connect any convenient oscillator to an input channel on the instrument under test and monitor this input with a calibrated digital frequency counter. (c) Adjust oscillator output to produce a convenient amplitude on recorder. Measure the amplitude of the oscillator output with a calibrated AC digital voltmeter capable of reading true r.m.s. volts and record this value. Increase oscillator frequency until the amplitude of waveform on recorder begins to attenuate. At this point of attenuation the frequency reading on the counter shall be recorded.
(d) In order to check all other channels repeat paras 11.Q.(2)(b) and 11.Q.(2)(c). (e) This calibration procedure shall be carried out at 12 monthly intervals. (3) All results and readings are to be recorded. It is also necessary to store any traces recorded during calibration and they shall be clearly labelled or identified for the instrument under test. These traces shall be kept and stored in an adequate and convenient place. (4) If the error at any point exceeds the appropriate limits specified on the record sheet then investigation will be undertaken and corrective action shall be taken. 12. Transducers and sensor calibration methods
A. Transducers and Sensor Types (1) The following types of transducers and sensors are covered by the procedures in this schedule. (a) Pressure (b) Temperature (c) Flow meters (d) Load cells (e) Torque (f) Accelerometers (g) Displacement Transducers (h) Speed Transducers B. Personal Computer Driven Calibration (1) Calibration of some transducers may be carried out by PC controlled methods. (2) Where stated, the calibrated digital DC voltmeter may be replaced by a PC Controlled Analogue Input Card, calibrated in accordance with para 11.B. (3) The PC shall have software pre-written to enable execution of the calibration procedure. (4) Any calibration procedure and documentation shall comply with the procedures and requirements of this Calibration Procedure Document. (5) The software shall prompt the engineer carrying-out calibration to the correct procedure and for information relevant to the transducer under investigation. (6) The software shall be able to store and print the data compliant with this specification requirement and to advise on the acceptability or otherwise of the transducer under calibration once it has been completed.
C. Pressure Transducers (1) Full certification is required for transducers from manufacturers and an annual re-calibration to be undertaken thereafter. (2) Pressure transducers are to be calibrated using a certified pressure transducer calibrator or deadweight tester, calibrated digital DC voltmeter and a stable DC voltage supply. (3) A calibrated PC Controlled Analogue Input Card may be substituted for the calibrated digital DC voltmeter, see para 12.B.
(4) Supply an accurate and stable voltage to the transducer and measure with a calibrated digital DC voltmeter. The voltage must be set to manufacturer's specification. (5) Before increasing pressure to transducer, measure the transducer output voltage with the calibrated digital DC voltmeter and record the reading. Increase the pressure in convenient increments (minimum of 5) to cover the declared range of the transducer. Measure the output with the voltmeter and compare the results obtained with those quoted in manufacturer's specification or previous calibration records. (6) All results and readings are to be recorded. (7) From the results obtained a graph shall be plotted of output voltage corrected for zero error against applied pressure. This graph shall be used to determine the transducer's sensitivity, e.g. millivolts per volt per psig or mV/V/psig. (8) Any deviation from the manufacturer's specification or record sheet will be investigated and corrective action shall be taken. D. Temperature (1) Soak Time (a) Care shall be taken in allowing sufficient time for the instrument under test to settle at each temperature increment selected. Compare the temperatures of the calibrator to those indicated on the instrument under test. Note: This is a flexible soak time definition and is more appropriate than a fixed period, since the mass of a particular sensor can vary and result in significantly different temperature rise times that are exponential in nature. (2) The following procedures in this section for calibrating temperature measuring and monitoring devices are based on the use of the following calibration equipment, (a) Joffra 0-2000C heat source (b) Cold calibration source TBD (c) Haven Automation Procal (d) Set of Temperature EMF tables (not included in this schedule). (3) Capillary Type Temperature Indicators (a) The sensing bulb of the indicator shall be placed in the calibrated heat source ensuring the bulb is fitted properly. The temperature produced by the heat source shall be increased in convenient increments to cover the full range of the instrument under test, taking a minimum of five readings. Care shall be taken in allowing sufficient time for the instrument under test to settle at each temperature increment selected. Compare the temperatures of the calibrator to those indicated on the instrument under test.
(b) All results and readings are to be recorded and calibration will be valid for three months. (c) Repeat paras 12.D.(3)(a) to 12.D.(3)(b) for temperatures below ambient to include minus 70 degrees centigrade. 1 The low figure requires calibration equipment capable of producing temperature conditions below ambient and through zero degrees Celsius to the minimum required temperature.
(d) If the error at any point exceeds the appropriate limit specified on the record sheet then investigation will be undertaken and corrective action shall be taken.
(4) Thermometers (a) All thermometers are to be subjected to temperature changes over a range governed by the full scale of the thermometer under test. This will be undertaken by placing the thermometer under test into the calibrator and readings compared over the range of the thermometer under test taking a minimum of five readings. (b) All results and readings are to be recorded and calibration will be valid for 12 months. (c) If error at any point exceeds the appropriate limit specified on the record sheet then the thermometer shall be replaced. (5) Thermocouples (a) Thermocouples whether bought out or made at Messier-Dowty Limited, must hold a certificate of calibration. Thermocouples thereafter will be calibrated at intervals of five years using calibrated equipment. (b) Before proceeding with calibration care shall be taken to note the type of thermocouple used and the cold junction compensation taken into account. (c) The thermocouple under test shall be placed in the calibrated heat source and the output from the thermocouple under test connected to the appropriate terminals of the temperature calibrator. Using the instruction manuals for the calibrators, increase the temperature output of the heat source in convenient intervals (minimum of five). Measure the temperature and corresponding EMF in millivolts produced by the thermocouple under test. (d) All readings and results are to be recorded. (e) Repeat paras 12.D.(5)(c) to 12.D.(5)(d) for temperatures below ambient to include minus 70 degrees centigrade. See 12.D.(3).(c)1. (f) Issuing a serial number and engraving the Thermocouple in a convenient position or a suitably attached label with thermocouple type and serial number shall separately identify each thermocouple. (g) If the error at any point exceeds that specified on the record sheet then the thermocouple shall be replaced.
(6) Platinum Resistance Thermometers (PT100) (a) The manufacturers shall issue platinum Resistance Thermometers (PRTs) with full calibration certification. PRTs thereafter shall be re-calibrated at five-year intervals. (b) The PRT under test shall be placed securely in the heat source and connected to the appropriate terminals of the temperature calibrator. Using the instruction manuals for calibrators increase the temperature in convenient intervals (minimum of five). Measure the temperature reading produced by the PRT. (c) All results and readings are to be recorded.
(d) Repeat paras 12.D.(6)(b) to 12.D.(6)(c) for temperatures below ambient to include minus 70 degrees centigrade. See para 12.D.(3)(c)1. (e) Each PRT shall be separately identified by issuing a serial number and engraving the PRT in a convenient place or attaching a metal label with type number and serial number. (f) If the error at any point exceeds that on the record sheet then the PRT shall be replaced. E. Temperature Indicators, Monitors and Recorders (1) Recorders and Data Loggers (a) Before proceeding with calibration it will be necessary to determine what type of temperature sensor or measuring device is used with the instrument under test. (b) Using instruction manuals for instrument under test and calibrators, proceed to calibrate the instrument under test throughout its specified range at convenient intervals taking a minimum of five readings. (c) For multi-channel data loggers the first channel shall be checked throughout specified range as mentioned in para 12.E.(1).(b). (d) The other channels shall be checked at a known value selected on the calibrator, as there is no necessity to repeat calibration throughout the range on each of the other channels as it is a selector switch or multiplexer check only. (e) All results and readings are to be recorded. (f) If the error at any point exceeds the appropriate value specified on the record sheet then investigation will be undertaken and corrective action shall be taken. (2) Analogue/Digital Temperature Indicators (a) Before proceeding with calibration it will be necessary to determine what type of temperature sensor or measuring device is used with the instrument under test. (b) Repeat procedure mentioned in para 12.E.(1)(b). (c) On instruments that have a multi-channel selection for selecting a number of sensors or measuring devices, Channel 1 shall be calibrated throughout its specified range at convenient intervals, taking a minimum of five readings. The other channels shall be checked at a known value selected on the calibrator as there is no necessity to repeat calibration throughout the range on each of the other channels as it is a selector switch check only.
(d) All readings and results are to be recorded. (e) If the error at any point exceeds the appropriate value specified on the record sheet then investigation will be undertaken and corrective action shall be taken. F. Flowmeters (1) The flowmeters dealt with in this section are the turbine type of device incorporating a magnetic pick up to sense the rotation of the turbine and thus produce an output proportional to flow. (2) The flowmeter will be calibrated on a suitable rig that uses an Avery Hardoll fixed displacement type flowmeter as the master calibrated instrument. Equipment required for calibration will be a calibrated digital frequency counter, oscilloscope and a calibrated digital AC voltmeter capable of reading true rms volts. (3) Connect the calibrated digital frequency counter, oscilloscope and calibrated digital AC voltmeter to the output of the flowmeter under test. The flowmeter is to be checked throughout its range at convenient intervals taking a minimum of five readings. Frequency values obtained from the counter over the specified range shall be recorded along with output amplitude measured on the voltmeter. The oscilloscope is used to monitor the waveform of the flowmeter output throughout its range. If the waveform is distorted or uneven then investigation will be undertaken and corrective action must be taken. (4) All readings and results are to be recorded and from the results obtained a graph shall be plotted of frequency values from the counter against steady state flow to produce a calibration curve. This calibration will be valid for 12 months. (5) If the error at any point exceeds the appropriate limit specified on the record sheet then investigation will be undertaken and corrective action shall be taken. G. Flow Indicators (1) Flow indicators shall be classed as either analogue or digital frequency meters and shall be calibrated separately to procedures mentioned in para 11.K. Frequency Meters Digital and Electronic Types. (2) When flowmeters are used with digital frequency counters having "dial up" variable time base, the time base shall be set to a value obtained from the calibration curve and from the certificate of calibration of the flowmeter under test. (3) (3) If the error at any point exceeds the appropriate limits specified on the record sheet then investigation will be undertaken and corrective action shall be taken. H. Load Cells (1) Load cells are required to have full calibration certification from manufacturers and an annual recalibration is to be undertaken thereafter. (2) The load cells dealt with in this section are the strain gauge bridge type and are used in compression and tension modes. In either case they produce an output voltage which is proportional to the applied load. (3) Load for the calibration of load cells is to be provided by a suitably calibrated testing machine. A stable DC supply and a calibrated digital DC voltmeter are also required.
(4) A calibrated PC Controlled Analogue Input Card may be substituted for the calibrated digital DC voltmeter, see para 12.B. (5) Supply an accurate and stable DC voltage to the load cell under test and measure this supply voltage with the calibrated DC digital voltmeter. The voltage is to be set to the value specified on the record sheet. (6) Before proceeding to increase the load, measure the output from load cell with the voltmeter for zero load condition and record the reading. Increase the load in convenient increments (minimum of five) to cover the declared range of the transducer under test. Measure the output with the voltmeter and compare results obtained with those quoted in the manufacturer's specification or previous calibration records. (7) All results and readings are to be recorded. (8) From the results obtained a graph shall be plotted of output voltage corrected for zero error against applied load. This graph shall be used to determine the transducers sensitivity, e.g. millivolts per volt per pounds force or mV/V/Ibf. (9) Any deviations greater than the accuracies specified on the record sheet shall be investigated and corrective action shall be taken. I. Torque Meters (1) Full certification is required from all manufacturers for all torque meters and an annual recalibration thereafter. (2) Most torque meters are calibrated by means of a lever and dead weights, an accurate stable voltage supply and a calibrated digital DC voltmeter. If a torque meter has its own signal conditioning, then this shall be incorporated into the calibration making reference to manufacturer's specifications and/or instruction manual. (3) A calibrated PC Controlled Analogue Input Card may be substituted for the calibrated digital DC voltmeter, see para 12.B. (4) Connect an accurate and stable DC voltage supply to the torque meter and measure and record this voltage with a calibrated digital DC voltmeter. The voltage supply level must be set to that specified on the record sheet. The lever and calibrated dead weights shall be suitably fixed to the torque meter under test. The output voltage from the torque meter shall be measured with the voltmeter at zero torque and the reading recorded. Increase the torque in convenient intervals (minimum of five) to cover the declared range of the torque meter under test. Measure the output with the voltmeter and compare the results obtained with those quoted in the manufacturer's specification or previous calibration records. (5) All results and readings are to be recorded. (6) From the results obtained a graph shall be plotted of output voltage corrected for zero error against applied torque. This graph shall be used to determine the transducer sensitivity, e.g. millivolts per volt per Newton metres or mV/V/Nm or mV/V/lbf etc. (7) Any deviations greater than the accuracies specified on the record sheet shall be investigated and corrective action shall be taken.
J. Accelerometers (1) Full certification is required from manufacturers for all accelerometers and an annual re-calibration thereafter. (2) Accelerometers are to be calibrated against a master or standard accelerometer using a suitable amplifier - vibrator system, calibrated signal conditioning amplifiers, calibrated AC digital voltmeters capable of reading true rms and a dual beam oscilloscope. (a) This vibration equipment may not be available. Should this be the case accelerometers shall be externally calibrated at an approved facility.
(3) The accelerometers are to be vibrated over a range of frequencies and amplitude (thus 'g') with a sinusoidal waveform. The outputs from the calibrated signal conditioning amplifiers shall be measured with the calibrated AC digital voltmeters. (4) The results obtained over the range of 'g' levels shall be recorded and compared in order that the sensitivity of the accelerometer under test can be established. (5) The output waveforms shall also be monitored with an oscilloscope in order to observe any distortion in waveform. (6) All results and readings are to be recorded. (7) If there are any errors greater than those specified on the record sheet then investigation will be undertaken and corrective action shall be taken. K. Displacement Transducers (1) Displacement can be divided into two classes for this schedule, i.e. linear and angular. (2) Linear Displacement Transducers (a) Linear displacement transducers within Messier-Dowty Limited are of three basic types, resistive, capacitive or inductive (LVDT). Both capacitive and inductive types require calibration with their respective signal conditioning equipment. (b) Calibration shall be carried out against a certified displacement over the specified range of the transducer taking a minimum of five readings. (c) Calibrated test equipment is to be used to measure output signal from either the transducer or the transducer / signal conditioning equipment types. The results are to be recorded over the full range of the transducer under test and compared with the manufacturers specification or previous calibration records. (d) If the error at any point exceeds the appropriate limits specified on the record sheet then investigation will be undertaken and corrective action shall be taken. (3) Angular Displacement Transducers (a) Angular displacement transducers used at Messier-Dowty Limited could be either of the following types, absolute measurement or incremental measurement.
(b) In both cases the transducers are to be calibrated with their appropriate signal conditioning equipment and calibrated against a certified dividing head. (c) Where appropriate a traceable calibrated inclinometer may be used in conjunction with the dividing head. (d) Calibrated test equipment must be used throughout calibration and all results are to be recorded over the full range of the transducer under test taking a minimum of five readings. All results are to be compared with those specified on the manufacturer's specification or previous calibration records.
(e) If the error at any point exceeds the appropriate limits specified on the record sheet then investigation will be undertaken and corrective action shall be taken. L. Speed Transducers (1) This schedule covers the calibration of the following types of speed measurement transducers / indicators. (a) Tacho-generators, Pulse probes (b) Haslers (c) Stroboscopes (2) For tacho-generators, pulse probes and Haslers, calibration shall be carried out on a suitable motor / speed control test rig and a calibrated frequency counter to measure shaft speed via a gearwheel and magnetic pick-up. Calibration shall be valid for 12 months. Stroboscopes shall be calibrated using a convenient oscillator and a calibrated digital frequency counter. (3) Tacho-generators and Pulse Probes (a) There are two types of tacho-generator used at Messier-Dowty Limited, either AC or DC types. The AC tacho-generator and pulse probe produce an AC output, the frequency of which is proportional to speed. The DC tacho-generator produces a DC output, which is proportional to speed. (b) In the case of AC tacho-generators and pulse probes a calibrated digital frequency counter shall be connected to the output of the transducer under test. The transducer shall be operated throughout its specified speed range at convenient intervals taking a minimum of five readings. All results obtained are to be recorded. From these results a graph shall be plotted of frequency output from the transducer under test against shaft speed. (c) For DC tacho-generators a calibrated DC digital voltmeter shall be connected to the output of the tacho-generator under test. The tacho-generator shall be operated throughout its specified speed range at convenient intervals and all results obtained are to be recorded taking a minimum of five readings. CAUTION: THE OUTPUT OF DC TACHOMETERS CAN VARY IF THE MAGNETIC FIELD STRENGTH OF THE TACHO IS SHUNTED BY ITS SURROUNDINGS. WHERE POSSIBLE TACHO CALIBRATIONS SHOULD TAKE PLACE IN ITS NORMAL WORK PLACE. IF THIS IS NOT PRACTICAL THEN THE TACHO SHALL BE CALIBRATED IN A SIMULATED SITUATION THAT REPRESENTS ITS NORMAL MOUNTING IN TERMS OF MATERIAL AND SHAPE.
(d) If the error at any point exceeds the appropriate limit stated on the record sheet then investigation will be undertaken and corrective action shall be taken. (4) Haslers (a) Place the Hasler at the end of the rotating shaft of the test rig and compare values with the calibrated digital frequency counter over the specified speed range of the Hasler at convenient intervals taking a minimum of five readings. (b) All results and readings are to be recorded.
(c) If the error at any point exceeds those specified on the record sheet then investigation will be undertaken and corrective action shall be taken. (5) Stroboscopes (a) There are two ways that a stroboscope can be calibrated, by its own internal calibration facility, or by external calibration facility using a convenient oscillator and a calibrated digital frequency counter. (b) Most stroboscopes have a flash rate indicator and the purpose of this calibration is to check that the indicator is accurate to the limits specified in the manufacturers specification or previous calibration records taking a minimum of five readings. (c) For external calibration facility, connect the oscillator and calibrated digital frequency counter to the stroboscope and with the aid of the stroboscope instruction manual, proceed to calibrate the stroboscope throughout its specified range. (d) The internal calibration integrity test facility, if available, shall indicate at the appropriate marker on the indicator scale. Reference shall be made to record sheet concerning marker. This facility shall be used for verification only between calibrations. (e) All results and readings are to be recorded. (f) If the error at any point exceeds those specified on the record sheet then investigation will be undertaken and corrective action shall be taken. 13. Multifunction and Range Meter A. Analogue or Digital Multimeters (1) This covers analogue and digital multi-function and range meters. (2) Each function shall be calibrated using the procedures in the preceding paragraphs, i.e. dc voltage, current, resistance, frequency etc. (3) Linearity of the instrument is to be carried out on one scale range with scale increments chosen dependent on the meter being calibrated. (4) Meter scaling must be calibrated for all ranges of the meter by applying the function under test at 50% and at a scale increment between 95% and 99% full range, for all meter functions.
14. System Calibration A. System Calibration definition (1) A 'system' usually comprises of a transducer / sensor connected to its corresponding signal conditioning equipment, the output from which shall be monitored e.g. Digital meter, computerised data logger. (2) A system calibration shall be performed after the initial transducer / sensor calibration as stated in para 12, Transducers and Sensor calibration, has been undertaken.
(3) System calibrations shall be performed as described in paragraph14.B Direct Transducer System Calibration or para14.C Simulated Transducer System Calibration. B. Direct Transducer System Calibration (1) A transducer, e.g. a load cell, mounted in a calibrated loading device, shall be subjected to a range of loads dependant on the application requirements. The signal conditioning shall be adjusted to produce the required scaled output for monitoring purposes. This output shall be measured and recorded along with the monitored reading and applied load. C. Simulated Transducer System Calibration (1) System calibration shall be performed using a calibrated source which simulates the output characteristics of a previously calibrated transducer / sensor. These output characteristics will be obtained from the transducer / sensor calibration certificate. (2) A load cell, for example, produces an output voltage proportional to applied load. Using a calibrated voltage source, a voltage shall be injected into the signal conditioning equipment over the required range of application. The signal conditioning shall be adjusted to produce the required scaled output for monitoring purposes. This output shall be measured and recorded along with the monitored reading, (3) Reconnect the transducer to the system to check that zero conditions are achieved. Adjustments to balance control shall be made accordingly. (4) All results and readings shall be recorded. D. General (1) All equipment within the system and calibrated equipment used for calibration of the system shall be recorded. (2) If any part of the system changes, e.g. faulty transducer or signal conditioning, then the system calibration shall be repeated using the rectified item. (3) Calibration interval periods shall be dependent on the duration of the component with the shortest calibration period in the system loop, or at a convenient interval within that period. I.e. if the test duration exceeds that of a load cell with a 12 month periodic calibration then the calibration shall be performed at a convenient point during the test, e.g. unit strip etc. but not greater than a twelve month interval since the last calibration. (4) Extending the calibration period beyond this shall not be permitted without statistical evidence. A system which maintains confirmation intervals without review, determined only by so-called engineering intuition, is not considered to be sufficiently reliable.
(5) Extending calibration periods to finish a test shall, where the extended period is small, i.e. daily, be at the discretion of the calibration authority and shall be recorded. (6) Following an extended calibration period, the system channel(s) effected shall be calibrated, should an error be identified the necessary action shall be taken to rectify the situation. 15. Cable Insulation Stripping Tools. A. Calibration Procedure (1) The system of calibration shall be in accordance with MANP 3.3.303.
(2) There shall be a functional test initially every three months for Guillotine Die and Thermal type stripping tools, or earlier following a tool repair which could affect its performance. This period shall be subject to review in accordance with MANP 3.3.303. (a) Guillotine tools are to be in good working order, smooth in operation and mechanically sound. The blades are to have a good edge and not crossing. Any blade re-set or changed shall be followed by a test procedure. (b) Thermal tools are to be clean, well kept and smooth in operation. There is to be good element electrical connection. Element blades are to be close mating with good shape. The power supply of the thermal stripper shall be checked for good switching and electrical safety. (c) The method of functional test shall be thus; two insulation strips of wire samples, about 9 inches long, of the wires currently in use shall be prepared for inspection. These samples shall be tagged, identifying the cable type, size, tool/s and die size/s used. These samples shall be prepared in accordance with Figure 1, Figure 2, Figure 3 and Wire Types (Pages 31, 32 and 33). (d) Using at least x 5 magnification, samples shall have: 1 2 3 4 5 6 7 8 9 No radial nicks or scores to conductors, No radial nicks or scores to insulation, No insulation shall be punctured, crushed or marked, No insulation deposits remaining on conductor, No charring or shrinkage of insulation. Slight scratching of conductor plating is acceptable. Slight indentations to conductor are acceptable. Not more than 10% damage to screening. Retaining insulation not frayed, split, ragged or stretched.
(3) Planning Department to make provision and maintain wire length stocks for each type in use for future calibrations and new equipment approval.
B. Precautions (1) Wire terminating can result in certain substances that can be hazardous to health. During cable stripping, soldering and jointing, adequate ventilation shall be used. Manufacturers provide data sheets which should be consulted for further information. C. Cable/Wire Strip Inspection Samples (1) Both strips are to be inspected.
1/4''
3/8''
3/4'' Length 'A'
Possible Sheath Retain 2nd. Strip as a Wire Hold Original Strip Position
2nd. Strip
Figure 1 (2) Return Tools for inspection periodically as instructed. (3) The measurements are approximate only. (4) Dimension A may be increased to achieve a satisfactory inspection sample. D. Suggested Basic Stripping Methods (1) Fibre sheathed and Pren composites, guillotine die cutters (Tool 1). Screen Fibre
Sheath
Figure 2
Pull
(a) Guillotine through fibre sheath to inner clear screen.
(b) Guillotine to conductor fibre, not through. (c) Obliquely cut fibre and clean-up pulls for easy contact-boot entry, avoiding tool contact with conductors. (d) Terminate all screen wires so as to avoid piercing of insulation. (2) Thermal Plastic Composites and Thermal Cutters (Tool 2).
Screen
Kapton
Wrap
Fibre
Figure 3 (a) Ensure suitable temperature and blade shape. (b) Heat through outer sheath to screen and, or, under cover, such as Kapton; multicore undulating surface forms can be separated through with a twisting motion. (c) Push back screening and nibble through sheaths as necessary with oblique cutters. (d) Heat through inner insulation to expose conductors, any residues are to be removed by hand to obtain the cleanest possible strip. Avoid charring or melt-back. (3) The above figures are representative sketches only.
Wire Types Table 1
16. Connection Crimping Tools. A. Calibration Procedure (1) The system of calibration shall be in accordance with the MANP 3.3.303. (2) There shall be a functional test initially every three months for crimping tools, or earlier following a tool repair which could affect its performance. (3) This initial period shall be subject to review in accordance with MANP 3.3.303. B. Calibration Method
(1) The methods of functional tests shall be in accordance with the latest British Standard BS G l78 with exceptions. These tests shall be conducted on 2 connection samples crimped to wires, not less than 9 inches long, currently in use, and stripped in the usual way in accordance with, Figure 2 or Figure 3 , (page 31 or 32) (2) These samples shall cover all variations of wire size to contact size to tool setting and positioners as is normally used. These samples shall be tagged identifying cable type, size, tool serial number, tool setting, adapter/s used and contact size. The combinations of contact size to wire size and tool used will be expected to cover only those laid out in M-DLPS902 Sections 3 to 8. Samples need to be only one of either Nickel, Tin or Silver Plated conductor types for each wire size in use. See Table 4 (page 39 onwards). (3) The tool is to be in good smooth working order and the adapter parts, positioners, etc. are not to be worn or damaged. (4) Using the appropriate Makers Tool Test Gauges as in M-DLPS902, or later test gauges ensure that the correct dimensions are being obtained. (5) It shall be verified that the correct combination of conductor, tool and setting have been used for samples provided. Using magnification of at least x 10, the crimped specimens shall be viewed for mechanical soundness, absence of rough sharp forming, the correct positioning of the crimp, length and depth of wire with no free strands. See Figure 2 (page 31). (6) The acceptable crimps shall then be electrically and then mechanically tested in accordance with paragraph 16.C and Table 2 or Table 3 (pages 37 or 38). If any sample fails to meet the requirements, the reason must be investigated with a view to correction. (7) Identify any previous work carried out with that tooling/work combination which may also be unsatisfactory. If any previous output is considered at risk, suitable checks must be carried out and corrective action taken. (8) Crimping tools not producing the required quality shall be WITHDRAWN FROM SERVICE until replaced or repaired and re-tested. (9) Test currents should be near those listed in Table 2 or Table 3 (pages 37 or 38). Test currents for large cables (AWG.14 upwards) may be conducted at 25 to 30 amps using the appropriate mV/ampere value for that cable only as an interim measure. The respective AWG's mV/ampere voltage drops shall not be exceeded. The minimum PULL-OFF forces shall be adhered to. C. Crimp Tool Calibration Method Exemptions (1) The exceptions referred to in para 16.B.(1) are as follows: (a) The prescribed method of millivolt drop measurement is as detailed in para 16.C.(1)(h).
(b) The method of classification of cable types for which higher millivolt drop figures are permissible. See para 16.C.(1)(g) and Table 2 (page 37). (c) On some of the smallest size cables the quoted millivolt drop figures exceed the original BS G 178 derived values. The sizes affected are indicated by an asterisk in Table 2 (page 37). See paragraph 16.C.(1)(h). (d) Also some of the pull-off load figures differ from those specified in the original BS G 178 from which they were derived. These are also indicated by an asterisk. See para 16.C.(1)(m).
(e) Only PULL - OFF load tests are required for steel thermocouple connection crimps. (f) When using Table 2 or Table 3 (pages 37 or 38) to determine the appropriate test limits, always refer to the wire size or CMA of the conductor, not the terminal size. Testing doubled back Conductors: if it is unavoidably necessary to double back conductor for a particular terminal barrel, the test values shall be to the original AWG or CMA size. (g) The electrical test shall be to measure the voltage drop between a conductor and its terminal (or IN-LINE conductors) measured at the appropriate current rating. It shall not exceed the value for that conductor as specified Table 2 or Table 3 (pages 37 or 38). The higher values for NICKEL plated wires cover such types as TERSIL, UNIEFGLAS, etc., and this classification is preferred to the complex temperature classification as in BS 5 G 178. (h) The millivolt drop shall be measured using a needle probe between a point adjacent to the forward end of the crimp barrel in the termination and a point on the conductor behind the terminal and determined by the probe spacing figures given below. This method is adopted as being more suitable for shop use than the complex method detailed in BS 5 G 178 but results in higher values. See para 16.C.(1)(c). (i) Wire Size (j) 30 to 10 AWG inclusive (k) 8 to 4 AWG inclusive Terminal End 0.65 in. 1.8 in. In-Line Splice 1.8 in. 3.0 in.
(l) For IN-LINE connection measurements the millivolt figures in Table 2 (page 37) require doubling. Each reading should be taken as quickly as possible so as to avoid increase in cable resistance caused by heating due to current flow. (m) The mechanical pull-off load tests shall be applied to a conductor and it's terminal (or IN-LINE conductors) using a suitable tensile testing machine where the load is applied at a steady rate of between one and two inches per minute. The minimum pull-off load for that conductor shall be as specified in Table 2 or Table 3 (pages 37 or 38).
Figure 4
Pull-Off Loads, Test Currents and Voltage Drop Values for Crimped Aircraft Cables Table 2
Wire Size
Equivalent Pren Amperes
Number & Diameter of Strands inch Mm
Maximum Diameter inch mm
Cross Sectional Area inch mm
Test Current Ampere
AWG
Maximum Tin/Silver Plated mV mV/A mp 15 14 14 12 8 7 7 10* 5.6* 4.0 1.7* 0.73 0.50 0.39
Volt Drop Nickel Plated mV mV/Amp
Minimum Pull-off lbs
CMA
30 28 26 24 22 20 18
4 6 9
7/ 7/ 7/ 19 / 7/ 19 / 19 / 19 / 48 / 33 / 19 / 1/
0.004 0.0048 0.006 0.004 0.0076 0.0048 0.006 0.0076 0.0048 0.0076 0.010 0.044 0.0076 0.0113 0.0076 0.0142 0.0076 0.0179 0.012 0.016 0.012 0.012 0.012
7/ 7/ 7/ 7/ 19 / 19 / 19 / 48 / 19 / 40 / 19 / 37 / 19 / 37 / 19 / 37 / 119 / 182 / 294 /
0,1 0,125 0,15 0,2 0,12 0,15 0,2 0,12 0,25 0,019 0,3 0,25 0,355 0,315 0,45 0,4 0,3 0,3 0,3
0.012 0.015 0.019 0.020 0.023 0.024 0.033 0.041 0.042 0.052 0.048 0.044 0.061 0.056 0.077 0.071 0.096 0.090 0.124 0.111 0.167 0.218 0.272
0,30 0,38 0,45 0,60 0,60 0,75 1 1,07 1,52 1,47 1,5 1,75 1,68 2,2 2,25 2,8 3,84 4,72 6,02
0.00009 0.00013 0.00022 0.00024 0.00030 0.00033 0.00054 0.00086 0.00087 0.00150 0.00150 0.00152 0.0018 0.0019 0.0032 0.0031 0.0050 0.0048 0.0083 0.0074 0.0136 0.0206 0.0333
0,055 0,086 0,124 0,220 0,215 0,336 0,597 0,561 0,933 1,17 1,34 1,82 1,68 2,89 3,02 4,65 8,11 12,85 20,75
1.5 2.5 3.5 7.0 11.0 14.0 18.0
21 21 18 12 10.5 10.5
8.4* 6.0 2.6* 1.10 0.75 0.58
2 3 6 9 12 19 32
115 165 252 305 410 438 685 1100 1105 1910 1900 1940
16 14 12 10 8 6 4
12 18 24 35 50 70 100
40 / 19 / 70 / 19 / 110 / 19 / 73 / 37 / 120 / 182 / 294 /
21.0 30.0 43.0 61.0 87.0 115.0 160.0
7 6 6 5 5 5 5
0.33 0.20 0.14 0.082 0.058 0.043 0.031
10.5 9.0 9.0 7.5 7.5 7.5 7.5
0.50 0.30 0.21 0.12 0.087 0.065 0.047
38 57 90* 135* 190* 270* 360
2310 2426 4045 3830 6355 6090 10515 9470 16597 25380 41010
* Deviation from the original BS G 178 from which this table was derived, see paragraph 16, C,(1).
THIS DOCUMENT IS THE PROPERTY OF MESSIER-DOWTY LIMITED AND MAY NOT BE COPIED OR DISCLOSED TO THIRD PARTIES WITHOUT AUTHORISATION.
Table 3 Crimping Test Figures For Non-Standard Cables and Terminations In Use At Messier-Dowty Limited (a) Cables
CMA
No. @ Diam. of strands 7 x 100 x 0.002ins. 4 x 16 x 0.0048ins 16 x 6 x 0.1mm 7 x 7 x 0.006ins 7 x 19 x 0.08mm 49 x 0.00472 ins 390 x 0.006 ins
Conductor Nom. Area 0.0022 ins 0.00115 ins 0.754 mm 0.00137 ins 0.669 mm 0.000859 ins Nickel plated
Used on
Min. Pull off lbs(BS 4G 178) 57 (40) 32 (25) 32 (25) 32 (30) 25 (21) 19 (18) (175)
2800 1472 1498 1760 1318 1093 14040
Brush Pigtails De-icing leads De-icing leads De-icing leads De-icing leads De-icing leads Earth Braid
Test Current (Amps) 4 4 4 4 4 4 75 (25)
mV Drop
6 6 6 5 6 7 (2.5)
(b) Terminations Description Mate - N - Lok (A.M.P.)* Wire Size (AWG) 20 18 * M-DLPS902 Section 7 for details CMA - Circular Mil Area Min. - Pull off lbs 15 20 Test current (Amps) 4 7 Max. mV drop 11 15
Terminal Crimping and Thermal Tool Testing Guide Table 4
This listing of terminals may not be complete. As a guide it will be reduced or extended from usage, information returned with the tool for calibration purposes as standards change. Other contacts may be used as available in accordance with M-DLPS902 tables. Tools & Turrets or Positioners MS 3191 A Connector and contact type Erma Buchanan 611210 (4 Indent) 612600 (8 Indent). ITT Cannon (PVW & PVX) (PAN6432-1) Pattern 602 030- 7988-000 030- 7988-000 030- 7987-000 030- 7987-000 030- 7987-000 030- 7986-000 030- 7986-000 030- 7986-000 P324525 P324525 P324523 P324523 P324523 P324521 P324521 P324521 12 12 16 16 16 20 20 20 12 14 16 18 20 20 22 24 P404106 P404105 P404104 P404103 P404102 P407171 P407183 P407177 Connector and contact stock AWG Test cable AWG Test cable Stock
M-DLPS902 M-DLPS902
Section 3
Table 1
10
with (Yellow) MS 3191 -12A (602520 - 4) with (Blue) MS 3191 -16A (602520 - 3) (602520 - 3) with (Red) MS 3191 -20A (611062) (611062)
Tools & Turrets or Positioners

