CHAPTER

3
METHODOLOGY

3.1 INTRODUCTION Methodology process of this mock up went through many processes. Each step is important to ensure the perfect ness of the part in terms of its physical design, suitable electrical circuit and good operation of mock up. 3.2 RESEARCH The research to find information regarding this low fuel warning mock up takes about almost one month. We have gone through so many sources to gain the appropriate information. Jepperson Sanderson !" Technician Te#tbook has been used to find information about aircraft fuel system. $esides that, we have search on related website such as www.wikipedia.com, www.smartcockpit.com, www.google.com.my and so on. %urthermore, we have consulted our advisor for the information especially on schematic diagram. Then, we proceed to the ne#t level which is analysis. 3.3 ANALYSIS The analysis for this pro&ect takes about a few days. fter collecting information regarding fuel system and the mock up to be made, we have done some analysis on the suitable part to be used for construction and suitable electrical circuit and components to be utili'ed.

3.4 CONSTRUCTION The construction of this low fuel warning mock up can be divided into two parts. (ne is the construction of mock up frame or structure and another one is construction of mock up electrical system. $oth constructions are a simple construction by using basic tools and e)uipment. *.+., Structure -onstruction The mock up structure is a simple structure which consists of a steel stand, hard glass board, a small plastic fuel tank, a float inside the tank and ,+mm ".- pipe. The purpose of steel stand is to mount the mock up panel. The mock up panel is mounted to the steel stand by using two bolts secured by nuts. The hard glass board is used to locate the warning lights, aural warning and other switches for easy operation. The hard glass has been drilled thru in appropriate si'e in accordance with component si'e before mount the components on the panel. The plastic tank is placed behind the mock up panel and its purpose is to fill the water which represents fuel. The float is mounted inside the tank and used to measure the water level inside the tank. While the ".- pipe is connected under the plastic tank with proper connector. The purpose of this ".- pipe is to drain out the water inside the tank. This is the simple construction of the mock up structure.

*.+./ Electrical System The electrical system of this mock up is also a simple system. 0ts a combination of series and parallel wiring system together to make the schematic diagram for this mock up electrical system. There are few electrical components used in this wiring system such as $attery 12.3, Switch 14"4T3, "ush5(6 Switch, Micro Switch, Warning 7amp, and also ural Warning. The power source for this electrical system is from 2. $attery. The battery is connected in series to the circuit. There is also a Switch 14"4T3 which is connected in series with the battery and circuit. When the switch is turned (6, the circuit will be closed and power from battery is supplied to the circuit. When the switch is turned (%%, the circuit will be open and there is no current flow in the circuit. Therefore, this switch is the Master Switch for this mock up electrical system. $esides that, the Micro Switch and "ush5(6 Switch are connected in parallel to each other but in series with the circuit. The Micro Switch is located in the plastic and will be activated when water reaches the low level. While the "ush5(6 Switch is located on the panel and it purpose is to test the system condition whether in operative condition or not. When the "ush5(6 Switch is pressed, the current will bypass the Micro Switch in the tank and complete the circuit. $oth Warning 7amp and ural Warning is connected in parallel to each other but connected in series with the circuit. When either Warning 7amp or ural Warning is not serviceable, the other component still can be activated when water reaches low level. ll of the components connected to the wire by using soldering method. The wires have been spliced properly prior to solder to the components. ll the safety precautions have been followed during this construction in order to prevent any unwanted incident occur.

%igure *.,8 Electrical Schematic 4iagram

3.5 FUNCTIONAL TEST The last procedure after all the construction of the mock up complete is to do functional test on the mock up and each component in the system. The battery voltage capacity can be tested by using .oltmeter or Multimeter. 0t can be done by connecting .oltmeter across the battery. The connection condition between each component is tested by continuity test using (hmmeter. The test can be done by connecting (hmmeter between the components and observe the pointer deflection. %urthermore, the voltage drop across the Warning 7amp and ural Warning also should be checked. 0t can be tested by connecting .oltmeter across the Warning 7amp and ural Warning. The .oltmeter should indicate the voltage drop value about 2. across each component. 0f all tests have been done and there is no error, it means the mock up can be operated well. "rior to operate the mock up, the operation of this mock up can be tested by pressing the "ush to Test Switch on the panel whether it is operating well or not.

