T-310251-O

CALIBRATION PROCEDURE WABCO FREIGHT CAR PRODUCTS FREIGHT DIVISION

Issue M Date: June 16, 2014

AUTOMATED SINGLE CAR TEST DEVICE REQUIREMENTS: A.

Calibration Kit P/N 310251

B.

ASCTD CALIBRATION FILL IN SHEETS These sheets are located In Appendix A on pages 38-40 at the end of this document.

C.

Software: Confirm the ASCTD has the current software revision. Software version can be viewed by pressing 7 from the main menu on a GEN II DOS and a GEN III DOS machine or the 6: Utilities button on a GEN III Windows machine.

D.

E.

Safety Warnings: 1.

General shop safety procedures must be followed at all times.

2.

Eye and ear protection must be worn while performing this procedure.

3.

Ensure connections are tight. When required to loosen connections, loosen them slowly to ensure air has been exhausted.

Important: Wabtec may revise this document at any time. It is the responsibility of the user of this product to ensure the latest issue of this procedure is being used. The Calibration Kit components must be in calibration when performing ASCTD calibration. Do not deviate from this procedure.

F.

Temperature: To properly complete this procedure, the ambient temperature should be within 60° to 80°F (15° to 26°C). Prior to performing this procedure, please ensure the ASCTD has adequate time to reach proper ambient temperature. If the temperature is out of this range, you may proceed with calibration, only if the unit is to be used at that temperature.

G.

Device: If you are testing a Generation II ASCTD or GEN III DOS, continue to the page 2. If you are testing a Generation III Windows ASCTD, please turn to page 18. (If clarification is needed, consult figures on page 3 and page 20.)

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CALIBRATION PROCEDURE

GEN II / III DOS ASCTD

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CALIBRATION PROCEDURE GEN II

GEN II TM

Gen II Downstream Pressure Transducer Figure 1

Gen II Motorized Regulator Location Figure 2

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CALIBRATION PROCEDURE

To Tester Access Plate/Interface Connector Hose Assembly Calibration Test Plate

Straight Hose

“T” Adapter

To Downstream Pressure

Digital Pressure Gauge

Gen II Pressure Calibration (Transducers) Set-Up Figure 3 T-310251-O Issue M

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CALIBRATION PROCEDURE

To Tester Access Plate/Interface Connector Hose Assembly

Straight Hose

Calibration Test Plate

Gen II Flow Calibration Set-Up

Flow

Figure Meter 4

Temperature Gauge is used for Choke Test only.

Temperature Gauge

Touch to Air Tank

Calibration Test Plate

Gen II Choke Calibration Set-Up

To Tester

Figure 5 T-310251-O Issue M

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CALIBRATION PROCEDURE

Gen III DOS Regulator Location Figure 6

Gen III DOS Downstream Pressure Transducer Figure 7

Calibration Test Plate

Access Plate/Interface Connector Hose Assembly

Straight Hose To Downstream Pressure Transducer Digital Pressure Gauge

“T” Adapter

Gen III DOS Pressure Calibration (Transducers) Set-Up Figure 8

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CALIBRATION PROCEDURE

Access Plate/Interface Connector Hose Assembly

Calibration Test Plate

Flow Meter

To Tester

Straight Hose

Gen III DOS Flow Calibration Set-Up Figure 9

Temperature Gauge is used for Choke Test only.

Remove the bolt from this location using a 7/32” hex-key wrench and insert the temperature probe into the bolt hole.

Temperature Gauge

Touch to Air Tank

Gen III DOS Flow Choke Set-Up Figure 10 T-310251-O Issue M

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CALIBRATION PROCEDURE Pressure Calibration (XDCRS)

Note:

Unless the ASCTD has a motorized regulator, the front door on GEN II TM devices must be opened prior to connecting the Access Plate/Interface Connector Hose Assembly. (See Figure 2, pg. 3)

1.

Turn on the ASCTD, blow supply line clear of moisture and foreign particles, connect supply air, and plug unit in if necessary.

Note:

Ensure the ASCTD has passed the daily test using the 4-port hose assembly. Run the daily test if necessary.

2.

Install blanking plate from calibration kit onto 4-port hose assembly.

3.

Turn on Digital Pressure Gauge; let it warm up for 10 minutes.

Note:

Some Digital Pressure Gauges may turn off automatically to conserve power.

4.

Once warmed up, zero the Digital Pressure Gauge until the display reads +/- 0.00 psi. To zero the gauge, see Appendix B on pages 41-44.

5.

The regulator in the ASCTD must be set between 90.5 psi and 91 psi prior to calibration. To adjust a motorized regulator on a GEN II ASCTD: 1. Ensure blanking plate is attached to 4 port access hose. 2. From MAIN MENU, press 5 for the UTILITIES MENU. 3. From UTITLITIES MENU press R. REGULATOR PAGE NO:EXIT UP/DN Arrows = Full, Left/Right = Pulse SUPPLY: 110.25 FLOW: 15.3 F=FCC BP: 90.81

Example values

S110 BP90.8 A0.0 E0.0 BC0.0 4. Use the arrow keys to adjust the BP pressure. Up and Down keys are for coarse adjustment and the left and right keys are for fine adjustment. 5. Press NO to exit when regulator pressure is between 90.5 to 91 psi. To adjust a non-motorized regulator on a GEN III ASCTD: 1. Locate the regulator (Figure 6, pg. 6). 2. Loosen the jam nut and turn the regulator shaft clockwise to increase the pressure or counterclockwise to decrease the pressure. 3. Adjust the regulator until the Digital Pressure Gauge is between 90.5 to 91 psi. 4. Tighten the jam nut ensuring the Digital Pressure Gauge reading stays 90.5 to 91; ensure ground wire is reconnected and replace front cover (if applicable).

6.

From MAIN MENU select option [5-UTILITIES].

7.

From UTILITIES MENU select option [1-CALIBRATION].

8.

