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T-310251-O

T-310251-O Issue M 1 of 44 F140616B

CALIBRATION PROCEDURE

WABCO FREIGHT CAR PRODUCTS Issue M FREIGHT DIVISION 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. 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.

E. 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.)


T-310251-O Issue M 2 of 44 F140616B

GEN II / III DOS ASCTD


T-310251-O Issue M 3 of 44 F140616B

GEN II GEN II TM

Gen II Downstream Pressure Transducer Figure 1

Gen II Motorized Regulator Location Figure 2


T-310251-O Issue M 4 of 44 F140616B

Gen II Pressure Calibration (Transducers) Set-Up Figure 3

“T” Adapter

Calibration Test Plate

To Tester

To Downstream Pressure

Straight Hose

Access Plate/Interface Connector Hose

Assembly

Digital Pressure Gauge


T-310251-O Issue M 5 of 44 F140616B

Gen II Flow Calibration Set-Up Figure 4

Gen II Choke Calibration Set-Up Figure 5

Temperature Gauge

Temperature Gauge is used for Choke Test only.


To Tester

Straight Hose


Assembly

Flow Meter

To Tester


Touch to Air Tank


T-310251-O Issue M 6 of 44 F140616B

Gen III DOS Regulator Location Figure 6

Gen III DOS Downstream Pressure Transducer

Figure 7

“T” Adapter

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

To Downstream Pressure Transducer



Assembly

Straight Hose



T-310251-O Issue M 7 of 44 F140616B

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

Gen III DOS Flow Choke Set-Up

Gen III DOS Flow Calibration Set-Up

Figure 9

Figure 10

Straight Hose



Assembly

To Tester

Flow Meter

Temperature Gauge


Touch to Air Tank


T-310251-O Issue M 8 of 44 F140616B

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 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.

Example values


T-310251-O Issue M 9 of 44 F140616B

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 MAX: 2 ENTER MASTER VALUE IN PSI PRESS YES: CONTINUE NO: REPEAT

16. 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

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

Example Values

ASCTD results may vary


T-310251-O Issue M 10 of 44 F140616B

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:______ CAL POINT: 2 MAX: 2 ENTER MASTER VALUE IN PSI PRESS YES: CONTINUE NO: REPEAT

19. 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 X1 4.10 [GEN II] VOLTS: BP 4.25 AX 4.25 EM 4.25 BC 4.25 X1 4.25 [GEN III] YES: ACCEPT VALUES NO: REPEAT QUIT: ABORT

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].

Example Values

ASCTD results may vary


T-310251-O Issue M 11 of 44 F140616B

TRANSDUCER MONITOR: SECURELY INSTALL BLANKING PLATE TO INTERFACE CONNECTOR PRESS YES TO CONTINUE

28. Press YES. TRANSDUCER MONITOR: 5: ADJUST NO: EXIT

VOLTS PSI VOLTS PSI VOLTS PSI BP: -4.028 5.49 AX: -4.032 5.50 [GEN II]

.200 5.49 .200 5.50 [GEN III]

EM: -4.489 5.50 BC: -4.053 0.40 X1: -4.030 5.50 [GEN II]

.200 5.50 .200 0.40 .200 5.50 [GEN III]

29. Press 5 to adjust.

ADJUST PRESSURE: YES: CONTINUE PSI BP=5.51 BC=0.45 CHARGE: 0-P1 CLOSED 9-BCC CLOSED EXHAUST: 1-E2 CLOSED 2-BCE CLOSED

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: 5: ADJUST NO: EXIT VOLTS PSI VOLTS PSI VOLTS PSI BP: 4.028 90.7 AX: 4.032 90.7 [GEN II]

4.255 90.7 4.255 90.7 [GEN III]

EM: 4.053 90.7 BC: 4.053 90.7 X1: 4.038 90.31 [GEN II]

4.255 90.7 4.255 90.7 4.255 90.31 [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: YES: CONTINUE PSI BP=90.31 BC=90.3 CHARGE: 0-P1 CLOSED 9-BCC CLOSED EXHAUST: 1-E2 CLOSED 2-BCE CLOSED

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

Example Values ASCTD results may vary





T-310251-O Issue M 12 of 44 F140616B

35. Press YES.

TRANSDUCER MONITOR: 5: ADJUST NO: EXIT

VOLTS PSI VOLTS PSI VOLTS PSI BP: -5.032 0.00 AX: -4.995 0.02 [GEN II]

.200 0.00 .200 0.00 [GEN III]

EM: -5.006 0.01 BC: -5.022 0.01 X1: -5.005 0.00 [GEN II]

.200 0.01 .200 0.01 .200 0.00 [GEN III]

36. 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. ASCTD will go to MAIN MENU 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.



