TECHNICAL MANUAL for FUEL QUANTITY TEST SET P/N 101-00420 P.O. BOX 527705 MIAMI, FLOBIA, 33182-7708, TLX $1-8808 FAX (305) 871-5629, cs Printed in U.S.A. Feb. 11, 1983Users are kindly requested to notify the manufacturer of any discrepancy, omission or error found in this manual, Please send your comments to: Publication Department Barfield instrument Corporation P. 0. Box 420537 ° Miami, FL 33242-0537 USA Telephone (305) 871 - 3900 TWX 51 8808BARFIELD 254eH (MOD C) FUEL QUANTITY TEST SET IAM, FLORIDA Tome ATTENTION Although every effort has been made to provide you, the end user of this equipment with the most current and accurate information, it may be neces- sary to revise this literature in the future. To insure that you will receive ALL revisions when published, the Technical Publications Department of Barfield Instrument Corporation MUST have your name and address of file. Please complete and mail the OWNER'S WARRANTY REGISTRATION card promptly. This pre-addressed card insures AUTOMATIC UPDATE OF PRINTED MATTER and vali- dation of warranty. Questions concerning interpretation of this manual shall be submitted in writing to: Tethnical Publications Department Barfield Instrument Corporation P.0. Box 527705 Miami, FL 33152-7705 USA Inquiries shall define the specific question supported with the publication title, number, chapter, page, figure, paragraph and effective date. Changes, when approved, will_be published by revisions to the basic manual and distributed to all REGISTERED owners. Attention Page ‘TM2548H-8103 Page 1THIS PAGE INTENTIONALLY LEFT BLANKBARFIELD Foes gusset Tes ser nat, ROR TECHNICAL MANWAL TABLE OF CONTENTS CHAPTER = TITLE PAGE a GENERAL INFORMATION 12 41.1 Purpose 12 1.2 Description 12 1.3 Capabilities & Specifications 15 1.4 Shipping 16 45 Storage 16 1.6 Accessories 16 2 PRINCIPLES OF OPERATION uu 21 Introduction 24 22 Power Supply a1 23° Metering 2 2.4 indicator Function 24 25 Insulation Function 24 2.6 Cap Sim Functions 22 2.7 Cap Bridge Functions 24 2.8 Stray Capacitance Compensation 25 3 OPERATION 31 5. General a Preliminary a4 Insulation Tests 8 Capacitance Tests 33 Fuel Gauge Indicator Tests 35 Signal Conditioner, Bridge Amplifier, Integral ind Test 3-7 ‘System Calibration, Preferred 39 ‘System Calibration, Alternate 3-10 Battery Test 3-10 Battery Replacement 3-10 AC Power Supply 310 4 MAINTENANCE at 44 User Maintenance at 42 Recertification a 43 Indicator Function Test a1 44 Battery Test a1 45 Insulation Function Test 42 4.6 Capacitance Simulator Test a3 47 Capacitance Bridge Test . 43 4.8 Compensator Simulator Test a4 49 Final Checkout aa 5 REPAIR 1 5.1 General 5s 5.2 Oscillator 541 $3 Filter x 5.4 Inverter Adjust 52 5S Calibration 52 CONTENTS ‘TM2548H-8103, Page 4 Rev. Feb. 14, 1983‘TM2548H-8103 BARFIELD aoe ovary TEST Set ‘usa, ono AL an TABLE OF CONTENTS TITLE ILLUSTRATED PARTS LIST introduction Case Assembly Panel Assembly Main PCB Assembly Meter PCB Assembly ‘AC Power Supply ‘Accessories FEDERAL SUPPLY CODE OF MANUFACTURERS UST OF ILLUSTRATIONS TITLE Chapter 1 Fuel Quantity Test set Leading Particulars Front Panel Layout Panel Components Specifications Chapter 2 Insulation Function ‘Tank Capacitance Simulator Capacitance Briage Chapter 3 Front Panel Layout Insulation Test Hookups Capacitance Measurements Hookups Capacitance Simulator Hookups Chapter 4 Equipment Required Chapter 5 Panel Schematic Main PCB Schematic Meter PCB Schematic ‘AC Power Supply Schematic Chapter 6 Case Assembly Panel Assembly Main PCB Assembly Meter PCB Assembly ‘AC Power Supply CONTENTS rage2 Rev. Feb. 14, 1983BABFIELD »\_ Senaryrn ‘aa FORDE ree aA LIST OF EFFECTIVE PAGES INSERT LATEST CHANGED PAGES DESTROY ANY SUPERSEDED PAGES That portion of the text affected by any changes, additions or deletions Is shown by a vertical black line in the left hand margin of text. PAGE DATE REVISION PAGE DATE REVISION