Type password and press ENTER. Default password is WABCO.

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CALIBRATION PROCEDURE 9.

Install Access Plate/Interface Connector Hose Assembly to the test device. Press YES to continue.

10.

From CALIBRATION UTILITY select option [1-SENSOR CALIBRATION].

11.

From SENSOR CALIBRATION UTILITY select option [1-CALIBRATE].

12.

From SELECT SENSORS TO CALIBRATE select option [1-XDCRS]. TRANSDUCER CALIBRATION THE AMBIENT TEMPERATURE MUST BE WITHIN 60 TO 80 °F (15 TO 26 °C). PRESS YES TO CONTINUE

13.

Press YES. TRANSDUCER CALIBRATION SECURELY INSTALL BLANKING PLATE TO INTERFACE CONNECTOR PRESS YES TO CONTINUE

14.

Connect the hose with “T” fitting to the Digital Pressure Gauge, connect the straight hose to the test plate and to the hose with “T” fitting, and connect the hose with “T fitting to the downstream pressure transducer. See Figure 3, pg. 4 for GEN II or Figure 8 pg. 6 for GEN III. MUST USE TWO CALIBRATION POINTS WITH ONE AT ZERO PSI AND THE OTHER APPROX. 90 PSI PRESS YES TO CONTINUE.

15.

Press YES. TRANSDUCER CALIBRATION MASTER: _______ CAL POINT: 1 ENTER MASTER VALUE IN PSI PRESS YES: CONTINUE

16.

MAX: 2 NO: REPEAT

Master (Digital Pressure Gauge) should read nominally 0.00 PSI. Enter 0.00 and press YES to continue. TRANSDUCER CALIBRATION MASTER: 0.00 CAL POINT: 1 MAX: 2 VOLTS: BP -5.0 AX -5.0 EM -5.0 BC -5.0 X1 -5.0 [GEN II] VOLTS: BP .20 AX .20 EM .20 BC .20 X1 .20 [GEN III] YES: ACCEPT VALUES NO:REPEAT QUIT: ABORT

Example Values ASCTD results may vary

17.

Prior to pressing YES, record the values (MASTER & XDCRS) on the ASCTD PRESSURE CALIBRATION FILL IN SHEET. Nominal examples are provided for each value.

18.

Press YES. ASCTD will automatically charge itself. TRANSDUCER CALIBRATION ADJUST REGULATOR NOW IF NECESSARY MASTER MUST BE 90.5 TO 91 PSI PRESS YES TO CONTINUE

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CALIBRATION PROCEDURE 17.

With a soapy mixture check all connections from the Digital Pressure Gauge (do not get the Digital Pressure Gauge wet) to the interface connector and from the Digital Pressure Gauge to the downstream pressure transducer. No leakage allowed in 30 seconds.

Note:

The pressure displayed on the MASTER (Digital Pressure Gauge) is the regulator setting. The regulator should have been previously adjust per Step 2, page 8.

18.

Press YES. TRANSDUCER CALIBRATION MASTER:______ ENTER MASTER VALUE IN PSI PRESS YES: CONTINUE

19.

CAL POINT: 2 MAX: 2 NO: REPEAT

MASTER (Digital Pressure Gauge) should read 90.5 to 91. Enter value to nearest tenth (Example: 90.7) and press YES to continue. TRANSDUCER CALIBRATION MASTER: 90.7 CAL POINT: 2 MAX: 2 VOLTS: BP 4.10 AX 4.09 EM 4.11 BC 4.10 VOLTS: BP 4.25 AX 4.25 EM 4.25 BC 4.25 YES: ACCEPT VALUES NO: REPEAT QUIT: ABORT

Example Values X1 4.10 [GEN II] X1 4.25 [GEN III]

ASCTD results may vary

21.

Prior to pressing YES, record the values (MASTER & TRANSDUCERS) on the ASCTD PRESSURE CALIBRATION FILL IN SHEET. Nominal examples are provided for each value.

22.

Press YES. TRANSDUCER CALIBRATION CALIBRATION POINTS ARE READY PRESS YES TO CONTINUE

23.

Press YES. SYSTEM VENT UTILITY - System vents and automatically proceeds to the next screen. This message flashes very quickly.

24.

From SENSOR CALIBRATION UTILITY select YES: SAVE SAVING CALIBRATION. Calibration is saved. This message flashes very quickly.

VERIFICATION OF CALIBRATION (XDCRS) 25.

From CALIBRATION UTILITY select option [1-SENSOR CALIBRATION].

26.

From SENSOR CALIBRATION UTILITY select option [2-MONITOR].

27.

From SELECT SENSORS TO MONITOR select option [1-XDCRS].

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CALIBRATION PROCEDURE TRANSDUCER MONITOR: SECURELY INSTALL BLANKING PLATE TO INTERFACE CONNECTOR PRESS YES TO CONTINUE 28.

29.

Press YES. TRANSDUCER MONITOR: VOLTS PSI BP: -4.028 5.49 .200 5.49

5: ADJUST VOLTS AX: -4.032 .200

NO: EXIT PSI 5.50 5.50

EM:

BC:

0.40 0.40

-4.489 .200

5.50 5.50

-4.053 .200

VOLTS

Example Values ASCTD results may vary

PSI

[GEN II] [GEN III]

X1: -4.030 .200

5.50 5.50

[GEN II] [GEN III]

Press 5 to adjust. ADJUST PRESSURE: PSI BP=5.51 CHARGE: 0-P1 CLOSED EXHAUST: 1-E2 CLOSED

YES: CONTINUE BC=0.45 9-BCC CLOSED 2-BCE CLOSED

Example Values ASCTD results may vary

30.

Press 0 then 9. The system will charge up; please allow pressure to stabilize for 30 seconds at approx. 90 PSI.

31.

