8500C/8500C+ System Maintenance Manual

This document contains technology under
The export jurisdiction of the U.S. Department

Manual No. 10902-4
Of Commerce, Export Administration Act of March 19, 2004
1979, as amended, Title 50, U.S.C., App
2401 et seq and EAR 15 CFR 730
ECCN: 9E990
U.S. Schedule B: 4906-00-0000
8500C/8500C+ System
Maintenance Manual
Model 8500C/C+ Balancer/Analyzer System
Chadwick-Helmuth
A Business Unit of Honeywell International, Inc.
Copyright Notice
Copyright © 2002 by Chadwick-Helmuth
All Rights Reserved
Six Edition, March 2004
Printed in the U.S.A.
This Manual is supplied to the User under license, subject to change without notice and/or recall by
Chadwick-Helmuth at any time. The Manual at all times remains the property of Chadwick-Helmuth.
The information contained in this Manual is considered confidential. No part of this Manual is to be
copied or reproduced or transmitted in any form whatsoever (including orally or by electronic
transmission), nor is any information in this Manual to be disclosed in any form whatsoever (including
orally or by electronic transmission) to anyone other than an authorized representative of the User's
employer who also shall agree not to disclose same, without express prior written consent of
Chadwick-Helmuth.
Chadwick-Helmuth
4601 N. Arden Drive
El Monte, CA 91731
(626) 575-6161
Fax: (626) 350-4236
BBS: (626) 350-9697
E-mail: [email protected]
Manual No. 10902-4
ii Chadwick-Helmuth A Business of Honeywell International, Inc.

Changes and Revisions
Chadwick-Helmuth reserves the right to issue changes and revisions to this user guide on an as-needed
basis.
Safety Notices
Throughout the user guide safety notices appear. The safety notices have the following headings and
formats.
NOTE:
A suggestion on how to carry out a task.
CAUTION
Potential for damage to equipment.
WARNING
Potential for minor, moderate, or serious injury.
Maintenance and Operation References

Please refer to the following Chadwick-Helmuth operator, maintenance and user guides for detailed
information concerning the 8500 Balancer and accessories.
Model 8500C/8500C+ Operators Manual, PN 9449-6
Photocell System Operation and Maintenance Manual, PN 10473-1
Strobex Model 135M-12 Operation and Maintenance Instruction, Manual PN 9076
FASTRAK Maintenance Manual, PN 13285
8500C/8500C+ System Maintenance Manual iii

Changes and Revisions
Revision Record
The following table shows the record of revisions for this user guide:
Revision Page/
Description Approval Date
Number Paragraph
3 All Initial release February 17, 2003
4 A.4.4.3 Correct channel numbers for P-3 March 19, 2004
Harness, P/N 14440, Test Procedure
iv Chadwick-Helmuth A Business Unit of Honeywell International, Inc.

Contents
List of Figures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ix
List of Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xi
Chapter 1. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

1.1 About This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.1.1 Purpose and Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.2 System Purpose And Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.3 System Physical Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.3.1 8500C/C+ Balancer/Analyzer (Figure 1-1) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.3.1.1 Balancer/Analyzer Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.3.1.2 Printer/Disk Drive Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.3.2 8520C Signal Selector (Figure 1-2). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
1.4 Leading Particulars . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
1.5 Related Publications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Chapter 2. 8500C/C+ Handling And Installation . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

2.1 Preparation For Use. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.1.1 Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.1.2 Cable Interconnections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.1.3 Disk Installation (Figure 2-1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2.1.4 Printer Paper Removal (Figure 2-2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2.1.5 Printer Paper Loading (Figure 2-3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2.2 Repacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
2.3 Storage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Chapter 3. 8500C/C+ Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

3.1 Softkey Functions (Figure 3-1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.2 8500C/C+ Warm-Start Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.3 8500C/C+ Cold-Start Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Chapter 4. System Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

4.1 System Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.2 Detailed Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
4.2.1 8500C/C+. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
4.2.1.1 Balancer/Analyzer Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
4.2.1.2 Printer/Disk Drive Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
8500C/8500C+ System Maintenance Manual v

Contents
4.2.2 8520C Signal Selector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

4.2.2.1 Controller Board (Figure 4-6). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
4.2.2.2 Velocimeter BIT (Figure 4-6). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
4.2.2.3 Power Supply Board (Figure 4-7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
4.2.2.4 Quad Peak Detector Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
Chapter 5. Maintenance And Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

5.1 Test Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
5.2 Routine Maintenance Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
5.3 Periodic Inspection Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
5.4 Functional Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
5.4.1 8500C/C+ Balancer/Analyzer System Test Procedure (with 8520C) . . . . . . . 5-3
5.4.1.1 Test Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
5.4.1.2 Power-Up Self-Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
5.4.1.3 Balance Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
5.4.1.4 Spectrum Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
5.4.1.5 Track Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
5.4.1.6 FasTrak . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
5.4.2 Disk Drive Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
5.5 Calibration Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
5.5.1 8500C/C+ Balancer/Analyzer Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . 5-12
5.5.1.1 Test Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
5.5.1.2 Power-Up Self-Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
5.5.1.3 Amplitude, Frequency, and Phase Accuracy Tests . . . . . . . . . . . . . . . 5-13
5.5.1.4 Noise and Spurious Signals Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15
5.5.1.5 Anti-Alias Filter Response . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15
5.5.2 8520C Signal Selector Test Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17
5.5.2.1 Test Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17
5.5.2.3 Amplitude, Frequency, and Phase Accuracy Test . . . . . . . . . . . . . . . . 5-17
5.5.2.4 Channel Crosstalk Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20
5.5.3 8500C/C+ Spectrum Accuracy Test (with 8520C) . . . . . . . . . . . . . . . . . . . . 5-21
5.5.3.1 Test Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21
5.5.3.3 Test Procedure: High Frequency Range . . . . . . . . . . . . . . . . . . . . . . . . 5-21
5.5.3.4 Test Procedure: Low Frequency Range . . . . . . . . . . . . . . . . . . . . . . . . 5-25
5.6 Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30
5.7 Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-44
5.7.1 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-44
5.7.1.1 Surfaces and Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-44
5.7.1.2 Disk Drive Cleaning Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-45
5.7.2 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-47
5.7.3 EPROM Change Procedure (Figure 5-15) . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-48
5.7.3.1 Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-48
5.7.3.2 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-48
5.7.4 Battery Pack Check and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-49
5.7.4.1 Battery Pack Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-49
vi Chadwick-Helmuth A Business Unit of Honeywell International, Inc.

Contents
5.7.4.2 Battery Pack Replacement (Figure 5-17). . . . . . . . . . . . . . . . . . . . . . . 5-49

5.7.5 Fuse Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-50
5.7.5.1 8520C Power Supply Board (A2) Fuse (Figure 5-20) . . . . . . . . . . . . . 5-50
5.7.5.2 8500C Power Supply Board (A3) Fuse (Figure 5-18) . . . . . . . . . . . . . 5-50
5.7.5.3 8500C Heater/EL Board (A4) Fuse (Figure 5-17) . . . . . . . . . . . . . . . . 5-50
5.8 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-51
5.8.1 8500C/C+ Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-51
5.8.1.1 Disassembly of Balancer/Analyzer Assembly (Figure 5-17) . . . . . . . 5-51
5.8.1.2 Disassembly of Printer/Disk Drive Assembly (Figure 5-18). . . . . . . . 5-52
5.8.2 Signal Selector 8520C Disassembly (Figure 5-20) . . . . . . . . . . . . . . . . . . . . 5-56
5.8.2.1 Quad Peak Detector Board A3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-56
5.8.2.2 Controller Board A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-56
5.8.2.3 Power Supply Board A2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-57
5.8.2.4 Harness Assemblies (Figure 5-21). . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-57
5.9 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-69
5.9.1 Signal Selector 8520C Reassembly (Figure 5-13) . . . . . . . . . . . . . . . . . . . . 5-69
5.9.1.1 Power Supply Board A2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-69
5.9.1.2 Controller Board A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-69
5.9.1.3 Quad Peak Detector A3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-69
5.9.2 8500C/C+ Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-69
5.9.2.1 Reassembly of Printer/Disk Drive Assembly . . . . . . . . . . . . . . . . . . . 5-69
5.9.2.2 Reassembly of Balancer/Analyzer Assembly (Figure 5-17) . . . . . . . . 5-70
5.10 List of Field-Replaceable Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-72
5.11 Cage Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-77
Appendix A. 8520C-36 Signal Selector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1

A.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
A.2 Physical Description (Figure A-10) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
A.3 Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
A.4 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2
A.5 8520C-36 List of Field-Replaceable Components . . . . . . . . . . . . . . . . . . . . . . . . . A-30
Appendix B. 8500C Heater Modification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-1
Appendix C. Chadwick-Helmuth Phase Measurement Convention. . . . . . . . . C-1
Appendix D. 8520CS Signal Selector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-1

D.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-1
D.2 Leading Particulars. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-1
D.3 Physical Description (Figure D-11) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-2
D.4 Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-2
D.5 Functional Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-3
D.6 Calibration - Charge Converter Amplifiers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-12
8500C/8500C+ System Maintenance Manual vii

Contents
D.7 Maintenance and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-16
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-1
viii Chadwick-Helmuth A Business Unit of Honeywell International, Inc.

List of Figures
Figure 1-1. 8500C/C+ Balance/Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Figure 1-2. 8520C Signal Selector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Figure 1-3. System Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Figure 1-4. System Accessories (not to scale) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Figure 2-1. Inserting Disk In Disk Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Figure 2-2. Removing Printer Paper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Figure 2-3. Loading Printer Paper. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Figure 3-1. 8500C Controls and Indicators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Figure 4-1. 8500C/C+ Balancer/Analyzer System Block Diagram . . . . . . . . . . . . . . . . 4-1
Figure 4-2. Analog Board Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Figure 4-3. Digital Board Block Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Figure 4-4. Heater/EL Control Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Figure 4-5. Power Supply Board Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Figure 4-6. Controller Board and Quad Peak Detector Board Block Diagram . . . . . . 4-11
Figure 4-7. Power Supply Board Block Diagram (8520C). . . . . . . . . . . . . . . . . . . . . . 4-13
Figure 5-1. Test Cable Fabrication Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Figure 5-2. Functional Test Setup (with Magnetic Pickup) . . . . . . . . . . . . . . . . . . . . . . 5-4
Figure 5-3. Typical Balance Test Displays for 900 RPM . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Figure 5-4. Typical Balance Test Displays for 1800 RPM . . . . . . . . . . . . . . . . . . . . . . . 5-6
Figure 5-5. Typical Spectrum Test Displays. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
Figure 5-6. Functional Test Setup (with Tracker). . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
Figure 5-7. Special Overlay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
Figure 5-8. 8500C/C+ Calibration Test Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
Figure 5-9. 8520C Calibration Test Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17
Figure 5-10. Spectrum Accuracy Test Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23
Figure 5-11. Troubleshooting Only: Spectrum Accuracy Test Setup w/o 8520C . . . . 5-29
Figure 5-12. Troubleshooting Flowchart: 8500 Pilot Light . . . . . . . . . . . . . . . . . . . . . 5-42
Figure 5-13. Troubleshooting Flowchart: 8520C Power Light. . . . . . . . . . . . . . . . . . . 5-43
Figure 5-14. Cable Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-46
8500C/8500C+ System Maintenance Manual ix

List of Figures
Figure 5-15. EPROM Locations on Digital Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-48

Figure 5-16. Opening 8500C/C+ Unit to Access Balancer/Analyzer Assembly. . . . . . 5-51
Figure 5-17. Balancer/Analyzer Assembly Parts Breakdown . . . . . . . . . . . . . . . . . . . . 5-53
Figure 5-18. Printer/Disk Drive Assembly Parts Breakdown . . . . . . . . . . . . . . . . . . . . 5-55
Figure 5-19. 8500C/C+ Harness Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-59
Figure 5-20. Signal Selector 8520C Parts Breakdown . . . . . . . . . . . . . . . . . . . . . . . . . 5-63
Figure 5-21. 8520C Harness Assemblies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-65
Figure A-1. 8520C-36 Controller Board and Mux Board Block Diagram . . . . . . . . . . .A-2
Figure A-2. Initial 8520C-36 Test Setup (w/C-130 Nacelle Harness) . . . . . . . . . . . . . .A-3
Figure A-3. 8520C-36 Test Setup w/Velos (C-130) . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-7
Figure A-4. 8520C-36 Test Setup w/Velos (single channel). . . . . . . . . . . . . . . . . . . . .A-10
Figure A-5. 8520C-36 Test Setup w/P-3 Nacelle Harness Assemble . . . . . . . . . . . . . .A-12
Figure A-6. 8520C-26 Test Setup w/Velos (P-3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-15
Figure A-7. 8500C/C+/8520C-36 Spectrum Accuracy Test Setup . . . . . . . . . . . . . . . .A-20
Figure A-8. 8520C-36 Test Cable Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-21
Figure A-9. 8520C-36 Channel Pin-outs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-22
Figure A-10. 8520C-36 Signal Selector Parts Breakdown . . . . . . . . . . . . . . . . . . . . . .A-25
Figure A-11. 8520C-36 Signal Selector Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . .A-26
Figure A-12. C-130 Nacelle Harness P/N 11690 Wiring Diagram . . . . . . . . . . . . . . . .A-27
Figure A-13. P-3 Nacelle Harness P/N 14440 Wiring Diagram . . . . . . . . . . . . . . . . . .A-28
Figure A-14. Cable P/N 11517 Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-29
Figure C-1. Velocimeter and Magnetic Pickup Signal Phase Relationships. . . . . . . . . .C-1
Figure D-1. Signal Conditioner Board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-3
Figure D-2. Functional Test Setup (with Magnetic Pickup) . . . . . . . . . . . . . . . . . . . . . .D-4
Figure D-3. Typical Balance Test Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-5
Figure D-4. Functional Test Setup (with High Temp Accelerometer and Photocell) . . .D-8
Figure D-5. Functional Test Setup (with Tracker) . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-11
Figure D-6. Special Overlay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-12
Figure D-7. Charge Converter Test Fixture. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-12
Figure D-8. Functional Test Setup Charge Converter Amplifier Calibration . . . . . . . .D-14
Figure D-9. Charge Converter Adjustments On PC Board. . . . . . . . . . . . . . . . . . . . . .D-15
Figure D-10. Charge Amplifier DIP Switch Setting. . . . . . . . . . . . . . . . . . . . . . . . . . .D-15
Figure D-11. 8520CS Signal Selector Illustrated Parts Breakdown . . . . . . . . . . . . . . .D-18
Figure D-12. Wiring Diagram 8520CS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-21
x Chadwick-Helmuth A Business Unit of Honeywell International, Inc.

List of Tables
Table 1-1. 8500C/C+ Balancer/Analyzer System, Major Components . . . . . . . . . . . . . 1-7
Table 1-2. System Interconnect Cables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Table 1-3. Basic System Accessories 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Table 1-4. Leading Particulars . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Table 1-5. Related Publications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
Table 5-1. Test Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Table 5-2. Routine Maintenance Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Table 5-3. Velocimeter and Magnetic Pickup Balance Test Channel Combinations . . . 5-8
Table 5-4. 8520C Velocimeter and Magnetic Pickup Amplitude, Frequency, and Phase
Accuracy Channel Combinations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
Table 5-5. Suggested 8520C Velocimeter Channel Crosstalk Combinations. . . . . . . . 5-20
Table 5-6. Spectrum Accuracy, High Frequency Range . . . . . . . . . . . . . . . . . . . . . . . 5-25
Table 5-7. Specification: Spectrum Accuracy, Low Frequency Range . . . . . . . . . . . . 5-28
Table 5-8. Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-31
Table 5-9. 8500C/C+ Balancer/Analyzer Functional Tests . . . . . . . . . . . . . . . . . . . . . 5-37
Table 5-10. 8500C/C+ Balancer/Analyzer Calibration Tests . . . . . . . . . . . . . . . . . . . . 5-39
Table 5-11. 8520C Signal Selector Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-41
Table 5-12. Minor Repair Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-44
Table 5-13. Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-47
Table 5-14. Tools for Disassembly/Reassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-51
Table 5-15. 8500C/C+ Balancer/Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-72
Table 5-16. 8520C Signal Selector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-75
Table A-1. 8520C-36 Signal Selector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-30
Table D-1. 8520CS Signal Selector (Only). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-1
Table D-2. Velocimeter and Magnetic Pickup Balance Test Channel Combinations . . D-6
Table D-3. Accelerometer and Photocell Balance Test Channel Combinations . . . . . D-10
Table D-4. Charge Amplifier Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-14
Table D-5. Bill Of Material For 8520CS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-19
8500C/8500C+ System Maintenance Manual xi

List of Tables
xii Chadwick-Helmuth A Business Unit of Honeywell International, Inc.

Chapter 1
1. Introduction
Section 1.1 About This Manual............................................................................................1-1

Section 1.2 System Purpose And Function ..........................................................................1-1
Section 1.3 System Physical Description.............................................................................1-2
Section 1.4 Leading Particulars ..........................................................................................1-7
Section 1.5 Related Publications .........................................................................................1-7
1.1 About This Manual
1.1.1 Purpose and Function

This manual contains maintenance instructions at the field replaceable component level for the
Chadwick-Helmuth 8500C/C+ Balancer/Analyzer Systems. Operating instructions are provided only
to the extent needed to test the system.
1.2 System Purpose And Function

The 8500C/C+ Balancer/Analyzer system is used for both balance/track operations as well as vibration
analysis. System uses:
• Track and balance helicopter main and tail rotors.
• Balance propellers.
• Balance shafts and blowers.
• Balance high-bypass fans.
As a vibration analyzer, the system can be used for:
• On-condition maintenance through vibration trend analysis.
• Pre- and post-maintenance documentation.
• Hardcopy record-keeping of vibration on new or overhauled aircraft.
• Vibration data collection for the VibraLog System.
• Vibration troubleshooting.
8500C/8500C+ System Maintenance Manual 1-1

Chapter 1 - Introduction
1.3 System Physical Description

The system components are shown in Figures 1-1 and 1-2 and listed in Table 1-1. The system
interconnect cables are shown in Figure 1-3 and listed in Table 1-2. The accessories that can be used
with the system are shown in Figure 1-4 and listed in Table 1-3.
1.3.1 8500C/C+ Balancer/Analyzer (Figure 1-1)

The 8500C/C+ consists of a balancer/analyzer assembly combined into one unit with a printer/disk
drive assembly.
1.3.1.1 Balancer/Analyzer Assembly

The balancer/analyzer assembly acquires, displays, and processes vibration data for fault analysis and
balance correction. The front panel includes liquid crystal display (LCD) with associated push buttons.
The LCD displays the operating program, instructs the user in gathering step-by-step vibration
measurements, and displays calculated results. The push buttons are used to enter data and commands,
including operating the printer/disk drive assembly. One external connector provides 28 VDC input
power and vibration inputs from an interconnect cable. The other external connector connects to the
Strobex.
The balancer/analyzer assembly consists of the following items:
• Digital board: Contains a microprocessor, which houses and runs the operating program,
processes the input data from disk information and aircraft vibration signals, and performs all
necessary calculations.
• Analog board: Converts analog input signals to digital signals for processing by the digital
board.
• EL/heater control board: Provides backlighting power for the display and heater power during
low outside temperature conditions.
• Graphics module: Converts digital data to alphanumeric characters for display on the front
panel.
• Harness assembly: Interconnects printed circuit boards and graphics module.
1.3.1.2 Printer/Disk Drive Assembly

The printer/disk drive assembly loads, stores, and prints vibration and related data. A disk drive
opening is located on the front panel and a paper feed slot is located on the rear panel. The disk drive is
used to upload to the balancer/analyzer software (“charts”) for the specific aircraft tests, and to
download acquired data. The vibration data balance solutions are printed on 4-3/8 inch wide thermal
paper.
1-2 Chadwick-Helmuth A Business Unit of Honeywell International, Inc.

System Physical Description
The 8500C/C+ printer/disk drive assembly is composed of the following items:

• Printer assembly: prints data and solutions on paper.
• Printer board: interfaces with the printer.
• Disk drive assembly: uploads software from the diskette to the balancer/analyzer assembly.
• Distribution board: interfaces with the disk drive assembly and balancer/analyzer assembly.
• Power supply: generates operating voltages for the printed circuit boards in the balancer/
analyzer assembly and printer/disk drive assembly.
• Harness assembly: interconnects the printed circuit boards, printer assembly, and disk drive
assembly.
Figure 1-1. 8500C/C+ Balance/Analyzer

Figure 1-2. 8520C Signal Selector

System Physical Description
Figure 1-3. System Cables

Figure 1-4. System Accessories (not to scale)

Leading Particulars
1.3.2 8520C Signal Selector (Figure 1-2)

The 8520C signal selector switches to the appropriate Velocimeter and magnetic pickup or photocell
channel as selected by the 8500C/C+, and sends those vibration signals to the 8500C/C+ for
processing. The 8520C also routes 28 VDC power to the 8500C/C+. The front panel contains 12
connectors for connection to Velocimeter sources, and four connectors for connection to magnetic
pickup, photocell, and optical tracker sources. There are two connectors on the rear panel: the first is
for 28 VDC input power and the second connector is for receiving and transmitting selected signals to
and from the 8500C/C+.
The 8520C unit contains the following items:
• Power supply board: Generates DC operating voltages for the printed circuit boards and
transducers.
• Controller board: Selects the input signal as directed by the 8500C/C+.
• Quad peak detector board: Required for use with the FasTrak optical tracker. Determines
whether incoming sync signals are from an optical tracker.
• 28 VDC power line filter: Filters out line spikes, noise generated on power line.
• Power/signal harness and Velocimeter/magnetic-pickup/photocell harness: Interconnects the
printed circuit boards and input connectors.
1.4 Leading Particulars

Leading particulars for the system and its major components are listed in Table 1-4.
1.5 Related Publications
Table 1-1. 8500C/C+ Balancer/Analyzer System, Major Components
Part No. Nomenclature Purpose Qty.

8500C/C+ Balancer/Analyzer Acquires, displays, and analyzes 1
Printer Disk Drive vibration data and presents balance
solution. Loads, stores, and prints
vibration and related data.
8520C Signal Selector Switches vibration and magnetic 1
pickup/photocell signals to send to
8500C/C+.

Table 1-2. System Interconnect Cables

10811-12 Cable, Signal Connects signals between 8500C/C+. 1
Selector (12 ft)
11210-50 Cable, Velocimeter Connects Velocimeter to 8520C or up to 12
(50 ft) 8500C/C+ via 8998 cable.
11210-20 Cable, Velocimeter Connects Velocimeter to 8520C or up to 12
(20 ft) 8500C/C+ via 8998 cable.
8998 Cable, Input Connects 8500C/C+ to power, 1
Adapter Velocimeter, and magnetic pickup/
photocell inputs when 8520C is not
used.
10813-12 Cable, DC Power Connects 28 VDC power to 8520C. 1
(12 ft)
10808-25 Cable, Magnetic Connects magnetic pickup to 8500C/ 1
Pickup (25 ft) C+ or 8520C via 10809 cable.
10185 Cable, Photocell Connects optical probe to photocell 1
processor 10170
3529 Cable, DC Power Connects DC power to 8500C/C+ or 1
Extension 8520C.
Table 1-3. Basic System Accessories 1

Model 11A Calibrator Bench tests 8500C/C+ system. 1
10170 Photocell Processor Processes optical inputs for the 1
8500C/C+ via the 8520C or cable
8998.
135M-12 Strobex Hand-held strobe, illuminates 1
reflective targets on blades for
tracking purposes.
11800 FasTrak Day-Night optical tracker, used in 1
place of Strobex. Communicates with
8500C/C+ Smart Chart software.
10200 Optical Probe Provides optical inputs to photocell 1
processor 10170.

Related Publications
Table 1-3. Basic System Accessories 1 (Continued)

11245 Gram Scale Pocket, Measures rotor balance weights. 1
120V
3030 Magnetic Pickup Provides magnetic pickup signals to 1
8500C/C+ via 8520C, or cable 8998
7310 Velocimeter Provides Velocimeter inputs to 2
8520C via cable 11210-50/11210-20
610-199 Printer paper Spare paper rolls for 8500C/C+ 1
printer assembly.
15361 Carrying case Holds major system components, 1
cables, and accessories.
16253 VibEasy for Training Aid - Instructions CD 1
8500C+
1All other accessories, such as DC power adapters, double-to-single interrupters, Velocimeter blocks,
Velocimeter brackets, etc., are specific to the aircraft. These accessories are not required for functional
and calibration tests of the 8500C/C+ system.

Table 1-4. Leading Particulars
8500C/C+ Balancer/Analyzer
Parameter Characteristic
Input power: balancer/analyzer 28 volts DC
Operating temperature: balancer/analyzer -40°C to +55°C (0° for printer/disk drive)
Microprocessor 8500C: 8 MHz Motorola 68008
8500C+: 25 MHz Motorola 68332
Memory 8500C: 256 KB dynamic RAM
8500C: Up to 256 KB ROM
8500C: Up to 128 KB static RAM
8500C+: Up to 2MB Static RAM, 1 MB Standard

8500C+: 1 MB EPROM Flash RAM
Display Liquid crystal display. 64 vertical by 256 horizontal
pixels.
Manual input Intergrated keyboard with 32 function keys
Sensitivity 19 mV/ips fixed (Velocimeter)
.0005 ips @ 0.5 ips fullscale through .25 ips @ 256
ips fullscale (instrument)
Automatically selected gain ranges 4080 gain settings from 1 to 512
Input impedance 2200 ohms
Minimum detectable signal 60 dB below full scale (typical)
Anti-alias filtering Two fixed corner frequency analog antialiasing
filters, 104 dB per octave initial rolloff.
Variable corner frequency digital antialiasing
filters, 685 dB per octave initial rolloff.
66 dB minimum stop band attenuation.
Overall flatness:
+0.2 dB from 2 to 500 Hz
+1 dB from 0.5 to 8 kHz
+2 dB from 8 kHz to 10 KHz
Frequency range (Fmax) 200 to 600,000 rpm in arbitrary, user-selected steps
FFT frequency resolution 461 lines up to 7.5 kHz, 400 lines up to 10 kHz
FFT time domain weighting Kaiser window
Frequency accuracy 0.22%, Fmax = 0.1%

Related Publications
Table 1-4. Leading Particulars (Continued)
Speed 1 spectrum per 3 seconds with 30,000 rpm range
(varies with Fmax).
Averaging (in balance mode only) 8 most recent balance measurements averaged
excluding measurement outside one average
deviation
Phase accuracy +2.0 degrees (electrical)
Phase measurement method Synchronizing input (magnetic pickup or photocell
pickup), FasTrak optical tracker, or Strobex
Corrective action presentation Arbitrary vibration reduction action, e.g. blade
sweep, weight addition/subtraction, pitch-link
shortening/lengthening, etc. System undergoing
vibration reduction is displayed for reference.
Changes are specified in aircraft specific units.
Multiplane balance capabilities with Smart chart
software, i.e., multiple corrective actions presented
for multiple measurements.
Timing resolution +200 nanoseconds
Amplitude accuracy 15% depending on frequency offset from FFT BIN
center (includes effect of window)
Input power: printer/disk drive 12 to 28 VDC (28 VDC nominal)
Operating temperature: printer/disk drive -10°C to +55°C
Printer Dot-matrix thermal printer
Mass storage PC/MS-DOS version 3.X compatible, 3.5 inch
double-sided, double-density disk drive (720 KB).
8500C+ can also use 1.44 MB HD disk.
Dimensions 10.81 x 7.5 w x 4.0 h in. (27.4 1 x 19.1 w x 10.2 h
cm)
Weight 7.1 lbs (3.22 kg)
8520C Signal Selector
Input power 28 VDC
Velocimeter signal input levels 12 Channels, 0 to 375 ips
Input impedance 100K (unselected channel), 2.5K (selected channel)
Magnetic pickup signal inputs 4 channels, 0 to 12x106 rpm

Table 1-4. Leading Particulars (Continued)
Dimensions 7.5 l x 10.75 w x 3.25 h in.
(19.1 l x 27.3 w x 8.2 h cm)
Weight 3.6 lbs (1.63 kg)
Table 1-5. Related Publications
Publication No. Title

9449-6 Model 8500/8500C Balancer/Analyzer and Model
8510 Printer Disk Drive Operator’s Manual
9077-1 Operation and Maintenance Instructions with
Illustrated Parts Breakdown, Calibrator Models 11,
11A, and 11A/11PS
9076 Operation and Maintenance Instructions with
Illustrated Parts Breakdown, Strobex Model 135M-
12
10473-1 Operation and Maintenance Manual for Photocell
System PN 10252
11211 Model 8500C/C+ Quick Reference Guide III
--- Specific Helicopter User’s Guide

Chapter 2
2. 8500C/C+ Handling And Installation
Section 2.1 Preparation For Use.........................................................................................2-1

Section 2.2 Repacking..........................................................................................................2-4
Section 2.3 Storage ..............................................................................................................2-4
2.1 Preparation For Use
2.1.1 Unpacking
a. Open shipping container and remove carrying case and accessories.
b. Open carrying case and remove major components, cables, and accessories.
c. Check contents of shipping container and carrying case against enclosed Packing List.
d. Carefully unwrap each major component, cable, and accessory.
e. After transit, ensure that printer paper roll is tightly wound again by removing and
reloading as instructed in sections 2.1.4 and 2.1.5.
NOTE: In the event of damaged or missing equipment report all details to Chadwick-
Helmuth.
2.1.2 Cable Interconnections

a. Connect cable 10811-12 to POWER/SIGNAL IN connector on 8500C/C+ and OUTPUT/
POWER to 8500C/C+ connector on 8520C.
WARNING
Ensure system is connected to a 28 VDC power source only. Serious damage to equipment
and/or personnel injury could result if connected to any AC power source.
b. Connect cable 10813-12 from DC POWER connector on 8520C to a 28 VDC power
supply.
c. If necessary, adjust contrast knob to read display (Figure 2-1).
NOTE: It is best practice to use minimum backlight.