Title 3-15-81 2-11-83 a4 3-15-81 2-11-83 Eff Pp 3-15-81 2-11-83 42 3-15-81 2-11-83 I 315-81 2-14-83 a3 3-15-81 2-11-83 ii 3-15-81 2-11-83 a4 3-15-81 2-11-83, ii 3-15-81 2-11-83 as 3-15-81 2-11-83 14 3-15-81 2-11-83 4-2 3-15-81 2-11-83 51 3-15-81 2-11-83 43 3-15-81 2-11-83, 5-2 3-15-81 2-11-83 44 3-15-81 2-14-83 53 3-15-81 2-11-83 15 3-15-81 2-11-83, Sa 3-15-81 (211-83, 1-6 3-15-81 2-11-83 35 3-15-81 2-11-83 24 3-15-81 2-11-83, 1 315-81 (2-11-83, 2-2 3-15-81 2-11-83, 62 3-15-81 2-11-83, 23 3-15-81 2-11-83, 63 3-15-81 2-11-83, 24 3-15-81 2-11-83 64 3-15-81 2-11-83, 25 3-15-81 2-11-83. 65 3415-81 2-11-83 66 315-81 2-11-83, 67 315-81 2-11-83 341 3-15-81 68 3-15-81 2-11-83 3-2 3-15-81 69 3-15-81 2-11-83 33 3-15-81 6-10 3-15-81 2-11-83 34 3-15-81 611 ‘3-15-81 2-11-83 35 3-15-81 612 ‘3-15-81 2-11-83 36 3-15-81 613 3-15-81 2-11-83 37 3-15-81 614 3-15-81 2-11-83 38 3-15-81 615 (3-15-81 2-11-83 ca 3-15-81 6-16 3-15-81 2-11-83 617 a15e1 | 24483 618 3-15-81 2-11-83, 7A 3-15-81 2-11-83 REVISIONS ‘TM2548H-8103 Page 1/2 Rev. Feb. 11, 1983THIS PAGE INTENTIONALLY LEFT BLANKa 2540 a100 0 BARFIELD aaa ‘AR, FLORIDA TECHNICAL MANGAL INTRODUCTION SCOPE OF MANUAL ‘This manual provides a complete description of the subject test set and all the necessary operating and maintenance procedures necessary for its use and support. REVISIONS Any subsequent changes which occur after the original printing of this technical manual will be noted in the Revision column of the Uist Of EFfective Pages at the Beginning of this manual. QUESTIONS AND COMMENTS ‘We welcome your comments concerning this manual. When reporting a specific ques- tion or problem, please describe it briefly and inciude the Publication Number, the paragraph or figure number, page number and effective date, if applicable. Please address your comments to: Publications Department Barfield instrument Corporation 4101 N.W. 29th Street Miami, Florida 33142 USA. APPLICABILITY ‘This manual applies to test sets up through modification status letters punched on the nameplate on the outside carrying case. as indicated by the INTRO | rwesaati-s103 Page 1/2 Rev. Feb. 11, 1983THIS PAGE INTENTIONALLY LEFT BLANKBARFIELD Bamwoog ‘aA, ROR AL Ma BARFIELD 2548H (MOD C) a TM2548H-8103 FUEL QUANTITY TEST SET Page 1/2 FIGURE 1 Rev. Feb. 11, 1983,THIS PAGE INTENTIONALLY LEFT BLANKBARFIELD Engi td ‘aaa, Roma "banca MAA GENERAL INFORMATION 4.1 PURPOSE ‘The Barfield Fuel Quantity Test Set (1/5) is specifically designed to meet the need for ser- vicing guarded capacitance type aircraft fuel and oil quantity measuring systems. Accuracy and reliability have been optimized together with portability and convenience. The T/S provides means for maintenance testing, trouble-shooting, and calibration of S.wire guarded systems. The accuracy of the T/S ensures meeting manufacturer's measure- ‘ment and calibration requirements, and the potentials and currents introduced are limited to ‘meet all safety specifications, 1.2. DESCRIPTION 1.2.1 Leading Particulars - See Figure 4 for illustration and Figure 2 for leading particulars, DIMENSIONS Length (max) Width (mar Height (lid closed max’ WEIGHT ...... opPnaaa HTD cece POWER REQUIREMENTS .... Four 9V NEDA 16044 Self contained alkaline batteries OPTIONAL POWER .........2.............,.£ither 445V or 230V ‘50 to 400 Hz LEADING PARTICULARS FIGURE 2 4.2.2 General - Three measurement and two capacitance simulator functions are provided through a function selector switch. with the exception of adapter leads, fittings, and harnesses, the T/S contains everything necessary for test and calibration of the aircraft system and its individual components. 1.2.3 Panel Components - see Figure 3 for panel illustration and reference numbers and see Figure @ for desc Gescnbuen oF all panel components, 4 TM2548H-8103 Page 2 Rev. Feb. 11, 1983,BABFIELD ek Hea rm Figures enclosed in parentheses in text refer to circied figures in istration above. 