PRESTON PRESSURE PS-525 Bedienungsanleitung

PS-525

Pitot-Static/Air Data Tester

OPERATION AND MAINTENANCE

MANUAL

For Models PS-525 and PS-525A

prestonpressure.com

Revision 8, November 1, 2013

To buy, sell, rent or trade-in this product please click on the link below:

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PRESTON PRESSURE LLC

PS-525/PS-525A

USER AND MAINTENANCE MANUAL

TABLE OF CONTENTS

Page

Warranty and Liability Statement---------------------------------------------------- 2

1. General Information------------------------------------------------------------------- 3

1. Description --------------------------------------------------------------------- 3

2. Pressure Sensors --------------------------------------------------------------- 3

3. Specifications ------------------------------------------------------------------ 4

4. Power Supply ------------------------------------------------------------------ 5

5. Vacuum and Pressure Pumps ------------------------------------------------ 6

6. Front Panel Layout------------------------------------------------------------- 7

7. Front Panel Description ------------------------------------------------------- 8

2. Theory------------------------------------------------------------------------------------- 10

1. Pneumatic Theory -------------------------------------------------------------- 10

2. Electronic Theory--------------------------------------------------------------- 11

3. Electrical Theory --------------------------------------------------------------- 12

4. Decoder Reader Theory ------------------------------------------------------- 12

3. Operation -------------------------------------------------------------------------------- 13

1. Preliminary Information -------------------------------------------------------13

2. Error Codes ----------------------------------------------------------------------13

2. Pre-testing ----------------------------------------------------------------------- 13

3. Testing Aircraft Pitot System -------------------------------------------------14

4. Testing Aircraft Static System ------------------------------------------------15

5. testing the Aircraft Pitot and Static systems simultaneously ------------- 15

6. Using the E.P.R. Function ---------------------------------------------------- 16

4. Calibration Procedures ----------------------------------------------------------------17

1. Altimeter Calibration ---------------------------------------------------------- 17

2. Airspeed Calibration ----------------------------------------------------------- 21

3. Decoder Reader Calibration -------------------------------------------------- 23

4. Calibration of Reservoir Gauges --------------------------------------------- 23

5. Maintenance Repairs and Troubleshooting --------------------------------------- 24

1. Annual Maintenance ----------------------------------------------------------- 24

2. Troubleshooting ---------------------------------------------------------------- 24

3. Pneumatic Diagram ------------------------------------------------------------ 28

4. Electrical Schematic ----------------------------------------------------------- 29

5. Power Supply Board Schematic ----------------------------------------------30

6. Shipping and Storage ------------------------------------------------------------------ 31

WARRANTY AND LIABILITY STATEMENT

Preston Pressure warrants its products against defects in workmanship and material under

normal, intended use for a period of two years from the date of purchase. The batteries

are warranted for a period of 90 days from the date of purchase. Valves are warranted for

a period of 180 days.

Preston Pressure’s limit of liability shall be to repair or replace the product at their

discretion. Transportation shall be pre-paid to the Preston Pressure factory or authorized

service facility. Preston Pressure shall not be liable for any consequential damage

expense.

This warranty shall be void if the product has been repaired or altered in any way that

adversely affects its performance or reliability. This warranty shall be void if the product

has been subject to abuse, misuse, contamination, negligence, accident, shipping damage,

or improper operation.

Preston Pressure reserves the right, at its own discretion, to make changes in materials,

designs, finish, or specifications, without obligation to install or incorporate such changes

in products previously manufactured.

This warranty shall, at Preston Pressure’s option, become void if the ownership is

changed, unless the prior owner or proposed owner obtains written approval of

continuation of coverage prior to the change of ownership.

Preston Pressure reserves the right to revise this manual and to make changes to content

from time to time in the content thereof, without obligation to notify any person of such

revision.

This device complies with part 15 of the

FCC Rules. Operation is subject to the following

two conditions: (1) This device may

not cause harmful interference, and (2) this

device must accept any interference received,

including interference that may

cause undesired operation.

CHAPTER 1

GENERAL INFORMATION

Description of the PS-525 Pitot-Static Test Box

The PS-525/PS-525A Air Data, pitot-static test box is a digital display tester used to test

aircraft altimeters, airspeed indicators, pitot-static systems, and other vacuum and low-

pressure devices. This test box incorporates transducer sensor technology that is largely

immune to the failures and costly repairs associated with analog instruments.

The PS-525 is battery powered and portable. (A non-battery version is also available.)

The vacuum and pressure sources are derived from independent internal pumps, and each

has its own reservoir, thus eliminating the complexity and maintenance of an additional

pressure/vacuum selector valve. The tester can simulate pressure and vacuum suitable for

up to 35K ft (for the PS-525 models), (50K ft for the PS-525A models) and 650 Knots.

The PS-525 measures altitude in feet and meters. Airspeed is displayed in miles-per-hour,

kilometers-per-hour, and knots. Vacuum and pressure are also selectable in various units

of measure, including inches Hg, milliBars, mm Hg, and Psia.