Press YES to continue. TRANSDUCER MONITOR: VOLTS PSI BP: 4.028 90.7 4.255 90.7

5: ADJUST VOLTS AX: 4.032 4.255

NO: EXIT PSI 90.7 90.7

EM:

BC:

90.7 90.7

4.053 4.255

90.7 90.7

4.053 4.255

VOLTS

X1: 4.038 4.255

Example Values ASCTD results may vary

PSI

[GEN II] [GEN III]

90.31 90.31

[GEN II] [GEN III]

32.

Record the values (MASTER and XDCRS) on the ASCTD PRESSURE CALIBRATION FILL IN SHEET. Nominal examples are provided for each value. XDCRS MUST BE +/- 0.5 OF Digital Pressure Gauge. THE MASTER (Digital Pressure Gauge) SHOULD BE 90.5 TO 91 psi.

Note:

IF VALUES ARE OFF, PRESS NO TO EXIT AND REPEAT CALIBRATION PROCEDURE FROM STEP 1.

33.

Press 5 to adjust. ADJUST PRESSURE: PSI BP=90.31 CHARGE: 0-P1 CLOSED EXHAUST: 1-E2 CLOSED

34.

YES: CONTINUE BC=90.3 9-BCC CLOSED 2-BCE CLOSED

Example Values ASCTD results may vary

Press 1 then 2. The system will drain, please allow pressure to stabilize for 30 seconds at approx. 0.0 PSI.

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CALIBRATION PROCEDURE 35.

36.

Press YES.

TRANSDUCER MONITOR: VOLTS PSI BP: -5.032 0.00 .200 0.00

5: ADJUST VOLTS AX: -4.995 .200

NO: EXIT PSI 0.02 0.00

EM:

BC:

0.01 0.01

-5.006 .200

0.01 0.01

-5.022 .200

VOLTS

X1: -5.005 .200

PSI

Example Values [GEN results II] ASCTD may vary [GEN III]

0.00 0.00

[GEN II] [GEN III]

Record the values (MASTER AND XDCRS) on the ASCTD PRESSURE CALIBRATION FILL IN SHEET. Nominal examples are provided for each value. XDCRS MUST BE +/- 0.5 OF Digital Pressure Gauge. THE MASTER (Digital Pressure Gauge) SHOULD BE NOMINALLY 0.00 IF VALUES ARE OFF, PRESS NO TO EXIT AND REPEAT CALIBRATION PROCEDURE FROM STEP 1.

37.

Press NO to exit. SYSTEM VENT UTILITY. System vents and automatically proceeds to the next screen. This message flashes very quickly.

38.

From SENSOR CALIBRATION UTILITY select NO: EXIT

39.

From CALIBRATION UTILITY select NO: EXIT

40.

From UTILITIES MENU select NO: EXIT.

41.

Disconnect and turn off the Digital Pressure Gauge, and remove the hose with “T” fitting. Leave the calibration test plate and straight hose connected. Return the hose with the “T” fitting and Digital Pressure Gauge to the Calibration Kit. Proceed to Flow Calibration.

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CALIBRATION PROCEDURE FLOW CALIBRATION 1.

Connect the Flow Meter to the straight hose assembly and calibration test plate; open the needle valve. The plate should already be installed from the Pressure Calibration procedure; if not, please install the calibration test plate at this time. See Figure 4, pg. 5 for GEN II or Figure 9 pg. 7 for GEN III.

Example showing 150 CIM

2.

Keep the Flow Meter vertical throughout this procedure. Do not block vent at the top on the backside of the meter. Flow Meter readings are taken at eye level using the middle of the ball.

3.

From MAIN MENU select option [6-VENT SYSTEM]

4.

From VENT SYSTEM MENU select option [1 – ACCESS PLATE/RECEIVER] READY TO VENT SYSTEM DO YOU WISH TO VENT THE SYSTEM (YES\NO)

5.

Press YES to vent system. SYSTEM VENT UTILITY WHEN SYSTEM IS COMPLETELY VENTED HIT YES BP: -0.0 AX: -0.0 EM: 0.0 BC: 0.0

6.

Press YES. ASCTD will go to MAIN MENU. Close the needle valve on the Flow Meter by turning the knob clockwise. Turning the knob counter-clockwise will open the needle valve. Do not over tighten.

7.

From MAIN MENU select option [5-UTILITIES].

8.

From UTILITIES MENU select option [1-CALIBRATION].

9.

Type password and press ENTER. Default password is WABCO

10.

INSTALL ACCESS PLATE/INTERFACE CONNECTOR HOSE ASSEMBLY TO TEST DEVICE. Press “YES” to continue.

11.

From CALIBRATION UTILITY select option [1-SENSOR CALIBRATION].

12.

Press ENTER

13.

From SENSOR CALIBRATION UTILITY select option [1-CALIBRATE].

14.

From SELECT SENSORS TO CALIBRATE select option [2-FLOW]. FLOW METER CALIBRATION THE AMBIENT TEMPERATURE MUST BE WITHIN 60 TO 80 °F (15 TO 26 °C). PRESS YES TO CONTINUE

15.

Press YES.

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CALIBRATION PROCEDURE FLOW METER CALIBRATION SECURELY INSTALL BLANKING PLATE WITH MASTER FLOW METER. CLOSE NEEDLE VALVE. PRESS YES TO CONTINUE 16.

Press YES.

Note:

ASCTD will automatically perform 90-second stabilization prior to showing the next screen. While waiting, with a soapy mixture check all connections from the FLOW METER to the interface connector. No leakage allowed in 30 seconds. FLOW METER CALIBRATION MASTER: 0.00 CAL POINT: 1 SET FLOW METER TO 0 CIM PRESS YES TO CONTINUE

17.

MAX: 12

The flow meter should be set to zero, needle valve closed. Press YES to continue. FLOW METER CALIBRATION MASTER: 0.00 CAL POINT: 1 MAX: 12 VOLTS: -X.XX YES: ACCEPT VALUES NO: REPEAT QUIT: ABORT

18.