Connector and contact type
Connector and contact stock
AWG
Test cable AWG
Test Cable Stock
M-DLPS902
M-DLPS902
Section
Table
MS 3191 -A
Erma Buchanan 612600 (8 Indent) ITT Cannon MS & CA (F80) 330-0351-012 pin 330-0351-012 pin 330-0351-016 pin 330-0351-016 pin 330-0345-016 pin 330-0345-016 pin 031-0560-161 socket 031-0560-161 socket 031-0554-161 socket 031-0554-161 socket FKI (Thorn) 75 69 P324472 P324472 P324471 P324471 P324471 P324471 P324471 P324471 P324471 P324471 12 12 16 16 16s 16s 16 16 16s 16s 12 14 16 18 16 18 16 18 16 18 P404106 P404105 P404104 P404103 P404104 P404103 P404104 P404103 P404104 P404103
with 600095 600095 600091 600091 600093 600093 600092 600092 600094 600094
4 P327102 P327102 P327102 12 12 12 16 16 12 14 12 16 20 P404106 P404105 P404106 P404104 P404102 4 P301403 P301402 P301401 12 16/16s 16/16s 12 16 16 P404106 P404106 P404106
with 603502 603502 603502 603502 603502 -
4 4 4 4 4
10 - 40561 pin 10 - 40561 pin 10 - 40560 socket 10 - 40557 pin 10 - 40557 pin Hellerman Deutsch Han
7A
with 604627 - 3 604627 - 2 604627 - 1
PS 22040 pin PS 22025 pin PS 22044 pin