CHAPTER

4
MANUAL

4.1 INTRODUCTION Whenever a part, component or mock up is produced, the manufacturer for the product is responsible to make and provide a manual for the product. $asically, a manual contains the procedures to operate the components or mock up and also the maintenance to be done on the component or mock up. Therefore, we have provided a relevant manual for the ircraft 7ow %uel Warning Mock 9p which will be very helpful to operate and maintain the mock up. 4.2 OPERATION PROCEDURE 0n order to operate the mock up safely, all the procedures must be strictly followed step by step. This is to prevent any unwanted incident to occur during the mock up operation. Therefore, the proper procedures have been provided over here and the steps are as listed on the ne#t page.

Procedure !

,. %irst of all, make sure this mock up is operated in a clean and well ventilated area. /. %ill the tank with water which represents fuel. *. Make sure the water level never e#ceed the ma#imum level. +. Then, make sure the 2. battery is connected to the circuit. :. Switch the master switch (6. ;. Test the mock up whether it is operative or not by push the "ush5To5Test switch located on the panel. <. 0f the warning light illuminates and aural warning activated, that means this mock up is in operative condition. =. Then, place any empty pail under the water drain out pipe. 2. fter that, drain out the water in the tank slowly. illuminate and aural warning will be activated. ,,. (bserve the fuel level and the mock up operation. ,/. -losed the pipe to stop draining out the water in tank. ,*. Switch the master switch (%%. ,+. ?efill the water into the tank. ,:. -lean the area if re)uired. ,>. (nce the water level reaches the minimum level, the low fuel warning light will

4.3 MAINTENANCE This ircraft 7ow %uel Warning Mock 9p must be maintained well in order to keep the mock up in good operation condition. Maintenance for this mock up can be divided into two sections which are structure maintenance and electrical system maintenance. +.*., Structure Maintenance Structure maintenance of this mock up is a simple cleaning process. ll of the structure parts should be kept clean to ensure long lasting of this mock up. The mock up panel must be whipped with appropriate cloth which will not scratch the panel. 4o not use any sharp material to clean the panel which will scratch it. The plastic tank must be cleaned as well. Mild soap can be used to wash and clean the tank when needed. 4o not use any cleaning solvent that could harm the plastic tank. Make sure the tank is empty without water which represents fuel whenever it is not used. Wipe the tank with dry cloth after cleaning process to make sure it is completely clean without any water inside. lways keep the mock in clean area whenever it is not used.

+.*./ Electrical System Maintenance The electrical system maintenance is necessary for this mock up to ensure the mock up operate in good condition and without any short circuit. 0f any electrical component is found unserviceable, the appropriate procedure is to replace the component with new component. The power supply for this mock up electrical circuit is a 2. 4- $attery which cannot last for a long term. Therefore, it should be replaced with new battery of same voltage and capacity when the old battery is fully utili'ed. The other components also should be replaced whenever it is not serviceable. Each of the component must be troubleshoot if the mock up not operating in good condition. The troubleshooting procedures are as listed on table on ne#t page.

COMPONENT $attery Master Switch -onnectivity Micro Switch -onnectivity "ush (6 Switch -onnectivity Warning 7ight -onnectivity ural Warning Speaker -onnectivity Warning 7ight ! ural Warning @ .oltage 4ropA

TROU"LESHOOT PROCEDURE 4o voltage capacity test by using .oltmeter 4o continuity test using (hmmeter 4o continuity test using (hmmeter 4o continuity test using (hmmeter 4o continuity test using (hmmeter 4o continuity test using (hmmeter 4o voltage drop test across both components using .oltmeter

Table +.,8 Troubleshooting "rocedure

4.4 SAFETY PRECAUTIONS

To ensure safe operation of the mock up and eliminate the danger of in&ury due to short5 circuit 1arcing3, the following safety precautions must be observed. "rior to operation of the mock up, check that the available power supply B2. $atteryC is properly connected and voltage corresponds to the voltage as specified. 4o not place the mock up on damp or wet surfaces. 4o not sub&ect the e)uipment to direct sunlight or e#treme temperatures 4o not sub&ect the e)uipment to e#treme humidity or dampness. ?eplace a defective component only with a component of the original rating. 6ever short circuit the component. -onduct measuring works only in dry clothing and in rubber shoes, i.e. on isolating mats. -omply with the warning labels and other info on the e)uipment. 4o not modify the e)uipment in any way. 4o not sub&ect the mock up to shocks or strong vibrations.