Chapter 2 - 8500C/C+ Handling And Installation
NOTE: The remaining cables, major components, and accessories are connected depending
on the particular application or aircraft being tested. Refer to the User’s Guide for your
aircraft model for specific installation instructions.
2.1.3 Disk Installation (Figure 2-1)

a. Hold disk with arrow facing up and pointing in as shown.
b. Insert disk completely into disk drive until drive button pops out.
NOTE: To remove a disk, push drive button in.
LCD CONTRAST ADJ.
BACKLIGHT ADJ.
RW
K.D
CD
O85
E:IS
FIL
DRIVE BUTTON
Figure 2-1. Inserting Disk In Disk Drive
2.1.4 Printer Paper Removal (Figure 2-2)

a. Tear off any excess paper.
b. Clear paper from paper path by turning advance gear forward to back out paper as shown.
Or if advance gear has no effect, pull paper out of paper path.
c. Push on paper release lever and remove roll.
2.1.5 Printer Paper Loading (Figure 2-3)

a. Trim any ragged edges on paper roll.
b. Tightly rewind roll and place in holder.
c. Feed paper into printer using advance gear as shown (or paper advance button if power is
applied).

Preparation For Use
NOTE: If paper is not feeding in straight, hold a finger against an edge to guide it into place
as it feeds; otherwise, wait until paper is coming out of unit and then pull it into position.
Ensure paper has no rumpled edges feeding into paper path.
TURN PAPER ADVANCE

GEAR FORWARD TO
TO REMOVE PAPER
FROM PRINTER PATH
PAPER OUT
REMOVE PAPER ROLL

AND REWIND TIGHTLY
PUSH TO
RELEASE
PAPER
Figure 2-2. Removing Printer Paper
PAPER IN
PAPER ADVANCE
GEAR PAPER OUT PAPER ADVANCE
(WITHOUT POWER) BUTTON
(WITH POWER)
PUSH TO
RELEASE
PAPER
Figure 2-3. Loading Printer Paper

Chapter 2 - 8500C/C+ Handling And Installation
2.2 Repacking
a. Install major components, cables, and accessories in carrying case.
2.3 Storage
a. Place component to be stored in a polyethylene bag, and pack in a fiberboard container.
b. Mark container with part number, serial number, and maintenance date.
c. The components can withstand a temperature range of -40°C to +71°C and a relative
humidity of up to 90% for extended periods. Store components in a cool, dry area.
d. Shelf life is 10 years.

Chapter 3
3. 8500C/C+ Operation
Section 3.1 Softkey Functions (Figure 3-1) .........................................................................3-1

Section 3.2 8500C/C+ Warm-Start Procedure ....................................................................3-1
Section 3.3 8500C/C+ Cold-Start Procedure ......................................................................3-1
3.1 Softkey Functions (Figure 3-1)

For maintenance purposes it helps to know what soft keys are and how they are manipulated. Although
not required to perform the procedures in this manual, more detailed information on operating the
8500C/C+ balancer/analyzer can be found in Model 8500C Operator’s Manual (#9449-6), 8500C
Quick Reference Guide III (#11211), or the 8500C/C+ User’s Guide for your aircraft.
The soft keys are the four unmarked keys whose labels are displayed on the screen. These labels can
change as the screen changes. Soft keys are affected by the following items:
• <brackets> - Whenever a soft key label is in brackets (except for <CHANGE>), pressing that
soft key changes its label (and the screen) to a new mode; pressing it again changes it back.
Whenever an item in a screen (often a SETUP screen) is enclosed in brackets, and the cursor is
placed on that item, pressing <CHANGE> will change that item.
• MORE KEYS - An asterisk at the right end of the soft key labels indicates that more soft key
functions are available when MORE KEYS is pressed.
• SHOW/HIDE - If the soft key labels are obstructing part of the display, press SHOW/HIDE
to make them disappear; to restore the labels, press SHOW/HIDE again.
3.2 8500C/C+ Warm-Start Procedure

To restart the instrument:
a. Press PRINT, ↑, and START simultaneously.
3.3 8500C/C+ Cold-Start Procedure

To restart the instrument and clear memory:
a. Hold down PRINT, ↑, and START simultaneously.
b. Release PRINT and ↑, wait approximately five seconds, then release START.

Chapter 3 - 8500C/C+ Operation
PRESS START TO RECORD LAST SOLUTION

AND START NEXT RUN.
RUN NUMBER: 1 FREQUENCY: 480 RPM
PHASE ANGLE: 12:05 VIB LEVEL: 0.870 IPS
Bell 412 Tail Rotor Photocell Balance
REDO MEAS SEL CHART CHART INFO SOLUTION *
SOFT KEY LABELS
BALANCER/ANALYZER
PRINT START
A PRESS START TO RECORD LAST SOLUTION

AND START NEXT RUN. W X
RUN NUMBER: 1 FREQUENCY: 480 RPM
SHOW/HIDE PHASE ANGLE: 12:05 VIB LEVEL: 0.870 IPS STOP
Bell 412 Tail Rotor Photocell Balance
B Y Z
REDO MEAS SEL CHART CHART INFO SOLUTION **
MORE/KEYS
BALANCE HELP STATUS 2 3

1 I
G H
D : E F .
4 5 6
SPECTRUM LOAD SETUP M N O
MODEL 8500C
J # K < L - 8 9
S 7 U
T HELMUTH
CHADWICK
TRACK STORE ANNOTATE
EL MONTE, CALIFORNIA
P % Q > R / V
0
SOFT KEYS
SHOWS/HIDES SOFT KEY LABELS

ASTERISK INDICATES
MORE LABELS ARE AVAILABLE
WHEN "MORE KEYS" IS PRESSED
FILE: SOFTKEY3.DRW
Figure 3-1. 8500C Controls and Indicators
3-2 Chadwick-Helmuth A Business Unito of Honeywell International, Inc.

Chapter 4
4. System Theory of Operation

Section 4.1 System Description............................................................................................4-1
Section 4.2 Detailed Description.........................................................................................4-2
4.1 System Description

A system block diagram is shown in Figure 4-1. The balancer/analyzer assembly acquires, displays,
processes, and analyzes vibration data for fault analysis and balance correction. The printer/disk drive
assembly loads, stores, and prints vibration and related data. The Signal Selector 8520C selects
vibration and pickup signals to send to the 8500C/C+.
BALANCER/ANALYZER/
PRINTER/DISK DRIVE 8500C
PRINTER/DISK DRIVE ASSEMBLY
DATA,
CONTROL,
& STATUS 12-28 VDC
12-28 VDC
STROBEX
CONTROL BALANCER/ANALYZER ASSEMBLY
135M-12
SIGNAL SELECTOR
8520C
12-28 VDC
VIBRATION INPUT
AIRCRAFT
UNDER TEST MAGNETIC/PHOTOCELL PICKUP INPUT
FASTRAK OPTICAL TRACKER
FILE: FIG4-1.DRW
Figure 4-1. 8500C/C+ Balancer/Analyzer System Block Diagram

Chapter 4 - System Theory of Operation
4.2 Detailed Description
4.2.1 8500C/C+
4.2.1.1 Balancer/Analyzer Assembly
The balancer/analyzer assembly contains four printed circuit boards, a digital board, an analog board, a
heater/EL control board, and a graphics module. The digital board contains memory, a microprocessor,
communications controllers, and a clock. The data acquisition (analog) board contains the analog
inputs, noise generator, input multiplexer, analog-to-digital converter (ADC), programmable gain
amplifier, anti-alias filters, and overload detector. The heater/EL control board provides backlighting
power for the display and heater power during low outside temperature conditions. The graphics
module contains an LCD and drivers for communicating with the user.
4.2.1.1.1 Analog Board (Figure 4-2)
The analog board receives analog input signals from the selected Velocimeter channel in the Signal
Selector 8520C or the onboard noise generator. The signals are then filtered, sampled, and converted to
digital form. The timing controller on the digital board provides programmable clock signals that
synchronize this process. The digitized output data are communicated over the system bus to the
microprocessor on the digital board. The data are then stored in memory for analysis and display as
directed by the user and firmware.
a. Noise Generator. The noise generator is a 12-bit, low drift, pseudorandom noise generator.
This precisely repeatable, broadband signal source provides a frequency, amplitude, and
phase reference for power-up characterization of the analog anti-alias filter. By injecting
this known signal into the input of the analog filter, the digital board firmware can
measure and record the unique frequency dependent characteristics of the analog filter
every time power is applied to the 8500C/C+. With this information, the firmware
compensates for filter component tolerances and drift that would otherwise degrade
system measurement accuracy. This feature also enables the system firmware to perform a
thorough front-to-back test of the analog board.
b. Multiplexer. The 2:1 multiplexer is controlled by the digital board timing controller. The
timing controller selects the signal from either the noise generator or the 8520C.
c. High-Pass Filter. The high-pass filter is a three-pole filter with a corner frequency of 2Hz.
The filter removes very low frequency signals and noise from the selected signal input.
Otherwise, high energy levels of these frequencies could affect the gain settings, reducing
the signal resolution.
d. Anti-Alias Filters. The anti-alias filters consist of an analog ten-pole Tchebyschev low-
pass filter which provides low passband ripple, short transition band, and high stopband
attenuation. The anti-alias filter consists of five two-pole sections. The initial two-pole
section has the lowest Q. The Q of each successive section is higher.
The first section is actually two side-by-side sections: a low-frequency section and a high-
frequency section. Only one of the two outputs is used at any given time. The appropriate
output is routed to the following section by a program-controlled 2:1 multiplexer. The
firmware automatically selects the low-frequency section for analysis of signals below
500 Hz. The high-frequency section is chosen for analysis above 500 Hz.

Detailed Description
Both of the initial sections are implemented with precision resistors, capacitors, and a
high-quality operational amplifier. This stage provides two functions. Its Q and corner
frequency are set so that it contributes to the overall ten-pole low-pass response. Its corner
frequency is low enough such that it also functions as an anti-alias filter for the following
sampled data filter section.
The middle three sections are implemented with general purpose switched capacitor
filters. The filter characteristics of these three sections are set by precision resistors and a
crystal-controlled realtime clock on the digital board. The corner frequency of these
sections is changed under program control, allowing them to be used during both low- and
high-range frequency analysis.
The final second-order filter section is similar to the first: it is actually side-by-side low-
and high-frequency sections. The same control line that selects the low- or high-frequency
filter output format on the first sections also selects the related filter output from the final
filter section.
e. Programmable Gain Amplifier. The programmable gain amplifier is a high resolution
amplifier which follows the first second-order analog anti-alias filter section.
The gain programming is managed by the system firmware. The firmware continually
monitors the incoming signal level, and adjusts the gain for optimum digitization
resolution and maximum signal-to-noise ratio. The position of the gain stage following the
first stage low-pass filter ensures that only in-band signals are amplified, further
enhancing the signal-to-noise characteristics. Up to 4080 different gain settings can be
selected from a gain of one to 512.
f. Track and Hold. The track and hold circuit tracks the filtered input signal and holds it until
ready for conversion by the analog-to-digital converter.
g. Analog-to-Digital Converter. The analog-to-digital converter (ADC) is a monolithic, 10-
bit ADC that digitizes the filtered and amplified input signal. The ADC performs
conversions at rates as high as 40,000 conversions per second under the command of the
digital board timing controller. The conversion resolution of the 10-bit ADC allows
simultaneous measurement of signal components differing in amplitude by as much 60
dB. The digitized data signal is applied to the digital board memory via the 10-bit system
bus.
h. Overload Detectors. The analog board contains two overload detectors, an input signal
level detector, and a gain amplifier signal level detector. The input overload detector
allows the system firmware to detect and report to the user any occurrences of signal
corruption caused by input signal overload.
The gain overload detector allows the system firmware to detect occurrences of
overdriving by the programmable gain amplifier. The firmware then lowers the gain of the
programmable gain amplifier to prevent signal distortion.

INPUT
VELOCIMETER OVERLOAD
SIGNAL DETECTOR
INPUT FROM
8520C
2:1
NOISE
MULTIPLEXER
GENERATOR
HIGH PASS
FILTER
ANTI-ALIAS
LOW-PASS
FILTER
(1 ST STAGE)
PROGRAMMABLE
GAIN
AMPLIFIER
ANTI-ALIAS
GAIN
LOW-PASS
OVERLOAD
FILTER
DETECTOR
(2 ND STAGE)
ANTI-ALIAS
LOW-PASS
FILTER
(3 RD STAGE)
TRACK
AND
HOLD
ANALOG- SYSTEM DATA BUS

TO-DIGITAL TO MEMORY
CONVERTER ON DIGITAL
BOARD
FILE: FIG4-2.DRW
Figure 4-2. Analog Board Block Diagram

4.2.1.1.2 Digital Board (Figure 4-3)

The digital board receives digital signals from the ADC on the analog board and digital serial
communications from the microcontroller on the controller board in the Signal Selector 8520C. The
signals from the analog board are analyzed and processed by the digital board, and the results are
displayed on the liquid crystal display (LCD) or printed out by the printer. The serial communications
from the 8520C are used to select the Velocimeter or magnetic pickup inputs. The analog board also
sends detected overload digital signals to the digital board. The overload signals are analyzed by the
digital board and control signals are sent to the analog board to control amplifier gain. The digital
board also uses the data retrieved from disk and the user’s keypanel input to analyze and process the
input data from the analog board.
a. Pulse Detector. The pulse detector is a threshold adaptive detector which is used to
translate the azimuth pickup input signal from the 8520C to digital logic levels. The
detector detects peak pulse levels as low as 0.5 volt.
b. Timing Controller. The timing controller is a monolithic, five-channel, high resolution
controller which is used to manage all data acquisition timing. The controller contains a 5
MHz crystal time base to provide stable time measurement with a resolution of 200
nanoseconds.
Four timing channels of the controller are used in various firmware programmed
configurations for vibration data sampling and azimuth pickup period measurement. The
fifth channel is used to generate a precise clock for the switched capacitor filters on the
analog board.
For measurements at frequencies up to 500 Hz, a counter/timer controls sample rates with
a worst-case resolution of one part in 2250. Above 500 Hz, the worst-case resolution is
one part in 196.
c. Communications Controller. The communications controller is a dualchannel,
asynchronous serial communications controller which is used to interface with the 8520C
and the printer. The controller includes a general purpose parallel interface which is used
to control both the programmable gain amplifier on the analog board and the realtime
clock.
d. Realtime Clock. The realtime clock is a battery sustained realtime clock which maintains
the system time, day, and date. The battery is only used when external power is not applied
to the 8500C/C+.
e. Digital Filters. The digital filters consist of decimating finite impulse response (FIR)
filters that further low-pass filter the digitized signal from the analog board. The filters
also provide sample rate conversion so that analysis at arbitrary frequencies is possible.
The low-pass filter characteristic achieved with the decimating FIR is nearly ideal, which
provides more unaliased bins after time-to-frequency domain conversion, 15% more than
usual.
The firmware configures the digital anti-alias filter with from one to eight stages. The
sample rate may thus be reduced by a factor as large as 256.
Amplitude response through all stages is flat within 0.05 dB. The phase response through
each stage is linearly dependent on frequency relative to sample frequency. By virtue of
their digital implementation, component values, tolerances, and temperature do not affect
the response of these filters.

f. Time-to-frequency Converter. The time-to-frequency converter converts the filtered

digitized signal to its frequency domain representation. The converter uses a block
floating point implementation of the decimation in time, radix two fast Fourier transform
(FFT) algorithm.
For spectrum analysis, a time domain Kaiser window is applied to 1024 samples, which
are then transformed into 1024 frequency domain points, of which 461 provide unique
unaliased information.
A high speed implementation of the Goertzel discrete Fourier transform (DFT) algorithm
is used to perform time-to-frequency domain conversion during balance data acquisition.
The firmware adjusts the number of samples used for input to the DFT according to the
specified measurement frequency.
g. Microprocessor. The 8500C microprocessor is an 8-MHz Motorola MC68008 with an 8-
bit external data bus capability. The 8500C+ uses a 25 MHz Motorla 68332 with a 16-bit
external data bus. The microprocessor performs the computations for the balancer/
analyzer System.
h. Memory. 8500C memory consists of 256 kilobytes (KB) of erasable, programmable, read-
only memory (EPROM), 128 KB of non-volatile random access memory (NVRAM), and
256 KB of dynamic random access memory (DRAM). The EPROM contains the system
operating firmware program, the NVRAM retains data in memory when power is
removed, and the DRAM is used for work space. 8500C+ memory consists of 1 MB of
non-volatile, random access memory (NVRAM), expandable to 2 MB. The EPROM is 1
MB of Flash memory and contains the system operating firmware program. The system
firmware is used for built-in self testing, display (LCD) management, user input
(keypanel) management, on-line context-sensitive help, print generation and printer
management, external storage (disk) management, internal storage (NVRAM and DRAM)
management, 8520C communications and control, single frequency vibration (balance)
measurement, and vibration spectrum analysis.
i. LCD. The LCD is the 8500C’s primary means of providing a visual output to the user. The
LCD has a display resolution of 256 columns by 64 rows. Its pixel pitch is 0.53 by
0.53mm (8500C) or 0.52 by 0.52 (8500C+) (1:1 aspect ratio). The microprocessor
interfaces directly to the LCD via the system data bus. The LCD resides in the 8500C/C+
behind a tough plastic window which protects it from damage without degrading
readability. A resistive heater and EL lamp are integrated into the display.

MAGNETIC CONTROL
PICKUP COMMANDS
PULSE TIMING
SIGNAL TO ANALOG
DETECTOR CONTROLLER
INPUT FROM BOARD
8520C
TO/FROM
PRINTER
BOARD
SERIAL
COMMUNICATIONS
COMMUNICATIONS LCD
CONTROLLER
TO/FROM 8520C
TO/FROM
DISK DRIVE
REALTIME
CLOCK KEYPANEL
VELOCIMETER
SIGNAL DIGITAL 68008
FROM ANALOG LOW-PASS MICRO-
BOARD FILTERS PROCESSOR
TIME-TO-
FREQUENCY MEMORY
CONVERTER
FILE: FIG4-3.DRW
Figure 4-3. Digital Board Block Diagram

j. Keypanel. The user interacts with the Balancer/Analyzer System through the 32-switch
keypanel. 28 of the keys have fixed functions. The functions of the remaining four keys
(soft keys) vary as determined by the system’s mode of operation.
k. Keypanel Filter. The keypanel filter is on the digital board near keypanel input. The filter
contains four low-pass filters which reduce the high frequency energy on four keypanel
scan lines to reduce keypanel emissions.

4.2.1.1.3 Heater/EL Control Board (Figure 4-4)

The heater/EL control board provides power and control of LCD screen heater and EL lamps used
behind the keypanel and LCD. The board contains a power supply filter, a display heater controller,
and an EL controller.
POWER SUPPLY FILTER

2.5A
FUSE
DIODE THERMAL
+28 VDC FILTER CUTOFF +27 VDC
BRIDGE
SWITCH
DISPLAY HEATER
VOLTAGE HEATER
+27 VDC
REGULATOR +12V CONTROLLER
HEATER
EL CONTROLLER
VARIABLE EL EL LAMPS
+27 VDC VOLTAGE INVERTER (KEYPANEL)
REGULATOR
10K EL LAMPS
(LCD DISPLAY)
BRIGHTNESS
ADJUSTMENT
FILE: FIG4-4.DRW
Figure 4-4. Heater/EL Control Board

a. Power Supply Filter. The 28 VDC input power is applied to the power supply filter from
the external power connector. The input power passes through a 2.5 Ampere fuse, a diode
bridge, and a filter. Voltages greater than 60 to 85 Volts are shorted to ground by a surge
protector which causes the fuse to open. The diode bridge supplies +27 VDC with the
correct polarity if the input +28 VDC polarity is reversed. The thermal cutoff switch shuts
off power to the display heater and EL lamps when the internal temperature is above
+65°C. This protects the EL lamps whose life span is decreased when operated at high
temperature. It also prevents the display heater from operating at high temperatures, in the
event of a controller failure.

b. Display Heater. The filtered +27 VDC power from the power supply filter is regulated at
+12 VDC and applied to the heater controller module. This module samples the resistance
of the heater every 10 seconds. If the resistance falls below approximately 83 ohms,
indicating that the screen temperature is below approximately 7°C, then the controller
begins heating the display. As the heater temperature rises, the heater resistance increases.
Once the resistance rises above approximately 83 ohms, the screen is at operating
temperature and the heater is turned off. The heater is capable of keeping the LCD screen
at +7°C with ambient temperatures down to -40°C.
c. EL Controller. The filtered +27 VDC power from the power supply is applied to a variable
voltage regulator. The voltage regulator output (+1.5 to +13 VDC) is changed by an
external BRIGHTNESS ADJ potentiometer on the control panel in the disk drive
compartment. This regulated voltage drives an 800 Hz, 100 Vrms inverter, which powers
the EL lamps behind the LCD and keypanel. The brightness of the lamps is proportional to
the inverter AC voltage. The inverter AC voltage output is proportional to the DC voltage
input to the inverter.
4.2.1.2 Printer/Disk Drive Assembly

The printer/disk drive assembly contains three printed circuit boards: a printer board, a distribution
board, and a power supply board; a printer assembly; and a disk drive assembly. The printer board
drives the printer. The distribution board provides an interface between the balancer/analyzer assembly
and printer/disk drive assembly. The power supply board generates the DC operating voltages for the
balancer/analyzer assembly and printer/disk drive assembly. The printer assembly prints the data. The
disk drive assembly reads the data from the diskette.
4.2.1.2.1 Printer Board
The printer board receives data and control commands from the communications controller in the
8500C/C+ digital board, and status signals are returned to the digital board. The data and control
commands are converted from serial form to parallel form to drive the print head. Three amplifiers
amplify the print drive signals to the proper levels needed to drive the print heads. The board also
contains a paper feed switch to index paper through the paper feed slot. An LED paper sensor informs
the processor when paper is in the unit.
4.2.1.2.2 Distribution Board
The distribution board provides cable interfacing between the balancer/analyzer assembly and printer/
disk drive assembly.
4.2.1.2.3 Power Supply Board (Figure 4-5)
The power supply board converts the 28 VDC input power from the aircraft to the DC voltages needed
to operate the circuit boards in the balancer/analyzer assembly and printer/disk drive assembly. The
input power from the aircraft can be 12 to 28 VDC of either polarity. The input power is applied to a
diode bridge to set the input voltage to the correct polarity. The output of the bridge is applied across a
FET switch and transformer. The transformer outputs are rectified and filtered to produce two +5
VDC, one +12 VDC, and one -12 VDC output voltage. The power supply contains a closed-loop
regulator, which keeps the output voltages constant for varying input voltage and load. An optoisolator
feeds back the output voltage across the isolation barrier. A light emitting diode (LED) indicates when
power is on.