AWG
Test cable AWG
Test Cable Stock
M-DLPS902
M-DLPS902
Section 4
Table 12
AB (Plessey) UK AN with 600048 600048 600048 600048 604227 604227 604227 604227 508 /2/ 508 /2/ 508 /2/ 508 /2/ 508 /1/ 508 /1/ 508 /1/ 508 /1/ 03603 pin 03603 pin 05604 pin 05604 pin 05601 socket 05601 socket 05602 socket 05602 socket P300972 P300972 P300971 P300971 P300482 P300482 P300481 P300481 16/18 16/18 16/20 16/20 16/18 16/18 16/20 16/20 16 18 16 20 16 18 16 20 P404104 P404103 P404104 P404102 P404104 P404103 P404104 P404102
1 1 1 1
AB (Plessey) Mk. 6 with 604922 604310 604226 604922 604659 604659 1 3 2 2 2 2 508 /2/ 508 /2/ 508 /2/ 508 /2/ 508 /2/ 508 /2/ 09520 pin 06586 pin 00630 pin 09524 socket 06588 socket 00623 socket P307023 12 16 20 12 16 20 12 16 20 12 16 20 P404106 P404104 P404102 P404106 P404104 P404102
13
MS 319 - 4 with MS 3193 - 3T
Erma-Buchanan No. 612179 Erma-Buchanan No. 612552 Amphenol 48 etc. (MS26500)
3 3 4
1 1 2

