Aerospace Group Conveyance Systems Division Carter Brand Ground Fueling Equipment IN64235 August 2009 Applicable addition manuals: IN64101 IN64108 IN64102 IN64802 SU64235 Installation Instructions Digital II Pressure Control Module Model 64235
Table of Contents Page 1.0 Scope...3 2.0 Cautions and Warnings...3 3.0 Product Options...3 4.0 Installation Specifications...3 5.0 Installation Steps...4 6.0 Additional Information...7 2
Installation Instructions Model 64235 Digital II Pressure Control Module 1. Scope 1.1. This manual covers the installation of the Eaton s Carter brand Model 64235 Digital II pressure control module and all of its options on any refueling vehicle as part of a complete digital pressure control system. 1.2. The installer should refer to other component manuals to complete the installation of the entire digital pressure control system. 1.3. This manual is written for both the installing technician and the equipment system designer. 1.4. In addition to this manual there may be other requirements enforced by national and local authorities that may affect the installation of these devices on refueling vehicles. It is the responsibility of the installer to understand and abide by all rules and regulations that govern the installation of this equipment. 2. Cautions and Warnings 2.1. Grounding Strap CAUTION Use a grounding strap when working around any exposed circuit board. The smallest electro-static discharge may damage the circuit board. 2.2 Transducer Wiring CAUTION Transducer wires must NOT be run parallel and in close proximity to other wiring. Doing so may cause electronic noise and false signals to the digital control module. 2.3 Potential Circuit Board Damage CAUTION Do not touch any components on the printed circuit board. Doing so may damage the circuit board. 3. Product Options Option None A Description The basic 64235 Digital Pressure Control Module Option A provides an amplifier in the pulser input circuit to accept a 5 volt square wave pulser input. 4. Installation Specifications Item Location of 64235 on the vehicle Grounding Strap Mounting Hardware Conduit Fittings Conduit Fitting Preparation Wire Size Wire Preparation Wire Routing Wiring Identification Power Requirements Circuit Protection Comments -The unit must be located for good visibility by the operator. -Consideration must be given to the 8 wiring ports (4 on each side) that will connect the module to other devices. -Consideration must be given to the RS232 port that connects the set up tool and the module. The cover must be easily removable with an allen wrench. -Consideration must be given to visibility of the deadman indicator on the top of the unit if this feature is desired. -Consideration must be given to the operator s access to the switch on the left side of the bottom of the unit. A grounding strap must be worn any time the installer is working around the module with the face plate off and the circuit board exposed. ¼ inch or 6 mm bolts and associated washers and nuts. ½ inch NPT, 8 Total Use Teflon tape to insure a good seal 18 22 AWG only If stranded wire is used, tin the ends to insure a good electrical connection. Transducer wiring must NOT run parallel to other wiring on the vehicle. It may cross other wiring perpendicularly, but it must not run parallel. The use of coded wiring (colored or numbered, etc.) is strongly recommended to simplify the installation and troubleshooting of the system. 12 or 24 VDC Install a 10 amp fuse in the power supply circuit. 3
Item Powering Up and Down Beacon Circuit (remote deadman indicator) Auxiliary Output Circuit Required Connections Pulser Signal Nozzle Switches Deadman Switch Comments The 64235 Digital Control Module should only be powered up when the vehicle is ready to fuel. This circuit has a maximum rating of 2 amps. If the light used for this function requires more than 2 amps, a relay must be installed in the circuit to limit the amperage seen by the 64235 control module. This output on the control module provides a path from the device it is controlling to ground. This circuit has a maximum rating of 2 amps. If the device used for this function requires more than 2 amps, a relay must be installed in the circuit to limit the amperage seen by the 64235 control module. This output on the control module provides a path from the device it is controlling to ground. To function as a complete digital pressure control system this module must be connected to at least the following items: pressure transducer (64108), meter pulser, one nozzle indicating device (usually an interlock switch), deadman switch, and a pressure controlling valve (inline valves, 64504, 64514, 64110, 64050; bypass valves, 64505, 64515, 64120, 64060; hydrant couplers, 64802, 64902 along with solenoid block 64102. -If the digital system will read out in gallons: 10-100 pulses per gallon -If the digital system will read out in liters: 10-100 pulses per liter -5 (when using option A ), 12, or 24 V signal -Square wave -From 0 volts to the system maximum (12 or 24 V), except when using option A, then a 0 to 5V signal is required Nozzle switches must provide a path from the digital module (64235) to ground when the nozzle is in use. The deadman switch must provide a path from the digital control module (64235) to ground when the deadman is activated. Figure 1 5. Installation Steps 5.1. Review figure 1 above. 5.2. Mount the 64235 using four ¼ in. (6mm) bolts through the four mounting tabs. 5.3. Put on a static grounding strap and remove the front cover by loosening the six screws on the face plate. The flange, front Lexan cover, and the gasket will pull off after the screws are removed. 4