4.2.1.2.4 Printer Assembly

The printer assembly is a high resolution thermal graphics printer. The printer prints data onto the 4-3/
8-inch paper roll. The printer is a 320-dot matrix thermal type printer whose print head is controlled by
the printer/disk board. At any time during operation on the aircraft, the user may request a printed
duplicate of the contents of the LCD display by pressing PRINT.
4.2.1.2.5 Disk Drive Assembly
The disk drive assembly is a small, rugged micro-floppy disk drive which provides a mechanism for
archival storage and retrieval of programs and data. The microprocessor in the 8500C allows reading,
writing, and generation of PC/MS-DOS 3.0 (or higher) formatted disks. The capacity of the drive is
720 KB when used with a double sided, double density, micro-floppy disk (8500C/C+) or 1.44 MB
when used with a high-density micro-floppy disk (8500C+ only).
REGULATOR/ OPTO-ISOLATOR/
PWM LED
DIODE RECTIFIER/
12 TO 28 VDC +5 VDC
BRIDGE FILTER
STEP-DOWN
TRANSFORMER
RECTIFIER/ +12 VDC

FILTER
RECTIFIER/ -12 VDC

FILTER
RECTIFIER/ +5 VDC
FILTER
FILE: FIG4-5.DRW
Figure 4-5. Power Supply Board Block Diagram
4.2.2 8520C Signal Selector

The 8520C Signal Selector contains two printed circuit boards: a controller and Velocimeter BIT
(Built-In Test) board, and a power supply board. The controller board selects the appropriate analog
vibration input and/or the appropriate magnetic or photocell pickup input from the aircraft, and
connects it to the 8500C/C+ inputs. The Velocimeter BIT portion of the board determines the presence
of a severe failure (open or short) of a Velocimeter or its cable. The power supply board generates the
DC operating voltages for the other two circuit boards.
4.2.2.1 Controller Board (Figure 4-6)

The controller board routes analog inputs from the Velocimeters and magnetic or photocell pickups for
processing by the 8500C/C+. The inputs are selected by the 8500C/C+.

a. Velocimeter Inputs. Twelve discrete Velocimeter connectors are mounted on the front
panel of the 8520C. All inputs may be simultaneously connected to twelve transducers
(Velocimeters). Each connector provides regulated +12 and -12 VDC power to a
connected Velocimeter.
b. Azimuth Pickup Inputs. Four discrete azimuth pickup connectors are mounted on the front
panel of the 8520C. All pickup inputs may be simultaneously connected to four pickups,
which may be any combination of magnetic or photocell types.
c. 12:4 Crosspoint Switch. The microcontroller in the controller board controls vibration
transducer switching with a 12:4 crosspoint switch array. Crosstalk between channels is
better than -80 dB from DC to 10 kHz.
d. Dual Sum/Difference Function Blocks. Two sum/difference function blocks derive both
the sums and differences of their two inputs. The four inputs to these circuits come from
the outputs of the crosspoint switch array. Each sum circuit implements (A+B)/2, which
allows measurement of the scaled sum of two distinct channels or, when the same, a single
channel. Similarly, the difference circuits implement (A-B)/2, which allows measurement
of the scaled difference between two distinct channels or, when channels A and B are the
same, a single channel.
e. 2:1 Multiplexers. The microcontroller controls electronic switches in the second 2:1
multiplexer, which selects either the sum or difference output of the first sum/difference
function block for buffering and routing to a peak detect and hold circuit.
VELOCIMETER INPUT 1
VELOCIMETER INPUT 2
VELOCIMETER INPUT 3
VELOCIMETER INPUT 4
VELOCIMETER BIT
POWER SWITCH
VELOCIMETER INPUT 5
+12 VDC
VELOCIMETER INPUT 6
VELOCIMETER INPUT 7
SHORT
VELOCIMETER INPUT 8 POWER
CIRCUIT LATCH
MONITOR
LAMP
VELOCIMETER INPUT 9
VELOCIMETER INPUT 10
2 CHANNELS
A+B FUNCTION BLOCK
ANALOG-TO-DIGITAL
2:1 MULTIPLEXER PEAK DETECT AND HOLD CONVERTER
A-B FUNCTION BLOCK
12:4
CROSSPOINT
SWITCH A+B FUNCTION BLOCK
2:1 MULTIPLEXER TO 8500

ANALOG BOARD SERIAL
A-B FUNCTION BLOCK
2 CHANNELS COMMUNCIATIONS 63A03A
TO/FROM 8500 MICROCONTROLLER
DIGITAL BOARD
PICKUP SIGNAL
PULSE DETECTOR DIGITAL BOARD
PICKUP INPUT 1
PICKUP INPUT 2 PULSE DETECTOR

4:1 MULTIPLEXER
PICKUP INPUT 3
PULSE DETECTOR
PICKUP INPUT 4
PULSE DETECTOR
QUAD PEAK DETECTOR BOARD A3
FILE: FIG4-6A.DRW
Figure 4-6. Controller Board and Quad Peak Detector Board Block Diagram

The microcontroller controls electronic switches in the second 2:1 multiplexer, which
selects either the sum or difference output of the second sum/difference function block for
buffering and routing to the analog board of the 8500C/C+.
f. Peak Detect and Hold. The peak detect and hold detects and holds the peak Velocimeter
input levels, which is used by the 8500C/C+ to look ahead at the next to-be-acquired
Velocimeter input. This enables the 8500C/C+ to set the input gain in the analog board
without delay after the next Velocimeter input has been selected.
g. Analog-to-Digital Converter. The analog-to-digital converter (ADC) digitizes the peaks
from the peak detect and hold, which are used by the 8500C/C+ for gain setting.
h. 4:1 Multiplexers. The microcontroller controls electronic switches which select one of
four azimuth pickup inputs for buffering and routing to a pulse detector.
The microcontroller controls electronic switches which select one of four azimuth pickup
inputs for buffering and routing to the pickup input of the digital board in the 8500C/C+.
i. Pulse Detector. The pulse detector is identical to that used in the digital board of the
8500C/C+. The output of the detector is connected to the microcontroller. The input period
of the selected pickup is monitored and reported to the 8500C upon command.
j. Microcontroller. The microcontroller is a very large scale integration microcontroller
which is used for all control and communication functions in the 8520C. The
microcontroller is an Hitachi 6303A. The microcontroller controls the timing of the
various multiplexers and switches of the controller board. The 6303’s built-in serial
communications controller is used for communications between the 8520C and the
8500C/C+.
4.2.2.2 Velocimeter BIT (Figure 4-6)

The Velocimeter BIT portion of the board determines the presence of a major failure (open or short) of
a Velocimeter or its cable. The board monitors the Velocimeter signal and searches for a characteristic
signature. If the Velocimeter signature is not recognized, the 8520C will inform the 8500C/C+ of the
failure.
a. Latch. The latch controls the power switch. The controller board microprocessor writes a
control word to the latch.
b. Power Switch. The power switch controls the +12 VDC and -12 VDC power to the
Velocimeters.
c. Power Monitor. The power monitor checks the +12 VDC and -12 VDC power lines. If
there is a short circuit present on the power lines, then the power monitor illuminates the
short circuit lamp.
d. Short Circuit Lamp. The short circuit lamp indicates the presence of a short circuit on the
+12 VDC or -12 VDC power lines.
4.2.2.3 Power Supply Board (Figure 4-7)

The power supply board converts the 28 VDC input power from the aircraft to the DC voltages needed
to operate the circuit boards in the assembly. The input power from the aircraft can be 12 to 28 VDC of
either polarity. The input power is applied to a diode bridge to set the input voltage to the correct
polarity. The output of the bridge is applied across a FET switch and transformer. The transformer
outputs are rectified and filtered to produce +5 VDC, one +12 VDC, and one -12 VDC output voltage.

The power supply contains a closed-loop regulator, which keeps the output voltages constant for
varying input voltage and load. An optoisolator feeds back the output voltage across the isolation
barrier. A light emitting diode (LED) indicates when power in on.
REGULATOR/ OPTO-ISOLATOR/
PWM LED
DIODE RECTIFIER/
12 TO 28 VDC +5 VDC
BRIDGE FILTER
STEP-DOWN
TRANSFORMER
RECTIFIER/ +12 VDC

FILTER
RECTIFIER/ -12 VDC

FILTER
Figure 4-7. Power Supply Board Block Diagram (8520C)
4.2.2.4 Quad Peak Detector Board

The quad peak detector board contains four circuits identical to the pulse detector described on the
digital board, one per syn input. Since these circuits are adaptive, this parallel architecture allows rapid
measurement among channels without adaptation latency.


Chapter 5
5. Maintenance And Repair

Section 5.1 Test Equipment..................................................................................................5-1
Section 5.2 Routine Maintenance Procedures .....................................................................5-3
Section 5.3 Periodic Inspection Procedures ........................................................................5-3
Section 5.4 Functional Tests ................................................................................................5-3
Section 5.5 Calibration Tests ...............................................................................................5-12
Section 5.6 Troubleshooting Guide......................................................................................5-30
Section 5.7 Repair................................................................................................................5-44
Section 5.8 Disassembly ......................................................................................................5-51
Section 5.9 Reassembly........................................................................................................5-69
Section 5.10 List of Field-Replaceable Components ...........................................................5-72
Section 5.11 Cage Codes .....................................................................................................5-77
5.1 Test Equipment

Table 5-1 lists the test equipment, accessories, and cables needed to perform maintenance on the
8500C/C+ balancer/analyzer system. Figure 5-1 shows schematics and materials needed to create test
cables #8278 and #10502.
Table 5-1. Test Equipment
Part No. Nomenclature Manufacturer Characteristics
9100 Power Supply Chadwick-Helmuth 12 to 28 VDC, 5 Amperes

HP-8904A Signal Hewlett-Packard 10 mV to 5 VAC (+.1%)
Generator from3 Hz to 10 KHz
(+0.01%), distortion plus
noise less than -60 dB, sync
to sine signal phase
relationship 180°. Rise and
fall time for square wave
signal input must be less
than 1µs.
11210-5 Cable (2 each) Chadwick-Helmuth Velocimeter cable, 5 ft
10813-12 Cable Chadwick-Helmuth Power cable

Chapter 5 - Maintenance And Repair
Table 5-1. Test Equipment Continued
Part No. Nomenclature Manufacturer Characteristics
11A Calibrator Chadwick-Helmuth N/A

HP-3561A Spectrum Hewlett-Packard Amplitude Accuracy
Analyzer +/- 0.15 dB @ 1 kHz
(1.74%)
8278 Cable Chadwick-Helmuth BNC-to-Velocimeter
10502 Cable Chadwick-Helmuth BNC-to-Magnetic Pickup
N/A BNC T- Any
connector
N/A Cable, coaxial Any BNC-to-BNC
(2 ea)
10808-5 Cable Chadwick-Helmuth Magnetic pickup cable, 5 ft
5876 Magnetic Chadwick-Helmuth See appropriate
(Model 3030) Pickup documentation
Test Cable #8278, Velocimeter-to-BNC

Use any of these 6-pin connectors (or similar
connectors--crimped or soldered):
C-H #402-1061E (crimped pins)
MS3476L10-6P (crimped pins)
ITT Cannon #PV76L10-6P (crimped pins)
RG-58 Coax Cable
D
B
SHIELD
Test Cable #10502, Magnetic Pickup-to-BNC

Use any of these 4-pin connectors (or similar connectors):
C-H #402-0841B (soldered pins)
MS3116F8-4P (soldered pins)
MS3126F8-4P (crimped pins)
ITT Cannon #KPSE06F8-4P (crimped pins)
ITT Cannon #KPT06F8-4P (soldered pins)
RG-58 Coax Cable
D
B
A NC
SHIELD
C NC
FILENAME: TESTCABL.DRW
Figure 5-1. Test Cable Fabrication Information

Routine Maintenance Procedures
5.2 Routine Maintenance Procedures

Table 5-2 lists the procedures that should be done every 12 months to keep the 8500C/C+ system in
good working order.
Table 5-2. Routine Maintenance Procedures.
Item Procedure
8500C/C+ Disk Drive Section 5.7.1.2 “Disk Drive Cleaning Procedure
8500C/C+ and 8520C Section 5.4 “Functional Tests”
8500C/C+ Battery Pack Section 5.7.4 “Battery Pack Check and Replacement”
5.3 Periodic Inspection Procedures

Inspect components every 12 months in accordance with Table 5-13.
5.4 Functional Tests

NOTE: These tests require firmware version 3.21 (or higher) in the 8500C/C+ balancer/
analyzer. For instructions on changing the firmware to a newer version, see Section 5.7.3,
“EPROM Change Procedure.”
This section contains instructions to test the 8500C/C+ system performance parameters. If a test step
fails, refer to the “Troubleshooting Guide” in Section 5.6 to locate the faulty component.
The functional tests provide a high confidence level that the instrument is operating properly and
within specifications. The functional test setups use, as much as possible, all the components
(transducers, cables, etc.) that are used in the field. This allows the user to verify the proper operation
of these components and aids in fault isolation.
5.4.1 8500C/C+ Balancer/Analyzer System Test Procedure (with

8520C)
NOTE: These tests build successively on the first test in this section. Any settings not
mentioned must be left as they were in the previous test.
5.4.1.1 Test Setup

a. Connect equipment as shown in Figure 5-2.
b. Adjust gap between magnetic pickup and screw to .04 in.
NOTE: Make sure calibrator Velocimeter cables are free to move so that Velocimeter
movement is not inhibited.

5.4.1.2 Power-Up Self-Test

a. Hold down START key on 8500C/C+ and turn on power supply.
NOTE: This erases all memory in 8500C/C+.
b. Wait until Power-Up Self-Test display appears and release START key.
5.4.1.3 Balance Test

a. Ensure that only one No. 6 screw is installed above “h” on logo on Calibrator 11A rotor
disk.
b. Set CAM RATE (RPM) switch to 900.
c. Set MOTOR switch to ON.
1 3 5 M -1 2 S T R O B E X
8 5 0 0 C B A L A N C E R /A N A L Y Z E R
B A L A N C E R /A N A L Y Z E R
P R IN T
S T A R T
P O W E R S U P P L Y 9 1 0 0 A A
S H O W /H ID E
W X
S T O P
B Y Z
M O R E /K E Y S
C A B L E 1 0 8 1 1
B A L A N C E H E L P S T A T U S
1 2 I
3
G H
D : E F .
4 5 6
L O A D S E T U P M O
S P E C T R U M N
M O D E L 8 5 0 0 C
J # K < L - 7 8 9
S T U
T R A C K S T O R E A N N O T A T E
C H A D W IC K HELM UTH
E L M O N T E , C A L I F O R N I A
P % Q > R / V
0
C A B L E 1 0 8 1 3
C A B L E 1 1 2 1 0 1 4 7 1 0
P O W E R B A L A N C E R
2 5 8 1 1
3 6 9 1 2
C A B L E 1 1 2 1 0 A B C D
8 5 2 0 C S IG N A L S E L E C T O R
V E L O C IM E T E R C A L IB R A T O R 1 1 A V E L O C IM E T E R
7 3 1 0 7 3 1 0
M A G N E T IC
P IC K U P
N O T E : 1 1 B u s e rs , b y p a s s 3 0 3 0
m a g p u ls e d o u b le r a n d C A B L E 1 0 8 0 8
c o n n e c t m a g n e tic p ic k u p
c a b le d ir e c tly to c h a n n e l A N O T E : T h e c a lib ra to r m u s t h a v e n o m o re th a n o n e s c r e w in s ta lle d o n its r o to r
o n 8 5 2 0 C . T h is s im u la te s d is k w h e n u s e d w ith th e 8 5 0 0 C ; h o w e v e r, th e c a lib r a to r w a s d e s ig n e d to h a v e a t
1 1 A u s e . le a s t tw o s c r e w s 1 8 0 d e g r e e s a p a r t. T o s im u la te a s e c o n d s c re w , e n te r th e
a c tu a l r p m ( h a lf th e "C A M R A T E " ) a s th e b a la n c e fre q u e n c y a n d " 2 " a s th e tim e s
fa c to r in th e 8 5 0 0 C b a la n c e s e tu p d is p la y . F o r e x a m p le , if th e C A M R A T E is
9 0 0 , e n te r "4 5 0 " a s th e b a la n c e fr e q u e n c y a n d " 2 " a s th e tim e s fa c to r.
F IL E : F U N C T IO N .D R W
Figure 5-2. Functional Test Setup (with Magnetic Pickup)

d. Adjust pot next to 900 CAM RATE switch position until 2nd ring from outside on rotor
disk appears frozen in place under 60 Hz light.2
e. Press BALANCE key on 8500C/C+.
f. Press SETUP key.
g. Key in 450 with numeric keys in BALANCE FREQUENCY field.
2
Attention, users outside U.S.: The 11A Calibrator can also be calibrated under 50 Hz light. For 1714
rpm and 923 rpm cam rates, inner two rings on rotor disk are used. Remember to enter half these rates
in 8500C/C+ setup screen, when called for in the following steps.

Functional Tests
NOTE: To undo mistaken entries, press the RESTORE soft key.

h. On same line, press right arrow key twice to select last number (called “times factor”) with
arrow keys.
i. Key in 2 as new times factor. This entry now reads: x 2.
j. Select BALANCE TYPE field with arrow keys.
k. Press CHANGE soft key to select <MAG PICKUP>.
l. Select <AUTO STOP> and press CHANGE soft key to select <MAN STOP>.
m. Select PHASE UNITS field with arrow keys.
n. Press CHANGE soft key to select <DEGREES>.
o. Select PICKUP field with arrow keys.
p. Press CHANGE soft key to select CHANNEL A.
q. Select INPUT field with arrow keys.
r. Key in <1> with numeric key.
s. Press ENTER soft key.
t. Wait 10 seconds.
u. Press START key.
v. Verify that display indicates (example in Figure 5-3):
900 +1 RPM
0.4 +0.04 IPS
275° +10°
ACQUISTION DISPLAY
FINAL RESULTS DISPLAY

Figure 5-3. Typical Balance Test Displays for 900 RPM

w. Press STOP key.

x. Set CAM RATE (RPM) switch on Calibrator 11A to 1800.
y. Adjust pot next to 1800 CAM RATE switch position until outside ring on rotor disk
appears frozen in place under 60 Hz light.
z. Press SETUP key on 8500C/C+.
aa. Key in <900> with numeric keys in BALANCE FREQUENCY field.
ab. Key in x2 as the times factor.
ac. Press ENTER soft key.
ad. Wait 10 seconds.
ae. Press START key.
ACQUISTION DISPLAY

Figure 5-4. Typical Balance Test Displays for 1800 RPM
af. Verify that display indicates (example in Figure 5-4):
1800 +2 RPM
0.8 +0.08 IPS
275° +10°
ag. Press STOP key.
ah. Press SETUP key.
ai. Select INPUT field with arrow keys.
aj. Key in <2> with numeric key.
ak. Press ENTER soft key.
al. Wait 10 seconds.

Functional Tests
am. Press START key.

an. Verify that display indicates (example in Figure 5-4):
1800 +2 RPM
0.8 +0.08 IPS
275° +10°
ao. Press STOP key.
ap. Set CAM RATE (RPM) switch on Calibrator 11A to 900.
aq. Press SETUP key on 8500C/C+.
ar. Key in 450 in BALANCE FREQUENCY field.
as. Key in x2 as times factor.
at. Press ENTER soft key.
au. Wait 10 seconds
av. Press START key.
aw. Verify the display indicates (example in Figure 5-3):
900 +1 RPM
0.4 +0.04 IPS
275° +10°
ax. Press STOP key.
ay. Move 11210 cables to next Velocimeter channel positions listed in Table 5-3, and move
cable 10808 to magnetic pickup channel position indicated in table.
az. Press SETUP on 8500C/C+.
ba. Select PICKUP field with arrow keys.
bb. Press CHANGE soft key to select pickup shown in Table 5-3.
bc. Select INPUT field with arrow keys.
bd. Key in channel number shown in Table 5-3 with numeric key.
be. Press ENTER soft key.
bf. Wait 10 seconds.

Table 5-3. Velocimeter and Magnetic Pickup Balance Test Channel

Combinations
Magnetic Pickup
Velocimeter Channels Channel
3-4 A
5-6 B
7-8 C
9-10 D
11-12 D
bg. Press START key.

bh. Verify that display indicates (example in Table 5-3):
900 +1 RPM
0.4 +0.04 IPS
275° +10°
bi. Press STOP key.
bj. Repeat steps ay through bi for remaining Velocimeter and magnetic pickup channels listed
in Table 5-3.
5.4.1.4 Spectrum Test

a. Press SPECTRUM key on 8500C/C+.
b. Press SETUP key.
c. Key in 5000 with numeric keys in MAXIMUM FREQUENCY field.
d. Press ENTER soft key.
e. Wait 10 seconds.
f. Press START key.
g. Verify that spectrum is displayed (examples in Figure 5-5).
900 RPM CAM RATE

Functional Tests
1800 RPM CAM RATE

Figure 5-5. Typical Spectrum Test Displays.
h. Use left or right arrow keys to move cursor (dotted line) to 900 RPM.
i. Verify that readout at top of display shows peak signal is 0.4 +0.04 IPS at 900 +5 RPM.
J. Switch Calibrator to 1800 RPM CAM RATE.
k. Press START key.
l. Verify that spectrum is displayed (examples in Figure 5-5).
m. Use left or right arrow keys to move cursor (dotted line) to 1800 RPM.
n. Verify that readout at top of display shows peak signal is 0.8 +0.08 IPS at 1800 +5 RPM.
5.4.1.5 Track Test

a. Press TRACK key on 8500C/C+.
b. Press MORE soft key to select 4 blades.
c. Press START key.
d. Aim Strobex at rotor disk on Calibrator 11A and pull trigger.
e. Verify that stem of “h” at center of rotor disk indicates the following pattern:
STEM OF "h"
FILE: CROSS.DRW
DATE: 12/10/90
f. Release trigger on Strobex.

g. Press STOP Key on 8500C/C+.
5.4.1.6 FasTrak
5.4.1.6.1 Test Setup (Ref. Figure 5-6)
NOTE: This test provides a high level of confidence that the FasTrak is operating properly
and is included here for completeness. The associate circuitry in the 8520 and 8500 has
already been tested.
Before doing the FasTrak test, apply the special overlay to the calibrator disk. See Figure 5-6 for
samples that can be copied or recreated.
NOTE: This test should be performed in a well-lit room.
a. Place calibrator on its back on a flat surface.
b. Place FasTrak on its side with the pin connector facing to the right. The window should be
facing the calibrator approximately six inches away.
c. Set CAM RATE (RPM) switch to 900.
d. Set MOTOR switch to ON.
e. Adjust pot next to 900 CAM RATE switch position until 2nd ring from outside on rotor
f. Press BALANCE key on 8500C/C+.
g. Press SETUP key.
h. Select PICKUP field with arrow keys.
i. Press CHANGE soft key to select PICKUP B.
j. Press STATUS key.
k. After a few seconds, the RPM on the screen should read approximately 900 RPM.
NOTE: If you cannot adjust the distance or alignment to obtain 900 RPM, there may be a
problem with the FasTrak. Return it to Chadwick-Helmuth for adjustment.
l. With a white index card or piece of paper, cover half of the rotating disk. Place the card
close to, but not touching, the disk, so as to cover 1/2 Mag Pickup sensor and one vibration
sensor.
m. The RPM should drop by approximately half, remove the card.
Night Mode Test

a. To simulate night operation, turn off all lights in room, or enclose the test setup within a
darkened enclosure, such as a large box. The RPM should drop to zero when the area is
dark enough.
b. Switch Tracker switch to Night mode. (in the cable)
c. After a few seconds, the RPM should appear on the display
3
Attention, users outside U.S.: The 11A Calibrator can also be calibrated under 50Hz light. For 1714

Functional Tests
.
8500C BALANCER/ANALYZER
BALANCER/ANALYZER
PRINT
START
POWER SUPPLY 9100A A
SHOW/HIDE
W X
STOP
B Y Z
MORE/KEYS
CABLE 10811
1 I
G H
D : E F .
4 5 6
MODEL 8500C
J # K < L - 8 9
S 7 U
T
TRACK STORE
CHADWICK
HELMUTH
ANNOTATE
P % Q > R / V
0
CABLE 10813
1 4 7 10
POWER BALANCER
2 5 8 11
3 6 9 12
A B C D
8520CS SIGNAL SELECTOR

CALIBRATOR 11A
MAG PICKUP 3030
CABLE 10808
CABLE 12700
NOTE: 11B users, bypass NOTE: The calibrator must have no more than one screw installed on its rotor
mag pulse doubler and disk when used with the 8500C; however, the calibrator was designed to have at
connect magnetic pickup least two screws 180 degrees apart. To simulate a second screw, enter the
cable directly to channel A actual rpm (half the "CAM RATE") as the balance frequency and "2" as the times
on 8520C. This simulates factor in the 8500C balance setup display. For example, if the CAM RATE is
11A use. 900, enter "450" as the balance frequency and "2" as the times factor.
Figure 5-6. Functional Test Setup (with Tracker)
Figure 5-7. Special Overlay

5.4.2 Disk Drive Test Procedure

c. Hold disk with arrow facing up and pointing in and insert disk in 8500C/C+ disk drive-
push in until drive button pops out (Figure 2-1).
NOTE: Do not use a chart disk or any other disk with important data on it because all data
on the disk will be erased.
d. Press STATUS on 8500C/C+.
e. Verify that display indicates Disk Unit Ready and Writable.
f. Press MORE KEYS key.
g. Press SELF-TEST soft key.
h. Press HW soft key.
i. Select Disk Drive on display with arrow keys.
j. Press EXECUTE soft key.
k. Press START key.
l. Wait until 8500C/C+ stops reading diskette (about 1 minute).
m. Verify that display indicates Disk Drive Test Successful.
n. Press OK soft key.
o. Press QUIT soft key.
5.5 Calibration Tests

NOTE: These tests require firmware version 3.21 (or higher) in the 8500C/C+ balancer/
analyzer. For instructions on changing the firmware to a newer version, see Section 5.7.3,
“EPROM Change Procedure.”
This section contains instructions to test the 8500C/C+ system design parameters. If a test step fails,
refer to the “Troubleshooting Guide” in Section 5.6 to locate the faulty component.
Calibration tests provide the highest level of confidence that the instrument is operating properly. Use
calibrated laboratory equipment to verify that the instrument conforms to its published specifications.
5.5.1 8500C/C+ Balancer/Analyzer Test Procedure

5.5.1.1 Test Setup

Connect equipment as shown in Figure 5-8.

Calibration Tests

5.5.1.3 Amplitude, Frequency, and Phase Accuracy Tests

This test uses a signal generator to input a signal with an exact amplitude, frequency, and phase
relationship to the 8500C/C+. This input is also connected to the signal input of the spectrum analyzer
so that the signal level can be verified on the spectrum analyzer. The output measurements are then
compared to specifications.
a. Turn on spectrum analyzer and set up to view a 13.44 mVrms, 100 Hz signal. Use the
following analyzer settings.
Frequency: Baseband, Start: 0 Hz, Stop: 200 Hz
Trigger: Free run
Average: Off
Window: Flat top
Source: Off
Input: DC Coupling, Auto range on
Units: X: Hz, Y: Volt
Vertical Scale: Linear

P O W E R S U P P L Y 9 1 0 0 A
C A B L E 8 9 9 8
V E L O C IM E T E R IN P U T M A G P IC K U P IN P U T 8 5 0 0 C B A L A N C E R /A N A L Y Z E R
(6 P IN ) (4 P IN )
S P E C T R U M A N A L Y Z E R B A L A N C E R /A N A L Y Z E R
H P -3 5 6 1 A A
P R IN T
W X
S T A R T
S H O W /H ID E S T O P
B Y Z
M O R E /K E Y S
H E L P S T A T U S 2 3
B A L A N C E 1 I
G H
D : E F .
4 5 6
S P E C T R U M N
M O D E L 8 5 0 0 C
J # K < L - 7 8 9
S T U
P % Q > R / V
0
C A B L E 8 2 7 8
S IG N A L G E N E R A T O R
H P -8 9 0 4 A
S IG N A L IN P U T
(B N C T -C O N N E C T O R )
S IG N A L (S Y N C ) O U T
S IG N A L O U T
C A B L E 1 0 5 0 2
F IL E : 8 5 C _ C A L .D R W
C O A X
Figure 5-8. 8500C/C+ Calibration Test Setup

b. Turn on signal generator and set up as follows:
(1) For channel connected to magnetic pickup signal input, set to Frequency = 100.00
+/- 0.01 Hz, Waveform = Square wave, Amplitude = 1 to 2 Vp-p.
(2) For channel connected to Velocimeter input, set to Frequency = 100.0 +/- 0.01 Hz,
Waveform = Sine wave, Amplitude = 19.0 mV pk.
NOTE: Phase shift between magnetic pickup signal and Velocimeter signal must be zero
degrees on the H-P signal generator. For a description of Chadwick-Helmuth phase
measurement convention, refer to Appendix C.
c. Press BALANCE key on 8500C/C+.
d. Press SETUP key.
e. Key in 6000 with numeric keys in BALANCE FREQUENCY field.
f. Select <RPM> on display by pressing right arrow key once.
g. Press CHANGE soft key to select <Hz>.
h. Select <AUTO STOP> field with arrow keys.
i. Press CHANGE soft key to select <MAN STOP>.
j. Select PHASE UNITS field with arrow keys.

Calibration Tests
k. Press CHANGE soft key to select <DEGREES>.

l. Press ENTER soft key.
m. Monitor signal generator output with spectrum analyzer with marker at 100 Hz. Adjust
signal generator output channel connected to Velocimeter input until amplitude is 13.44 +/
- 0.05 mV RMS.
n. Wait 10 seconds for 8500C/C+ gain to settle.
o. Press START key on 8500C/C+.
p. Verify that display indicates:
FREQUENCY: 100.0 +/- 0.1 Hz
VIB LEVEL: 1.000 +/- 0.04 IPS
PHASE ANGLE: 180° deg. +/- 3°
q. Press STOP key.
5.5.1.4 Noise and Spurious Signals Test

This test measures the level of noise and spurious signals generated in the 8500C/C+.
a. Disconnect Velocimeter and magnetic pickup coax cables from cable 8998.
b. Press SPECTRUM key on 8500C/C+.
c. Press SETUP key.
d. Key in 1000 (Hz) with numeric keys in MAXIMUM FREQUENCY field.
e. Select SEEK: field with arrow keys.
f. Press CHANGE soft key to select SEEK:<OFF>.
g. Press ENTER soft key and wait 10 seconds.
h. Press START key.
i. Verify that no noise signal is present on display above 0.005 IPS.
NOTE: At minimum display scale, each dot on display = .001 IPS.
NOTE: If any noise signals appear, you can use left-right arrows to move cursor to noise
peak. IPS level and frequency of peak will read out at top of display.
5.5.1.5 Anti-Alias Filter Response

This test measures the ability of the two anti-alias filters to reject frequencies caused by aliasing. This
test uses a signal generator to inject a signal known to cause an alias frequency into the 8500C/C+. The
8500C/C+ then measures the alias frequency to determine how well the alias frequency was rejected.
5.5.1.5.1 500 Hz Anti-Aliasing
a. Set up spectrum analyzer to view a 13.44 mV RMS, 1722-Hz signal. Use the following
analyzer settings:
Trigger: Free run
Average: Off

Window: Flat top

Source: Off
b. Reconnect Velocimeter coax cable to cable 8998.
c. Set up signal generator as follows: For channel connected to Velocimeter input, set to
Frequency = 1722 +/- 1 Hz, Waveform = Sine wave, Amplitude = 19.0 mV pk. Monitor
signal generator output with spectrum analyzer with marker at 1722 Hz. Adjust signal
generator output channel connected to Velocimeter input until amplitude is 13.44 +/- 0.05
mV RMS.
d. Press SETUP key.
e. Key in 500 (Hz) with numeric keys in MAXIMUM FREQUENCY field.
f. Press ENTER key.
g. Wait 10 seconds.
h. Press START key.
i. Verify that no signal aliasing remains on display above 0.005 IPS.
5.5.1.5.2 10 kHz Anti-Aliasing
a. Set up spectrum analyzer to view a 13.44 mVrms, 15,600 Hz signal.
Use the following analyzer settings:
Trigger: Free run
Average: Off
Window: Flat top
Source: Off
b. Turn on signal generator and set up as follows: For channel connected to Velocimeter
input, set to Frequency = 15,600 +/- 10 Hz. Waveform = Sine wave, Amplitude = 19.0 mV
pk. Monitor signal generator output with spectrum analyzer with marker at 15,600 Hz.
Adjust signal generator output channel connected to Velocimeter input until amplitude is
13.44 +/- 0.05 mV RMS.
c. Press SETUP key.
d. Key in 10000 (Hz) with numeric keys in MAXIMUM FREQUENCY field.
e. Press ENTER key.
f. Wait 10 seconds.