T-310251-O Issue M 13 of 44 F140616B

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.

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.

Example showing 150 CIM


T-310251-O Issue M 14 of 44 F140616B

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 MAX: 12 SET FLOW METER TO 0 CIM PRESS YES TO CONTINUE

17. 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 MAX: 12 SET FLOW METER TO 50 CIM PRESS YES TO CONTINUE

19. 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.


23. From SENSOR CALIBRATION UTILITY select YES: SAVE



T-310251-O Issue M 15 of 44 F140616B

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 900 CIM

28. Allow 90 SECONDS FOR THE FLOW TO STABILIZE TO APPROXIMATELY ZERO.

FLOW METER MONITOR: FLOW (CIM) = 0.63 V 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.


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.



T-310251-O Issue M 16 of 44 F140616B

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.


T-310251-O Issue M 17 of 44 F140616B

CHOKE CALIBRATION UTILITY ELEVATION = 760 FEET ATM PRESSURE = 29.11 INCHES OF HG PRESS ENTER/YES: CONTINUE

14. 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.

Nominal Examples


T-310251-O Issue M 18 of 44 F140616B

GEN III Windows ASCTD


T-310251-O Issue M 19 of 44 F140616B

Windows 10” Touch Screen

Windows 7” Key Pad


T-310251-O Issue M 20 of 44 F140616B

Gen III Windows Regulator Location Figure 11

Gen III Windows Downstream Pressure Transducer

Figure 12

“T” Adapter

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

To Downstream Pressure Transducer



Assembly

Straight Hose



T-310251-O Issue M 21 of 44 F140616B

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

Gen III Windows Flow Choke Set-Up

Gen III Windows Flow Calibration Set-Up

Figure 14

Figure 15

Straight Hose



Assembly

To Tester

Flow Meter

Temperature Gauge


Touch to Air Tank


T-310251-O Issue M 22 of 44 F140616B

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 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. On ASCTD MAIN MENU select option 6:Utilities 5A. Press 6 on the key pad.

6. UTILITIES MENU select option Calibration 6A. Press Enter/Submit on the key pad.

7. CALIBRATE MENU select option 1: Calibrate 7A. Press 1 on the key pad.

8. CALIBRATE SENSORS MENU select

option 1:Transducers 8A. Press 1 on the key pad.


T-310251-O Issue M 23 of 44 F140616B

9. Type default password of 8472. 9A. Type 8472 on the key pad.

10. Press Submit 10A. Press Enter/Submit on the key pad.

11. Press Yes if temperature is in between the

range. If temperature is not within range, refer to Requirement F on page 1.

11A. Press Yes/Continue on the key pad.

12. Securely install blanking plate to interface

connector. 13. Press Yes 13A. Press Yes/Continue on the key pad.

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. Press YES 15A. Press Yes/Continue on the key pad.

16. Ensure Master Digital Pressure Gauge is reading

0.00. Enter 0.00 into prompt. 16A. Type 0.00 on the key pad. 17. Press Yes to continue. 17A. Press the Down Arrow. Press Yes/Continue on

the key pad.


T-310251-O Issue M 24 of 44 F140616B

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. 19A. Press the Down Arrow. Press Enter/Submit on

the key pad.

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 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 Figure 11, page 20. for the location of the regulator. Loosen the jam nut and turn the

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.

Tighten the jam nut ensuring the Digital Pressure

Gauge reading stays 90.5 to 91 psi. 22. Press YES. 22A. Press Yes/Continue on the key pad.

23. MASTER (Digital Pressure Gauge) should read

90.5 to 91 psi. Enter value to nearest tenth (Example: 90.7).

23A. Type the value on the key pad. 24. Press YES to continue. 24A. Press the Down Arrow. Press Yes/Continue on

the key pad.