The PS-525 also includes an internal digital altitude encoder reader. This reader can

measure encoder outputs from -1200 feet to 62,700 feet. Inputs can be selected from

either gray code or RS232.

•Pressure Sensors

The sensors used in the PS-525 test box are proprietary transducer sensors assembled by

Preston Pressure. The pitot sensor is not a differential pressure sensor as is most typically

used. Instead, the pressure information from the static sensor is sent digitally to the

airspeed’s microprocessor, where it is subtracted mathematically from the pitot pressure,

thus giving the differential pressure value. This design eliminates several components,

with their associated costs and maintenance.

The sensor has an overpressure rating of 10 times the normal range.

PS-525 SPECIFICATIONS

Digital Altimeter:

Display Range – model PS-525: -1000 to 35,000 feet (-305 to 10,700 meters)

Display Range – model PS-525A: -1000 to 50,000 feet (-305 to 15,240 meters)

Vacuum Pump Range – model PS-525: -1000 to 35,000 feet (-305 to 10,700 meters)

Vacuum Pump Range – model PS-525A: -1000 to 50,000 feet (-305 to 15,240 meters)

Resolution: from -1500 to 20,000 feet resolution is in 1-foot increments

from 20,001 to 30,000 feet resolution is in 2-feet increments

from 30,005 to 50,000 feet resolution is in 5-feet increments

all metric resolution is in 1-meter increments

Sensor Accuracy: approximately 0.03 %

Temperature range: 32 degrees F to 120 degrees F (0 C to 50 C)

Altitude units: Feet or Meters

Other Measurement Units:

inHg (inches of mercury): 0.295 to 32.48 in increments of 0.01

mBar (milli bars): 10 – 1100 in increments of 0.1

PSIA (pounds/square inch): 0.145 to 15.95 in increments of 0.01

mm HG (millimeters of mercury): 7.5 – 825 in increments of 0.1

Digital Airspeed:

Range: 18 – 650 Knots, 34 –1204 KPH, 21 – 748 MPH, 0.00 – 1.00 Mach

Resolution: 1 MPH, 1 KPH, 0.1 Knot, or 0.01 Mach

Sensor Accuracy: approximately 0.03%

Temperature range: 32 degrees F to 120 degrees F (0 C to 50 C)

Other Measurement Units:

inHg (inches of mercury): 0.295 to 56.10

mBar (milli bars): 10 – 1900

PSI (pounds/square inch) 0.145 to 27.55

mm HG (millimeters of mercury): 7.5 – 1425

E.P.R. (engine pressure ratio): 0.07-6.00

Display Type:

LCD

Size:

Altimeter and Airspeed: 99 x 24 mm Decoder display: 38 x 16 mm

Physical Dimensions:

12.25”D X 15”L X 9.75”H (31x38x24.5 cm)

Weight:

approximately 20 lbs (9 Kg)

Decoder Inputs: Gray Code, RS232: 1200, 2400, & 9600 baud

Power Source:

External: 24 VDC (from a 110/220 VAC adaptor)

Internal: 12/24 VDC (from internal rechargeable batteries)

Optional: 110/220 VAC Mains powered, without internal batteries

Current draw: Display only: 125 mA

370 mA with vacuum pumps operating

320 mA with pressure pump operating

540 mA with all systems operating (and no encoder attached)

Other Features:

Leak test feature: 2 minutes (10 minutes for European models), selectable down to 30 seconds

VSI (vertical speed indicator)

Note: The PS-525 does NOT have the precision required to test RVSM altimeter

systems.

Encoder Reader:

The Encoder Reader is compatible with outputs of the following altitude encoders:

ACK (gray code, 1200, 2400, 9600 baud)

Shadin (gray code, 9600 baud)

Trans-Cal (gray code, 1200, 2400, 9600 baud)

Ameri-King (gray code)

The Encoder Reader is compatible with the following RS-232 protocols:

Garmin 1200, 9600 baud

Northstar 2400 baud

Shadin 9600 baud

UPS AT, Apollo 1200 baud

Trimble 9600 baud

•Power Supply

The PS-525 power supply consists of an external transformer with an output of 24 volts

DC. This supply is plugged into the round connector on the left-hand side of the tester.

The transformer charges the two 12-volt gel-cell lead acid batteries that are internal to the

PS-525. The batteries enable the test box to be used in a portable fashion, without a need

for external power while the tester is in operation. The test box can be used while

charging, if so desired, and may be mounted in any position or angle.

The PS-525 incorporates a trickle-charge circuit that will maintain the batteries at

optimum voltage if left charging continuously, and will not over-charge.

A battery monitoring circuit is also incorporated. This circuit disconnects power to the

motors if the battery voltage drops below 18 VDC. This enables the display to continue

working, and prevents the user from having the display suddenly blank out if the voltage

goes too low when a motor is turned on. The decoder display will flash a “Low Battery”

warning when the battery voltage is near 18.5 volts. The purpose for this circuit is to

protect the batteries from excessive discharges.