AWG
Test cable AWG
Test Cable Stock
M-DLPS902
M-DLPS902
Section
Table
Setting 7 (Yellow) 6 (Yellow) 5 (Blue) 5 (Blue) 4 (Blue) 4 (Red) 3 (Red) 2 (Red) 1 (Red) M22520/1 -01 with M22520/1 -02
030 - 7988 000 030 - 7988 000 030 - 7987 000 030 - 7987 000 030 - 7987 000 030 - 7986 000 030 - 7986 000 030 - 7986 000 030 - 7986 000 Erma-Buchanan No. 15708 Erma-Buchanan No. 15709 Matrix MB1 and 944 etc.
P324525 P324525 P324523 P324523 P324523 P324521 P324521 P324521 P324521
12 12 16 16 16 20 20 20 20
12 14 16 18 20 20 20 24 26
P404106 P404105 P404104 P404103 P404102 P407171 P407183 P407177 19/0.1mm
3 3 4 P324525 P324525 P324523 P324523 P324523 P324521 P324521 P324521 P324521 12 12 16 16 16 20 20 20 20 12 14 16 18 20 20 20 24 26 P404106 P404105 P404104 P404103 P404102 P407171 P407183 P407177 19/0.1mm 4 4 4
1 1 1 7 8 9
Setting 8 (Yellow) 7 (Yellow) 6 (Blue) 5 (Blue) 4 (Blue) 4 (Red) 3 (Red) 2 (Red) 1 (Red)
030 - 7988 000 030 - 7988 000 030 - 7987 000 030 - 7987 000 030 - 7987 000 030 - 7986 000 030 - 7986 000 030 - 7986 000 030 - 7986 000