Prior to pressing YES, record the voltage value reading in the CALIBRATION column of the ASCTD FLOW CALIBRATION FILL IN SHEET for the first CAL POINT (0 CIM). Press YES to accept values. FLOW METER CALIBRATION MASTER: 50.00 CAL POINT: 2 SET FLOW METER TO 50 CIM PRESS YES TO CONTINUE

19.

MAX: 12

Set the flow meter to value of flow (starting at 50 CIM, the 2nd line up from the bottom of the Flow Tube). Press YES to continue. FLOW METER CALIBRATION MASTER: 50.00 CAL POINT: 2 MAX: 12 VOLTS: X.XX YES: ACCEPT VALUES NO: REPEAT QUIT: ABORT

20.

Prior to pressing YES, wait 10 seconds and record the voltage value in the CALIBRATION column of the ASCTD FLOW CALIBRATION FILL IN SHEET for the CAL POINT. Press YES to accept values.

21.

Repeat Steps 19 and 20 for the remaining ten calibration points. After pressing YES to accept values for the last calibration point (CAL POINT 12) the ASCTD will display the following screen: FLOW METER CALIBRATION CALIBRATION POINTS ARE READY! PRESS YES TO CONTINUE

22.

Press YES. SYSTEM VENT UTILITY. System vents and automatically proceeds to the next screen. This message flashes very quickly.

23.

From SENSOR CALIBRATION UTILITY select YES: SAVE SAVING CALIBRATION. Calibration is saved. This message flashes very quickly.

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CALIBRATION PROCEDURE VERIFICATION OF CALIBRATION (FLOW)

Note:

Close the FLOW METER needle valve (by turning it clockwise).

24.

From CALIBRATION UTILITY select option [1-SENSOR CALIBRATION]

25.

From SENSOR CALIBRATION UTILITY select option [2-MONITOR]

26.

From SELECT SENSORS TO MONITOR select option [2-FLOW] FLOW METER MONITOR: SECURELY INSTALL BLANKING PLATE WITH MASTER FLOW METER. CLOSE NEEDLE VALVE. PRESS YES TO CONTINUE

27.

Press YES FLOW METER MONITOR FLOW (IN CIM) = 10V

28.

900 CIM

Allow 90 SECONDS FOR THE FLOW TO STABILIZE TO APPROXIMATELY ZERO. FLOW METER MONITOR: FLOW (CIM) = 0.63 V

Example Values ASCTD results may vary

0.00 CIM

29.

Record the voltage and flow values for CAL POINT 1 under the VERIFICATION OF CALIBRATION columns of the ASCTD FLOW CALIBRATION FILL IN SHEET. The CIM (cubic inches per minute) reading must be within +/-15 CIM of zero.

30.

The CIM reading for the remaining CAL POINTS must be within +/- 20 CIM of the corresponding setting on the FLOW METER. Dial the FLOW METER to the next CAL POINT (which would be 50 CIM). Let stabilize for 10 seconds and record the values for the second CAL POINT. Repeat Step 29 for the remaining CAL POINTS. After the last calibration point (CAL POINT 12) is recorded press NO to exit. SYSTEM VENT UTILITY. System vents and automatically proceeds to the next screen. This message flashes very quickly.

31.

From SENSOR CALIBRATION UTILITY select NO: EXIT.

32.

From CALIBRATION UTILITY select NO: EXIT.

33.

From UTILITIES MENU select NO: EXIT. ASCTD will go to MAIN MENU.

34.

Disconnect the FLOW METER, close the needle valve, and remove the hose assembly.

35.

Continue to CHOKE CALIBRATION procedure.

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CALIBRATION PROCEDURE CHOKE CALIBRATION 1.

Ensure the Access Plate/Interface Connector Hose Assembly and calibration test plate is installed. See Figure 5, pg. 5 for GEN II or Figure 10 pg. 7 for GEN III.

2.

Turn on the temperature gauge and allow the temperature to stabilize.

3.

Touch air tank with temperature probe as indicated in Figure 5, pg. 5 for GEN II or Figure 10 pg. 7 for GEN III. Record temperature to the nearest whole degree in °F on ASCTD CHOKE CALIBRATION FILL IN SHEET.

4.

Turn off temperature gauge and return to CALIBRATION KIT.

5.

From MAIN MENU select option [5- UTILITIES].

6.

From UTILITIES MENU select option [1 – CALIBRATION].

7.

Type password and press ENTER. Default password is WABCO.

8.

CALIBRATION UTILITIES select option [3 – CHOKE TESTING]. VALID CHOKE CALIBRATION REQUIRES UNIT TO PASS SELF LEAKAGE TEST (Daily Test) AND FOR TRANSDUCERS TO BE PROPERLY CALIBRATED. PRESS YES: CONTINUE NO: EXIT

9.

Press YES. CHOKE CALIBRATION UTILITY ENTER TEMPERATURE IN DEGREES F MUST BE BETWEEN 0 AND 110 TEMP: PRESS ENTER/YES: CONTINUE

10.

Enter temperature recorded from step 3.

11.

Press YES. CHOKE CALIBRATION UTILITY ENTER ELEVATION IN FEET MUST BE BETWEEN 0 AND 9,999 ELEV: PRESS ENTER/YES: CONTINUE

12.

Enter the elevation of your location to the nearest foot.

13.

Press YES.

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CALIBRATION PROCEDURE CHOKE CALIBRATION UTILITY ELEVATION = 760 FEET ATM PRESSURE = 29.11 INCHES OF HG PRESS 14.

Nominal Examples

ENTER/YES: CONTINUE

Press YES SYSTEM VENT UTILITY PLEASE WAIT BP: 0.0 AX: 0.0 EM: 0.0 BC: 0.0 WHEN SYSTEM IS COMPLETELY VENTED PRESS YES.

15.

Press YES. CHOKE CALIBRATION UTILITY 1-E3 2-E5 3-E7 4-E8 5-E2 6-P1 7-P2 8-ALL NO:EXIT

16.