Figure 2 - Board Layout Figure 2 - Board Layout 5.4. Review figure 2, above 5.5. Remove electrical connectors A, and B (and C if installing a remote display) from the circuit board by inserting a dime or similarly thin coin in the groove just to the inside of the screws and twisting it to pry the connector loose. 5.6. Remove the necessary plugs from both sides of the housing to accommodate the required wiring conduits. 5.7. Install the necessary fittings, conduit, and wiring into the open ports. Use Teflon tape on the fitting threads to insure a good seal. 5.8. Connect the appropriate wires to connectors A and B (and C if installing a remote display) per the following table. 5
Connector Terminal Connection Comment B 1 12 or 24 VDC Power Protect with a 10 amp fuse B 2 Ground B 3 Ground Connect the transducer shield wire here. B 4 B 5 Pulser 1 Power B 6 Pulser 1 Signal B 7 Pulser 1 Common B 8 Pulser 2 Power Only used if there is a second pulser on the vehicle B 9 Pulser 2 Signal Only used if there is a second pulser on the vehicle B 10 Pulser 2 Common Only used if there is a second pulser on the vehicle B 11 System Transducer Power 64108 mounted on the vehicle. Red wire. CAUTION, see paragraph 2.2. B 12 System Transducer Signal 64108 mounted on the vehicle. White wire. CAUTION, see paragraph 2.2. B 13 System Transducer Common 64108 mounted on the vehicle. Black wire. CAUTION, see paragraph 2.2. B 14 Not Used B 15 Not Used B 16 Not Used C 17 Remote Display Terminal 1 Only used if there is a remote display on the vehicle. C 18 Remote Display Terminal 2 Only used if there is a remote display on the vehicle. C 19 Pressure Override Switch and Remote Display Terminal 3 Override switch is connected by Eaton at the factory. Also used if there is a remote display on the vehicle. C 20 Remote Display Terminal 4 Only used if there is a remote display on the vehicle. C 21 Remote Display Terminal 5 Only used if there is a remote display on the vehicle. C 22 Remote Display Terminal 6 Only used if there is a remote display on the vehicle. C 23 Remote Display Terminal 7 Only used if there is a remote display on the vehicle. C 24 Remote Display Terminal 8 Only used if there is a remote display on the vehicle. C 25 Remote Display Terminal 9 Only used if there is a remote display on the vehicle. C 26 Pressure Override Switch Ground and Remote Display Terminal 10 Override switch ground connected by Eaton at the factory. Also used if there is a remote display on the vehicle. A 27 Nozzle 1 Ground seeking A 28 Nozzle 2 Ground seeking A 29 Nozzle 3 Ground seeking A 30 Nozzle 4 Ground seeking A 31 Nozzle 5 Ground seeking A 32 Nozzle 6 Ground seeking A 33 Deadman Ground seeking A 34 Pressure Override A 35 Beacon 2 amp max A 36 Auxiliary Output 2 amp max. Can be programmed to mimic the deadman, or flash during the last 30 seconds of the deadman timer function. A 37 Solenoid C Power A 38 Solenoid C Control A 39 Solenoid B Power A 40 Solenoid B Control A 41 Solenoid A Power A 42 Solenoid A Control 5.9. If an overwing nozzle is used, the deadman circuit must be automatically activated when the overwing nozzle is removed from its interlock AND all of the underwing nozzles are stowed. If an underwing nozzle is not stowed properly, the manual deadman operator must control the deadman circuit. It is the responsibility of the system designer to make sure the system operates in this fashion. 5.10. Push connectors A and B (and C if it was removed) back onto the corresponding mating connectors. 5.11. Wipe the surface of the enclosure clean to prepare to reinstall the cover. 6
5.12. Apply a thin coat of petroleum jelly to both surfaces of the gasket and position it on the surface of the enclosure. 5.14. Refer to the set up manual for complete set up and testing of the Digital II system. 5.13. Place the front Lexan cover and the flange over the gasket and screw them in place. 6. Additional Information 6.1. More information about electro-static discharge 6.1.1. Modern solid state electronic items contain components which can be ruined by very, very small static electricity discharges when you touch them. You can accumulate the deadliest of static electricity by just scuffing your shoes on the ground or brushing your sleeve against your shirt. A damaging discharge can be so small that you will never know it has occurred. Yet the damage is irreversible. Carter recommends that you use a grounding strap (worn around your wrist with a wire and an alligator clip to connect to a good ground like the frame of the vehicle you will be working on) to safely eliminate your static charge whenever working near the internal components of the 64235 Digital Pilot Control Module. Such ground straps are sold in most major radio and electronic shops. 6.2. Typical Digital System Installation. Figure 3 7
Aerospace Group Conveyance Systems Division 9650 Jeronimo Road Irvine, CA USA 926218 Ph: (949) 452-9500 Fax: (949) 452-9992