AWG
Test cable AWG
Test Cable Stock
M-DLPS902
M-DLPS902
Section
Table
With M22520/1 - 04
Erma Buchanan No. 615711 ITT Cannon KJA (MIL - C - 38999) MS27493 12 pin MS27493 12 pin MS27493 16 pin MS27493 16 pin MS27493 16 pin MS27493 20 pin MS27493 20 pin MS27493 20 pin Erma-Buchanan (8 Indent) Amphenol 418-1 (MIL - C - 38999) MS27493-22D pin MS27493-22D pin MS27490-22D pin MS27490-22D socket MS27491-22D socket MS27491-22D socket ITT Cannon DPX4M P334641 P334641 22D 22D 22D 22D 22D 22D 22 24 22 24 22 24 P407183 P407177 P407183 P407177 P407183 P407177 12 12 16 16 16 20 20 20 12 14 16 18 20 20 20 24 P404106 P404105 P404104 P404103 P404102 P407102 P407101 P407177
3 4 4 4
1 3 4 4A
Setting 8 7 6 5 4 3 2 1 M22520/2 - 01
3A 4 4 4 3 4 4A
with MS22520/2-09 MS22520/2-09 MS22520/2-07 MS22520/2-07 MS22520/2-06 MS22520/2-06
MS22520/2-23 MS22520/2-23
M39029/11-22 pin M39029/11-22 pin
22 22
22 24
P407183 P407177 M-DLPS3006 Page 43 Issue 2