1 ‘TM2548H-8103 FRONT PANEL LAYOUT Pages FIGURE 3 Rev. Feb. 11, 1983PRESS TO MEASURE GND Loz HZ ‘TEST FUNCTION INS TEST POINTS RANGE INDICATOR METER ADJUST BATTERY COMPARTMENT ON, OFF BATT TEST TANK CAP pF HZ COAX LO-Z TANK 10-2 coMP ‘COMP sim COMP CAL Pushbutton Banana Jack BNC Receptacle polarized BNC Receptacle S-position rotary switch position rotary switch position toggle switch ‘Two Banana jacks Unear Potentiometer} ‘Taut-band panel meter Battery or AC power supply position toggle switch Pushbutton Five section digital select switch BNC Receptacle BNC Receptacle Polarized BNC Receptacle Polarized Decade selectable and a variabie capacitor Pushbutton Engages bridge VCC supply and switches bridge for external use External connection to case ground insulation Test LO-Z Insulation Test HI-Z Selects one of five test functions. Selects one of six pairs of test points Selects X1 or X.01 Megohms scale insulation range input connections for 01100 uA meter testing or substitution Controls 0-1100 uA test current or adjusts megohmmeter for infinity setting Provides 0-1100 uA current scale, 05000 megohm scale, and battery condition scale Contains batteries or optional AC Power supply Controls battery or output of AC supply Connects panel meter as 0.33.1 V Meter across battery supply (BAT Ok line Is 24.8 V0 Selects capacitance simulator valuel between Hi-Z COAX and LO-Z TANK Jacks or bridge value HIz connection for bridge and simulators LO-Z connéction for bridge and tank simulators LO-Z connection for the compensator simulator Compensator simulator capacitance between HI-Z COAX and LO-2 COMP Connects compensator simulator to capacitance bridge | rwesaan-e10s 1 Page 4 Rev. Feb. 11, 19832548H we00 0 BARFIELD FUEL QUANTITY TEST SET 1.3. CAPABILITIES AND SPECIFICATIONS 4.34 plilties “When connected through appropriate adapter cables, the following func- tions hay be Darformeds a, . Measure capacitance of individual or interconnected tank sensor probes or probe simulators. Measure the insulation resistance of system wiring, probes, or other discrete components. Test the performance of indicators and signal conditioners or bridge amplifiers. Simulate capacitances representative of empty or full probes or systems, or the added capacitance effect of the fuel between empty and full. Substitute T/S meter for OC meter-movement type gages, and provide ac- Justable metered current to test these gages. 1.3.2 Specifications - See Figure 5 for listing, INSULATION Range: 0 to infinity in two scales, 5 to 5000 megohms and SOK ohms to 50 megohms. ‘Accuracy: + 5% Of reading nominal, but not in excess OF + 2% of scale lengtn throughout range. Applied Voltage: 40 VOC nominal. Current: 50 nA maximum, INDICATOR Range: 0-1100 uA in 10 uA increments. Accuracy: & 1% of full scale, CAPACITANCE BRIDGE Range: 0 to 999.9 pF in 0.1 pF increments. Accuracy: ++ (0.1% of reading + 0.1 pr) Signal: 400 Hz at 5.7V r.ms. nominal, CAPACITANCE SIMULATORS Tank Range: 0 to $99.9 pF in 0.1 pF increments. Accuracy: ‘Same as Capacitance Bridge. Comp. Range: 10-400 pF continuously adjustable ‘Accuracy: Set with Capacitance Bridge ‘Max. input: 75V r.ms., 220V p-p (above 3 KHz, Tank simulator limit decreases proportionately to 10V rms. at 25 KHz, 1 | TM2548H-8103 Page 5 Rev. Feb. 11, 1983BARFIELD suse rest sr ‘at, ORDA FEDINCAL MARL 1.4. SHIPPING It is recommended that the original shipping container be saved for future shipment. However, a minimum of 1% inches of packing type foam rubber should be used between ali six sides of the T/S case and a sturdy pasteboard carton. All of the space between the case and. “carton must be filled with the packing material, [CAUTION: DO NOT PACK ANY LOOSE CABLES OR OTHER ACCESSORIES INSIDE THE TEST CASE. ‘Allaccessories should be contained within separate packing material and preferably not stored within the T/S carrying case, The batteries should be removed from the test set before shipping. Make certain that all ‘T/S panel screws and panel components are securely fastened, 1.5. STORAGE Remove all batteries for prolonged storage, and store in a cool, dry place. If T/S should become exposed to water or very high humidity, dry completely as soon as possible. Remov- Ing from case and temporarily storing in a dehumidified area is recommended. 