25. Prior to pressing Accept, record the values

(MASTER & TRANSDUCERS) on the ASCTD PRESSURE CALIBRATION FILL IN SHEET. Nominal examples are provided for each value.

26. Press Accept 26A. Press the Down Arrow. Press Enter/Submit on

the key pad.

Example values

Example values


T-310251-O Issue M 25 of 44 F140616B

27. Press YES. 27A. Press Yes/Continue on the key pad.

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

28. Press Continue 28A. Press Yes/Continue on the key pad.

29. Press 3: Save & Quit 29A. Press 3 on the key pad. SAVING CALIBRATION. Calibration is saved. This message flashes quickly.

VERIFICATION OF CALIBRATION (TRANSDUCERS)

30. UTILITIES MENU select option CALIBRATION 30A. 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.


T-310251-O Issue M 26 of 44 F140616B

31. CALIBRATE MENU select option 2: Monitor 31A. Press 2 on the key pad.

32. Monitor Sensors select option 1: Transducers 32A. Press 1 on the key pad.

33. Press YES 33A. Press Yes/Continue on the key pad. 34. Press Charge 34A. Use the arrows keys on the key pad to select

Charge. Press Space/Select 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. 36A. Use the arrows keys on the key pad to select

Exhaust. Press Space/Select on the Key pad.

37. Record values on screen in the VERIFICATION

OF CALIBRATION section of the ASCTD PRESSURE CALIBRATION FILL IN SHEET.

38. Press Quit 38A. Press Quit/Back on the key pad.


Example values

Example values


T-310251-O Issue M 27 of 44 F140616B

39. The system will drain. Press Continue 39A. 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

41. Press 3: Save & Quit 41A. Press 3 on the key pad.

42. Press Main Menu 42A. Press Quit/Back on the key pad.

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.

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.

3. From MAIN MENU select option 4: Vent System 3A. Press 4 on the key pad.

Example showing 150 CIM


T-310251-O Issue M 28 of 44 F140616B

7A. Press Space/Select on the key pad. 12A. With Calibration selected, press Enter/Submit on

the key pad.

4. Select 4 PORT 4A. Press the Down Arrow key on the key pad

then press Space/Select.


6. Press OK 6A. Press Enter/Submit on the key pad.

7. Select Yes


9. Press Continue 9A. 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. On ASCTD MAIN MENU select option 6- Utilities 11A. Press 6 on the key pad.

12. UTILITIES MENU select option CALIBRATION


T-310251-O Issue M 29 of 44 F140616B

13. CALIBRATE MENU select option

1: CALIBRATION 13A. Press 1 on the key pad.

14. From Calibrate Sensors Menu select option 2:

Flow 14A. Press 2 on the key pad.



17. Press Yes if temperature is between range. If

temperature is not within range, refer to Requirement F on page 1.

17A. 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 20A. Type 0 on the key pad.


T-310251-O Issue M 30 of 44 F140616B

21. Press YES to continue. 21A. Press Yes/Continue on the key pad.

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. Press Accept 23A. 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. Enter value of flow (in CIM) 25A. Type value on the key pad. 26. Press YES to continue. 26A. 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.

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. Press YES. 29A. Press Yes/Continue on the key pad. SYSTEM VENT UTILITY. System vents and automatically proceeds to the next screen. This message flashes quickly.

30. The system will drain. Press Continue 30A. Press Yes/Continue on the key pad.


Example values


T-310251-O Issue M 31 of 44 F140616B


VERIFICATION OF CALIBRATION (FLOW)

Note: Close the FLOW METER needle valve.

32. From Utilities Menu select option Calibration 32A. From the MAIN MENU, press 6 on the keypad. From the UTILITIES MENU, with Calibration Selected, press Enter/Submit on the keypad.

33. From Calibrate Menu select option 2-MONITOR. 33A. Press 2 on the key pad.

34. From Monitor Sensors Menu select option 2-FLOW 34A. Press 2 on the key pad.


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

Example values


T-310251-O Issue M 32 of 44 F140616B

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

38. 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.

39. Repeat Step 38 for the ten remaining CAL

POINTS.

40. After the last calibration point (CAL POINT 12) is

recorded press Quit to exit. 40A. Press Quit/Back on the key pad. SYSTEM VENT UTILITY. System vents and automatically proceeds to the next screen. This message flashes very quickly.