Calibration Tests
g. Press START key.

h. Verify that no signal aliasing remains on display above 0.005 IPS.
5.5.2 8520C Signal Selector Test Procedure

5.5.2.1 Test Setup


5.5.2.3 Amplitude, Frequency, and Phase Accuracy Test

This test uses a signal generator to input a signal with an exact amplitude, frequency, and phase
relationship through the 8520C, to the 8500C/C+. This input is also connected to the signal input of the
spectrum analyzer so that the signal level can be verified with the spectrum analyzer. The output
measurements are then compared to specifications.
P O W E R S U P P L Y 9 1 0 0 A
C A B L E 1 0 8 1 3
C A B L E 1 0 8 1 1
1 4 7 1 0 P R IN T
S T A R T
A W X
2 5 8 1 1 B
M O R E /K E Y S
Y Z
H E L P S T A T U S 2 3
B A L A N C E 1
3 6 9 1 2
G H I
D : E F .
4 5 6
S P E C T R U M N
M O D E L 8 5 0 0 C
J # K < L - 7 8 9
S T U
T R A C K S T O R E
A N N O T A T E
A B C D
P % Q > R / V
0
S IG N A L (S Y N C ) O U T
C A B L E 1 0 5 0 2
S P E C T R U M A N A L Y Z E R
S IG N A L G E N E R A T O R H P -3 5 6 1 A
C A B L E 8 2 7 8
H P -8 9 0 4 A
S IG N A L O U T S IG N A L IN P U T
B N C T -C O N N E C T O R
C O A X
F IL E : 8 5 2 0 C C A L .D R W
Figure 5-9. 8520C Calibration Test Setup

a. Turn on spectrum analyzer and set up to view a 13.44 mVrms, 100 Hz signal.
Trigger: Free run
Average: Off
Window: Flat top
Source: Off
b. Turn on signal generator and set up as follows:
(1) For channel connected to magnetic pickup input, set to Frequency = 100.00 +/-
0.01 Hz, Waveform = Square wave, Amplitude = 1 to 2 Vp-p.
(2) For channel connected to Velocimeter input, set to Frequency = 100.00 +/- 0.01
Hz, Waveform = Sine wave, Amplitude = 19.0 mV pk.
c. Press BALANCE key on 8500C/C+.
d. Press SETUP key.
e. Key in 6000 with numeric keys in BALANCE FREQUENCY field.
f Select <RPM> on display with arrow keys.
h. Select <AUTO STOP> field with arrow keys.
i. Press CHANGE soft key to select <MAN STOP>.
j. Select PHASE UNITS field with arrow keys.
k. Press CHANGE soft key to select <DEGREES>.
l. Press ENTER soft key.
m. Monitor signal generator output with spectrum analyzer with marker at 100 Hz. Adjust
- 0.05 mV RMS.
n. Wait 10 seconds.
o. Press START key on 8500C/C+.
p. Verify that 8500C/C+ display indicates:
FREQUENCY: 100.0 +/- 0.1 HZ
VIB LEVEL: 1.000 +0.04/-0.05 IPS
PHASE ANGLE: 180° +/- 3°
q. Press STOP key.
r. Move cable 8278 to next Velocimeter channel position listed in Table 5-4 and move cable
10502 to next magnetic pickup cable position.

Calibration Tests
Table 5-4. 8520C Velocimeter and Magnetic Pickup Amplitude, Frequency, and
Phase Accuracy Channel Combinations
Velocimeter Magnetic Pickup

Channel Channel
(Cable 8278) (Cable 10502)
2 A
3 A
4 B
5 B
6 B
7 C
8 C
9 C
10 D
11 D
12 D
s. Press SETUP key.

t. Select INPUT field with arrow keys.
u. Key in Velocimeter channel number with numeric keys.
v. Select PICKUP field with arrow keys.
w. Press CHANGE soft key to select magnetic pickup channel.
x. Press ENTER soft key.
y. Monitor signal generator output with spectrum analyzer with marker at 100 Hz. Adjust
- 0.05 mV RMS.
z. Wait 10 seconds.
aa. Press START key.
ab. Verify that 8500C/C+ display indicates:
FREQUENCY: 100.0 +/- 0.1 HZ
VIB LEVEL: 1.000 +0.04/-0.05 IPS
PHASE ANGLE: 180° +/- 3°
ac. Press STOP key.

ad. Repeat steps r through ac for the Velocimeter channel and magnetic pickup channel
combinations listed in Table 5-4.
5.5.2.4 Channel Crosstalk Test

This test measures the amount of energy induced by a signal on another 8520C channel. This is done
by placing a signal level on one channel and then measuring the relative signal amplitude of the other
channels listed in Table 5-5.
Table 5-5. Suggested 8520C Velocimeter Channel Crosstalk Combinations
Velocimeter
Velocimeter
Channels
Channel
(selected one at a time in test
(Cable 8278)
step)
1 2-12
2 3-12
3 4-12
4 5-12
5 6-12
6 7-12
7 8-12
8 9-12
9 10-12
10 11-12
11 12
a. Connect cable 8278 to Velocimeter channel 1 and remove cable 10502 from magnetic
pickup channel. Set up signal generator as follows:
(1) For channel connected to magnetic pickup input, set to Frequency = 100.00 +/-
0.1 Hz, Waveform = Sine wave, Amplitude = 19.0 mV pk.
(2) Monitor signal generator output with spectrum analyzer with marker at 100 Hz.
Adjust signal generator output channel connected to Velocimeter input until
amplitude is 13.44 +/- 0.05 mV RMS.
b. Press SPECTRUM key on 8500C/C+.
c. Press SETUP key.
d. Key in 1000 <Hz> with numeric keys.
e. Select SEEK field with arrow keys.
f. Press CHANGE soft key to select <SEEK OFF>.
g. Select INPUT field with arrow keys.

Calibration Tests
h. Key in channel number with numeric keys (for example, 2 for first channel 1 test).
i. Press ENTER soft key.
j. Wait 10 seconds.
k. Press START key.
l. Verify that no noise signal is present on display above 0.01 IPS.
m. Repeat steps c through l for remaining channel combinations listed in Table 5-5. For
example, after channels 2 through 12 have been tested while cable 8278 was connected to
channel 1, move cable 8278 to channel 2 and repeat test.
5.5.3 8500C/C+ Spectrum Accuracy Test (with 8520C)

This test uses a signal generator to input a square wave with an exact amplitude and frequency to the
8500C/C+. This input is also connected to the signal input of the spectrum analyzer so that the signal
level can be verified on the spectrum analyzer.
5.5.3.1 Test Setup


5.5.3.3 Test Procedure: High Frequency Range

a. Turn on spectrum analyzer and set up to view a 134.4 mVrms, 580.0 Hz signal. Use the
following analyzer settings:
Trigger: Free run
Average: Off
Window: Flat top
Source: Off
b. Set up signal generator as follows:
(1) For channel connected to Velocimeter input, set to Frequency = 580.0 +/- 0.1 Hz,
Waveform = Square wave, Amplitude = 150 mV pk.

(2) Monitor signal generator output with spectrum analyzer with marker at 580.0 Hz.
Adjust signal generator output channel connected to Velocimeter input until
amplitude is 134.4 +/- 0.5 mV RMS.
NOTE: The following steps (c-q) may be replaced by the equivalent test in hardware self-test
menu (STATUS, MORE KEYS, SELF-TEST, HW TEST) if the version of firmware under
test supports it. If it is not supported, the manual method is listed below.
c. Press SPECTRUM key on 8500C/C+.
d. Press SETUP key.
e. Key in 600000 (rpm) with numeric keys in MAXIMUM FREQUENCY field.
f. Select <RPM> on display with arrow keys.
h. Select SEEK: field with arrow keys.Press CHANGE soft key to select SEEK <OFF>.
i. Select <SINGLE> field with arrow keys. Press CHANGE softkey to select
<MULTIPLE>.
j. Press ENTER soft key and wait 10 seconds. Press START key.
k. After 5 seconds or more. Press and hold STOP until the <MULTIPLE> indicator on the
display disappears.
The acquired spectrum shows a range of odd harmonic peaks on the 8500C/C+ display, from the 1st
(fundamental) to the 17th. For each peak, you will write down 5 measurements in Table 5-6 the
amplitude of the peak itself, the 2 next amplitudes to the left of the peak, and the 2 next amplitudes to
the right. This process is described in the following steps.

Calibration Tests
P O W E R S U P P L Y 9 1 0 0 A
C A B L E 1 0 8 1 3
C A B L E 1 0 8 1 1
P R IN T
S T A R T
1 4 7 1 0 A
S H O W /H ID E
W X
S T O P
B Y Z
M O R E /K E Y S
2 5 8 1 1
C
1 2 I
3
G H
D : E F .
4 5 6
S P E C T R U M N
M O D E L 8 5 0 0 C
3 6 9 1 2 J
T R A C K
# K
S T O R E
< L
A N N O T A T E
-
S 7
T
8
U
9
P % Q > R / V
0
A B C D
H P -3 5 6 1 A
C A B L E 8 2 7 8
H P -8 9 0 4 A
S IG N A L O U T S IG N A L IN P U T
B N C T -C O N N E C T O R
C O A X
F IL E : S P E C T S E T .D R W
Figure 5-10. Spectrum Accuracy Test Setup

l. Use 8500C/C+ arrow keys to move cursor (dotted line) to fundamental peak. The
amplitude readout (in IPS) is shown at the top of the display. Write down this
measurement in Column C of Table 5-6.
NOTE: Make sure the frequency readout on the 8500C/C+ display matches that in Column
C to within 0.1 Hz. In this example, the frequency would be 573.0 Hz (34379 RPM).

m. Press the left arrow key once to move the cursor to the next measurement to the left of the
fundamental peak. The 8500C/C+ readout changes to show the frequency 548.1 Hz
(32884 RPM) and amplitude at this point. Write down this amplitude in Column B. Press
the left arrow key once more, and write down the next amplitude in Column A.
n. Press the right arrow key to move the cursor to the 2 closest amplitudes to the right of the
fundamental peak, and write down these amplitudes in Columns D and E.
o. Fill in amplitude measurements for the remaining harmonic peaks in Table 5-6.
p. Calculate the true amplitude of each harmonic peak in Table 5-6 as follows, and write
down this value in the “True Amp,” column of Table 5-6.
T r u e A m p . = 0 .7 9 8 3 4 3 1 x (a m p . A )2 + (a m p . B )2 + (a m p . C )2 + (a m p . D )2 + (a m p . E ) 2
q. The true amplitude of each harmonic peak should fall between the minimum and
maximum values listed inTable 5-6; if any are out range, refer to Section 5.6,
“Troubleshooting Guide.”

Calibration Tests
NOTE: These frequencies are based on a 580.0 Hz, square wave input.
8500C/C+ Firmware Version: ___________ 8500C/C+ Serial Number: ___________ Date:________
Table 5-6. Spectrum Accuracy, High Frequency Range

A B C D E
True Amp. 2nd Amp. to 1st Amp. to Harmonic 1st Amp. to 2nd Amp. to
Harmonic
(IPS) Left of Peak Left of Peak Peak Right of Peak Right of Peak
1st Max. Allowed: 31390 RPM 32884 RPM 34379 RPM 35874 RPM 37368 RPM
11.411
(FUND) Actual:_____ IPS
______ IPS ______ IPS ______ IPS ______ IPS ______ IPS
Min. Allowed:8.761 523.2 Hz 548.1 Hz 573.0 Hz 597.9 Hz 622.8 Hz
3rd Max. Allowed:3.804 101642 Hz 103137 RPM 104632 RPM 106126 RPM 107621 RPM
Actual:_____ IPS
Min. Allowed:2.920
1694.0 Hz 1718.9 Hz 1743.9 Hz 1768.8 Hz 1793.7 Hz
5th Max. Allowed:2.282 170400 RPM 171895 RPM 173390 RPM 174884 RPM 176379 RPM
Actual:_____ IPS
Min. Allowed:1.752
2840.0 Hz 2864.9 Hz 2889.8 Hz 2914.7 Hz 2939.7 Hz
Actual:_____ IPS
Min. Allowed:1.252
4010.9 Hz 4035.8 Hz 4060.7 Hz 4085.6 Hz 4110.5 Hz
Actual:_____ IPS
Min. Allowed:0.973
5181.8 Hz 5206.7 Hz 5231.6 Hz 5256.5 Hz 5281.4 Hz
Actual:_____ IPS
Min. Allowed:0.796
6327.7 Hz 6352.6 Hz 6377.6 Hz 6402.5 Hz 6427.4 Hz
Actual:_____ IPS
Min. Allowed:0.674
7498.6 Hz 7523.5 Hz 7548.4 Hz 7573.3 Hz 7598.3 Hz
Actual:_____ IPS
Min. Allowed:0.519
8644.6 Hz 8669.5 Hz 8694.4 Hz 8719.3 Hz 8744.2 Hz
17th Max. Allowed: 0.752 588927 RPM 590422 RPM 591916 RPM 593411 RPM 594906 RPM
Actual:_____ IPS
Min. Allowed:0.458
9815.4 Hz 9840.4 Hz 9865.3 Hz 9890.2 Hz 9915.1 Hz
5.5.3.4 Test Procedure: Low Frequency Range
CAUTION
You must allow the 8500C/C+ to warm up for at least 30 minutes prior to running this test
procedure or else test results will be invalid.
a. Turn on spectrum analyzer and set up to view a 134.4 mVrms, 490.0 Hz signal. Use the
following analyzer settings:

Trigger: Free run

Average: Off
Window: Flat top
Source: Off
b. Turn on signal generator and set up as follows: for channel connected to Velocimeter
input, set to Frequency = 490.0 +/- 0.1 Hz, Waveform = Square wave. Monitor signal
generator output with spectrum analyzer with marker at 490 Hz. Adjust signal generator
output channel connected to Velocimeter input until amplitude is 134.4 +/- 0.5 mV RMS.
c. Press STATUS key on 8500C/C+.
d. Press MORE KEYS.
e. Press SELF-TEST soft key.
f. Press HW TEST soft key. The Self Test menu appears.
g. Select ANALOG FILTER TEST with arrow keys.
h. Press EXECUTE soft key.
CAUTION
You cannot proceed until the Analog Filter test passes. Occasionally the Analog Filter test
may fail with nothing permanently wrong with the 8500C/C+. If it does fail, press OK soft
key and the EXECUTE soft key to run again. If it continues to fail, refer to Table 5-8,
“Troubleshooting Guide”.
i. After Analog Filter Test passes, return to Self Test menu by pressing OK soft key.
j. Exit Self Test menu by pressing QUIT soft key.
k. Press SPECTRUM key on 8500C/C+.
l. Press SETUP key.
m. Select <Hz> on display with arrow keys.
n. Press CHANGE soft key change to <RPM>. These units give a finer resolution for this
test.
o. Key in 29788 (rpm) with numeric keys in MAXIMUM FREQUENCY field.
p. Select SEEK: field with arrow keys.
q. Press CHANGE soft key to select SEEK: <ON>.
r. Press ENTER soft key.
s. Wait 10 seconds and then press START key.
The acquired spectrum shows a range of odd harmonic peaks on the 8500C/C+ display, from the
1st (fundamental) on.

Calibration Tests
t. Use 8500C/C+ arrow keys to move cursor (dotted line) to fundamental peak. The
amplitude readout (in IPS) is shown at the top of the display. Write down this
measurement in Table 5-8.
u. Repeat Steps s and t at the following signal generator frequency: 406.0 +/- 0.1 Hz, 308.0
+/- 0.1 Hz, 210.0 +/- 0.1 Hz, 154.0 +/- 0.1 Hz, 98.0 +/- 0.1 Hz.
NOTE: Each time you change to a new signal generator frequency, move marker on
spectrum analyzer to signal frequency. Re-adjust signal source amplitude, if necessary, until
amplitude on spectrum analyzer displays 134.4 +/- 0.5 mV RMS.
v. Press SETUP key.
w. Key in 16596 (rpm) with numeric keys in MAXIMUM FREQUENCY field.
x. Press ENTER soft key.
y. Set up signal generator as follows: for channel connected to Velocimeter input, set to
Frequency = 51.0 +/- 0.05 Hz, Waveform =Square wave. Monitor signal generator output
with spectrum analyzer with marker at 51.0 Hz. Adjust signal generator output channel
connected to Velocimeter input until amplitude is 134.4 +/- 0.5 mV RMS.
z. Wait 10 seconds and then press START to acquire another spectrum at the new input
signal frequency. Write down the amplitude of the fundamental peak in Table 5-7.
aa. Repeat Step z at the following signal generator frequencies: 21.0 +/- 0.1 Hz, 9.0 +/- 0.05
Hz, 6.0 +/- 0.05 Hz, 3.0 Hz.
NOTE: Each time you change to a new signal generator frequency, move marker on
spectrum analyzer to signal frequency. Re-adjust signal source amplitude, if necessary, until
amplitude on spectrum analyzer displays 134.4 +/- 0.5 mV RMS.
ab. The amplitude of the peak at the signal frequency (fundamental) should be within range of
9.5 to 10.4 IPS inclusive. If any values are out of range, refer to Section 5.6.
“Troubleshooting Guide.”

NOTE: Fundamental peaks must be within range of 9.5 to 10.4 IPS inclusive.
8500C/C+ Firmware Version: _________ 8500C/C+ Serial Number: ________ Date: _______
Table 5-7. Specification: Spectrum Accuracy, Low Frequency Range
Input Fundamental
Frequency Peak
490.0 Hz
(29400 rpm) ______ IPS
406.0 Hz
(24360 rpm) ______ IPS
308.0 Hz
(18480 rpm) ______ IPS
210.0 Hz
(12600 rpm) ______ IPS
154.0 Hz
(9240 rpm) ______ IPS
98.0 Hz
(5880 rpm) ______ IPS
51.0 Hz
(3060 rpm) ______ IPS
21.0 Hz
(1260 rpm) ______ IPS
9.0 Hz
(540 rpm) ______ IPS
6.0 Hz
(360 rpm) ______ IPS
3.0 Hz
(180 rpm) ______ IPS

Calibration Tests
P O W E R S U P P L Y 9 1 0 0 A
C A B L E 8 9 9 8
M A G P IC K U P IN P U T
V E L O C IM E T E R IN P U T U N U S E D
(6 P IN )
H P -3 5 6 1 A
P R IN T
S T A R T
A W X
B Y Z
M O R E /K E Y S
1 2 I
3
G H
D : E F .
4 5 6
S P E C T R U M N
M O D E L 8 5 0 0 C
J # K < L - 7 8 9
S T U
P % Q > R / V
0
C A B L E 8 2 7 8
H P -8 9 0 4 A
S IG N A L IN P U T
(B N C T -C O N N E C T O R )
S IG N A L O U T
F IL E : S P E C S E T 2 .D R W
C O A X
Figure 5-11. Troubleshooting Only: Spectrum Accuracy Test Setup w/o 8520C

5.6 Troubleshooting Guide

If any test step fails during the functional tests or the calibration tests, or if a problem occurs during
operation, use the troubleshooting guide to determine the probable cause. Perform the solution steps in
the order they are presented, proceeding to the next step only if the problem has not been solved. The
troubleshooting guide isolates the problem to the field-replaceable component. If the unit still is not
functioning properly, return to Chadwick-Helmuth for repair.
WARNING
This equipment contains voltages capable of causing injury or death. Remove power before
removing the covers and servicing the equipment.
CAUTION
Observe static discharge precautions. The circuit boards in this equipment contain
electrostatic-sensitive devices. Do not use magnetic tools when servicing the equipment and
avoid touching the microcircuits on the circuit boards.

Troubleshooting Guide
Table 5-8. Troubleshooting Guide

Problem Solution
“EXCEPTION ERROR” NOTE: If the exception error is
caused by pressing the PRINT key,
NOTE: This type of error can also be skip ahead to the troubleshooting
caused by a problem with software procedure for this situation.
currently running in the unit. If a
1. Write down all information displayed on
chart or other program was running at
8500C/C+.
the time of the failure, it should be
suspect and the problem reported to 2. To try to preserve the contents of the
Chadwick-Helmuth. 8500C/C+’s memory, simply power down
the 8500C/C+, wait 10 seconds, and turn
power back on.
NOTE: The error codes displayed on 3. Power down 8500C/C+. After ten seconds,
the 8500C/C+ are Motorola 68000 hold down START key and turn power
assembly language error codes. back on (this erases all memory in 8500C/
C+).
4. Verify that EPROM’s (Figure 5-15) and S-
RAM (U10) (Only the 8500C has S-RAM)
are plugged correctly into digital board.
Check for bent pins, etc.
5. Verify that keyboard connection
(Figure 5-19, Sheet 2, P4/J4) is correct.
6. Check 8500C/C+ harness assembly
(Figure 5-19) for shorted or open
connections which can be caused by loose
or pinched wires, unplugged connector, or
worn-through insulation.
7. Digital board is most likely at fault. Replace
digital board (Figure 5-17, A1).
Pressing PRINT causes “EXCEPTION 1. Cold-start the 8500C/C+ in accordance with
ERROR.” Section 3.3, “8500C/C+ COLD-START
PROCEDURE.”
2. Remove analog board (Figure 5-17, A2).
Wait at least 5 minutes, and reinstall analog
board.
3. Go back and perform “EXCEPTION
ERROR” steps.


Problem Solution
“BAD DYNAMIC MEMORY” (8500C Only) 1. Check 8500C harness assembly
or pinched wires, unplugged connectors, or
2. Make sure all socketed IC’s are properly
seated on Digital and Analog boards
(Figure 5-17 A1 and A2).
“EPROM TEST HAS FAILED” (8500C Only) 1. Verify that EPROM’s (Figure 5-15) are
plugged correctly into digital board. Check
for bent pins, etc.
2. Remove EPROM’s in accordance with
Section 5.7.3, “EPROM Change
Procedure.” Check EPROM’s for bent pins,
etc. Reinstall EPROM’s.
3. Replace EPROM’s.
“ANALOG FILTER FAILURE” 1. Write down all information displayed on
8500C/C+.
2. Press TRY AGAIN soft key. This failure
can occur occasionally with nothing
permanently wrong with unit.
3. Power down 8500C/C+. After ten seconds,
hold down START key and turn power
back on (this erases all memory in 8500C/
C+).
5. Persistent analog filter failures could be
caused by the keypad panel. To determine
whether it is at fault, disconnect keypad
panel connector (Figure 5-19, Sheet 2, J4/
P4) from digital board (Figure 5-17, A1). If
error message has not reappeared upon
power-up, replace keypad panel
(Figure 5-17, (1)).


Problem Solution
“ANALOG FILTER FAILURE” (cont’d) NOTE: Intermittent failures are not
likely to be caused by the keypad panel
6. Analog board is most likely at fault.
Replace analog board (Figure 5-17, A2).
“DISK INCORRECTLY FORMATTED” NOTE: In the following step, do not
use a chart disk or any other disk with
important data on it because all data
on the disk will be erased.
1. Format a disk several times in disk drive
(for format procedure, see Section 5.7.1.2).
2. Try formatting another disk.
3. Verify that ribbon cables and disk drive
power connection are connected properly.
or pinched wire, unplugged connector, or
5. Clean disk drive heads (Section 5.7.1.2,
“Disk Drive Cleaning Procedure”).
6. Replace disk drive.
8500C/C+ pilot light is not on and screen 1. Adjust LCD CONTRAST and
display is blank. BACKLIGHT ADJ knobs on 8500C/C+. If
NOTE: The backlight may still be screen is still blank and backlight is not
working in this situation. working, verify that unit is receiving power.
2. Check fuse on power supply board A3 in
accordance with Section 5.7.5, “Fuse
Replacement.”
3. Make sure item (8) on Figure 5-19, Sheet 2,
is connected.
5. To determine whether one of the 8500C/C+
boards may be causing the problem,
perform the steps shown in the flowchart in
Figure 5-12.


Problem Solution
8520C power indicator is not on. 1. Verify that 8520C is receiving power. If
8520C light is off, but 8500C/C+ light is on,
problem is isolated to 8520C.
2. Check 8520C harness assembly
3. To determine whether one of the 8520C
boards may be causing the problem,
perform the steps shown in the flowchart in
Figure 5-12.
8500C/C+ screen display is scrambled. 1. Cold-start the 8500C/C+ in accordance with
Section 3.3, “8500C/C+ COLD-START
PROCEDURE.
2. Remove EPROM’s in accordance with
Section 5.7.3, “EPROM Change
Procedure.” Check EPROM’s for bent pins,
etc. Reinstall EPROM’s.
3. 8500C Only: Remove SRAM U10
(Figure 5-15), while observing antistatic
precautions (which are discussed in Section
5.7.3, “- EPROM Change Procedure”).
Check SRAM for bent pins, etc. Reinstall
SRAM.
8500C/C+ LCD does not operate in cold NOTE: If backlight does not work,
temperature. skip ahead to backlight
troubleshooting procedure.
1. Verify that heater connection J3/P3 on
Heater/EL board (Figure 5-17, A4) is
connected and wired correctly
(Figure 5-19) Sheet 2.
or pinched wires, unplugged connector, or
3. Measure resistance across P3 connector
which connects to Heater/EL board.
Resistance must be less than 100 Ω: if it is
not, replace graphics module (Figure 5-17,
(24)).


Problem Solution
8500C/C+ LCD does not operate in cold 4. Heater/EL board is most likely at fault.
temperature. (cont’d.) Replace Heater/EL board A4.
5. Graphics module is next most likely at fault
Replace graphics module (Figure 5-17
(24)).
Backlight does not work. 1. Check fuse on Heater/EL board
(Figure 5-17).
3. Heater/EL board is most likely at fault.
Replace graphics module (Figure 5-17,
(24)).
Date and time is not correct and/or flight data 1. Check 8500C/C+ battery in accordance
does not remain in 8500C/C+ memory after with Section 5.7.4 “Battery Pack Check and
power has been turned off and on. Replacement.”
8520C short light illuminated. 1. Remove Velocimeter cables, one at a time,
from 8520C until short light goes out.
Check cable for shorts (Figure 5-14). If
cable at fault, replace/repair cable.
Otherwise, replace Velocimeter.
2. Cycle power on 8520C.
4. 8520C controller board is most likely at
fault. Replace 8520C controller board
(Figure 5-20, A1).
8500C/C+ does not recognize 8520C. 1. Cycle power on 8520C.
2. Check cabling between 8500C/C+ and
8520C. (Figure 5-14).
3. Check 8520C power cable (Figure 5-14).
or pinched wire, unplugged connectors, or


Problem Solution
8500C/C+ does not recognize 8520C. (cont’d.) 5. Check A1P5 serial connector on 8500C/C+
harness assembly (Figure 5-19).
6. 8520C controller board is most likely at
fault. Replace 8520C controller board
(Figure 5-20, A1).
7. 8500C/C+ digital board is next most likely
at fault. Replace 8500C/C+ digital board
(Figure 5-17, A1).
Printer does not print. 1. Cycle power on 8500C/C+.
NOTE: This erases any print jobs
waiting to be printed.
2. Check whether paper roll is empty.
3. Paper may have pulled away from sensor.
Tighten paper roll and reinstall.
4. Remove tear bar (Figure 5-18, (11) & (27))
and check for paper debris that may be
jamming the gears. Check that gears are
able to turn; if they cannot, remove thin
metal strip on printer and check behind that
for debris.
5. Press STATUS and verify that screen
display indicates print jobs are waiting to be
printed.
7. Printer assembly is most likely at fault.
Replace printer assembly (Figure 5-18
(13)).