AWG
Test cable AWG
Test Cable Stock
M-DLPS902
M-DLPS902
Section
Table
Thermocouple (Reserved Tools) M22520/1-01 with M22520/1/04 D38999/26KA98SN 4 M39029/88-488 (Ni/Al) M39029/88-487 (Ni/Cr) Matrix MT37K1212 PN or P5 MS 3191-A with MS 3191-20A 5000-070-220 (Ni/Al) 5000-070-120 (Ni/Cr) 400B Tool ITT Cannon (MS345) with 414DA-8 and locator 4046 locator 4001 M39029/29-8-8 (pin) Boeing BACC 63BY 8 8 8 8 Pren 50 Pren 50 4 15 20 20 20 20 P407171 P407171 4 9 CAB130030 CR73236 20 20 20 20 P407171 P407171 4A

AWG
Test cable AWG
Test cable Stock
M-DLPS902
M-DLPS902
Section
Table
CZ72111
Plessey tool kit 588/1/01023 Plessey-Erma lugs 12109 12107 120105 120105 * Erma tool 12107 HD Erma tool 12107 HC 12105 HB 12105 HB 12105 HB Erma tool 12109 HD 12107 HC 12105 HB 12105 HB Erma tool 19009-0/12 Erma tool replaced by AMP tool 49935. P305904 P305906 P305903 P305903 12 14 18/16 18/16 12 14 16 18 P404106 P404105 P404104 P404103 P305904 P305906 P305903 P305903 12 14 18/16 18/16 12 14 16 18 P404106 P404105 P404104 P404103
with Z75130/36 Z75131/37 Z75132/38 Z75132/38 19010 19114 JAW 19009 19009 19009 19009 * 19009-9/12 29020 with 29214 29210 29209 29209 600293 *NOTE:
5 P305904 12 12 P404106
P305906 P305903 P305903 P305903
14 18/16 18/16 18/16
14 16 18 19
P404105 P404104 P404103 RA60225
Erma tools are now obsolescent.