From CHOKE CALIBRATION UTILITY select option [8 – ALL] SECURELY INSTALL SELF TEST PLATE TO INTERFACE CONNECTOR. PRESS YES WHEN COMPLETE.

17.

Press YES.

Note: Test device will automatically complete the Choke Calibration. This will take approximately 40 minutes. 18.

Enter the actual choke times for each individual choke on the ASCTD CHOKE CALIBRATION FILL IN SHEET. (Choke times are displayed on three separate pages. Use the arrow keys to changes pages.)

Note:

Choke times must be between the minimum and maximum limits listed on the ASCTD CHOKE CALIBRATION FILL IN SHEET.*

19.

Press YES to go to the next screen.

20.

Press NO to go to the next screen.

21.

Press NO to go to the next screen.

22.

Press NO to exit to MAIN MENU.

23.

Slowly remove the test plate from the Calibration test plate and return it to the Calibration Kit.

24.

Run a daily test to verify ASCTD operation. Fill out a new ASCTD calibration sticker (located in the Calibration Kit) and apply it to test device.

*Note: If any chokes are outside the minimum or maximum limits contact the Wabtec Kansas City Service Center (816-245-5450) for repairs. Note: ASCTD Calibration Fill In Sheets and the Test Equipment Calibration Certificates must be maintained in your records to have a valid calibration. T-310251-O Issue M

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GEN III Windows ASCTD

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CALIBRATION PROCEDURE

Windows 10” Touch Screen

Windows 7” Key Pad T-310251-O Issue M

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CALIBRATION PROCEDURE

Gen III Windows Regulator Location Figure 11

Gen III Windows Downstream Pressure Transducer Figure 12

Calibration Test Plate

Access Plate/Interface Connector Hose Assembly

Straight Hose

To Downstream Pressure Transducer

“T” Adapter Digital Pressure Gauge

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Gen III Windows Pressure Calibration (Transducers) Set-Up Figure 13

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CALIBRATION PROCEDURE

Access Plate/Interface Connector Hose Assembly

Calibration Test Plate

Flow Meter

To Tester

Straight Hose

Gen III Windows Flow Calibration Set-Up Figure 14

Temperature Gauge is used for Choke Test only.

Remove the bolt from this location using a 7/32” hex-key wrench and insert the temperature probe into the bolt hole.

Temperature Gauge

Touch to Air Tank

Gen III Windows Flow Choke Set-Up Figure 15 T-310251-O Issue M

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CALIBRATION PROCEDURE PRESSURE TRANSDUCER CALIBRATION Note:

Numbered steps pertain to both 10” touch screen and the 7” key pad ASCTDs. Steps containing the letter ‘A’ are clarification for the 7” key pad ASCTD only.

1.

Turn on the ASCTD, blow supply line clear of moisture and foreign particles, connect supply air, and plug unit in if necessary.

Note:

Ensure the ASCTD has passed the daily test using the 6. 4-port hose assembly. Run the daily test if necessary. 6A.

2.

UTILITIES MENU select option Calibration Press Enter/Submit on the key pad.

Install blanking plate from calibration kit onto 4port hose assembly.

3.

Turn on Digital Pressure Gauge; let it warm up for 10 minutes.

Note: Some Digital Pressure Gauges may turn off automatically to conserve power. 4. Once warmed up, zero the Digital Pressure Gauge until the display reads +/- 0.00 psi. To zero the 7. gauge, see Appendix B on pages 41-44. 7A.

8. 8A. 5. 5A.

CALIBRATE MENU select option 1: Calibrate Press 1 on the key pad.

CALIBRATE SENSORS MENU select option 1:Transducers Press 1 on the key pad.

On ASCTD MAIN MENU select option 6:Utilities Press 6 on the key pad.

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CALIBRATION PROCEDURE

9. 9A.

Type default password of 8472. Type 8472 on the key pad.

10. 10A.

Press Submit Press Enter/Submit on the key pad.

11.

11A.

14.

Connect the hose with “T” fitting to the Digital Pressure Gauge, connect the straight hose to the test plate and to the hose with “T” fitting, and connect the hose with “T fitting to the downstream pressure transducer. See Figure 13, pg. 20.

15. 15A.

Press YES Press Yes/Continue on the key pad.

16.

Ensure Master Digital Pressure Gauge is reading 0.00. Enter 0.00 into prompt. Type 0.00 on the key pad.

Press Yes if temperature is in between the range. If temperature is not within range, refer to Requirement F on page 1. Press Yes/Continue on the key pad.

16A.

17. 17A.

12.

Securely install blanking plate to interface connector.

13. 13A.

Press Yes Press Yes/Continue on the key pad.

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Press Yes to continue. Press the Down Arrow. Press Yes/Continue on the key pad.

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CALIBRATION PROCEDURE regulator shaft clockwise to increase the pressure or counterclockwise to decrease the pressure. Adjust the regulator until the Digital Pressure Gauge reads 90.5 to 91 psi.

Example values Tighten the jam nut ensuring the Digital Pressure Gauge reading stays 90.5 to 91 psi. 22. 22A.

18.

Prior to pressing YES, record the values, MASTER and TRANSDUCERS on the ASCTD PRESSURE CALIBRATION FILL IN SHEET. Nominal examples are provided for each value. The EX transducer is the same as the X1 transducer on the ASCTD Fill-In Sheet.

19.

Press Accept. ASCTD will automatically charge itself. Press the Down Arrow. Press Enter/Submit on 23. the key pad.

19A.

23A.

24. 24A.

Note:

COMPLETE STEP 19 AND REVIEW STEP 20 PRIOR TO PRESSING YES in Step 21.

20. With a soapy mixture check all connections from the Digital Pressure Gauge (do not get the Digital Pressure Gauge wet) to the interface connector and from the Digital Pressure Gauge to the downstream pressure transducer. No leakage 25. allowed in 30 seconds. 21.