Table 5-9. 8500C/C+ Balancer/Analyzer Functional Tests
Problem Solution
5.4.1.3 Balance Test
Readings do not meet specifications. 1. Ensure gap between magnetic pickup and
screw is .030 +.010 in.
2. Perform 5.5.1.3, “Amplitude, Frequency,
and Phase Accuracy Tests,” to determine
whether fault is with 8500C/C+.
and Phase Accuracy Test,” only for those
8520C channels that failed balance test.
4. Check calibrator in accordance with
Chadwick-Helmuth manual, Calibrator:
Operation & Maintenance Instructions, P/
N 9077A.
5. Replace Velocimeter/mag pickup and retest.
5.4.1.4 Spectrum Test
Vibration level and/or frequency do not meet 1. Perform 5.5.1.3, “Amplitude, Frequency,
specifications. and Phase Accuracy Tests,” to determine
whether fault is with 8500C/C+.
and Phase Accuracy Test.”
3. Check calibrator in accordance with
Chadwick-Helmuth manual. Calibrator:
Operation & Maintenance Instructions, P/
N 9077A.
4. Replace Velocimeters/mag pickup and
retest.

Table 5-9. 8500C/C+ Balancer/Analyzer Functional Tests
Problem Solution
5.4.1.5 Track Test
Stem of “h” on calibrator rotor disk does not 1. Check Velocimeter/magnetic pickup cables
flash in cross pattern as shown in illustration. (Figure 5-14).
2. Replace Velocimeter/mag pickup and retest.
3. Ensure gap between magnetic pickup and
screw is .030 +.010 in.
5. Digital board is most likely as fault.
Replace digital board (Figure 5-17, A1).
5.4.2 Disk Drive Test Procedure 1. Repeat test with another diskette.
2. Perform disk drive cleaning procedure
(Section 5.7.1.2).
4. Disk drive most likely at fault. Replace disk
drive (Figure 5-18, 10).
5. Digital board next most likely at fault.
Replace digital board (Figure 5-17, A1).

Table 5-10. 8500C/C+ Balancer/Analyzer Calibration Tests
Problem Solution
5.5.1.3 Amplitude, Frequency, and Phase
Accuracy Tests
Vibration level does not meet specifications. 1. Check 8500C/C+ harness assembly
connectors which can be caused by loose or
pinched wires, unplugged connectors, or
Frequency reading and/or phase angle do not 1. Check 8500C/C+ harness assembly
meet specifications. (Figure 5-19) for shorted or open
5.5.1.4 Noise and Spurious Signals Test
Noise above 0.005 IPS is present on display. 1. Turn EL backlight (Figure 2-1) all the way
down. Wait ten seconds and retest. Repeat
five times.
5.5.1.5.1 500 Hz Anti-Aliasing
Signal aliasing above 0.005 IPS remains on 1. Check 8500C/C+ harness assembly
display. (Figure 5-19) for shorted or open
2. If noise is not at 500 Hz, it is not an aliased
signal; however, the noise and spurious
signals test (Section 5.5.1.4) should be
performed.

Table 5-10. 8500C/C+ Balancer/Analyzer Calibration Tests
Problem Solution
5.5.1.5.1 500 Hz Anti-Aliasing (cont’d.)
Signal aliasing above 0.005 IPS remains on 3. If noise is at 500 Hz, it is an aliased signal
display most likely caused by analog board.
5.5.1.5.2 10 kHz Anti-Aliasing
Signal aliasing above 0.005 IPS remains on 1. Check 8500C/C+ harness assembly
display. (Figure 5-19) for shorted or open
2. If noise is not at 10 kHz, it is not an aliased
signal: however, the noise and spurious
signals test (Section 5.5.1.4) should be
performed.
3. If noise is at 10 kHz, it is an aliased signal
most likely caused by analog board.
Replace analog board (Figure 5-17 A2).
5.5.4 8500C/C+ Spectrum Accuracy Test
True amplitude which was calculated for a 1. Check all cables for shorts, proper
harmonic peak does not fall between minimum connections.
and maximum limits in Table 5.4a or 5.4b. 2. To isolate whether the 8520C is at fault,
redo Spectrum Accuracy Test without
8520C. To do this, set up equipment in
accordance with Figure 5-11.

Table 5-11. 8520C Signal Selector Tests
Problem Solution
5.5.2.3 amplitude, Frequency, and Phase
Accuracy Test
Vibration level, frequency reading, or phase 1. Check 8520C harness assembly

angle does not meet specifications. (Figure 5-19) for shorted or open
2. Disconnect 8520C and retest according to
5.5.1.3, “Amplitude, Frequency, and Phase
Accuracy Tests.”
3. If 5.5.1.3, “Amplitude Frequency, and
Phase Accuracy Tests, “ pass, 8520C is
most likely at fault. Replace 8520C
controller board (Figure 5-19, A1).
5.5.2.4 Channel Crosstalk Test
Noise signal above .01 IPS is displayed. 1. Disconnect 8520C and retest according to
5.5.1.4, “Noise and Spurious Signals Test.”
2. If 5.5.1.4, “Noise and Spurious Signals
Test,” passes, 8520C is most likely at fault.
Replace 8520C controller board
(Figure 5-19, A1).

8500C PILOT LIGHT NOT ON:

NOTE: THIS FLOWCHART ASSUMES THAT FUSES AND
DISCONNECT P2
FROM P/S BOARD
HARNESS ASSEMBLIES HAVE ALREADY BEEN CHECKED.
A3
NO REPLACE P/S
PILOT LIGHT ON?
BOARD A3
YES
RECONNECT P2 &
DISCONNECT P3
FROM DIGITAL
BOARD A1
YES RECONNECT P3 &

PILOT LIGHT ON? REMOVE ANALOG
BOARD A2
NO
RECONNECT P3 &
YES REPLACE ANALOG
DISCONNECT P4 PILOT LIGHT ON?
FROM DIST. BOARD BOARD A2
A5
NO
YES RECONNECT P4 & REPLACE DIGITAL

PILOT LIGHT ON? REMOVE ANALOG BOARD A1
BOARD A2
NO
DISCONNECT P3 ON
PRINTER BOARD
YES
PILOT LIGHT ON? REPLACE PRINTER
ASSY.
NO
REMOVE POWER
CONNECTOR FROM
DISK DRIVE
YES
PILOT LIGHT ON? REPLACE DISK
DRIVE
NO
RETURN 8500C TO
FACTORY FOR
REPAIR
FILENAME: FLOWCHTA.DRW
Figure 5-12. Troubleshooting Flowchart: 8500 Pilot Light

8520C POWER LIGHT NOT ON:

DISCONNECT J1
FROM CONTROLLER NOTE: THIS FLOWCHART ASSUMES THAT THE FUSE AND
BOARD A1 HARNESS ASSEMBLIES HAVE ALREADY BEEN CHECKED.
NO REPLACE P/S
POWER LIGHT ON? BOARD A2
YES
RECONNECT A1 &
DISCONNECT QUAD
PEAK DET. BOARD
A3 FROM
CONTROLLER
BOARD A1
YES REPLACE QUAD

POWER LIGHT ON? PEAK DET. BOARD
A3
NO
REPLACE
CONTROLLER
BOARD A1 AND
RECONNECT A3
YES
POWER LIGHT ON? PROBLEM SOLVED
NO
RETURN 8520C TO
FACTORY FOR
REPAIR
FILENAME: FLOWCHTB.DRW
Figure 5-13. Troubleshooting Flowchart: 8520C Power Light

5.7 Repair
WARNING
This equipment contains voltages capable of causing injury or death. Remove power before
removing the covers and servicing the equipment.
CAUTION
Observe static discharge precautions. The circuit boards in this equipment contain
electrostatic-sensitive devices. Do not use magnetic tools when servicing the equipment, and
avoid touching the microcircuits on the circuit boards.
Repair of the 8500C/C+ and 8520C is limited primarily to replacement of components listed in
Table 5-15 and Table 5-16. Minor repair procedures are described in Table 5-12.
Table 5-12. Minor Repair Procedures
Item Repair
Print circuit boards No repair authorized. Return damaged boards to
Chadwick-Helmuth.
Cable or harness connectors Straighten bent pins on male connectors. Remove any
obstructions from contact pins of female connectors.
Remove corrosion or arcing damage with a stiff bristle
brush. Replace cable or harness if damage is excessive.
Cables (Fig. 1-3) Repair tears, fraying, or burns with electrical friction tape.
Replace cable if damage is excessive.
5.7.1 Cleaning
5.7.1.1 Surfaces and Cables
Clean exterior surfaces of major components and cables as follows:
a. Wipe surfaces with a clean, lint-free cloth moistened with a solution of water and a mild
detergent.
CAUTION
Do not use solvents on the 8500C/C+ display window.

b. Wipe surfaces with a clean, lint-free cloth moistened with clean water to remove detergent
residue.

Repair
c. Dry surfaces with a clean, dry, lint-free cloth, or allow to air dry.
5.7.1.2 Disk Drive Cleaning Procedure

Disk drive heads can become dirty from extended use; symptoms usually include an increased number
of disk read and write errors. Commercially available 3.5-inch disk drive cleaning kits provide special
disks that are specifically designed to clean dirty heads. Use one of these kits to clean the 8500C/C+
disk drive as follows:
a. Follow cleaning kit instructions to apply cleaning fluid to disk.
b. Close (or tape over) write-protect window located on corner of disk.

J109 P1
A BLK 28V STROBE RTN
A
L WHT +28V STROBE
L
M RED +28V
M
N GRN 28V RTN
N
P NC NC P
C NC NC C A BLK -V A
GRN P/U GND
R R B GRN GND B
GRY P/U SIG P2
D D C RED +V
P1 C
E NC NC E WHT SIGNAL
D D
F NC NC F
GRN VEL GND E
S S
WHT VEL SIG F NC
H H
G NC NC G
J NC NC J
K ORN Txd
K 11210 VELOCIMETER CABLE
BLU Rxd
U U
B NC NC B
T NC NC T
10811 SIGNAL SELECTOR CABLE P1 P2
A A
P1
A NC P2 B B
B BLK
B
C NC 3529 DC POWER EXTENSION CABLE
WHT A
D
10808 MAGNETIC PICKUP CABLE P2 8520C
A RED 28V
B
WHT
C POWER
GRN
B A
BLK 28V RTN
D
A A E
B B
C C
D D 10813 8520C SIGNAL SELECTOR CABLE
10185 PHOTOCELL CABLE
P109
A BLK
N GRN A PWR GND
WHT PWR
L
RED B +28 VDC PWR
M
POWER/SIGNAL C BLK A +V 12-15 VDC

INPUTS GRN
R B GND
RED MAG/PHOTOCELL
P C +28 VDC
WHT
D
BRAID D SIGNAL
E
BLK A -V
J
GRN GND
S B
RED
T C +V VELOCIMETER
WHT
H D SIGNAL
BRAID
G N/C E
N/C F
B N/C
K P5-1 FROM DIGITAL BOARD
U P5-3 FROM DIGITAL BOARD
F N/C
8998 INPUT ADAPTER CABLE

FILE: CABLES.DRW
Figure 5-14. Cable Schematics

Repair
c. Hold disk with arrow facing up and pointing in and insert disk in 8500C/C+ disk drive-
push in until drive button pops out (Figure 2-1).
d. Press STATUS.
e. Press FORMAT DSK soft key.
f. Press FORMAT soft key.
g. Because the cleaning disk contains no magnetic media, the message, DISK IS NOT
CORRECTLY FORMATTED! will appear. Press CANCEL soft key to continue format
procedure.
h. Press EXIT soft key when format is complete.
5.7.2 Inspection
Inspect components of the 8500C/C+ system in accordance with Table 5-13.
Table 5-13. Inspection
Item Inspect for Remedy

Major components 1. Dust, dirt, or other 1. Clean as necessary.
foreign matter.
2. Check printed circuit
2. Replace circuit boards as
boards for cracks or
necessary.
breaks, peeling circuit
traces, loose or missing
electrical parts, and
solder joints for corrosion
or damage.
3. Check connectors for 3. Repair connectors or
bent or broken pins, replace harness
corrosion, arcing, or assemblies as necessary.
damage.
Cables 1. Breaks, tears, fraying, 1. Repair or replace cables

burrs, or other damage. as necessary.
2. Check connectors for 2. Repair connectors or
bent or broken pins, replace as necessary.
corrosion, arcing, or
damage.

5.7.3 EPROM Change Procedure (Figure 5-15)

NOTE: The firmware in the 8500C+ is changed through a programming disk and does not
require the unit to be opened. The EPROMS are shown here in the event the device fails.
This procedure is for changing EPROM’s (U8) and (U9) on the digital board (A1) of the balancer/
analyzer assembly. The program code (“firmware”) that operates the unit is contained in these
EPROM’s, so over the life of the 8500C balancer/analyzer, this part may be changed several times as
features are added.
This procedure is best performed by a qualified electronics technician, but if the procedure is followed
precisely and with care, it can be done by any person generally familiar with electronic equipment.
Precautions against a static discharge to the EPROM are the most critical part of this procedure.
5.7.3.1 Preparation
Prepare a static-free work area. If you don’t have access to a static-free work station with a grounded,
conductive table top and a grounded wrist strap, the following will suffice.
On a normal wood or plastic table top, cover a one-half to one-meter-square area with aluminum foil
taped down at the edges. Touch the foil with your bare hand and set the 8500C balancer/analyzer and
the EPROM container on the foil. During the entire procedure, do not grab any materials not in contact
with the foil, especially sheets of paper or plastic. During the entire procedure, keep your skin in
contact with the foil by leaning on a bare elbow.
Tools required: one small Phillips-head screwdriver and one small straight-blade screwdriver.
5.7.3.2 Procedure
a. Remove ten screws (Figure 5-17, (32)) and four screws (33) and remove bezel (4).
b. Fold back printer/disk drive assembly so that it stands straight up on its side with keypad
panel (1) lying flat on table. With unit in this position, 2 EPROM’s (Figure 5-15, (U8) and
(U9)) are accessible on face-up side of digital board A1 (Figure 5-17). A paper label
covers center portion of each EPROM. Label for (U8) is stamped with P/N 10927-X and
(U9) is stamped with P/N 10928-X.
FILE: EPROMSA.DS4
U6 U9
8500C+
U8
+
10927-X U9
10928-X U10
8500C
DIGITAL BOARD A1
NOTE: NOTCHED ENDS ON EPROMS MUST BE IN DIRECTION SHOWN. LEFT ENDS OF EPROMS U8 & U9 MUST
BE ALIGNED WITH U10. U8 & U9 MAY DIFFER IN SIZE.
Figure 5-15. EPROM Locations on Digital Board

Repair
c. Remove both EPROM’s as follows: using a small, straight-blade screwdriver, carefully

pry up one end of EPROM just a little bit. Pry up other end a little. Go back and forth until
EPROM is loose.
CAUTION
Trying to pry out the EPROM in one step will bend the EPROM pins.
d. Remove new EPROM’s from container. They should have a higher dash number or letter
than ones removed.
CAUTION
Precautions against electrostatic discharge are critical at this stage.

e. Install new EPROM’s as follows: orient EPROM with notched end in direction shown in
Figure 5-15. Align left end of EPROM with left end of SRAM memory IC (U10) and
make sure pins are all straight and part-way into each socket hole when EPROM is set on
socket - look along the board, beneath the EPROM for pins bent under. Once pins all align
properly, push EPROM slowly but firmly into socket, keeping it straight.
NOTE: If pins do not align well, very carefully push EPROM against a flat surface to form
pins inward until they are parallel.
f. Install bezel (Figure 5-17 (4)) on keypad panel (1) and secure with ten screws (32) and
four screws (33).
5.7.4 Battery Pack Check and Replacement

5.7.4.1 Battery Pack Check
a. Power the 8500C/C+ unit continuously for 72 hours. This ensures the battery pack has
become fully charged.
b. To access battery pack, remove ten screws (Figure 5-17, (32)) and four screws (33) and
remove bezel (4).
c. Fold back printer/disk drive assembly so that it stands straight up on its side with keypad
panel (1) lying flat on table, as shown in Figure 5-16.
d. Check battery voltage for 3.6 V. Replace battery pack, if necessary, in accordance with the
next section.
e. Install bezel (Figure 5-17 (4)) on keyboard panel (1) and secure with ten screws (32) and
four screws (33).
5.7.4.2 Battery Pack Replacement (Figure 5-17)

The battery pack is located on analog board A2. Replace battery pack as follows:
a. To access analog board A2, remove digital board A1 in accordance with instructions in
Section 5.8.1.1.1.

b. To access battery pack, disconnect connector A2P1 on analog board A2 and remove
analog board.
c. Desolder red and black leads from battery pack.
d. Cut ties that secure battery pack, and remove battery pack.
e. Put new battery pack P/N 610-189, in place on analog board, and resolder red lead to
positive terminal and black lead to negative terminal on battery pack. Insure this
replacement pack is fully charged.
f. Secure battery pack with new ties, and reassemble 8500C/C+ in accordance with Section
5.9.2.2.3.
5.7.5 Fuse Replacement

5.7.5.1 8520C Power Supply Board (A2) Fuse (Figure 5-20)
a. Turn unit upside down, remove eighteen screws (5) and washers (7), and remove bottom
cover (12).
b. Remove old fuse from power supply board A2, and replace with a new fuse, P/N 301-
20258.
c. Reinstall bottom cover (12) and secure with eighteen 4-40 x 3/8” pan php. blk. screws (5)
and #4 std. intl. lck. .260” washers (7).
5.7.5.2 8500C Power Supply Board (A3) Fuse (Figure 5-18)

a. Turn unit upside down.
b. Remove eight screws (32), two screws (33), and remove bottom cover (3).
c. Remove old fuse from power supply board A3, and replace with a new fuse, P/N 301-
20258.
d. Reinstall bottom cover (3), and secure with eight 3/16” pan php. blk. screws (32) and two
1/4” pan php. blk. screws (33).
5.7.5.3 8500C Heater/EL Board (A4) Fuse (Figure 5-17)

a. Remove ten screws (32) and four screws (33), and remove bezel (4).
c. Remove old fuse from Heater/EL board A4, and replace with a new fuse, P/N 301-20258.
d. Close unit while watching for pinched connector wires.
e. Install bezel (4) on keypad panel (1), and secure with ten 4-40 x 3/16 php. blk. screws (32)
and four 4-40 x 1/4 pan. blk. screws (33).

Disassembly
5.8 Disassembly
Table 5-14. Tools for Disassembly/Reassembly

#1 Phillips Head Screwdrive
1/4” Hex Driver
5.8.1 8500C/C+ Disassembly

NOTE: Harness dressing and routing are important to ensure proper operation and fit.
Note original factory routing for reassembly. In most cases, the connectors are not marked.
Before disconnecting any connectors, tag the connectors to ensure proper installation
during assembly.
NOTE: It is important that proper length screws be returned to their original location.
5.8.1.1 Disassembly of Balancer/Analyzer Assembly (Figure 5-17)

5.8.1.1.1 Digital Board A1
a. Remove ten screws (32) and four screws (33) and remove bezel (4).
panel (1) lying flat on table, as shown in Figure 5-16. NOTE: Further disassembly is not
necessary when changing EPROM’s (see Section 5.7.3, “EPROM Change Procedure”).
W
.DR
NB
OP
5C_
8
E:
FIL
NiCad Battery Pack
Figure 5-16. Opening 8500C/C+ Unit to Access Balancer/Analyzer Assembly

c. Disconnect six connectors from digital board A1 in this order: A1J7, A1J4, A1J12, A1J3,
A1J13, A1J10.
d. Remove six screws (43), two screws (44), eight shoulder washers (20) and two spacers
(38) from digital board A1. Note size and location of screws and shoulder washers for
proper installation during assembly. Lift away protective sheet (52).
e. Lift up digital board A1 from analog board A2 and graphics module (24) and disconnect
connectors A1J11, A1J6, and A1J5 from digital board A1.
5.8.1.1.2 Analog Board A2
a. Remove digital board A1 (Section 5.8.1.1.1).
b. Disconnect connector A2P1.
5.8.1.1.3 Graphics Module
a. Remove digital board A1 (Section 5.8.1.1.1)
b. Disconnect connectors A4J3 and A4J4 from heater/EL control board A4.
c. Remove four standoffs (40) and remove graphics module (24) from keypad panel (1).
d. Remove three spacers (41) and one “D” spacer (55).
NOTE: Take care to keep graphics module free of fingerprints, dust, etc.
5.8.1.1.4 Heater/EL Control Board A4
a. Remove graphics module (Section 5.8.1.1.3).
b. Disconnect five connectors (A4J1-A4J5) from heater/EL control board A4.
c. Remove four nuts (49) and one washer (42), and remove heater/EL control board A4 from
keypad panel (1).
d. Remove three spacers (28).
5.8.1.1.5 Harness Assembly (Figure 5-19)
The harness assembly consists of the parts that remain in the keypad panel (Figure 5-17, (1)) after the
circuit boards have been removed.
5.8.1.2 Disassembly of Printer/Disk Drive Assembly (Figure 5-18)

5.8.1.2.1 Power Supply Board A3
a. Turn unit upside down.
b. Remove eight screws (32), two screws (33), and remove bottom cover (3).
c. Disconnect connectors A3J2 and A3J3 from power supply board A3.
d. Disconnect power supply board junction (Figure 5-19, (8)) from harness assembly.
e. Remove four nuts (47), 2 washers (42), and remove power supply board A3 from chassis
(2).
f. Remove two spacers (28).

Disassembly
Figure 5-17. Balancer/Analyzer Assembly Parts Breakdown

This page intentionally left blank.

Disassembly
31, 3 PL
5, 3 PL
27
7, 3 PL 6
3 PL 11
36 3
49 48
4 PL
2 PL
21
4 PL
32
8 PL
J3
49
2 PL
J5 J2
J6
PAPER ADVANCE
30 J7
4 PL J4 GEAR 13 (13)
43, 2 PL
10
51 42, 4 PL
29
2 PL 13(17) &
43
PRINTER
4 PL
BOARD
46
4 PL 9 13 PAPER
15 HOLDER
14 BRACKET
8 53
17 16
2 PL
2
34
47
42 4 PL
2 PL
46, 2 PL 28 FILE: ILLUST5A.DRW
43, 2 PL 2 PL FUSE
J2
Figure 5-18. Printer/Disk Drive Assembly Parts Breakdown

5.8.1.2.2 Distribution Board A5

a. Unplug ribbon cable from A5J2.
b. Unplug A5 ribbon cable from disk drive (10).
c. Disconnect connectors A5J3-A5J6 from distribution board A5.
d. Remove two nuts (49) and remove distribution board A5 from disk drive bracket (9).
a. Unplug ribbon cable from A5J2.
b. Unplug A5 ribbon cable from disk drive (10).
c. Disconnect power connector from disk drive (10).
d. Remove four screws (43) and four washers (46) and remove disk drive assembly (10) from
disk drive bracket (9).
5.8.1.2.4 Printer Assembly with Printer Board A1
a. Tear off excess paper and clear paper from paper path by turning paper advance gear
forward to back out paper.
b. Press down on paper holder bracket, and remove paper roll and paper bar 13(13).
c. Disconnect connector 13 (A1J3) from printer board.
d. Remove two screws (29), two screws (43) and four washers (42) and remove printer
assembly (13) (with printer board attached) from chassis (2).
NOTE: The printer board and printer assembly (13) must be replaced as a complete
assembly.
5.8.1.2.5 Harness Assembly (Figure 5-19)
The harness assembly consists of the parts that remain in the chassis (Figure 5-18, (2)) after the circuit
boards, disk drive assembly, and printer assembly have been removed.
5.8.2 Signal Selector 8520C Disassembly (Figure 5-20)

5.8.2.1 Quad Peak Detector Board A3
cover (12).
b. Remove four screws (19) and spacers (22) and remove quad peak detecter board A3 from
controller board A1.
5.8.2.2 Controller Board A1

a. Disconnect seven connectors (J1, J2, J3, J4, J5, J6, J8) from controller board A1.
b. Remove two screws (19) and standoffs (8) and remove controller board A1 from chassis
(11).

Disassembly
5.8.2.3 Power Supply Board A2

a. Disconnect three connectors (J1, J2, J3) from power supply board A2.
b. Remove four hex nuts (6) and two spacers (9), and remove power supply board A2 from
chassis (11).
5.8.2.4 Harness Assemblies (Figure 5-21)

The harness assemblies consist of the parts that remain in the chassis after the circuit boards have been
removed.

This page is intentionally left blank.

Disassembly
Figure 5-19. 8500C/C+ Harness Assembly

(Sheet 1 of 2)

This page is intentionally left blank

Disassembly
Figure 5-19 8500C/C+ Harness Assembly

(Sheet 2 of 2)


Disassembly
13 11
5
2
27
J3
26
25
7 J2
5 FUSE
J6
J1
J8
J4 J5 J1
J3 6
J2
22
10
18
12
7
19
FILE: 8520CIPB.DRW
Figure 5-20. Signal Selector 8520C Parts Breakdown


Disassembly
Figure 5-21. 8520C Harness Assemblies

(Sheet 1 of 2)


Disassembly
Figure 5-21. 8520C Harness Assemblies

(Sheet 2 of 2)


Reassembly
5.9 Reassembly
Follow original factory routing.
5.9.1 Signal Selector 8520C Reassembly (Figure 5-13)

5.9.1.1 Power Supply Board A2
a. Install power supply board A2 on chassis (11) and secure with four 4-40 nylon lock std.
hex nuts (6) and two #4 clear rnd. 1/4” o.d. standoffs (9).
b. Connect three connectors (J1, J2, J3) to power supply board A2.
5.9.1.2 Controller Board A1

a. Install controller board A1 on chassis (11) and secure with six 4-40 x 1-3/8” hex standoffs
(8) and 4-40 x 1/4” pan php. cad. screws (19).
b. Connect seven connectors (J1, J2, J3, J4, J5, J6, J8) to controller board A1 (J7 is unused).
5.9.1.3 Quad Peak Detector A3

a. Install four 4-40 x .5” spacers (22) on controller board A1.
b. Align pins on quad peak detector board A3 with socket on controller board A1 below, and
carefully connect the two.
c. Secure quad peak detector board A3 with four 4-40 x 1/4” php. cad. screws (19)
d. Install bottom cover (12), secure with eighteen 4-40 x 3/8” pan php. blk. screws (5) and #4
std. intl. lck. .260” washers (7).
5.9.2 8500C/C+ Reassembly

5.9.2.1 Reassembly of Printer/Disk Drive Assembly
(Figure 5-18 and Figure 5-19)
5.9.2.1.1 Printer Assembly
a. Install printer assembly (13) (with printer board attached) on chassis (2) and secure with
two 3/16” pan php. cad. screws (29), two 1/4” pan php. cad. screws (43), and four #4 std.
flt. .315” washers (42).
b. Place spring (53) in paper holder bracket.
c. Connect harness assembly connector (Figure 5-19, printer P3) to printer board connector
13(A1J3).
d. Trim any ragged edges on paper roll and tightly rewind roll.
e. Place paper roll and paper bar 13(13) in paper holder bracket so that paper feeds up
(Figure 2-3).

f. Feed paper into printer paper path by turning paper advance gear. If paper is not feeding in
straight, hold your finger against an edge to guide it into place as it feeds, or wait until
paper is coming out of unit and then pull it into position.
a. Install disk drive assembly (10) in disk drive bracket (9) and secure with four 1/4” pan
php. cad. screws (43) and four #4 standard split ring lock washers (46).
b. Connect harness assembly four-pin power connector to disk drive (10).
c. Connect A5 ribbon cable to disk drive (10).
d. Connect ribbon cable to A5J2.
5.9.2.1.3 Distribution Board A5
a. Attach distribution board A5 to disk drive bracket (9) and secure with two 4-40 nylon lock
thin nuts (47).
b. Connect connectors to distribution board A5 as follows:
(1) Harness assembly connector R1P5 to A5J5.
(2) Harness assembly connector R2P6 to A5J6.
(3) Harness assembly connector A3P2 to A5J4.
(4) Ribbon connector to A5J2.
(5) Printer board connector 13(A1P3) to A5J3.
NOTE: Connector A5J7 is unused.
c. Connect A5 ribbon cable to disk drive (10) (if not already connected).
5.9.2.1.4 Power Supply Board A3
a. Install power supply board A3 on chassis (2) and secure with two #4 std. flt. .315” washers
(42) and four 4-40 nylon lock thin nuts (47).
b. Connect harness assembly connector (Figure 5-19, A3P2) and LED connector
(Figure 5-19, A3P3) to power supply board A3.
c. Replace bottom cover (3) on unit and secure with eight 3/16” pan php. blk. screws (32)
and two 1/4” pan php. blk. screws (33).
5.9.2.2 Reassembly of Balancer/Analyzer Assembly (Figure 5-17)

5.9.2.2.1 Heater/EL Control Board A4
a. Install three #4 clear rnd. 1/4 o.d. standoffs (28).
b. Install heater/EL control board A4 on keypad panel (1) and secure with one std. flt. .315”
washer (42) and four 4-40 nylon lock standard nuts (49).
NOTE: Be sure to reapply thermal grease between diode bridge, heatsink, and chassis.
c. Connect the following to heater/EL control board A4: two harness assembly connectors
(Figure 5-19, A4P1-A4P2), keyboard backlight connector A4P5, and graphics module
(24) connectors A4P3 and A4P4.