AWG
Test cable AWG
Test Cable Stock
M-DLPS902
M-DLPS902
Section
Table
AB (Plessey) Standard Breeze with 615712 615712 Z28147 Z27323 Plessey tool 588/1/00989 with Z50100 Z50101 Mk3 / --Mk3 / 0W Mk3 / 0W Mk3 / 1W Mk3 / 1W Mk3 / 2W Mk3 / 2W Mk4 / 3W Mk3 / 3W Mk3 / 1P or Mk3 / 1PW Mk3 / 1T Mk3 / 1T Z28147 Z27323 Hellerman Mk3 Range tools Hellerman HC / HCP (Green) HC1240C (Green) HC1240C (Red) HC1241C (Red) HC1241C (Blue) HC1242C (Blue) HC1242C (Yellow) HC1243C (Yellow) HC1243C (Red) HC2651 (Red) HC2651 (Red) HCP302 (Red) HCP302 12 16 12 16 P404106 P404104 12 16 12 16 P404106 P404104
11
6 P312181 P312181 P312182 P312182 P312183 P312183 P312184 P312184 P327921 P327921 P307363 P307363 20/24 20/24 16/22 16/22 12/16 12/16 10/12 10/12 16/22 16/22 16/22 16/22 20 24 16 22 12 16 12 10 16 22 16 22 P404102 P404177 P404104 P404101 P404108 P404104 P404106 PREN 35 P404104 P404101 P404104 P404101
Tools & Turrets or Positioners HD16/20-15500

AWG
Test cable AWG
Test Cable Stock
M-DLPS902
M-DLPS902
Section
Table
Hellerman Deutsch tool Hellerman Deutsch LPT 0004-135-000 pin 0007-013-000 socket AMP tool AMP Termashield Ferrules. Red Blue Yellow AMP tool MATE -N LOK 163557-2 163304-2 AMP tools Pre Insulated Diamond Grip (PIDG) 320563 blue 320563 36151 red 36151 36161 yellow 36161 36161 321017 yellow 321017 P301405 P301428 20 16 20 16 P404102 P404104 -
Red Stop with red 15500-20/29 Blue stop with blue0229-036-000 59500 * Various
8 -
575937 Setting A Setting B A or B 47387 or 525691 47387 or 525691 59239 or 59239-4 or 525692 46121 46121
7 P332181 22/19 20/18 P404103 P404102
7 P337591 P337591 P301001 P301001 P301015 P301015 P301015 P301019 P301019 13/17 13/17 15/23 15/23 9/13 9/13 9/13 21/27 21/27 14 16 16 22 10 12 22 26 P404105 P404104 P404104 P407183 PREN 35 P404106 P407183 19/0.1mm

AWG
Test cable AWG
Test Cable Stock
M-DLPS902
M-DLPS902
Section 7
Table
Solistrand Strato Therm FOR REFERENCE ONLY WHEN PRINTED UNLESS OTHERWISE SPECIFIED Check revision level prior to use for possible updates 48 69355 69355 49935 49935 49935 49935 48835 48835 49592 49592 323166 33462 33457 33457 34107 34107 34120 34120 Plasigrip Closed end. Paired conductors 36964 Vinyl 36964 35115 Nylon 35115 Nylon 324067 Nylon 324067 Nylon 35115 Nylon Plasti-Grip 34144 red 34144 342144 blue 342144 342185 yellow 342185 P338533 P301010 P301016 P301016 8 8 9/13 9/13 15/23 15/23 13/17 13/17 13/11 13/11 7.5 8 10 12 22 16 14 16 14 12 P338551 PREN 50 PREN 35 P407183 P407183 P404104 P404105 P404104 P404105 P404106
7 15/23 15/23 13/17 13/17 9/13 9/13 15/23 22 14 16 14 12 10 22 P407183 P404105 P404104 P404105 P404106 PREN 35
48087 48087 45330 45330 59239-4 59239-4 45216
7 15/23 15/23 13/17 13/17 9/13 9/13 16 22 14 16 10 12 P404104 P407183 P404105 P404104 PREN 35 P404106
45449 45449 45450 45450 59270 59270