The pressure displayed on the MASTER (Digital Pressure Gauge) is the regulator setting. Should the regulator require adjustment, please refer to 26. Figure 11, page 20. for the location of the 26A. regulator. Loosen the jam nut and turn the

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Press YES. Press Yes/Continue on the key pad.

MASTER (Digital Pressure Gauge) should read 90.5 to 91 psi. Enter value to nearest tenth (Example: 90.7). Type the value on the key pad.

Press YES to continue. Press the Down Arrow. Press Yes/Continue on the key pad.

Example values

Prior to pressing Accept, record the values (MASTER & TRANSDUCERS) on the ASCTD PRESSURE CALIBRATION FILL IN SHEET. Nominal examples are provided for each value. Press Accept Press the Down Arrow. Press Enter/Submit on the key pad.

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CALIBRATION PROCEDURE

27. 27A.

29. 29A.

Press YES. Press Yes/Continue on the key pad.

Press 3: Save & Quit Press 3 on the key pad.

SAVING CALIBRATION. Calibration message flashes quickly.

is saved. This

VERIFICATION OF CALIBRATION (TRANSDUCERS)

SYSTEM VENT UTILITY - System vents and automatically proceeds to the next screen. This message flashes quickly.

30. 30A. 28. 28A.

Press Continue Press Yes/Continue on the key pad.

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UTILITIES MENU select option CALIBRATION From the Main Menu, press 6 on the key pad. From the Utilities Menu with the Calibration selected, press Enter/Submit on the key pad.

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CALIBRATION PROCEDURE

Example values

31. 31A.

CALIBRATE MENU select option 2: Monitor Press 2 on the key pad.

35.

Record values on screen in the VERIFICATION OF CALIBRATION section of the ASCTD PRESSURE CALIBRATION FILL IN SHEET.

36.

Press Exhaust. Wait 30 seconds for system to vent and stabilize. Use the arrows keys on the key pad to select Exhaust. Press Space/Select on the Key pad.

36A.

Example values 32. 32A.

Monitor Sensors select option 1: Transducers Press 1 on the key pad.

33. 33A.

Press YES Press Yes/Continue on the key pad.

34. 34A.

Press Charge Use the arrows keys on the key pad to select Charge. Press Space/Select on the Key pad.

T-310251-O Issue M

37.

Record values on screen in the VERIFICATION OF CALIBRATION section of the ASCTD PRESSURE CALIBRATION FILL IN SHEET.

38. 38A.

Press Quit Press Quit/Back on the key pad.

SYSTEM VENT UTILITY. System vents and automatically proceeds to the next screen. This message flashes very quickly.

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CALIBRATION PROCEDURE FLOW CALIBRATION 1. Connect Flow Meter to the straight hose assembly and calibration test plate; open the needle valve. The plate should already be installed from the Pressure Calibration procedure; if not, please install the calibration test plate at this time. See Figure 14, page 21. 39. 39A.

The system will drain. Press Continue Press Yes/Continue on the key pad.

40.

Disconnect and turn off the Digital Pressure Gauge, and remove the hose with “T” fitting. Leave the calibration test plate and straight hose connected. Gauge. Return the hose with the “T” fitting and Digital Pressure Gauge to the Calibration Kit. Proceed to Flow Calibration

Example showing 150 CIM

Note: Do not block vent at the top on the backside of the meter. 2. Keep the Flow Meter vertical throughout this procedure. Flow Meter readings are taken at eye level using the middle of the ball. Be sure not to cover exhaust vent at the top of the backside of the meter.

41. 41A.

Press 3: Save & Quit Press 3 on the key pad.

3. 3A.

42. 42A.

From MAIN MENU select option 4: Vent System Press 4 on the key pad.

Press Main Menu Press Quit/Back on the key pad.

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CALIBRATION PROCEDURE

4. 4A.

Select 4 PORT Press the Down Arrow key on the key pad then press Space/Select.

5. 5A.

Press Submit Press Enter/Submit on the key pad.

6. 6A.

Press OK Press Enter/Submit on the key pad.

7.

Select Yes

7A.

Press Space/Select on the key pad.

T-310251-O Issue M

8. 8A.

Press Submit Press Enter/Submit on the key pad.

9. 9A.

Press Continue Press Yes/Continue on the key pad.

10.

ASCTD will go to MAIN MENU. Close the needle valve on the Flow Meter by turning the knob clockwise. Turning the knob counter-clockwise will open the needle valve. Do not over tighten.

11. 11A.

On ASCTD MAIN MENU select option 6- Utilities Press 6 on the key pad.

12.

UTILITIES MENU select option CALIBRATION

12A.

With Calibration selected, press Enter/Submit on the key pad.

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CALIBRATION PROCEDURE

13. 13A.

14. 14A.

CALIBRATE MENU select option 1: CALIBRATION Press 1 on the key pad.

From Calibrate Sensors Menu select option 2: Flow Press 2 on the key pad.

15. 15A.

Type default password of 8472. Type 8472 on the key pad.

16. 16A.

Press Submit Press Enter/Submit on the key pad.

17.

17A.

Press Yes if temperature is between range. If temperature is not within range, refer to Requirement F on page 1. Press Yes/Continue on the key pad.

18. 18A.

Press YES Press Yes/Continue on the key pad.

19.

ASCTD will automatically perform 90-second stabilization prior to showing the next screen. While waiting, check all connections from the FLOW METER to the interface connector with a soapy mixture. No leakage allowed in 30 seconds.

20.

After the flow meter on the ASCTD has been set to zero, ENTER 0 Type 0 on the key pad.

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CALIBRATION PROCEDURE 21. 21A.

Press YES to continue. Press Yes/Continue on the key pad.

28.

Repeat Steps 24 - 27 for the remaining ten calibration points. After pressing YES to accept values for the last calibration point (CAL POINT 12) the ASCTD will display the following screen:

29. 29A.