The “Select Code” button may be pressed to toggle the decoder display to a setting that

will read the battery voltage (not the voltage going to the encoder). This enables the

operator to maintain awareness of the battery voltage level. The useable charge duration

of the batteries will vary, mostly depending on how long the vacuum and pressure pumps

are left on. In order to obtain maximum charge durability, as well as extend pump

and battery life, it is recommended that the pumps be left on only for the amount of

time needed to charge their respective reservoirs, as shown in the gauges. Then the

pumps should be cycled on and off as needed. When used properly, the user should be

able to obtain several hours of operation directly from the batteries before needing to re-

charge. In factory tests, with fully charged batteries, the batteries lasted for over 12 hours

when powering only the displays.

OPTIONAL: 110/220 VAC mains powered without internal batteries. In this case, the

batteries are replaced by two internal transformers of 12 VDC each. These transformers

replace the batteries. The unit is powered with a standard power chord.

•Vacuum and Pressure Pumps

The vacuum side uses two pumps, connected in series to achieve a vacuum level required

for high altitude tests. The pressure side uses one pump, which is sufficient to reach all

the pressures necessary for normal pressure tests.

Vacuum and Pressure pumps should not be

allowed to run continuously. Toggle the

switches as needed to re-charge the reservoirs

as seen on the vacuum and pressure gauges.

FRONT PANEL LAYOUT

Front Panel Description

•The front panel’s Altimeter buttons function as follows:

The UNITS button is used to toggle between the various units of measurement available

from the vacuum/altimeter section. (Altitude – feet, Altitude – meters, mBar, mmHg,

inHg, PSIA)

The EXIT button is used to exit out of the leak check mode.

The LEAK CHECK button is functional only when in the Altimeter mode. Pressing this

button will begin a 120 second timer (600 seconds for European models), and the display

will also show the gain or loss of altitude experienced during the displayed time period. If

the operator wishes to select a different length of time, the Leak Check button may be

pressed repeatedly, which will cause a reduction in the timer counter in 30-second

increments. The timer will not toggle above 120 seconds (600 seconds for European

models) nor under 30 seconds. Pressing the Units button will start the counter and display

the leakage.

•The front panel’s Airspeed buttons function as follows:

The UNITS button is used to toggle between the various units of measurement available

from the pressure/airspeed section. (Airspeed – MPH, Knots, KPH, mBar, mmHg, inHg,

PSIA, EPR)

The EXIT button is used to exit out of the leak check mode.

The LEAK CHECK button is functional only when in the Airspeed mode. Pressing this

button will begin a 120 second timer, and the display will also show the gain or loss of

airspeed experienced during the displayed time period. If the operator wishes to select a

different length of time, the Leak Check button may be pressed repeatedly, which will

cause a reduction in the timer counter in 30-second increments. The timer will not toggle

above 120 seconds seconds (600 seconds for European models) nor under 30 seconds.

Pressing the Units button will start the counter and display the leakage.

•The front panel’s Select Code functions as follows:

Upon initial power application, the decoder will always default to the Gray Code

function. Pressing the Select Code button will cause the decoder to toggle through the

following functions, after which it will return to the Gray Code function again:

•Gray Code – altitude numerical readout

•Gray Code – inputs A1, A2, A4 binary readout

•Gray Code – inputs B1, B2, B4 binary readout

•Gray Code – inputs C1, C2, C4 binary readout

•Gray Code – input D4 binary readout

•Battery voltage (used to monitor the voltage level of the tester’s internal

batteries). This is not necessarily the voltage going to the encoder, which is

selected by the power switch.

•1200 Baud rate, from Port A (pin 14 of front encoder connector)

•1200 Baud rate, from Port B (pin 7 of front encoder connector)

•2400 Baud rate, from Port A (pin 14 of front encoder connector)

•2400 Baud rate, from Port B (pin 7 of front encoder connector)

•9600 Baud rate, from Port A (pin 14 of front encoder connector)

•9600 Baud rate, from Port B (pin 7 of front encoder connector)

The Encoder Reader is compatible with outputs of the following altitude encoders:

ACK (gray code, 1200, 2400, 9600 baud)

Shadin (gray code, 9600 baud)

Trans-Cal

Ameri-King (gray code)

The Encoder Reader is compatible with the following RS-232 protocols:

Garmin 1200, 9600 baud

Northstar 2400 baud

Shadin 9600 baud

UPS AT 1200 baud

Trimble 9600 baud

Note: The Power Switch may be toggled up or down. Either position will turn on the test

box. The only difference is that in the UP position the switch will transfer 24 VDC to the

encoder connector (pin 8), and in the DOWN position the switch will transfer 12 VDC to

the encoder connector (pin 8). The position of this switch does not change the voltage

going to the PS-525 display circuitry, which always operates at 24 VDC.

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