1.6 ACCESSORIES jhe Barfield 2548H Fuel Quantity Test Set includes a standard lead package P/N 101-00401. Refer to Chapter 6 for a list of components. 1.7. OPTIONS Size AS Power Supply - A 101-00700 115V or 107-00701 230V AC power supply is available as an option: 4.72 inal Me - A two terminal megohmmeter is standard, but a three terminal megohmmeter is avaliable as an option or modification. 1 | TMasaaH-s103 Page 6/7 Rev. Feb. 11, 1983,THIS PAGE INTENTIONALLY LEFT BLANKPRINCIPLES OF OPERATION 2.1 INTRODUCTION 2.1.1 General - in addition to tne schematics included in this chapter, refer also to Chapter 5, 2.2 POWER SUPPLY 224 | Four 9'v batteries, 81 through 84, are connected to provide a bipolar 18 VDC supply which Is switched through an ON-OFF switch, 1. 2.2.2. AC Power - An optional 115 VAC or 280 VAC power supply assembly Is directly Inter- Changable with the battery supply assembly. The AC supplies use potted modular assemblies which are short-circuit protected and warranted by the manufacturer. 2.3 METERING 2.5.1, General - The panel meter, M1, is a 0-1000 Dc taut-band microammeter with an internal fesistance of approximately 14 ohms. R6 and Pt on the meter PC board form an adjustable shunt for all test functions to set full scale at 1100 uA. 23.2 Battery Test - BATT TEST pushbutton, $4, connects M1 as a 33.1 V fullscale voltmeter Siigy, ne four batteries in series through Rad. The BAT Ok radial on meter dial represents 2.4. INDICATOR FUNCTION When the “INDICATOR” function is selected, METER ADJ, P6, provides an adjustable cur- rent through M1 to the indicator jacks, J6 and 1 2.5. INSULATION FUNCTION 25-3, pqutselector - The ins TEST POINTS switch, $2, selects a pair of input test points from.1, 72,25, or M1 shield, and on the three terminal version simuttaneousty connects a guard £0 the ‘two unused points. 2.5.2 Megohmr - Refer to Figure 4 for the essential circuit used in the "INSULATION" func: fion. METER ADT Peprovides an adjustable input to iC7 of approximately 50 mv, The gain of IC7 {s Set at 200 by R59 and R320 that IC7 outputs 10 VDC to the Inputs selected by S2A This Outpuc 2 ‘TM2548H-8103, Page1 Rev. Feb. 11, 1983ARFIELD oe Susan rest ser ‘waa, Foe "TROUEAL Mann INSULATION FUNCTION Figure 1 233 flleering -c36 and Rat form a low-pass input filter to reduce noise response and C35 in- creases the circuit time constant to reduce high amplitude tarsiens seston: Foe wr Sage Sete - 8 shunts Re2 with Rao to reduce the megonmmeter Tange by a factor of hen the 100 wt ” range is selected. 255 PHEgtING - R57 andi Ra provide current limiting in the event of a catastrophic failure OF IC7 oF Ks, 2.6 CAP SiM FUNCTIONS BSL Seteeal Two capacitance simulators, TANK and COMP), have a common connection ac Cone eee HM The COMP SiM is an uncallorated capacitance commerien reece Ja and Lo-z Blawned Gh.Z@: The TANK CAP pF simulator consists of a Fad eapsciear ent ye divider as ex- plained in'2.6.3. 2.6.2 Penner Sater simulator - The COMP SIM consists of fixed capacitors digitally selectea by $9 lus a smail variable capacitor, C33. Hon mgct¥ariable combination has a range from 10 pF to over 400 pF. The "CAP BRIDGE” Func- on must be used to set the COMP SIM to a callbrated vale’ 26.3 aanulater ~IF the Input to a 3-wire guarded capacitor is reduced, the ines E,tne. Same a5 reducing the capacitance by the same ares The principle is illustrated Grreue qUNaIeNE Circuit of Figure 2. The circultry used m teens Ilustrated in the Essential Cireuit of the same figure. 