AWG
Test cable AWG
Test Cable Stock
M-DLPS902
M-DLPS902
Section 7
Table
48070 574872 574874 572875 AD1377 Position Red Red Blue Blue Yellow Yellow IR 1759 with AT 3132
Diamond Grip 31096 30993 Raychem tool (Crimp) Raychem Butt D-436-36 D-436-36 D-436-37 D-436-37 D-436-38 D-436-38 Raychem tool (Thermal) Raychem Solder Sleeve * D144 00
P301011 PS10096 -
21/27 15/23 13/17 9/13
26 22 16 10
19/0.1mm P407183 P404104 PREN 35
6 P337731 P337731 P337732 P337732 P337733 P337733 26/20 26/20 20/16 20/16 16/12 16/12 26 20 20 16 16 12 19/0.1mm P407171 P407171 P404104 P404104 P404106
*NOTE:
Raychem 5024A.1311-0 See M-DLPS915
Cable Types used in Testing Crimps Type PREN 35 and 50 P404 - - P407 - - P338551
Plating Tin Tin Nickel Nickel Phosphor Bronze CMA Stock No.1395, AWG 19 Stock No.2800, AWG 15
Test 1 1 1 1A 1A 1A
RA60225 Brush Pig Tails F50
17. Soldering Irons and Stations A. Calibration Procedure (1) The system of calibration shall be in accordance with MANP 3.3.303. (2) The calibration period shall be initially every three months or earlier following a bit or any combination of sub-parts being changed. This initial period shall be subject to review in accordance with MANP 3.3.303. (3) Soldering iron stations shall be calibrated using a 240V ac (+ / -2%) power source. The recommended instrument for temperature measurement of the Bit is the Zero Load Weller Iron Temperature Monitor WTT1000D. A Fluke Model 51 with R.S. Components probe (or similar) may be used on large mass Bits. B. Calibration Method (1) The method of test shall be thus: (a) With iron Bit horizontal and switched on for not less than 3 minutes, place temperature probe firmly into a fresh pool of solder at Bit tip, find best position for maximum reading, hold for sufficient time to settle and note minimum and maximum readings. Ensure Bit is not loose in holder. Lower readings can be expected using a thermocouple probe on fine tipped Bits. There can be up to a + / - 30 degrees C variation depending on probe angle. (2) A Magnastat soldering iron station shall be returned for calibration together with its current bit in use, as required, and shall meet the following requirements:Weller Bit Number --5 --6 --7 --8 --9 Nominal Temperature(degrees C) 260 315 370 430 480
Bit Temperature Tolerance, All Ranges: Bit Temperature Control Differential
+ / -30 degrees C + / -10 degrees C
(3) Electronically controlled soldering iron stations to be returned for calibration and shall meet the following requirements: -
Selected Temperature (degrees C): Temperature Tolerances:
200 Read Bit
300
400
+ / - 8 degrees C to SET + / - 8 degrees C to READ
(4) These tolerances are for Bits type ETA, ETB, ETC, ETH, ETP & ETD only. Other Bits such as ETM, ETL, ETR, ETK & ETS will run cooler, ranging down by up to 14 degrees Centigrade less. These measurements are by using an Electro welded thermocouple of not greater than 30 SWG wires (without heat sink) or the Zero Load instrument, (5) The soldering iron station may be serviced and recalibrated if required. (6) Other soldering irons such as the Henley SOLON 240, 125 and 65 watt types 240V a.c. powered, do not require calibration. (a) These irons shall receive an inspection for Safety-in-Use every twelve months. (b) These irons shall be suitably cooled and have records kept.
(c) These irons shall only be used on work such as soldering clips to metal braid of harnesses, overshoe elements and spinner heater wires to terminal adaptor braid leads. (d) This may include wire banding on electrical machine armatures and rotors, ring sealing and label fixing where temperature controlled irons have an insufficient heat storage mass. C. Precautions (1) Wire terminating can result in certain substances which can be hazardous to health. During cable stripping, soldering and jointing, adequate ventilation shall be used, especially at temperatures exceeding 400 degrees C. Manufacturers provide data sheets which should be consulted for further information. All portable electrical tools shall receive a regular examination as required by the Electricity at Work Regulations 1989. 18. Hot Air and Infra Red Tools. A. Calibration Procedure (1) The system of calibration shall be in accordance with MANP 3.3.303. (2) The test period initially shall be every three months or earlier following a tool repair, which could affect its performance. This period shall be subject to review in accordance with MANP 3.3.303. (3) Prior to testing the tool shall be examined to ensure: (a) That it is not likely to fail or be dangerous due to defective parts and to have repaired or replaced any of these parts as necessary. (b) That airways be free of dust and debris. (c) That blower motors run constantly irrespective of operating plane.
(d) That reflectors shall be polished and filters clean according to manufacturers instructions. (e) Lamp replacement shall require a tool retest. (f) Tools and power boxes shall be checked according to the manufacturers or agents instruction manual and meet the criteria therein. B. Calibration Method
(1) The method of test for hot air guns shall be to install a UKAS calibrated temperature probe (type K) at 56mm downstream of the nozzle and UKAS calibrated temperature display to record the air temperature for a given air flow and wattage setting. Each setting shall be timed for a sixty (60) second interval using a calibrated stop-watch. (2) For Raychem CV1981 and CV1983 hot air guns use Raychem calibration tool part number AD-1999 modified to take a temperature probe (type K) at the 56mm dimension as above. (3) Allow an initial sixty (60) second warm-up period before commencing calibration. (4) Operating from a 240 volt AC supply, these are some typical values expected: Wattage 750W 900W 1200W 1460W 2260W Type CV1980 CV1980 CV1981 CV1983 MFC R.S. & Other Raychem Raychem Raychem Raychem Vent Open 300/350C 260C 330C 580/620C 580/620C Vent Closed 375C 480C 230 l/min 500l/min Flow
Results should be within + / - 5%. Results will vary with actual wattage consumed. Excessive temperatures may indicate faulty blower. (a) The method of test for an infra-red gun shall be to produce a sample joint. Using a suitable length of Cheminax 5024A 1311-9 coaxial cable (or equivalent), position a D144-00 solder sleeve over a 7mm stripped window section of the cable. The whole assembly is then positioned in the external reflector with the solder preform in line with the centre-line mark on the reflector. (b) Operate the trigger switch until the solder preform has completely melted. (c) For a Raychem 'Miniray IR.1759 with reflector AT.3132 and Supply Box ED - 7 - 003 combination, the tool is considered to function satisfactorily if the time taken to achieve a complete solder melt is not greater than 8 seconds. (d) Do not heat for periods in excess of thirty (30) seconds. (5) Tools not meeting the Manufacturers specification shall be withdrawn from service for repair or replacement.
(6) Planning Department in co-operation with the Inspection Department make provision and maintain supplies for the Infra-Red heat gun test sample cable and sleeve. C. Precautions (1) Wire terminating can result in certain substances that can be hazardous to health. During cable stripping, soldering and jointing, adequate ventilation shall be used. These tools should not be used where the atmosphere is charged with explosive or toxic gases. Wear safety glasses and do not operate the tool with the front output area towards you. Manufacturers provide data sheets that should be consulted for further information. (2) All portable electrical tools shall receive a regular examination as required by the Electricity at Work Regulations 1989 or relevant European Commission Council Directive.

PS3006 e

Uploaded by

Document Information

Original Description:

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

PS3006 e

Uploaded by

Copyright:

Available Formats

M-DLPS3006 ELECTRICAL CALIBRATION SCHEDULE SPECIFICATION ISSUE RECORD Spec Issue Amendment Approval Issue Date 1 2 3 4 Page No.

Page Issue Status

Compiled by Approved by Agreed by Issuing Authority

M-DLPS3006 Page 1 Issue 2

SPECIFICATION ISSUE RECORD Spec Issue 11 12 13 14 15 16 17 Page No. 18 19 20 21 22 23 24 25

Page Issue Status 1 2

SPECIFICATION ISSUE RECORD Spec Issue Page No. 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40

Page Issue Status 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2

M-DLPS3006 Page 2 Issue 2

SPECIFICATION ISSUE RECORD Spec Issue 41 42 43 44 45 46 47 Page No. 48 49 50 51 52 53

Page Issue Status 1 2

M-DLPS3006 Page 3 Issue 2

M-DLPS3006 Page 4 Issue 2

M-DLPS3006 Page 5 Issue 2

B. BS 5 G 178 C. SR 1359 D. E. F. G. MIL-STD-45662A BS EN 30012-1 BS 5781 ISO 10012-1

Quality Assurance Requirements for Measuring Equipment.

M-DLPS3006 Page 6 Issue 2

M-DLPS3006 Page 7 Issue 2

M-DLPS3006 Page 8 Issue 2

Soldering Irons Hot Air Guns

M-DLPS3006 Page 9 Issue 2

M-DLPS3006 Page 10 Issue 2

M-DLPS3006 Page 11 Issue 2

M-DLPS3006 Page 12 Issue 2

M-DLPS3006 Page 13 Issue 2

M-DLPS3006 Page 14 Issue 2

M-DLPS3006 Page 15 Issue 2

Hence the ratio is 50:1

M-DLPS3006 Page 16 Issue 2

M-DLPS3006 Page 17 Issue 2

M-DLPS3006 Page 18 Issue 2

M-DLPS3006 Page 19 Issue 2

M-DLPS3006 Page 20 Issue 2

M-DLPS3006 Page 21 Issue 2

M-DLPS3006 Page 22 Issue 2

M-DLPS3006 Page 23 Issue 2

M-DLPS3006 Page 24 Issue 2

M-DLPS3006 Page 25 Issue 2

M-DLPS3006 Page 26 Issue 2

M-DLPS3006 Page 27 Issue 2

M-DLPS3006 Page 28 Issue 2

M-DLPS3006 Page 29 Issue 2

M-DLPS3006 Page 30 Issue 2

3/4'' Length 'A'

(a) Guillotine through fibre sheath to inner clear screen.

M-DLPS3006 Page 31 Issue 2

M-DLPS3006 Page 32 Issue 2

Wire Types Table 1

M-DLPS3006 Page 33 Issue 2

M-DLPS3006 Page 34 Issue 2

M-DLPS3006 Page 35 Issue 2

M-DLPS3006 Page 36 Issue 2

Equivalent Pren Amperes

Number & Diameter of Strands inch Mm

Maximum Diameter inch mm

Cross Sectional Area inch mm

Test Current Ampere

Volt Drop Nickel Plated mV mV/Amp

Minimum Pull-off lbs

7/ 7/ 7/ 7/ 19 / 19 / 19 / 48 / 19 / 40 / 19 / 37 / 19 / 37 / 19 / 37 / 119 / 182 / 294 /

1.5 2.5 3.5 7.0 11.0 14.0 18.0

8.4* 6.0 2.6* 1.10 0.75 0.58