Actuation Test Equipment

Actuation Test Equipment

ATE-CFM56-3 Manual98-4-5page 1 of 6

Actuation Test Equipment

ATE-CFM56-3 Electrical Test Kit Introduction Brochure

Actuation Test Equipment

3393 Eddie Road

Winnebago, IL 61088-8736

Ph# 815.335.1143


February 16,2015

Rev 1.


The ATE-CFM56-3 test box is designed as a Prime Mover Control (PMC) Simulator for control signals into a CFM56-3 gas turbine engine’s hydromechanical fuel control during calibration and test. The test set excites and monitors the inputs and output of the electrical devices of a CFM56-3 fuel control, including torquemotor input, power lever RVDT input and output voltages and energizes the Idle Reset Solenoid (IRS) and Variable Bleed Valve (VBV) solenoid. An integral 100-volt insulation resistance test and a 1-mA coil resistance test circuit are provided to measure the insulation and coil resistances of the electrical speed trim torque motor, PLA RVDT (both primary and secondary) and the IRS and VBV solenoids on the fuel control.

Three configurations of the equipment are available.

The Narrow profile enclosure provide a minimum configuration of the CFM56-3 test kit that will fit in an 11” x 12” opening in a pre-existing test stand.

Figure 1 Custom Minimum Configuration Enclosure

The Equipto case is a standard enclosure for benchtop use.

Figure 2 Equipto Equipment Case

A Roll-Around cart facilitates 19” rack mount equipment. Pneumatic tires provide a smooth ride to minimize vibration and shock while moving the equipment from place to place.

Gasketed doors and side/top panels seal the cart for air purging.

Figure 3 RollAround Front and Rear View

This manual describes the functional capabilities, installation, set-up, operation and maintenance procedures for the ATE-CFM56-3 test box.

This manual is subject to change at any time. To see the latest, greatest revision levels, always consult the ATECo website.

Packaging options for ATE-100

Figure 4 Front View

Figure 5 Rear View

Calibration Cycle Recommended Practice

Each time the test box is calibrated, note and record the change in the electrical performance of the circuits. This data will allow subsequent determination of appropriate calibration cycles.

To determine appropriate calibration interval, performance checks are recommended at 1-month intervals for the first six months. At six months, if less than 1% change is noted at any time, extend calibration cycle to 2 months. After 1 year, again with less than 1% change, extend calibration cycle to 6 months.

Overview of Calibration Process

Start by measuring and recording Ohms from power cord ground prong to the test kit chassis.

Energize the test kit and measure the +47 (Solenoid board only), +25, +15and +5 volt power supplies on all of the PC Boards.

Measure and record output RVDT excitation with external NIST calibrated AC RMS DMM and Datel Meter simultaneously at 5 different amplitudes.

Take readings at 0, 2.5, 5 7.5 & 10 positions on the SetPoint calibrated dial.

Measure total harmonic distortion of the 3kHz excitation if a distortion analyzer is available. If unavailable, visually examine 3kHz sine wave on an Oscilloscope. If it’s visibly not a clean sine wave, call ATECo at (815) 335-1143.

Measure and record AC RMS and Datel Meter indication for Secondary RVDT signal voltage simultaneously at 0.5, 1.0, 1.5, 2.0, 2.5, 3.0, 3.5, 4.0, 4.5, 5.0, 5.5, 6.0, 6.5, 7.0, 7.5 VAC RMS to check linearity.

Verify Secondary Phase LEDs change state at 0 deg PLA and is proper.

Measure and record torquemotor output current DC mA on an external NIST calibrated DMV meter and the Datel Meter and the AC noise component (AC RMS)at 0, 2.5, 5, 7.5 & 10 on the 10-turn SetPoint dial.

Measure and record Solenoid output voltage range, the AC noise component and calibration values at 0, 2.5, 5.0, 7.5 & 10 positions on the calibrated SetPoint dial.

Measure and record Coil Resistance test 1mA current output. Test functionality with known resistances at end of test cables.

Measure and record the 20M Ohm Insulation Resistance testthreshold. Test Insulation Resistance test of all conductors in test cables.

Required calibration tools include:

  • Two resistor sets measured at 19.5M and 20M Ohms. Use 1/4W 1% metal film resistors. Connect them from the connector pin under test to ground as a go/no-go determination of the Insulation Resistance test of that conductor path. Adjust Resistance Threshold trimpot to get the Pass LED lit 20M Ohms and Fail LED lit at 19.5M Ohms and below.
  • A Small “tweaker” screwdriver to adjust 25 turn trimpots.
  • A DMM capable of measuring 1mA, 250VDC and 3 to 8VAC at 3kHz.
  • An optional connector breakout block with BNC connectors for all Input and Output signals.

Figure 6 ATE-100 Connector Breakout Connector

All signal test points can be accessed via this test block.

Organization of these manuals

There are 5 individual calibration manuals for the ATE-100 Test Box:

  1. Chassis options and functional introduction (this manual)
  2. Insulation Resistance Circuit Board
  3. RVDT/LVDT Circuit Board Manual
  4. TorqueMotor Circuit Board Manual
  5. Solenoid Circuit Board Manual
  6. ATE-100 Calibration Data Sheet
  7. ATE-100 Calibration Data Excel Spreadsheet

End of file.