2 TwaseaH-9103 page? Rev. Feb, 11, 1983BARFIELD 24aH w409 © IAA, FLORA TMA Ma RIA c ¢ RIA + RI = @ 1 WN our y ¢ RIA to EQUIVALENT ESSENTIAL cicurr cRCUIT ‘COMMON ‘TANK CAPACITANCE SIMULATOR FIGURE 2 | A high impedance input divider consisting of R1, R2, and P1, divides the input by a ratio Of approximately 8:1. C7 and C3 provide high frequency compensation to minimize phase shift that would otherwise appear as dissipation if left uncorrected. 1 R1A is selected to further divide the input across. digital Varley divider, P7, so that its set- tings will be an accurate equivalent capacitance ratio of Teference capacitors. IC1 and IC2 are I unity-gain amplifiers to isolate P7. 26.4 Cap sim2-The connections to jacks 14 and JS are reversed from the Functional Circuit of Figure 2, J4 remains common to both TANK and COMP simulators but now may be cor sidered LO-2. JS and J9 are outputs and should be considered as Hi-Z. 2.8.5 Metering in Can sim - in the “CAP SiM 1" and "CAP SiM 2” functions, the meter M1, con- ects directy between the INDICATOR jacks J6 and J7. The meter may then be conveniently Substituted for a DC meter type fue! quantity indicator, 2 Page 3 Rev. Feb. 11, 1983 1 rwaseenst03BARFIELD 2am mao ‘aa ‘QUANTIFY TEST set "TECHNICAL MANUAL, 2.7. CAP BRIDGE FUNCTION 274 Fe noes geea Figure 3 for the basic circultry of the capacitance bridge, or to Chapter 5 for more detailed schematics. FIGURE 3 222 , Qecllator - ICSD is a two-pole low-pass active filter which, together with Integrator, Teaneferins 2 low dlstortion sinewave generator. capacitors c18, C19; and cau room seek the sonneaz 220. and Ras and potentiometer P3, determine the frequency and smratmrce es ‘oscillation, orn ase emitter junction of OS together with bridge connected diodes, 07 through 10, forms a bi-polar zener to regulate oscillator amplitude. 2 ‘TM2548H-8103 Page 4 Rev. Feb, 11, 1983‘28480 a400 0 BARFIELD UBL QUANTITY Test ser 273 1658 Inverts the oscillator output from ICSA to a precisely equal amplitude and opposite shaee as ‘adjusted by P4 and C31 repectively. 274 ¢ The oscillator Output from ICSA Is connected to either: TANK LO-2Z jack, through Wik beten capacitance and simulator are excited with equal amplitude signals thelr actors OF on eaually proportioned to thelr effective capacitances. since their excitation sloruk wee Pf.Oprosite phase, thelr summed outputs wil be equal to thelr differences In consreyee When their effective capacitances are equal, the resultant current will be sero, I Fi2ig pPetecter - 163 Is a current to voltage converter. 01 and D2 provide input amplitude imiting. 2:28 , Atgplier- 07 and a2, together with icac, form a logarithmic amplifier with the output Bron Sea es logarithmic relationship between the collector current and emitter bsce verter Roan and 22 results in an amplifier gain which is maximum at low levels near bridge nei ana logarithmically decreasing gain as the bridge unbalance increases, 27.7 igi * ICAB, and ICAO form a bandpass filter network with P2 providing the fre- quency tuning, 2.8 STRAY CAPACITANCE COMPENSATION 284 : A certain amount of stray capacitances exists within the test set due to ex- and Detcrcansnlelded lead wire at connecting points, capacitance between switch contace, and between any Hl-Z to LO-Z conductors which cari not be effectively shielded fron ses another, . ghese stray capacitances change from one function to another due to addition: and celetions of circultry and due to the differences in the mechanical position of movaticcwiten Soaract armatures. These strays are compensated by a circult mounted on the merer on card, TRE CAP BRIDGE”. "CAP SIM 1”, and “CAP SiM 2" Functions, Thus, permitting the yerave Iioncn ct ‘these functions to be canceled. 2 | rwasearsi0s rage 8 rev. Fen