Press YES. Press Yes/Continue on the key pad.

Example values

22.

Prior to pressing Accept, record the counts value reading in the CALIBRATION column of the ASCTD FLOW CALIBRATION FILL IN SHEET for the first CAL POINT (0 CIM).

23. 23A.

Press Accept Press the Down Arrow. Press Yes/Continue on the key pad.

24.

Set the flow meter to the next value. (50 CIM is 2nd line up from the bottom of the Flow Tube).

25. 25A.

Enter value of flow (in CIM) Type value on the key pad.

26. 26A.

Press YES to continue. Press Yes/Continue on the key pad.

27.

Prior to pressing Accept, record the counts value reading in the CALIBRATION column of the ASCTD FLOW CALIBRATION FILL IN SHEET for the next CAL POINT.

T-310251-O Issue M

SYSTEM VENT UTILITY. System vents and automatically proceeds to the next screen. This message flashes quickly.

30. 30A.

The system will drain. Press Continue Press Yes/Continue on the key pad.

31. 31A.

Press 3: Save & Quit Press 3 on the key pad.

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CALIBRATION PROCEDURE SAVING CALIBRATION. Calibration is saved. This message flashes very quickly.

VERIFICATION OF CALIBRATION (FLOW) Note:

Close the FLOW METER needle valve. 34.

32. 32A.

From Utilities Menu select option Calibration From the MAIN MENU, press 6 on the keypad. From the UTILITIES MENU, with Calibration Selected, press Enter/Submit on the keypad.

34A.

From Monitor Sensors Menu select option 2-FLOW Press 2 on the key pad.

35. 35A.

Press YES Press Yes/Continue on the key pad.

Example values

33. 33A.

From Calibrate Menu select option 2-MONITOR. Press 2 on the key pad.

T-310251-O Issue M

36.

ALLOW 90 SECONDS FOR THE FLOW TO STABILIZE TO APPROXIMATELY ZERO.

37.

Record the counts and flow values for CAL POINT 1 under the VERIFICATION OF CALIBRATION columns of the ASCTD FLOW CALIBRATION FILL IN SHEET. The CIM

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CALIBRATION PROCEDURE (cubic inches per minute) reading must be within +/-15 CIM of zero. 38.

39.

The CIM reading for the remaining CAL POINTS must be within +/- 20 CIM of the corresponding setting on the FLOW METER. Dial the FLOW METER to the next CAL POINT (which would be 50 CIM). Let stabilize for 10 seconds and record the values for the second CAL POINT.

42A.

SAVING CALIBRATION. Calibration message flashes very quickly.

is saved. This

43.

Disconnect the FLOW METER, close the needle valve, and remove the hose assembly.

44.

Continue to CHOKE CALIBRATION procedure.

Repeat Step 38 for the ten remaining CAL POINTS.

40.

Press 3 on the key pad.

Choke Calibration

After the last calibration point (CAL POINT 12) is

40A.

recorded press Quit to exit. Press Quit/Back on the key pad.

SYSTEM VENT UTILITY. System vents and automatically proceeds to the next screen. This message flashes very quickly.

41. 41A.

1. 1A.

UTILITIES MENU select option CALIBRATION Press Enter/Submit on the key pad.

2.

CALIBRATE MENU select option 1: CALIBRATION Press 1 on the key pad.

Press Continue Press Yes/Continue on the key pad.

2A.

42.

Press 3: Save & Quit

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CALIBRATION PROCEDURE

3. 3A.

CALIBRATE SENSORS MENU select option 4: Choke Press 4 on the key pad.

4. 4A.

Type default password of 8472. Type 8472 on the key pad.

5. 5A.

Press Submit Press Enter/Submit on the key pad.

6. 6A.

Press Continue Press Yes/Continue on the key pad.

T-310251-O Issue M

7.

Using a 7/32" hex-key wrench remove the bolt indicated in Figure 15 (pg. 21) from the top cover of the test device and insert temperature probe into the open hole. Contact air tank with temperature probe.

8.

Turn on the temperature gauge and allow the temperature to stabilize.

9.

Record the temperature from the temperature gauge on the ASCTD CHOKE CALIBRATION FILL SHEET. (start temperature will be the same for all seven chokes)

10.

Turn off temperature gauge and return to CALIBRATION KIT.

11.

Enter temperature displayed on gauge to the nearest whole degree in °F. Type the temperature displayed on gauge on the key pad to the nearest whole degree in °F.

11A.

12. 12A.

Press Submit. Press Enter/Submit on the key pad.

13. 13A.

Press Continue Press Yes/Continue on the key pad.

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CALIBRATION PROCEDURE

14. 14A.

Select ALL to test all chokes. Press the Up arrow key two times. Press Space/Select on the key pad.

Note:

Test device will automatically complete the Choke Calibration. To test all chokes will take approximately 30 minutes.

Note: If the ALL button is unable to be seen, press 16. Enter the actual choke times for each individual the Restore Down button to change the size of the choke window. Use the scroll bar at the right side of the on the ASCTD CHOKE CALIBRATION FILL IN window to change viewing area. If buttons still SHEET. cannot be seen, hover mouse pointer over corner of window until an appears. Click and hold to Note: Choke times must be between the minimum and change size of window. maximum limits listed on the ASCTD CHOKE CALIBRATION FILL IN SHEET.* 15. Press Submit 15A. Press Enter/Submit on the key pad. 17. Press Continue 17A. Press Yes/Continue on the key pad.

Note:

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If Continue button cannot be seen, adjust size of as performed previously.

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CALIBRATION PROCEDURE

24A.

18. 18A.

19. 19A.

20. 20A.

Press 3: Save & Quit Press 3 on the key pad.

Press Main Menu The 7” display should already be at the main menu. If not, press Quit/Back on the key pad.

Press 4: Vent System Press 4 on the key pad.