Reassembly
5.9.2.2.2 Graphics Module A2

a. Install three #4 x 5/16” nylon rnd. spacers (41) and one #4 x 5/16” “D” spacer (55).
b. Install graphics module (24) on keypad panel (1) and secure with four 4-40 X 13/16” hex
standoffs (40).
NOTE: Take care to keep graphics module free of fingerprints, dust, etc.
5.9.2.2.3 Digital Board A1 and Analog Board A2
NOTE: The digital board A1 and analog board A2 must be installed at the same time.
a. Install graphics module (Section 5.9.2.2.2).
b. Attach connector (A1J11) to digital board A1
c. Attach connector pins A1J2 on underside of digital board A1 to connector A2P2 on analog
board A2.
d. Attach six connectors (Figure 5-19) to digital board A1 in this order: A1J10, A1J13, A1J3,
A1J6, A1J5, and A1J12.
e. Attach connector pins on underside of digital board A1 to connector on graphics module
(24). Make sure connectors mate properly, with no bent pins.
CAUTION
Ensure that connector wires are not pinched.

f. Attach connectors A1J7 and A1J4 to digital board A1.
g. Attach connector A2P1 to analog board A2.
h. Place protective sheet (52) on digital board A1 and secure digital board with eight #4
shoulder washers (20), six 4-40 x 1/4 pan php. cad. screws (43), two 4-40 x 7/8 pan. php.
cad. screws (44), and two 1/2” 1/4 o.d. #4 nylon spacers (38).
i. Close unit, again watching for pinched connector wires.
j. Install bezel (4) on keypad panel (1) and secure with ten 4-40 x 3/16 php. blk. screws (32)
and four 4-40 x 1/4 pan. php. blk. screws (33).

5.10 List of Field-Replaceable Components
Table 5-15. 8500C/C+ Balancer/Analyzer
FIG REF COMPONENT

NO. NO. 1 2 3 4 6 7 8 (Assy. Level) CAGE MFG. P/N C-H P/N
5-17 − * 8500C Balancer/Analyzer 99866 − 10800A
5-18
5-17 − * 8500C+ Balancer/Analyzer 99866 − 10800-2
5-18
5-17 A1 * * 8500C Digital Board 99866 − 11084
5-17 A1 * * 8500C+ Digital Board 99866 − 14541-1
5-17 A-2 * * Analog Board 99866 − 13824
5-18 A3 * * Power Supply Board 99866 − 11032A
5-18 − * * * Fuse, 2.5A 250V FAST 5x 03614 GDB2.5A 301-20258
5-17 A4 * * Heater/EL Control Board 99866 − 10827
5-17 − * * * Fuse, 2.5A 250V FAST 5x 03614 GDB2.5A 301-20258
5-18 A5 * * Distribution Board 99866 − 11160
5-15 U8 * * 8500C EPROM, Low Memory 99866 − 10927-X
5-15 U6 * * 8500C+ EPROM, Low Memory 99866 − 14820-X

5-15 U9 * * 8500C EPROM, High Memory 99866 − 10928-X
5-15 U9 * * 8500C+ EPROM, High Memory 99866 − 14821-X
5-17 1 * * 8500C Keypad Panel 99866 − 11004

5-17 1 * * 8500C+ Keypad Panel 99866 − 14568
5-18 2 * * Chassis 99866 − 10737A
5-18 3 * * Cover 99866 − 10676B
5-17 4 * * Bezel 99866 − 10689A
5-18 5 * * Door Latch 99866 − 10771
5-18 6 * * Base, Door Latch 99866 − 10770A

5-18 7 * * Spring, Door Latch 99866 − 10772
5-18 8 * * Plate, Disk Mount 99866 − 10694
5-18 9 * * Bracket, Disk Support 99866 − 10677
X = Latest eprom configuration

List of Field-Replaceable Components
Table 5-15. 8500C/C+ Balancer/Analyzer (Continued)
FIG REF COMPONENT

5-18 10 * * Drive, 3.5” Floppy Disk, 720K 8V413 MP F920-1/121 610-253
(8500C)
5-18 10 * * Drive, 3.5” Floppy Disk, 144MB 99866 - 12645
(8500C+)
5-18 11 * * Tear Bar 99866 − 10998
5-18 13 * * Printer Assembly 99866 − 10832
5-18 − * * * Printer, Mech. Thermal 320 Dot 62712 STP411B-320 610-195
5-18 13 (13) * * * Paper Bar 99866 − 8697
5-18 13 (17) * * * Shield 99866 − 11334
5-18 14 * * Rubber Gromment Shockmount Cabot G601-1 610-197

Qty. 4
5-18 15 * * Nut Fin Shockmount Qty. 4 99866 − 8745
5-18 16 * * Standoff, Spring Qty. 1 99866 − 10797
5-18 17 * * Knob, 1/2 Dia., 1/8 Shaft, Black 95146 KLN-500B-1/8 601-004
Qty. 2
5-17 20 * * Washer Shoulder #4 Qty. 10 04713 B51547F019 654-4SBA
5-18 21 * * Bumper, Rubber Qty. 4 76385 ZB-1160-MI 610-094
5-17 22 * * Sandoff 4-40 1/2” Nylon Hex Qty. 83330 4306 660-3444
2
5-17 24 * * Graphics Module (8500C) 99866 − 10828
5-17 24 * * Graphics Module (8500C+) 99866 − 14574
5-18 27 * * Tear Bar 99866 − 10997
5-17 28 * * Standoff, #4 Clear Rnd. 1/4 O.D., 83330 8481 660-2424

5-18 Qty 5
5-18 29 * * Screw, 4-40 X 3/16 Pan Php, Cad., 96906 MS35206-212 651-4550
Qty. 2
5-18 30 * * Screw, 4-40 X 3/16 Flt., Php. Cad, 96906 MS35190-220 651-4570
Qty. 4
5-18 31 * * Screw, 4-40 X 3/8, Blk, 82 Deg. 96906 MS51959-16B 651-4573B

Flt. Qty. 3
5-17 32 * * Screw, 4-40 X 3/16 Php. Blk. Qty. 96906 MS51957-12B 651-4520
5-18 18
5-17 33 * * Screw, 4-40 X 1/4 Pan Php. Blk. 96906 MS51957-13B 651-4521
Qty. 4

FIG REF COMPONENT

5-18 34 * * Harness Assembly 99866 − 11201
5-19
5-18 36 * * Screw, 10-32 X 5/16 Php. Blk., ............. − 651-9422
Qty. 4
5-17 38 * * Spacer, 1/2” 1/4 O.D. #4 Nylon, 83330 4018 660-D444

Qty. 2
5-17 39 * * Standoff, 4-50 X 5/8 Hex Met. 83330 8404 660-1454

Qty. 2
5-17 40 * * Standoff, 4-40 X 13/16” Hex, Qty. 83330 9289 660-1475B

4
5-17 41 * * Spacer, #4 X 5/16” Nylon (Rnd), 83330 4009 660-D434

Qty. 3
5-18 42 * * Washer, #4 Std. Flt, 315” Qty. 7 96906 MS51412-20 654-4SFC
5-17 43 * * Screw, 4-40 X 1/4 Pan Php. Cad., 96906 MS51957-13 651-4531
5-18 Qty. 16
5-17 44 * * Screw, 4-40 X 7/8 Pan Php. Cad., 96906 MS51957-20 651-4537
Qty. 2
5-17 45 * * Screw, 4-40 X 3-8 Pan Php. Blk 96906 MS51957-15B 651-4523
Qty. 4
5-17 46 * * Washer #4 Lock Split Ring qty. 6 83330 5850-11 654-4SPA
5-18 47 * * Nut 4-40 Nylon Lock Thin Qty. 4 39428 90633A005 654-45NT
5-18 48 * * Screw, 4-40 X 1/2 Php. Black, 96906 MS35216-16B 651-4524

Qty. 2
5-17, 49 * * Nut, 4-40 Nylon Lock Standard, 39428 90631A005 652-45NS

5-18 Qty. 13
5-18 50 * * Gasket 0N083 GS2100-060- 610-258

0250-SC
5-18 51 * * Insulator, Disk Drive 99866 − 10894
* * Insulator, Analog PCB 99866 − 10958

5-17 53 * * Spring, Paper Holder 99866 − 610-205
− − * * Gasket, Form 1/4” THK X 3/8” 91573 1211T 610-265

Wide Polyurethane
5-17 55 * * Spacer, Nylon #4 X 5/16 “D” 99866 − 11421
5-17 − * * Battery Pack, 3.6V NiCad 500-103 610-189

List of Field-Replaceable Components
FIG REF COMPONENT

2-3 − * * Printer Paper 62712 TP411-451-25C 610-199
5-17 56 * * Label, Serial 99866 − 11287
Table 5-16. 8520C Signal Selector
FIG REF COMPONET

5-20 * 8520C Signal Selector 99866 − 11130A
5-20 A1 * * Controller/Bit Board 99866 − 11082A
* * * IC, Programmed U12, V. 99866 − 9866-7
* * * IC, Programmed U15, V. 99866 − 9964B
5-20 A2 * * Power Supply Board 99866 − 10835-1
* * * Fuse, 2.5A 250V FAST 5x 03614 GDB2.5A 301-20258
5-20 A3 * * Quad Peak Detector Board 99866 − 12508-1
5-20 2 * * Filter Assy., Dual 99866 − 10857A
5-21 * * Harness Assy., PWR/SIG 99866 − 11127
5-21 * * Harness Assy., VEL/MAG 99866 − 9689
5-20 5 * * Screw, 4-40 X 3-8 Pan. Php. 96906 MS51957-15B 651-4523
Blk. Qty. 94
5-20 6 * * Nut, 4-40 Nylon Lock 39428 90631A005 652-45NS
Standard Qty. 12
5-20 7 * * Washer, #4 Std. Intl. Lck. 260”, 96906 MS35333-36 654-4SIA
Qty. 28
5-20 8 * * Standoff, 4-40 X 1 3/8 Hex 1/4 83330 130-21 ST 4- 660-14B4
Qty. 6 40-x
5-20 9 * * Standoff, #4 Clear Rnd. 1/4 83330 8481 660-2424
O.D. Qty. 2
5-20 10 * * Bumper, Rubber Qty. 4 76385 ZB-1160-MI 610-094
5-20 11 * * Chassis 99866 − 10831A
5-20 12 * * Cover 99866 − 10830

Table 5-16. 8520C Signal Selector
FIG REF COMPONET

5-20 13 * * LED, Green Panel Mount Qty. 61544 PMR125-EG2 251-L502
2
5-20 18 * * Screw, 10-32 X 5/16 Php. Blk. − − 651-9422
Qty. 4
5-20 19 * * Screw, 4-40 X 1/4 Pan. Php. 96906 MS51957-13 651-4531
Cad. Qty. 6
5-20 22 * * Spacer, M/F 4-40 x .5 Hex Qty. 6R744 4534-440-B- 660-1445
4 12
5-20 25 * * Nut Ring, #14 w/Stud Qty. 2 04967 FSS7-1401 405-14Z5R

Cage Codes
5.11 Cage Codes
----- Cabot Industries, Ear Div. 77820 Amphenol Corporation

7911 Zionsville Rd. Bendix Connector Opns
Indianapolis, IN 46268 Delaware St.
317-872-1111 Sydney, NY
0N083 Gore, W.L. and Associates 8V413 Sony Corp. of America
5872 Engineer Dr. Sony Drive
Huntington Beach, CA 92649 Park Ridge, NJ 07656
03614 Bussman 83330 Seastrom Mfg. Co.
Div. of Cooper Industries 701 Sonora Ave.
114 Old State Rd. Glendale, CA 9120-2431
P.O. Box 14460 213-245-9121
04713 Motorola Semiconductors 91573 Able Industrial Products
5005 E. McDowell Rd. 2329 Lee Ave.
Phoenix, AZ 85008 South El Monte, CA 91733-
602-244-7357 2511
626-443-1326
04967 Fastener Specialty 95146 ALCO Electronic Products
2435 109th St. 1551 Osgood St.
Grand Prairie, TX 75050 North Andover, MA 01845-
1014
28520 Heyco Molded Products 96906 Military Standard
750 Boulevard Department of Defense
P.O. Box 160 Washington, DC
Kenilworth, NJ 07033-1721
39428 McMaster-Carr Supply Co. 99866 Chadwick-Helmuth Co.
600 County Line rd. 4601 N. Arden Dr.
Elmhurst, IL 60126 El Monte, CA 91731
312-834-9600 626-575-6161
51506 Accurate Screw Machine Co. 6R744 BISCO Industries, Inc.
19 Baltimore St. 2055 O’Toole Ave.
Nutley, NJ 07110-1303 San Jose, CA 95131-1301
62712 Seiko Instruments U.S.A. 61544 Stanley Electronics
2990 Lomita Blvd. 100 Pine Aire Dr. NY 11706
Torrance, CA 90505-5102 516-231-6400
310-530-8777
76385 Minor Rubber Co.
49 Ackerman St.
Bloomfield, NJ 07003-4201


Appendix A. 8520C-36 Signal Selector
A.1 Introduction
The 8520C-36 signal selector is similar to the 8520C signal selector, but it has inputs for 36
Velocimeter channels, rather than 12 channels. The 8520C-36 also has a bandpass filter to conform to
Allison T-56 broadband requirements. The following sections highlight the differences between the
8520C-36 and 8520C in the areas of physical description, theory of operation, and testing.
Disassembly/reassembly instructions and a parts list are also included.
A.2 Physical Description (Figure A-10)

The 8520C-36 has 8 Velocimeter connections: 4 multichannel connectors that take 8 Velocimeter
signals each and 4 discrete single-channel connectors. This provides a total of 36 Velocimeter
channels. Like the 8520C, the 8520C-36 has 4 magnetic pickup/photocell connectors, a 28 VDC input
power connector, and a connector for receiving commands from and transmitting selected signals to
the 8500C/C+.
A.3 Theory of Operation
A.3.1 A1 Connector Boards

Instead of using a connector harness as the 8520C does, the 8520C-36 uses four A1 connector boards
to route signals to the multiplexer board A4.
A.3.2 A4 Multiplexer Board (Figure A-1)

The multiplexer board routes any of 36 Velocimeter inputs to the 8500C/C+. All of the math features
and conditioning are the same as that of the 8520C signal selector with quad peak detector board.
Aside from the number of input channels, the only other difference between the 2 models is that any
8520C-36 channel can be passed through a broadband filter and measured on this board.
A.3.3 A3 Controller Board (Figure A-1)

The 8520C-36 controller board A3 is very much like the 8520C controller board, except all mux
functions have been moved to the 8520C-36 multiplexer board A4. The 8520C-36 controller board has
the following features, which function the same as their counterparts on the 8520C controller board:
• Analog-to-Digital Converter
• 4:1 Multiplexers
8500C/8500C+ System Maintenance Manual A-1

Appendix A - 8520C-36 Signal Selector
• Pulse Detector
• Microcontroller
• Velocimeter Built-in Test (BIT)
The 8520C-36 controller board also contains four pulse detectors, which have the same function as the
8520C quad peak detector board A3.
A.3.4 Power Supply Board A2

The power supply board A2 is identical in function to the power supply board in the 8500C/C+ (see
Section 4.2.1.2.3, “Power Supply Board”).
VELOCIMETER INPUT 1
VELOCIMETER BIT
POWER SWITCH
VELOCIMETER INPUT 2
+12 VDC
VELOCIMETER INPUT 3
VELOCIMETER INPUT 4
SHORT
VELOCIMETER INPUTS 5 THRU 12 POWER
CIRCUIT LATCH
MONITOR
LAMP
VELOCIMETER INPUTS 13 THRU 20
VELOCIMETER INPUTS 21 THRU 28
VELOCIMETER INPUTS 29 THRU 36 BROADBAND
2 CHANNELS
A+B FUNCTION BLOCK
ANALOG-TO-DIGITAL
2:1 MULTIPLEXER CONVERTER
A-B FUNCTION BLOCK
36:4 PEAK DETECT AND HOLD
CROSSPOINT
SWITCH A+B FUNCTION BLOCK

ANALOG BOARD SERIAL
A-B FUNCTION BLOCK
2 CHANNELS COMMUNCIATIONS 63A03A
TO/FROM 8500 MICROCONTROLLER
DIGITAL BOARD
PICKUP SIGNAL
PULSE DETECTOR DIGITAL BOARD
PICKUP INPUT 1
PICKUP INPUT 2 PULSE DETECTOR

4:1 MULTIPLEXER
PICKUP INPUT 3
PULSE DETECTOR
PICKUP INPUT 4
PULSE DETECTOR
MUX BOARD CONTROLLER BOARD
FILE: SS36BLK.DRW
Figure A-1. 8520C-36 Controller Board and Mux Board Block Diagram
A.4 Maintenance
A.4.1 Introduction
To test the 8500C/C+/8520C-36 system with a nacelle harness assembly, you will use a test that was
adapted from the function test in Chapter 5, “Maintenance.” Certain procedures in this Chapter will
reference those found in Chapter 5 as well.
A.4.2 Test Equipment

For the most part, you will be using test equipment listed in Table 5-1. In addition, you must fabricate
a test cable to perform tests that do not use the nacelle harness. For fabrication instructions, see Section
A.4.6, “Testing 8520C-36 without Nacelle Harness Assembly.”
A-2 Chadwick-Helmuth A Business Unit of Honeywell International, Inc.

Maintenance
A.4.3 8500C/C+/8520C-36 Balance Test for C-130 Setup

This balance test is similar to the balance test in Section 5.4: therefore, if any failures occur, refer to the
functional test items in the Troubleshooting Guide in Section 5.6.
mentioned must be left as they were in the previous section.
A.4.3.1 Test Setup (with C-130 Nacelle Harness)

a. Connect equipment as shown in Figure A-2.
135M-12 STROBEX
BALANCER/ANALYZER
PRINT
START
A X
W
POWER SUPPLY 9100A

SHOW/HIDE STOP
B Y Z
MORE/KEYS
BALANCE HELP STATUS

G 1 2 3
D : E F . H I
M 4 5 6
SPECTRUM
J # K
LOAD
< L
SETUP
-
N O MODEL 8500C
S 7 8 9
T U
CHADWICK
HELMUTH
P % Q > R / 0 EL MONTE, CALIFORNI
V
MAGNETIC PICKUP
3030
POWER
CABLE 10813
BALANCER
ACCELEROMETER
906-7569A ACCELEROMETER
906-7569A
CABLE 10811
CABLE 10808
CALIBRATOR 11A
10700B HI-TEMP CABLE
#4 F COMP
#5 COORD
#1 PROP
#3 ADH
#2 RGB
5-12 13-20 21-28 29-36

CABLE 11517
1 2 3 4
A B C D
8520C-36
SIGNAL SELECTOR
AFT COMP
TURBINE
#7
#6
11690 NACELLE HARNESS

FILENAME: C-130A.DRW
Figure A-2. Initial 8520C-36 Test Setup (w/C-130 Nacelle Harness)

NOTE: Make sure accelerometer cables are free to move so that accelerometer movement is
not inhibited.

A.4.3.2 Power-Up Self-Test

A.4.3.3 Test Procedure (C-130 Setup)

disk.
disk appears frozen in place under 60 Hz light1.
f. Press SETUP key.
h. On same line, select last number (called “times factor”) with arrow keys.
i. Key in x2 as new times factor.
j. Select <AUTO STOP> field with arrow keys.
k. Press CHANGE soft key to select <MAN STOP>.
l. Select PHASE UNITS field with arrow keys.
m. Press CHANGE soft key to select <DEGREES>.
n. Select PICKUP field with arrow keys.
o. Press CHANGE soft key to select CHANNEL <A>.
p. Select INPUT field with arrow keys.
q. Key in 10 with numeric key (for #6 AFT COMP cable).
s. Wait 10 seconds.
t. Press START key.
u. Verify that display indicates:
900±1 RPM
0.4±0.04 IPS
1Attention, users outside U.S.: The 11A Calibrator can also be calibrated under 50Hz light. For
1714 rpm and 923 rpm cam rates, inner two rings on rotor disk are used. Remember to enter half
these rates in 8500C/C+ setup screen, when called for in the following steps.

Maintenance
v. Press STOP key.

w. Set CAM RATE (RPM) switch on Calibrator 11A to 1800.
x. Adjust pot next to 1800 CAM RATE switch position until first ring from outside on rotor
disk appears frozen in place under 60 Hz light.
y. Press SETUP key on 8500C/C+.
z. Key in 900 with numeric keys in BALANCE FREQUENCY field.
aa. Key in X2 as the times factor.
ab. Press ENTER soft key.
ac. Wait 10 seconds.
ad. Press START key.
ae. Verify that display indicates:
1800±2 RPM
0.8±0.08 IPS
af. Press STOP key.
ag. Press SETUP key.
ah. Select INPUT field with arrow keys.
ai. Key in 11 with numeric key for #7 TURBINE cable.
aj. Press ENTER soft key.
ak. Wait 10 seconds.
al. Press START key.
am. Verify that display indicates:
1800±2 RPM
0.8±0.08 IPS
an. Press STOP key.
ao. Set CAM RATE (RPM) switch on Calibrator 11A to 900.
ap. Press SETUP key on 8500C/C+.
aq. Key in 450 in BALANCE FREQUENCY field.
ar. Key in x2 as times factor.
as. Press ENTER soft key.
at. Wait 10 seconds.
au. Press START key.
av. Verify the display indicates:
900±1 RPM
0.4±0.04 IPS
aw. Press STOP key.

ax. Replace accelerometers with Velocimeters and connect nacelle harness cables #2 RGB and
#3 ADH as shown in Figure A-3.
ay. Press SETUP on 8500C/C+.
az. Select INPUT field with arrow keys.
ba. Key in 6 with numeric key for #2 RGB cable.
NOTE: The correlation between C-130 nacelle harness cables and 8520C-36 channels is
summarized in the wiring diagram in Figure A-12.
bb. Press ENTER soft key.
bc. Wait 10 seconds.
bd. Press START key.
be. Verify that display indicates:
900±1 RPM
0.4±0.04 IPS
275°±10°

Maintenance
135M-12 STROBEX
BALANCER/ANALYZER
PRINT
START
A X
W
POWER SUPPLY 9100A SHOW/HIDE
B Y Z
STOP
MORE/KEYS
HELP STATUS
BALANCE
G 1 2 3
D : E F . H I
M 4 5 6
SPECTRUM
# K
LOAD
< L
SETUP
-
N O MODEL 8500C
J 8 9
S 7
T U
CHADWICK
HELMUTH
P % Q > R / 0 EL MONTE, CALIFORN
V
MAGNETIC PICKUP
3030
POWER
CABLE 10813
BALANCER
VELOCIMETER
7310 VELOCIMETER
7310
CABLE 10811
CABLE 10808
CALIBRATOR 11A
#2 RGB #3 ADH
#4 F COMP
#5 COORD
#1 PROP
5-12 13-20 21-2829-36

CABLE 11517
1 2 3 4
A B C D
8520C-36
SIGNAL SELECTOR
AFT COMP
TURBINE
#7
#6
11690 NACELLE HARNESS FILENAME: C-130B.DRW
Figure A-3. 8520C-36 Test Setup w/Velos (C-130)

bf. Press STOP key.
bg. Press SETUP on 8500C/C+.
bh. Select INPUT field with arrow keys.
bi. Key in 7 with numeric key for #3 ADH cable.
bj. Press ENTER soft key.
bk. Wait 10 seconds.

bl. Press START key.

bm. Verify that display indicates:
900±1 RPM
0.4±0.04 IPS
275°10°
bn. Press STOP key.
bo. Disconnect cables #2 RGB and #3 ADH from Velocimeters and connect #5 COORD and
#4 F COMP cables.
bp. Press SETUP on 8500C/C+.
bq. Select INPUT field with arrow keys.
br. Key in 8 with numeric key for #4 F COMP cable.
bs. Press ENTER soft key.
bt. Press START key.
bu. Verify that display indicates:
900±1 RPM
0.4±0.04 IPS
275°±10°
bv. Press STOP key.
bw. Press SETUP key.
bx. Select INPUT field with arrow keys.
by. Key in 9 with numeric key for #5 COORD cable.
bz. Press ENTER soft key.
ca. Wait 10 seconds.
cb. Verify that display indicates:
900±1 RPM
0.4±0.04 IPS
275°±10°
cc. Press STOP key.
cd. Disconnect cable #4 F COMP from Velocimeter and connect #1 PROP cable.
ce. Press SETUP key.
cf. Select INPUT field with arrow keys.
cg. Key in 5 with numeric key for #1 PROP cable.
ch. Press ENTER soft key.
ci. Wait 10 seconds.
cj. Press START key.