42. Press 3: Save & Quit

42A. Press 3 on the key pad.

SAVING CALIBRATION. Calibration is saved. This message flashes very quickly. 43. Disconnect the FLOW METER, close the needle

valve, and remove the hose assembly. 44. Continue to CHOKE CALIBRATION procedure.

Choke Calibration

1. UTILITIES MENU select option CALIBRATION 1A. Press Enter/Submit on the key pad.

2. CALIBRATE MENU select option 1: CALIBRATION 2A. Press 1 on the key pad.


T-310251-O Issue M 33 of 44 F140616B

3. CALIBRATE SENSORS MENU select option 4: Choke 3A. Press 4 on the key pad.




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. 11A. Type the temperature displayed on gauge on the key pad to the nearest whole degree in °F.

12. Press Submit. 12A. Press Enter/Submit on the key pad.



T-310251-O Issue M 34 of 44 F140616B

14. Select ALL to test all chokes. 14A. Press the Up arrow key two times. Press

Space/Select on the key pad.

Note: If the ALL button is unable to be seen, press the Restore Down button to change the size of the

window. Use the scroll bar at the right side of the window to change viewing area. If buttons still cannot be seen, hover mouse pointer over corner of window until an appears. Click and hold to change size of window.


Note: Test device will automatically complete the

Choke Calibration. To test all chokes will take approximately 30 minutes.

16. Enter the actual choke times for each individual

choke on the ASCTD CHOKE CALIBRATION FILL IN SHEET.

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


Note: If Continue button cannot be seen, adjust size

of as performed previously.


T-310251-O Issue M 35 of 44 F140616B

24A.


19. Press Main Menu 19A. The 7” display should already be at the main

menu. If not, press Quit/Back on the key pad.

20. Press 4: Vent System 20A. Press 4 on the key pad.

21. Select 4 PORT 21A. Use the arrows keys on the key pad to select 4

PORT. Press Space/Select on the Key pad. 22. Press Submit 22A. Press Enter/Submit on the key pad.


24. Select Yes 24A. Press Space/Select on the key pad.


T-310251-O Issue M 36 of 44 F140616B



27. Select Yes 27A. Press Yes/Continue on the key pad. 28. Press Submit 28A. Press Enter/Submit on the key pad.

29. Press Continue 29A. 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.

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 37 of 44 F140616B

APPENDIX A

ASCTD

Calibration Fill In Sheets


T-310251-O Issue M 38 of 44 F140616B

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 READING MASTER AT 0 PSI BP 0 PSI V AX 0 PSI V EM 0 PSI V BC 0 PSI V EX or X1 0 PSI V MASTER AT 90.5-91.0 PSI BP 90 PSI V AX 90 PSI V EM 90 PSI V BC 90 PSI V EX or X1 90 PSI V

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

VERIFICATION OF CALIBRATION TEST LIMIT READING(V) READING(PSI) BP

APPROX 90 PSI

+/- 0.5 PSI OF MASTER

V PSI AX V PSI EM V PSI BC V PSI EX or X1 V PSI MASTER 90.5-91.0 PSI BP

APPROX 0 PSI

+/- 0.5 PSI OF MASTER

V PSI AX V PSI EM V PSI BC V PSI EX or X1 V PSI MASTER 0.00 PSI


T-310251-O Issue M 39 of 44 F140616B

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 VERIFICATION OF CALIBRATION

CAL POINT

MASTER Voltage Reading Or Counts

Voltage Reading Or Counts

Reading (CIM) LIMIT

1 0 CIM CIM +/-15 CIM

2 50 CIM CIM

+/- 20 CIM OF MASTER

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


T-310251-O Issue M 40 of 44 F140616B

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


T-310251-O Issue M 41 of 44 F140616B

APPENDIX B

How to Zero the Digital Pressure

Gauge


T-310251-O Issue M 42 of 44 F140616B

1. Turn on pressure gauge.

2. Allow gauge to warm up.

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.


T-310251-O Issue M 43 of 44 F140616B

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

5. Press the button under the word Settings

6. Use the down arrow to select 0.0 Zero.


T-310251-O Issue M 44 of 44 F140616B

7. Press the Menu/OK button.

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

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

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