T-310251-O Issue M

21. 21A.

Select 4 PORT Use the arrows keys on the key pad to select 4 PORT. Press Space/Select on the Key pad.

22. 22A.

Press Submit Press Enter/Submit on the key pad.

23. 23A.

Press OK Press Enter/Submit on the key pad.

24. 24A.

Select Yes Press Space/Select on the key pad.

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CALIBRATION PROCEDURE 25. 25A.

26. 26A.

Press Submit Press Enter/Submit on the key pad.

Press OK Press Enter/Submit on the key pad.

29. 29A.

Press Continue Press Yes/Continue on the key pad.

30.

Slowly remove the Calibration test plate and return it to the Calibration Kit.

31.

Remove the temperature probe and replace the bolt as indicated in Figure 15 (pg. 21).

32.

Run a daily test to verify ASCTD operation. Fill out a new ASCTD calibration sticker (located in the Calibration Kit) and apply it to test device.

*Note: If any chokes are outside the minimum or maximum limits contact the Wabtec Kansas City Service Center (816-245-5450) for repairs.

27. 27A.

Select Yes Press Yes/Continue on the key pad.

28. 28A.

Press Submit Press Enter/Submit on the key pad.

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Note: ASCTD Calibration Fill In Sheets and the Test Equipment Calibration Certificates must be maintained in your records to have a valid calibration.

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APPENDIX A ASCTD Calibration Fill In Sheets T-310251-O Issue M

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CALIBRATION PROCEDURE ASCTD PRESSURE CALIBRATION FILL IN SHEET CALIBRATION DATE:___________________________

NEXT CALIBRATION DUE DATE:__________________

LOCATION:___________________________________________________________________________________ CALIBRATED BY:______________________________________________________________________________ CIRCLE ONE:

GENERATION II / GENERATION III DOS / GENERATION III WINDOWS

ASCTD SERIAL NUMBER:_______________________________________________________________________ Digital Pressure Gauge Serial Number and Due Date: __________________________________________________

CALIBRATION TEST MASTER AT 0 BP 0 PSI AX 0 PSI EM 0 PSI BC 0 PSI EX or X1 0 PSI MASTER AT 90.5-91.0 BP 90 PSI AX 90 PSI EM 90 PSI BC 90 PSI EX or X1 90 PSI

READING PSI V V V V V PSI V V V V V

NOTE: EX or X1 will only appear if unit is equipped with a Downstream Pressure Transducer.

VERIFICATION OF CALIBRATION TEST BP AX EM BC EX or X1 MASTER BP AX EM BC EX or X1 MASTER

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LIMIT APPROX 90 PSI

+/- 0.5 PSI OF MASTER

READING(V) V V V V V

90.5-91.0 APPROX 0 PSI

+/- 0.5 PSI OF MASTER

0.00

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V V V V V

READING(PSI) PSI PSI PSI PSI PSI PSI PSI PSI PSI PSI PSI PSI

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CALIBRATION PROCEDURE ASCTD FLOW CALIBRATION FILL IN SHEET

CALIBRATION DATE:_____________________

NEXT CALIBRATION DUE DATE:_________________________

LOCATION:____________________________________________________________________________________ CALIBRATED BY:_______________________________________________________________________________ CIRCLE ONE:

GENERATION II / GENERATION III DOS / GENERATION III WINDOWS

ASCTD SERIAL NUMBER: _______________________________________________________________________ Flow Meter Serial Number and Due Date: ____________________________________________________________

CALIBRATION CAL POINT

MASTER

1

Reading (CIM)

LIMIT

0 CIM

CIM

+/-15 CIM

2

50 CIM

CIM

3

100 CIM

CIM

4

120 CIM

CIM

5

150 CIM

CIM

6

200 CIM

CIM

7

250 CIM

CIM

8

300 CIM

CIM

9

350 CIM

CIM

10

400 CIM

CIM

11

450 CIM

CIM

12

500 CIM

CIM

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Voltage Reading Or Counts

VERIFICATION OF CALIBRATION Voltage Reading Or Counts

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+/- 20 CIM OF MASTER

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CALIBRATION PROCEDURE ASCTD CHOKE CALIBRATION FILL IN SHEET CALIBRATION DATE:______________________

NEXT CALIBRATION DUE DATE:________________________

LOCATION:____________________________________________________________________________________ CALIBRATED BY:_______________________________________________________________________________ CIRCLE ONE:

GENERATION II / GENERATION III DOS / GENERATION III WINDOWS

ASCTD SERIAL NUMBER: _______________________________________________________________________ Temperature Gauge Serial Number and Due Date: _____________________________________________________

CHOKE CALIBRATION TEST RESULTS TEMPERATURE

°F

ELEVATION

FT

CHOKE TIMES CHOKE

MINIMUM

READING

MAXIMUM

E3

14.50 SEC

SEC

16.70 SEC

E5

1.22 SEC

SEC

1.48 SEC

E7

6.40 SEC

SEC

6.80 SEC

E8

23.70 SEC

SEC

27.30 SEC

E2

21.50 SEC

SEC

25.50 SEC

P1

2.00 SEC

SEC

10.00 SEC

P2

27.00 SEC

SEC

33.00 SEC

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APPENDIX B How to Zero the Digital Pressure Gauge T-310251-O Issue M

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CALIBRATION PROCEDURE

1. Turn on pressure gauge.

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2. Allow gauge to warm up.

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3. Calibration date on screen does not necessarily reflect calibration of gauge. Actual calibration of gauge is located on white sticker above the display screen.

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CALIBRATION PROCEDURE

4. After the gauge has warmed up the display will read a non-zero pressure. The gauge must be zeroed.

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5. Press the button under the word Settings

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6. Use the down arrow to select 0.0 Zero.

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7. Press the Menu/OK button.

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8. Press the Menu/OK button. The gauge will now zero itself.

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9. Ensure display reads ±0.00. If not, repeat steps 5-8.

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