Maintenance
ck. Verify that display indicates:

900±1 RPM
0.4±0.04 IPS
275°±10°
cl. Press STOP key.
cm. Move cable #11517 to connector labeled “13-20” on 8520C-36 and move magnetic pickup
cable #10808 to channel B on 8520C-36. Repeat Steps f through cl, but when the steps call
for you to enter pickup and channel information in the setup screen, substitute the
following values:
PICKUP: CHANNEL <B>
#7 TURBINE: CHANNEL 19
#6 AFT COMP: CHANNEL 18
#3 ADH: CHANNEL 15
#2 RGB: CHANNEL 14
#5 COORD: CHANNEL 17
#4 F COMP: CHANNEL 16
#1 PROP: CHANNEL 13
cn. Move cable #11517 to connector labeled “21-28” on 8520C-36 and move magnetic pickup
cable #10808 to channel C on 8520C-36. Repeat steps f through cl, using the following
values:
PICKUP: CHANNEL <C>
#3 ADH: CHANNEL 23
#2 RGB: CHANNEL 22
#1 PROP: CHANNEL 21
co. Move cable #11517 to connector labeled “29-36” on 8520C-36 and move magnetic pickup
cable #10808 to channel D on 8520C-36. Repeat steps f through cl, using the following
values:
PICKUP: CHANNEL <D>
#3 ADH: CHANNEL 31
#2 RGB: CHANNEL 30

#1 PROP: CHANNEL 29
cp. To test the 8520C-36 single-channel connectors, make connections as shown in Figure A-
4.
135M-12 STROBEX
BALANCER/ANALYZER
PRINT
START
A X
W
B Y Z
STOP
MORE/KEYS
HELP STATUS
BALANCE
G 1 2 3
D : E F . H I
M 4 N 5 6
SPECTRUM
J # K
LOAD
< L
SETUP
-
O MODEL 8500C
S 7 8 9
T U
CHADWICK
HELMUTH
P % Q > R / 0 EL MONTE, CALIFOR
V
MAGNETIC PICKUP
3030
POWER
CABLE 10813
BALANCER
VELOCIMETER
7310
CABLE 10811
CABLE 10808
CALIBRATOR 11A
CABLE 11210
VELOCIMETER 7310
(NOT USED, BUT LEFT
INSTALLED TO PREVENT
IMBALANCE OF 5-12 13-20 21-2829-36
CALIBRATOR)
1 2 3 4
A B C D
8520C-36
SIGNAL SELECTOR
FILENAME: C-130C.DRW
Figure A-4. 8520C-36 Test Setup w/Velos (single channel)

cq. Press SETUP.
cr. Key in the following values:
PICKUP: CHANNEL <A>
INPUT: CHANNEL 1
cs. Press ENTER soft key.
ct. Wait 10 seconds and press START key.
cu. Verify that display indicates:
900±1 RPM
0.4±0.04 IPS

Maintenance
275°±10°
cv. Press STOP key.
cw. Move magnetic pickup cable #10808 to channel B and Velo cable #11210 to channel 2 on
8520C-36. Repeat steps cq through cv, but substitute the following values:
PICKUP: CHANNEL <B>
INPUT: CHANNEL 2
cx. Move magnetic pickup cable #10808 to channel C and Velo cable #11210 to channel 3 on
PICKUP: CHANNEL <C>
IINPUT: CHANNEL 3
cy. Move magnetic pickup cable #10808 to channel D and Velo cable #11210 to channel 4 on
PICKUP: CHANNEL <D>
INPUT: CHANNEL 4
A.4.3.4 8500C/C+/8520C-36 Spectrum Test (C-130 Setup)

NOTE: The same test setup and 8500C/C+ settings are to be left as they were in Section
A.4.3.3, “Test Procedure (C-130 Setup).”
Perform Section 5.4.1.4, “Spectrum Test.”
A.4.3.5 8500C/C+/8520C-36 Track Test (C-130 Setup)

A.4.3.3, “Test Procedure (C-130 Setup).”
Perform Section 5.4.1.5, “Track Test.”
A.4.4 8500C/C+/8520C-36 Balance Test for P-3 Setup

This balance test is similar to the balance test in Section 5.4; therefore, if a failure occurs, refer to the
functional test items in the Troubleshooting Guide in Section 5.6.
mentioned must be left as they were in the previous section.
A.4.4.1 Test Setup (with P-3 Nacelle Harness)

a. Connect equipment as shown in Figure A-5.
NOTE: Make sure accelerometer cables are free to move so that accelerometer movement is
not inhibited.

135M-12 STROBEX
BALANCER/ANALYZER
PRINT
START
A X
W
B Y Z
STOP
MORE/KEYS
HELP STATUS
BALANCE
G 1 2 3
D : E F . H I
M 4 5 6
SPECTRUM
# K
LOAD
< L
SETUP
-
N O MODEL 8500C
J 8 9
S 7 U
TRACK STORE ANNOTATE T CHADWICK
HELMUTH
V
MAGNETIC PICKUP
3030
POWER
CABLE 10813
BALANCER
ACCELEROMETER
906-7569A ACCELEROMETER
906-7569A
CABLE 10811
CABLE 10808
CALIBRATOR 11A
CABLE 11517
5-12 13-20 21-2829-36
1 2 3 4
#4 FWD COMP #3 ENG ACC
#5 ENG COOD #2 AFT G/B A B C D

#1 PROP 8520C-36
SIGNAL SELECTOR
A2
A1
14440 NACELLE HARNESS FILENAME: P-3A.DRW
Figure A-5. 8520C-36 Test Setup w/P-3 Nacelle Harness Assemble
A.4.4.2 Power-Up Self-Test


Maintenance
A.4.4.3 Test Procedure (P-3 Test Setup)

disk.
disk appears frozen in place under 60 Hz light2.
f. Press SETUP key.
h. On same line, select last number (called “times factor”) with arrow keys.
i. Key in x2 as new times factor.
j. Select <AUTO STOP> field with arrow keys.
k. Press CHANGE soft key to select <MAN STOP>.
l. Select PHASE UNITS field with arrow keys.
m. Press CHANGE soft key to select <DEGREES>.
n. Select PICKUP field with arrow keys.
o. Press CHANGE soft key to select PICKUP A.
p. Select INPUT field with arrow keys.
q. Key in 11 with numeric key for #A1 nacelle harness cable.
NOTE: The correlation between P-3 nacelle harness cables and 8520C-36 channels are
shown in the wiring diagram in Figure A-13.
s. Wait 10 seconds.
t. Press START key.
u. Verify that display indicates:
900±1 RPM
0.4±0.04 IPS
v. Press STOP key.
w. Set CAM RATE (RPM) switch on Calibrator 11A to 1800.
x. Adjust pot next to 1800 CAM RATE switch position until first ring from outside on rotor
disk appears frozen in place under 60 Hz light.
y. Press SETUP key on 8500C/C+.
2
Attention, users outside U.S.: The 11A Calibrator can also be calibrated under 50Hz light. For
1714 rpm and 923 rpm cam rates, inner two rings on rotor disk are used. Remember to enter half
these rates in 8500C/C+ setup screen, when called for in the following steps.

z. Key in 900 with numeric keys in BALANCE FREQUENCY field.

aa. Key in X2 as the times factor.
ab. Press ENTER soft key.
ac. Wait 10 seconds.
ad. Press START key.
ae. Verify that display indicates:
1800±2 RPM
0.8±0.08 IPS
af. Press STOP key.
ag. Press SETUP key.
ah. Select INPUT field with arrow keys.
ai. Key in 10 with numeric key for #A2 nacelle harness cable.
aj. Press ENTER soft key.
ak. Wait 10 seconds.
al. Press START key.
am. Verify that display indicates:
1800±2 RPM
0.8±0.08 IPS
an. Press STOP key.
ao. Set CAM RATE (RPM) switch on Calibrator 11A to 900.
ap. Press SETUP key on 8500C/C+.
aq. Key in 450 in BALANCE FREQUENCY field.
ar. Key in x2 as times factor.
as. Press ENTER soft key.
at. Wait 10 seconds.
au. Press START key.
av. Verify the display indicates:
900±1 RPM
0.4±0.04 IPS
aw. Press STOP key.
ax. Replace accelerometers with Velocimeters and connect nacelle harness cables #2 AFT G/B
and #3 ENG. ACC as shown in Figure A-6.

Maintenance
135M-12 STROBEX
BALANCER/ANALYZER
PRINT
START
A X
W
B Y Z
STOP
MORE/KEYS
HELP STATUS
BALANCE
G 1 2 3
D : E F . H I
M 4 5 6
SPECTRUM
# K
LOAD
< L
SETUP
-
N O MODEL 8500C
J S 8 9
7 U
T
CHADWICK
HELMUTH
V
MAGNETIC PICKUP
3030
POWER
CABLE 10813
BALANCER
VELOCIMETER
7310 VELOCIMETER
7310
CABLE 10811
CABLE 10808
CALIBRATOR 11A
CABLE 11517
5-12 13-20 21-2829-36
1 2 3 4
#4 FWD COMP #3 ENG ACC
#5 ENG COOD #2 AFT G/B A B C D

#1 PROP 8520C-36
SIGNAL SELECTOR
A2
A1
14440 NACELLE HARNESS FILENAME: P-3B.DRW
Figure A-6. 8520C-26 Test Setup w/Velos (P-3)

ay. Press SETUP on 8500C/C+.
az. Select INPUT field with arrow keys.
ba. Key in 6 with numeric key for #2 AFT G/B cable.
bc. Wait 10 seconds.

bd. Press START key.

be. Verify that display indicates:
900±1 RPM
0.4±0.04 IPS
275°±10°
bf. Press STOP key.
bg. Press SETUP on 8500C/C+.
bh. Select INPUT field with arrow keys.
bi. Key in 7 with numeric key for #3 ENG. ACC cable.
bj. Press ENTER soft key.
bk. Wait 10 seconds.
bl. Press START key.
bm. Verify that display indicates:
900±1 RPM
0.4±0.04 IPS
275°±10°
bn. Press STOP key.
bo. Disconnect cables #2 AFT G/B and #3 ENG. ACC from Velocimeters and connect #5 ENG
COOD and #4 FWD COMP cables.
bp. Press SETUP on 8500C/C+.
bq. Select INPUT field with arrow keys.
br. Key in 8 with numeric key for #4 FWD COMP cable.
bs. Press ENTER soft key.
bt. Press START key.
bu. Verify that display indicates:
900±1 RPM
0.4±0.04 IPS
275°±10°
bv. Press STOP key.
bw. Press SETUP key.
bx. Select INPUT field with arrow keys.
by. Key in 9 with numeric key for #5 ENG COOD cable.
bz. Press ENTER soft key.
ca. Wait 10 seconds.
cb. Verify that display indicates:

Maintenance
900±1 RPM
0.4±0.04 IPS
275°±10°
cc. Press STOP key.
cd. Disconnect cable #4 FWD COMP from Velocimeter and connect #1 PROP cable.
ce. Press SETUP key.
cf. Select INPUT field with arrow keys.
cg. Key in 5 with numeric key for #1 PROP cable.
ch. Press ENTER soft key.
ci. Wait 10 seconds.
cj. Press START key.
ck. Verify that display indicates:
900±1 RPM
0.4±0.04 IPS
275°±10°
cl. Press STOP key.
cm. Move cable P/N 11517 to connector labeled “13-20” on 8520C-36 and move magnetic
pickup cable #10808 to channel B on 8520C-36. Repeat Steps f through cl, but when the
steps call for you to enter pickup and channel information in the setup screen, substitute
the following values:
PICKUP: CHANNEL S<B>
#A1: CHANNEL 19
#A2: CHANNEL 18
#3 ENG. ACC: CHANNEL 15
#2 AFT G/B: CHANNEL 14
#5 ENG COOD: CHANNEL 17
#4 FWD COMP: CHANNEL 16
#1 PROP: CHANNEL 13
cn. Move cable P/N 11517 to connector labeled “21-28” on 8520C-36 and move magnetic
pickup cable #10808 to channel C on 8520C-36. Repeat steps f through cl, using the
following values:
PICKUP: CHANNEL <C>
#A1: CHANNEL 27
#A2: CHANNEL 26


#1 PROP: CHANNEL 21
co. Move cable P/N 11517 to connector labeled “29-36” on 8520C-36 and move magnetic
pickup cable P/N 10808 to channel D on 8520C-36. Repeat steps f through cl, using the
following values:
PICKUP: CHANNEL <D>
#A1: CHANNEL 35
#A2: CHANNEL 34
#1 PROP: CHANNEL 29
cp. To test the 8520C-36 single-channel connectors, make connections as shown in Figure A-
4.
cq. Press SETUP.
cr. Key in the following values:
PICKUP: CHANNEL <A>
INPUT: CHANNEL 1
cs. Press ENTER soft key.
ct. Wait 10 seconds and press START key.
cu. Verify that display indicates:
900±1 RPM
0.4±0.04 IPS
275°±10°
cv. Press STOP key.
cw. Move magnetic pickup cable P/N 10808 to channel B and Velo cable P/N 11210 to
channel 2 on 8520C-36. Repeat steps cq through cv, but substitute the following values:
PICKUP: CHANNEL <B>
INPUT: CHANNEL 2
cx. Move magnetic pickup cable P/N 10808 to channel C and Velo cable P/N 11210 to
PICKUP: CHANNEL <C>
INPUT: CHANNEL 3

Maintenance
cy. Move magnetic pickup cable P/N 10808 to channel D and Velo cable P/N 11210 to
PICKUP: CHANNEL <D>
INPUT: CHANNEL 4
A.4.4.4 8500C/C+/8520C-36 Spectrum Test (P-3 Setup)

A.4.4.3, “Test Procedure (P-3 Setup).”
Perform test procedure in Section 5.4.1.4, “Spectrum Test.”
A.4.4.5 8500C/C+/8520C-36 Track Test (P-3 Setup)

A.4.4.3, “Test Procedure (P-3 Setup).”
Perform test procedure in Section 5.4.1.5, “Track Test.”
A.4.5 8500C/C+/8520C-36 Spectrum Accuracy Test

a. Set up equipment as shown in Figure A-7.
b. Perform test procedure in Section 5.5.3, “Spectrum Accuracy Test.”

POWER SUPPLY 9100A
CABLE 10813
CABLE 10811
BALANCER/ANALYZER
PRINT
START
A X
W
SHOW/HIDE STOP
5-12 13-20 21-2829-36 B

MORE/KEYS
Y Z
HELP STATUS
BALANCE
G 1 2 3
D : E F . H I
M 4 5 6
SPECTRUM
J # K
LOAD
< L
SETUP
-
N O MODEL 8500C
1 2 3 4 TRACK STORE ANNOTATE
S 7
T
8
U
9
CHADWICK
HELMUTH
P % Q > R / 0 EL MONTE, CALIFORNIA
V
A B C D
8520C-36
SIGNAL SELECTOR
SPECTRUM ANALYZER
SIGNAL GENERATOR
HP-3561A
CABLE 8278
HP-8904A
SIGNAL OUT SIGNAL INPUT

BNC T-CONNECTOR
COAX
FILE: SPEC-36C.DRW
Figure A-7. 8500C/C+/8520C-36 Spectrum Accuracy Test Setup
A.4.6 Testing 8520C-36 without Nacelle Harness Assembly

To use the 8520C-36 without a nacelle harness, you will need to make a special test cable so that you
can isolate individual 8520C-36 channels for testing. Fabrication instructions are shown in Figure A-8.
Figure A-9 shows where each channel is located on the 8520C-36 connectors. To use the cable, it is a

Maintenance
good idea to attach connector pins to the test clips; this way, the pins are easily inserted into holes in
the 8520C-36 connectors. To test a particular channel, insert the red test clip pin into the appropriate
hole in the 8520C-36 channel connector; insert the ground test clip pin into the “P” hole in the same
connector. In this manner, you can use a signal generator to simulate signals or perform the calibration
tests in Section 5.5.
8520C-36 Test Cable, Test-Clip-to-BNC
MALE BNC
CONNECTOR
RG-58 Coax Cable
RED CLIP, "SIGNAL"

BLACK CLIP, "P"
SHIELD
LABEL TEST CLIPS AS SHOWN
FILENAME: TESTC36B.DRW
Figure A-8. 8520C-36 Test Cable Schematic

CHANNEL 5 CHANNEL 11 CHANNEL 17 CHANNEL 23 CHANNEL 29 CHANNEL 35

5-12 5-12 13-20 21-28 29-36 29-36
AL AL AL AL AL AL
B K B K B K B K B K B K
M M M M M M
C N R J C N R J C N R J C N R J C N R J C N R J
P P P P P P
D H D H D H D H D H D H
E F G E F G E F G E F G E F G E F G
CHANNEL 6 CHANNEL 12 CHANNEL 18 CHANNEL 24 CHANNEL 30 CHANNEL 36

5-12 5-12 13-20 21-28 29-36 29-36
AL AL AL AL AL AL
B K B K B K B K B K B K
M M M M M M
C N R J C N R J C N R J C N R J C N R J C N R J
P P P P P P
D H D H D H D H D H D H
E F G E F G E F G E F G E F G E F G
CHANNEL 7 CHANNEL 13 CHANNEL 19 CHANNEL 25 CHANNEL 31

5-12 13-20 13-20 21-28 29-36
AL AL AL AL AL
B K B K B K B K B K
M M M M M
C N R J C N R J C N R J C N R J C N R J
P P P P P
D H D H D H D H D H
E F G E F G E F G E F G E F G

5-12 13-20 13-20 21-28 29-36
AL AL AL AL AL
B K B K B K B K B K
M M M M M
C N R C N R C N R C N R C N R
J J J J J
P P P P P
D H D H D H D H D H

5-12 13-20 21-28 21-28 29-36
AL AL AL AL AL
B K B K B K B K B K
M M M M M
P P P P P
D H D H D H D H D H

5-12 13-20 21-28 21-28 29-36
AL AL AL AL AL
B K B K B K B K B K
M M M M M
P P P P P
D H D H D H D H D H
NOTE:
Insert GROUND clip in pin P
Insert SIGNAL clip in designated pin as shown above FILENAME: 36_CONN.DRW
Figure A-9. 8520C-36 Channel Pin-outs

Maintenance
A.4.7 8520C-36 Disassembly (Figure A-10)
A.4.7.1 Controller Board A3

cover (12).
b. Disconnect four connectors (J1, J2, J3, P2) from controller board A3.
c. Remove five screws (5) and nylon washers (30), one screw (29), nylon washer (30), cable
clamp (31), and shoulder washer (4). Remove controller board A3 from chassis (11).
A.4.7.2 Mux Board A4

a. Remove six spacers (9) and flat washers (30) from Mux board A4.
b. Lift Mux board A4 and disconnect four connectors (J1, J2, J3, J4) from Mux board.
c. Remove Mux board from chassis (11).
A.4.7.3 Connector Boards A1

a. Remove forty-eight screws (3) and discard. Remove eight nut rings (26, 27) and four
connector boards A1.
NOTE: Nut ring (25) remains attached to connector board.
A.4.7.4 Dual Filter Assy. and Cable Harnesses

a. Remove four screws (3) and washers (7) from filter (2) and eight screws (3) from
OUTPUT and DC POWER connectors/harness.
A.4.7.5 Power Supply Board A2

b. Remove four nuts (6) and two spacers (9), and remove power supply board A2 from
chassis (11).
A.4.8 8520C-36 Reassembly (Figure A-10 and Figure A-11)
A.4.8.1 Power Supply Board A2

a. Install power supply board A2 on chassis (11) and secure with four 4-40 nylon lock nuts
and two #4 1/4” o.d. spacers (9).
b. Connect three connectors (J1, J2, J3) to power supply board.

A.4.8.2 Dual Filter Assy. and Cable Harnesses

a. Install filter (2) in chassis (11) and secure with four 4-40 X 3/8 php. blk. screws (3) and
four #4 intl. lock .260” washers (7).
b. Install external connectors and harness (19, 20) in chassis (11) and secure with eight 4-40
X 3/8 php. blk. screws (3).
A.4.8.3 Connector Boards A1

NOTE: Do not reuse old screws to install nut rings.
a. Install eight nut rings (26, 27) and four connector boards A1.
NOTE: Make sure ground wire is attached to connector lug as shown in Figure A-11.
A.4.8.4 Mux Board A4

a. Make sure Mux board A4 has six #4 shoulder washers wedged into its holes and connect
four connectors (J1, J2, J3, J4) to Mux board.
b. Align Mux board with hexagonal posts in chassis.
c. Place six #4 .25” o.d. spacers (9) and six flat nylon washers (30) on top of Mux board
holes (temporarily hold in place with spare wires or the like).
A.4.8.5 Controller Board A3

a. Place controller board A3 on top of Mux board spacers and secure at 5 places with five 4-
40 X 3/4 php. blk. screws (5) and five flat nylon washers (30). Secure the sixth hole with
one 4-40 X 7/8 php. blk. screw (29), one washer (30), and one cable clamp (31).
b. Connect four connectors (J1, J2, J3, P2) on controller board A3.
c. Install bottom cover (12) and secure with eighteen 4-40 X 3/8 pan php. blk. screws (3) and
eighteen #4 intl. lock .260” washers (7).

Maintenance
22 (not shown)
24, 13
3
21 (not shown)
7
11
3
1
UTH
LM
ChE
H
K
WIC
AD
CH
L
DE
MO
P/N
L
RIA
SE
2
27
26
20
19 5
9
25
23 (not shown)
FUSE
4
8 6
30
30 31
9 29
4
30
30
5
12
W
.DR
34
20
E:1
AM
10 EN
FIL
18
Figure A-10. 8520C-36 Signal Selector Parts Breakdown

A.4.9 Wiring Diagrams

CABLE ASSY: OUTPUT/POWER
CABLE ASSY: DC POWER
GRN 3 8
BLK 5
4
EMI FILTER ASSY 10
9
2
1 7 CABLE ASSY: PWR
RED 6
SUPPLY/FILTER
WHT/BLK
WHT/RED
WHT/RED
WHT/BLK
RED
BLK
BLK
RED
A1
J6
CONTROLLER ASSY A2
POWER SUPPLY ASSY
CABLE ASSY:
LED POWER
J2
J3
J2
RED (LONG) BLK
(SHORT) RED (LONG)
CABLE ASSY LED
CABLE ASSY:
PWR SUPPLY/CONTRLR
J3 J3 J3 J3
A4 PCB ASSY: MUX
1 20
1 20
1 20
1 20
J4 J4 J4 J4
GROUND A3 PCB ASSY: CONTROLLER

LUG
J2 J2 J2 J2 A1 PCB ASSY: CONNECTOR
4 PLACES
J1 J1 J1 J1 FILENAME: 11518S2.DRW
Figure A-11. 8520C-36 Signal Selector Wiring Diagram

Maintenance
TO 8520C-36 CHANNEL:
CH5, CH13, CH21, CH29
CH6, CH14, CH22, CH30
CH7, CH15, CH23, CH31
CH8, CH16, CH24, CH32
CH9, CH17, CH25, CH33

#3 ADH
#5 COORD
#2 RGB
#4 F COMP
#1 PROP
12 WHT M
5 1 5 1 5 1 5 1 11 GRN P
10 BLK R
J5 J6 J7 J8 12 9 RED N
8 WHT/GRN E
7 YEL D
A3 J9 6 ORN C
5 WHT/RED B
4 BRN A
J4 J3 J2 J1 1 3 GRY H
2 VIO G
1 5 1 5 1 5 1 5 1 BLU F
J9 J3
5
4 GRN 1
3 BLK 4
2 RED 5
1 WHT 2
A3,J1-J2 P6.P7
P7 P6
D WHT 1
C RED 2
#7 #6 A BLK 3
TURBINE AFT COMP B GRN 4
5
PLUG END A3,J4-J8
A1 A2
1 WHT A
2 BLU B
P9 P8 3 GRN C
P8,P9 J1,J2
CH10, CH18, CH26, CH34
CH11, CH19, CH27, CH35
FILENAME: 11690.DRW
Figure A-12. C-130 Nacelle Harness P/N 11690 Wiring Diagram

J3
M
R
N
D
C
G
P
A
B
F
WHT/GRN
WHT/RED
TO 8520C-36 CHANNELS:
CH8, CH16, CH24, CH32
WHT
GRN
ORN
GRY
RED
BRN
BLU
BLK
YEL
VIO
CH5, CH13, CH21, CH29

CH6, CH14, CH22, CH30
CH7, CH15, CH23, CH31
CH9, CH17, CH25,CH33
J9
12
11
10
9
8
7
6
5
4
3
2
1
#4 FWD COMP
#5 ENG COOD
J1
J8
5
1
1
12
#3 ENG ACC
1 5
5 1
J7
J2
#2 AFT G/B
A3
1 5
51
J6
J3
#1 PROP
1 5
51
J5
J4
5
SPARE
4 GRN 1
3 BLK 4
5
2 RED 5
#6 AFT COMP
1 WHT 2
A3,J5-J6 P6.P7
D WHT 1
C RED 2
A BLK 3
B GRN 4
8225
A2
5
P8
#7 TURBINE
PLUG END
A3,J1-J3, J7-J8
CH10, CH18, CH26, CH34
8225
A1
P9
CH11, CH19, CH27, CH35
1 WHT A
2 BLU B
3 GRN C
P8,P9 J1,J2
FILENAME: 11516-1.DRW
Figure A-13. P-3 Nacelle Harness P/N 14440 Wiring Diagram

Maintenance
BACKSHELL CLAMP ON SHIELD
A BRN A
B RED B
C ORN C
D YEL D
E GRN E
F BLU F
G WHT G
H BLK H
J J
K K
L WHT L
M M
N RED N
R BLK R
P GRN P
P1 P2
(PINS) (SOCKETS)
FILENAME: 11517S.DRW
Figure A-14. Cable P/N 11517 Schematic

A.5 8520C-36 List of Field-Replaceable

Components
Table A-1. 8520C-36 Signal Selector
FIG REF COMPONENT

* 8520C-36 Signal Selector 99866 11518A
A-10 A1 * * PCB Assy, Connector, Qty. 4 99866 11671
A-10 A3 * * Controller/Bit Board 99866 11676
* * * IC, Programmed V. 1.03 (or 99866 11843-1
higher)
A-10 A2 * * Power Supply Board 99866 10835A
A-10 * * * Fuse, 2.5A 250V FAST 5x 03614 GDB2.5A 301-20258
A-10 A4 * * Mux, PCB Assy 99866 11678
A-10 2 * * Filter, Assy., Dual 99866 10857A
A-10 3 * * Screw, 4-40 X 3/8 Php. Blk., 96906 MZ35216-14 651-4523
Qty. 78
A-10 4 * * Washer Shoulder, #4, Qty. 13 04713 B51547F019 654-4SBA
A-10 5 * * Screw, 4-40 X 3/4 Pan. Php. 96906 MS35216-18B 651-4526
Blk. Qty. 5
A-10 6 * * Nut, 4-40 Nylon Lock 39428 90631A005 652-45NS
Standard Qty. 6
A-10 7 * * Washer, #4 Std. Intl. Lck. 260” 83330 1127C 654-4SIA
Qty. 22
A-10 8 * * Standoff, 4-40 X 1.25 Hex 83330 8408 660-14A4
Metal 1/4 Qty. 6
A-10 9 * * Standoff, #4 Clear Rnd. 1/4 83330 8481 660-2424
O.D., .25 Long Qty. 8
A-10 10 * * Bumper, Rubber Qty. 4 76385 ZB-1160-MI 610-094
A-10 11 * * Chassis, 8520C-36 99866 11679A
A-10 12 * * Cover 99866 10830

8520C-36 List of Field-Replaceable Components
Table A-1. 8520C-36 Signal Selector
FIG REF COMPONENT

A-10 13 * * LED, Green Panel Mount Qty. 61544 SDB-505B- 251-L502
2 GD
A-10 18 * * Screw, 10-32 X 5/16 Php. Blk. ............. Order by 651-9422
Qty. 4 Description
A-10 19 * * Harness Assy., OUTPUT/ 99866 11864
A-11 PWR
A-10 20 * * Harness Assy., DC POWER 99866 11865
A-11
A-10 21 * * Harness Assy., Power Supply- 99866 11866
A-11 Controller
A-10 22 * * Harness Assy., LED POWER 99866 11867
A-11
A-10 23 * * Harness Assy., Power Supply- 99866 11868
A-11 Filter
A-10 24 * * Harness Assy., LED 99866 11978
A-11
A-10 25 * * Nut Ring, #14 w/Stud Qty. 6 04967 FSS7-1401 405-14Z5R
A-10 29 * * Screw, 4-40 x 7/8 Php. Blk. 96906 MS35216-19B 651-4527
SS, Qty. 5
A-10 30 * * Washer, Flat 116 x 250 x 031 51506 64-.030-N-1 654-4SBT
Nylon, Qty. 12
A-10 31 * * Cable Clamp, 1/4” 28520 3304 602-017
33 * * Solder Lug, #4 Bent Locking, 83330 1416-4 408-B442C
Qty. 4


Appendix B. 8500C Heater Modification
This modification is to be performed on 8500C units shipped prior to 1992.
a. (Reference Figure 5-17) Remove ten screws (32) and four screws (33), and remove
bezel(4).
c. (Reference Figure 5-19 Sheet 2 of 2) Locate 3-pin mta connector J3/P3 on heater/EL
control board A4. Move wire from pin 2 over to pin 3. Take care when pushing the wire
down into the connector that the wire insulation is cut through to make actual contact with
the connector.
d. Close unit, again watching for pinched connector wires.
e. Install bezel (4) on keypad panel (1) and secure with ten 4-40 x 3/16 php. blk. screws (32)
and four 4-40 x 1/4 pan. php. blk. screws (33).
8500C/8500C+ System Maintenance Manual B-1

Appendix B - 8500C Heater Modification
B-2 Chadwick-Helmuth A Business Unit of Honeywell International, Inc.

Appendix C. Chadwick-Helmuth Phase
Measurement Convention
When you use a signal generator to simulate signals to the 8500C/C+, it is important that you
understand how the 8500C/C+ measure phase. As shown in Figure C-1, a zero degree phase interval
measured on the 8500C/C+ occurs when the falling zero crossing of the vibration signal happens at the
same time as the magnetic pickup pulse. Therefore, on an H-P 3561A signal generator, a 180° phase
difference between two output signals would produce a 0° phase measurement on the 8500C/C+. A 0°
phase difference on the H-P would produce a 180° phase difference on the 8500C/C+. If you want to
adjust phase shift when using a signal generator, you must shift the vibration signal and not the
magnetic pickup signal.
SINEWAVE ( VIBRATION INPUT) SINEWAVE ( VIBRATION INPUT)
MAG P/U MAG P/U
SQUARE WAVE SQUARE WAVE
PHASE INTERVAL=0 PHASE INTERVAL

8500C PHASE INDICATION = 0 DEGREE ( 12:00 CLOCK) 8500C PHASE INDICATION = 180 DEGREES ( 6:00 CLOCK)
(SIGNAL GENERATOR IS SET FOR 180 DEGREE PHASE SHIFT (SIGNAL GENERATOR IS SET FOR 0 DEGREE PHASE SHIFT
BETWEEN TWO SIGNALS) BETWEEN TWO SIGNALS)
SINEWAVE ( VIBRATION INPUT) SINEWAVE ( VIBRATION INPUT)
MAG P/U MAG P/U
SQUARE WAVE SQUARE WAVE
PHASE INTERVAL PHASE INTERVAL

8500C PHASE INDICATION = 90 DEGREES ( 3:00 CLOCK) 8500C PHASE INDICATION = 270 DEGREES ( 9:00 CLOCK)
FILE: SINWAVD.DRW
Figure C-1. Velocimeter and Magnetic Pickup Signal Phase Relationships
8500C/8500C+ System Maintenance Manual C-1

Appendix C - Chadwick-Helmuth Phase Measurement Convention
C-2 Chadwick-Helmuth A Business Unit of Honeywell International, Inc.

Appendix D. 8520CS Signal Selector
D.1 Introduction
The 8520CS Signal Selector is similar to the 8520C Signal Selector referenced in Section 4, but it has
inputs for 8 Velocimeter channels, rather than 12 channels. The 8520CS also has the following input
channels: 4 balanced differential output Accelerometers, 2 Magnetic Pickups and 2 Photocells
compatible with the Chadwick-Helmuth 10200 Photoprobe. The following sections highlight the
differences between the 8520CS and 8520C in the areas of physical description, theory of operation,
and testing. Disassembly/reassembly instructions and a parts list are also included.
D.2 Leading Particulars
Table D-1. 8520CS Signal Selector (Only)

Input Power 28VDC
Velocimeter signal input levels 8 Channels, 0 to 7.125Vpk
Input Impedance 100K (unselected channel), 2.5K (selected)
Accelerometer (balanced differential output) 4 Channels, 10-150 pC/g (programmable)

- Frequency Response: +/-2% 14Hz to 20kHz
-5% at 8Hz (nominal)
-12% at 5Hz (nominal)
Magnetic pickup signal inputs 2 channels, 0.5Vpk to 12Vpk
Photocell input: 2 channels, compatible with Chadwick-

Helmuth’s high speed Photocell Probe 10200
(ref Manual 10473-1)
Dimensions: 7.1 x 10.81 w x 4.01 h in.
Weight 4.5 lbs
8500C/8500C+ System Maintenance Manual D-1

Appendix D - 8520CS Signal Selector
D.3 Physical Description (Figure D-11)

The 8520CS has 8 discrete velocimeter single-channel connectors, 2 magnetic pickup/tracker
connectors, 2 discrete photocell connectors, 4 High Temp Accelerometers connectors (balanced
differential output type), a 28 VDC input power connector, a connector for receiving commands from
and transmitting selected signals to the 8500C/C+, and 2 multichannel connectors to interface with the
umbilical cables. All the inputs on the to of the units are available on these high density connectors.
D.4 Theory of Operation

D.4.1 Connector Harness
The 8520CS uses a connector harness as the 8520C does, to route signals to the singal conditioner and
controller boards. The top panel connectors are connected in parallel with the 2 high density umbilical
connectors J1 and J2. The intent of these high density connectors is to simplify installation on
permanently wired aircraft. The top connector and its corresponding high density pins are wired in
parallel and therefore should not be used at the same time.
D.4.2 A3 Controller Board

The 8520CS controller board A3 is a modified 8520C controller board. The modification is to allow
the signal conditioning PCB (A1) to be inserted between A3 and the harness. The contoller board
firmware has been modified to map the external channels to the proiper internal channel numbers. (See
Section 4.2.2.1 “ Controller Board”).
D.4.3 Signal Conditioner Board (Figure D-1)

This new board adds the following signal processing functions:
Two high speed photocell processor circuits.
Four High Temperature Accelerometer (balance differential output type) channels. (equivalent to
Chadwick-Helmuth’s 8225 integratiing charge converter).
The channel sensitivity calibration of these accelerometer channels is marked on a label on the unit.
(i.e. 50 pC/g’s 100 pC/g’s etc). Each channel sensitivity can be individually set:
D-2 Chadwick-Helmuth A Business Unit of Honeywell International, Inc.

Functional Tests
Figure D-1. Signal Conditioner Board
D.4.4 Power Supply Board A2

The power supply board A2 is identical in function to the power supply board in the 8500C/C+ (see
Section 4.2.1.2.3 “Power Supply Board”.
D.5 Functional Tests

NOTE: These tests require firmware version 3.21 (or higher) in the 8500C/C+ Balancer/
Analyzer. For instructions on changing the firmware to a newer version. see Section 5.7.3,
“EPROM Change Procedure.” In Appendix D, “8500C/C+” refers to either 8500C or
8500C+, units.
This section contains instructions to test the 8500C/C+ system performance parameters. If a test step
fails. refer to the “Troubleshooting Guide” in Section 5.6 to locate the faulty component.
The functional tests ensure that the instrument is operating properly and within specifications. The
functional test setups use, as much as possible. All the components (transducers, cables, etc.) that are
used in the field. This allows the user to verify the proper operation of these components and aids in
fault isolation.
D.5.1 8500C/C+ Balancer/Analyzer System Test Procdure (with 8520CS)

NOTE: these tests build successively on the first test in this section. any settings not

D.5.1.1 Test Setup

a. Connect equipment as shown in Figure D-2.
NOTE: Make sure calibrator Velocimeter cables are free to move so that Velocimeter
BALANCER/ANALYZER
PRINT
START
SHOW/HIDE
W X
STOP
B Y Z
MORE/KEYS
CABLE 10811
1 I
G H
D : E F .
4 5 6
MODEL 8500C
J # K < L - 8 9
S 7 U
T HELMUTH
CHADWICK
P % Q > R / V
0
CABLE 10813
CABLE 11210 1 4 7 10
POWER BALANCER
2 5 8 11
3 6 9 12
CABLE 11210 A B C D
VELOCIMETER CALIBRATOR 11A VELOCIMETER

7310 7310
MAGNETIC
PICKUP
NOTE: 11B users, bypass 3030
mag pulse doubler and CABLE 10808
connect magnetic pickup
cable directly to channel A NOTE: The calibrator must have no more than one screw installed on its rotor
on 8520C. This simulates disk when used with the 8500C; however, the calibrator was designed to have at
11A use. least two screws 180 degrees apart. To simulate a second screw, enter the
actual rpm (half the "CAM RATE") as the balance frequency and "2" as the times
factor in the 8500C balance setup display. For example, if the CAM RATE is
900, enter "450" as the balance frequency and "2" as the times factor.
Figure D-2. Functional Test Setup (with Magnetic Pickup)
D.5.1.2 Power-Up Self-Test


Functional Tests
D.5.1.3 Balance Test
ACQUIRSTION DISPLAY

Figure D-3. Typical Balance Test Display
a. Ensure that only one No. 6 screw is installed able “h” on the Chadwick-Helmuth logo on
Calibrator 11A rotor disk.
b. Set CAM RATE (RPM) switch on Calibrator 11A to 1800.
c. Adjust pot next to 1800 CAM RATE switch position until outside ring on rotor disk
appears frozen in place under 60 Hz light.
d. Press SETUP key on 8500C/C+.
e. Key in 900 with numberic keys in BALANCE FREQUENCY field.
f. On same line, press right arrow key twice to select last number (called “time factor”) with
arrow keys.
g. Key in 2 as new times factor. This entry now reads: x2.
h. Select AUTO STOP field with arrow keys and press CHANGE soft key to select MAN
STOP.
i. Select PHASE UNITS field with arrow keys.
j. Press CHANGE soft key to select <DEGREES>.
k. Select PICKUP field with arrow keys.
l. Press CHANGE soft key to select PICKUP A.
m. Select INPUT field with arrow keys.
n. Key in <1> with numeric key.

o. Press ENTER soft key.

p. Wait 10 seconds.
q. Press START key.
r. Verify that display indicates (example in Figure D-3):
1800 +2 RMP
0.8+0.08 IPS
275+10°
s. Press STOP key.
t. Press SETUP key.
u. Select INPUT field with arrow keys.
v. Key in 2 with numeric key.
w. Press ENTER soft key.
x. Wait 10 seconds.
y. Press START key.
z. Verify that display indicates (example in Figure D-3):
1800+2 RPM
0.8+0.08 IPS
275+10°
aa. Press STOP key.
bb. Move 11210 cables to next Velocimeter Channel positions and cable 10808 to magnetic
pickup channel position marked in Table D-2.
cc. Press SETUP on 8500C/C+.
dd. Select PICKUP field with arrow keys.
ee. Press CHANGE soft key to select pickup shown in Table D-2.
ff. Press INPUT field with arrow keys.
gg. Key in channel number with numeric key.
hh. Press ENTER soft key.
ii. Wait 10 seconds.
Table D-2. Velocimeter and Magnetic Pickup Balance Test Channel

Combinations
Velocimeter Channels Magnetic Pickup Channel

1, 2, 4, 5 A
7, 8, 10, 11 B

Functional Tests
jj. Press START key.

kk. Verify that display indicates (example in Figure D-3):
1800+2 RPM
0.8+0.08 IPS
275+10°
ll. Press STOP key.
mm. Repeat steps bb. through ll. for all channels in Table D-2.
D.5.2 8500 Balancer/Analyzer System Test Procedure with 8520CS (Using

High Temp Accelerometers and Photocells)
NOTE: Thes tests build successively on the first test in this section. Any settings not
D.5.2.1 Test Setup

a. Connect equipment as shown if Figure D-4.
NOTE: Make sure calibrator Accelerometer cables are free to move so that Accelerometer
D.5.2.2 Power-Up Self-Test

b. Hold down START key on 8500C/C+ and turn on power supply.
c. Wait until Power-Up Self-Test display appears and release START key.
D.5.2.3 Balance Test

d. Ensure that the only one piece of reflective tape is installed on the Calibrator 11A rotor
CAM.
e. Set CAM RATE (RPM) switch to 1800.
f. Set MOTOR switch to ON.

BALANCER/ANALYZER
PRINT
START
SHOW/HIDE
W X
STOP
B Y Z
MORE/KEYS
CABLE 10811
BALANCE HELP STATUS
1 2 3
G H I
D : E F .
4 5 6
MODEL 8500C
J # K < L - 8 9
S 7 U
T CHADWICK
HELMUTH
P % Q > R / 0
V
CABLE 10813
CABLE 10700 1 4 7 10
POWER BALANCER
2 5 8 11
ACCELEROMETER
ADAPTER BRACKET 3 6 9 12
CABLE 10700 A B C D

10494 CALIBRATOR 11A 10494
10200 PHOTOPROBE
NOTE: 11B users, bypass

mag pulse doubler and CABLE 14883
connect magnetic pickup
cable directly to channel A NOTE: The calibrator must have no more than one screw installed on its rotor
on 8520C. This simulates disk when used with the 8500C; however, the calibrator was designed to have at
11A use. least two screws 180 degrees apart. To simulate a second screw, enter the
actual rpm (half the "CAM RATE") as the balance frequency and "2" as the times
factor in the 8500C balance setup display. For example, if the CAM RATE is
900, enter "450" as the balance frequency and "2" as the times factor.
Figure D-4. Functional Test Setup (with High Temp Accelerometer and
Photocell)
g. Adjust pot next to 1800 CAM RATE switch position until outside ring on rotor disk
appears froze in place under 60 Hz light1.
h. Press BALANCE key on 8500C/C+.
i. Press SETUP key.
j. Key in 900 with numeric keys in BALANCE FREQUENCY field.
k. On same line, press right arrow key twice to select last number (calle “times factor”) with
arrow keys.
l. Key in 2 as new times factor. This entry now reads: x2.
m. Select <AUTO STOP> field with arrow keys and press CHANGE soft key to select MAN
STOP.
n. Select PHASE UNITS field with arrow keys.
o. Press CHANGE soft key to select <DEGREES>.
1
Attention, users outside U.S.: The 11A Calibrator can also be calibrated under 50Hz light. For 1714

Functional Tests
p. Select PICKUP field with arrow keys.

q. Press CHANGE soft key to select PICKUP C.
r. Select INPUT field with arrow keys.
s. Key in 3 with numeric key.
t. Press ENTER soft key.
u. Wait 10 seconds.
v. Press START key.
w. Verify that final results display indicates.
1800 +2 RPM
0.8 +0.10 IPS
NOTE: This response assumes that internal charge converters have been properly
programmed for the sensors under test. (ref. Section D.6 for charge amplifier programming/
calibration).
x. Press STOP key.
y. Press SETUP key.
z. Select INPUT field with arrow keys.
aa. Key in 6 with numeric key.
cc. Wait 10 seconds.
dd. Press START key.
ee. Verify that final results display indicates.
1800 +2 RPM
0.8 +0.10 IPS
ff. Press STOP key.
gg. Move 10700 cables to High Temp Accelerometer 9 and 12 channel positions and move
cable 14883 to photocell channel D.
hh. Press SETUP on 8500C/C+.
ii. Select PICKUP field with arrow keys.
jj. Press CHANGE soft key to select pickup shown in Table D-3.
kk. Select INPUT field with arrow keys.
ll. Key in channel number 9 with numeric key.
mm. Press ENTER soft key.
nn. Wait 10 seconds.

Table D-3. Accelerometer and Photocell Balance Test Channel Combinations
Accelerometer Channels Photocell Channels Channel

3 and 6 C
9 and 12 D
oo. Press START key.

pp. Verify that final results display indicates.
1800 +1 RPM
0.8 +0.10 IPS
qq. Press STOP key.
rr. Repeat steps gg. through pp. for channel 12.
D.5.3 FasTrak Test
D.5.3.1 Test Setup (Ref. Figure D-5)

NOTE: This test provides a high level of confidence that the FasTrak is operating properly.
Before doing the FasTrak test, apply the special overlay to the calibrator disk. See Figure D-6 for
samples that can be copied or recreated. Unplug the 14883 cable from the “D” connector on the
8520CS Signal Selector.
NOTE: This test should be performed in a well-lit room.
a. Place calibrator on its back on a flat surface.
b. Place FasTrak on its side with the pin connector facing to the right. The window should be
facing the calibrator approximately six inches away.
c. Set CAM RATE (RPM) switch to 900.
d. Set MOTOR switch to ON.
e. Adjust pot next to 900 CAM RATE switch position until 2nd ring from outside on rotor
f. Press BALANCE key on 8500C/C+.
g. Press SETUP key.
h. Select PICKUP field with arrow keys.
i. Press CHANGE soft key to select PICKUP B.
2Attention,
users outside U.S.: The 11A Calibrator can also be calibrated under 50Hz light. For 1714

Functional Tests
j. Press STATUS key.

k. After a few seconds, the RPM on the screen should read approximately 900 RPM.
NOTE: If you cannot adjust the distance or alignment to obtain 900 RPM, there may be a
problem with the FasTrak. Return it to Chadwick-Helmuth for adjustment.
l. With a white index card or piece of paper, cover half of the rotating disk. Place the card
close to, but not touching, the disk, so as to cover 1/2 Mag Pickup sensor and one vibration
sensor.
m. The RPM should drop by approximately half, remove the card.
Night Mode Test

a. To simulate night operation, turn off all lights in room, or enclose the test setup within a
darkened enclosure, such as a large box. The RPM should drop to zero when the area is
dark enough.
b. Switch Tracker switch to Night mode. (in the cable)
c. After a few seconds, the RPM should appear on the display.
BALANCER/ANALYZER
PRINT
START
SHOW/HIDE
W X
STOP
B Y Z
MORE/KEYS
CABLE 10811
1 I
G H
D : E F .
4 5 6
MODEL 8500C
J # K < L - 8 9
S 7 U
T HELMUTH
TRACK STORE
CHADWICK
ANNOTATE
P % Q > R / 0
V
CABLE 10813
1 4 7 10
POWER BALANCER
2 5 8 11
3 6 9 12
A B C D

CALIBRATOR 11A
MAG PICKUP 3030
CABLE 10808
CABLE 12700
NOTE: 11B users, bypass NOTE: The calibrator must have no more than one screw installed on its rotor
mag pulse doubler and disk when used with the 8500C; however, the calibrator was designed to have at
connect magnetic pickup least two screws 180 degrees apart. To simulate a second screw, enter the
cable directly to channel A actual rpm (half the "CAM RATE") as the balance frequency and "2" as the times
on 8520C. This simulates factor in the 8500C balance setup display. For example, if the CAM RATE is
11A use. 900, enter "450" as the balance frequency and "2" as the times factor.
Figure D-5. Functional Test Setup (with Tracker)

Figure D-6. Special Overlay
D.6 Calibration - Charge Converter Amplifiers

The calibration of the four Charge Converter Amplifiers in the 8520CS on the Signal Conditioner
Board may be checked and adjusted according to the following procedure.
D.6.1 Charge Test Fixture

Build the following passive charge fixture.
Figure D-7. Charge Converter Test Fixture

Calibration - Charge Converter Amplifiers
Procedure
1. With nothing connected to the input of the Charge Fixture, connect its output the 8520CS input.
2. Measure the 8520CS input capacitance (between TP1 and TP2 of the Charge Fixture). Record this
value as Cin(pF) (should be about 0.1 mfd = 100,000 pF).
3. Determine the capacitance and charge sensitivity of the intended acclerometer:Caac (pF) and
SQ(pC/g).
N O T E : S e n s o r C a c c (p F ) S Q ( p C / g )
6 2 3 3 C -5 0 1 3 5 0 5 0
7 7 0 4 A -5 0 2 8 0 0 5 0 ( N o m in a l)
4. Connect the input of the Charge Fixture to a signal generator. Configure the generator for a 100
+0.1 Hz sinewave. Using a floating DVM, monitor the voltage between TP1 and TP2. Adjust the
generator for a DVM reading of 100 +0.1 mVrms.
5. Connect the 8520CS according to Figure D-8.
6. Remove the cover from the 8520CS and set the DIP switch for the charge sensitivity closest to that
of the intended accelerometer. This switch is set according to the Decal inside the instrumenct. See
Table D-4 for channel switch and potentiometer adjustments. See Figure D-10 for DIP switch
settings. See Figure D-9 for potentiometer and DIP switch locations on the Signal Conditioner PC
board.
7. Calculate the required 8500C/C+ ips reading:
ip s 8 5 0 0 C = V in 2
( 6 1 .4 5
f
(C
S
in
Q
+ C a c c )
)
W h e r e : V in :
C in :
C au:
f:
S Q :
8. Set up the 8500C/C+ for BALANCE. In SETUP set the balance frequency to 100 hz, and the
balance type to STROBEX. Also select MANUAL STOP.
9. Press ENTER softkey, wait 10 seconds, then press START and adjust the 8520CS trimpot (see
Table D-4) for an 8500C/C+ reading of the value calculated in step 7. Ignore the STROBEX
instructions; press STOP when finished.
EXAMPLE: You wish to calibrate and 8520CS which is intended to be used with an
Endevco 6233C-50 accelerometer connected to 8520CS.
You’ve measured the input capacitance of the 8520CS: Cin = 100400 pF.
You’ve set the generator for: Vin = 100 mVrms between TP1 and TP2 (f = 100 hz sine wave).
Assume the 6233C-50 accelerometer has:
SQ = 50 pC/g, Cacc = 1350 pF.
Hence,
ip s 8 5 0 0 C = 0 .1 0 0 2 ( 6 1 .4 5 (1 0 0 4 0 0 + 1 3 5 0 )
1 0 0 5 0
) = 1 7 6 .8 ip s ( p K ) + 1 %

NOTE: Now that you have a calibrated 8520CS/8500C/C+ system, you can verify the charge
sensitivity of the Endevco 6233C50 accelerometer. Simply affix this accelerometer to a
calibrated shaker system set for a known vibration level approximately 10 ips (pk) at 100 hz,
sine. Verify the 6233C-50 output on the 8500C/C+.
Table D-4. Charge Amplifier Adjustments
Channel DIP Switch Potentiometer

3 S1 R73
6 S2 R92
9 S3 R111
12 S4 R130
SIGNAL
GENERATOR
TP1
CHARGE TRUE RMS
TEST 8500C BALANCER/ANALYZER
METER
FIXTURE TP2
POWER SUPPLY 9100A
BALANCER/ANALYZER
PRINT
START
A W X
SHOW/HIDE STOP
B Y Z
MORE/KEYS
CABLE 10811
1 I
G H
D : E F .
4 5 6
MODEL 8500C
J # K < L - 7 8 9
S T U
TRACK STORE
CHADWICK
HELMUTH
ANNOTATE
P % Q > R / V
0
CABLE 10813
1 4 7 10
2 5 8 11
3 6 9 12
A B C D
Figure D-8. Functional Test Setup Charge Converter Amplifier Calibration

Calibration - Charge Converter Amplifiers
Figure D-9. Charge Converter Adjustments On PC Board.
Figure D-10. Charge Amplifier DIP Switch Setting.

D.7 Maintenance and Repair

D.7.1 Signal Selector 8520CS Disassembly (Figure D-11)
D.7.1.1 Controller Board and Signal Conditional Board Assembly

cover (12).
b. Disconnect nine connectors from the assembly. On Signal Conditioning board J2, J4, J5,
J8, J11 and two 2 pin connectors going to front panel LED lights. On Controller board J5
and J8.
c. Remove six screws (19) and spacers (15) and remove Controller Board and Signal
Conditioning Board Assembly.
d, Remove the dual board assembly.
e. Pull apart the two boards by disconnecting them at the J3, J5, J7, J9 and J10 on Signal
Conditioner Board.
D.7.1.2 Power Supply Board A2

b. Remove four hex nuts (6) and two spacers (9), and remove power supply board A2 from
chassis (11).
D.7.1.3 Harness Asseblies

The harness assemblies consist of the parts that remain in the chassis after the circuit boards have been
removed.
D.7.2 Reassembly
Follow original factory routing.
D.7.2.1 Power Supply Board A2

a. Install power supply board A2 on chassis (11) and secure with four 4-40 nylon lock std.
hex nuts (6) and 2 #4 clear rnd. 1/4” o.d standoffs (9).
b. Connect three connectors (J1, J2, J3) to power supply board A2.
D.7.2.2 Controller Board and Signal Condtioner Board Assembly

a. Connect the two boards together at the 5 headers J3, J5, J7, J9 and J10 on the Signal
Conditioner board. Align the connector pins on the Controller Board with the sockets on
the Signal Conditioning Board and carefully connect the two.
b. Install the two board assembly on the chassis and secure using 6 screws (19) spacers (15).

Maintenance and Repair
c. Connect the nine connectors from the harness assembly, front panel and power supply to
the following connectors. Signal Conditioning Board - J2, J4, J6, J8, J11 and two 2 pin
connectors from the front panel LEDs. Also connect the harness to the Contoller Board -
J5 and J8. Insure connectors are properly seated. Use a small amount of RTV to secure the
4 harness connectors in place.
d. Install bottom cover (12), secure with eighteen 4-40 x3/8” pan php. blk. screws (5) and #4
std. intl. lck. 260” washers (7).

Figure D-11. 8520CS Signal Selector Illustrated Parts Breakdown

Table D-5. Bill Of Material For 8520CS
REF. CAGE MFG.

COMPONENT QTY. C-H P/N
NO. CODE P/N
*8520CS SIGNAL SELECTOR 99866 14880
A1 **PCB ASSY. SIGNAL CONDITIONER 1 99866 801-14871

A2 PCB ASSY. POWER SUPPLY 1 99866 801-10835A
A3 ** PCB ASSY. 8520CS CONTROLLER 1 99866 801-14918
1 ** LABEL SERIAL 1 99866 753-11287
2 ** FILTER DUAL 8520C TE 99866 820-10857A
3 ** HARNESS ASSY. PWR/SIG 99866 802-11127
4 ** HARNESS ASSY. 2 99866 802-14876
5 ** SCREW 4-40 X 3/8 PHP 94 99866 651-4523
6 ** NUT 4-40 NYLOCKSTD. 4 99866 652-45NS
7 ** WASHERS #4 STD INT LOCK 28 99866 654-4SIA
8 ** STANDOFF 4-40 X 1-3/4 6 99866 660-14B4
9 ** SPACER #4 I.D. .25 O.D. 2 99866 660-2424
10 ** BUMPER RUBBER 4 99866 610-094
11 ** CHASSIS 8520CS EMI 1 99866 751-14868

12 ** COVER 8520CS EMI 1 99866 562-14867
13 ** LED GREEN PANEL MOUNT 2 99866 251-L502
14 ** WASHER HOLDER #4 6 99866 654-4SBA
15 ** SPACER 1/2” X 1/4 O.D 6 99866 660-D444
16 ** TY-WRAP 15 99866 660-T01
18 ** SCREW 10-32 X 5/16 PHP 4 99866 651-9422

19 ** SCREW 4-40 X 7/8 PHP 6 99866 651-4527
20 ** WIRE GREEN 18AWG STRANDED 1 99866 702-185
21 ** #4 SOLDER LUG BENT 1 99866 408-B442C

25 ** NUT RING #14 W/STUD 4 99866 405-14Z5R
26 ** NUT RING #10 W/STUD 8 99866 405-10Z5R
27 ** NUT RIGN *8 W/STUD 8 99866 405-08Z5R

28 ** LABLE “CE” MARK 1X1X 1 99866 752-13594
29 ** LED RED PANEL MOUNT 2 99866 251-L503

Table D-5. Bill Of Material For 8520CS
REF. CAGE MFG.

COMPONENT QTY. C-H P/N
NO. CODE P/N
S1 ** SWITCH TOGGLE DPDT 6 1 99866 315-2212
31 ** HARNESS ASSY, 8520CS 1 99866 802-14876

Figure D-12. Wiring Diagram 8520CS

(Sheet 1 of 2)


Figure D-12. Wiring Diagram 8520CS

(Sheet 2 of 2)


Index
11A 1-1, 1-8 accessories,
11B instructions 5-4 8500C/C+ system 1-9
11B 1-1 illustration 1-6
135M-12 1-8 ADC,
36-channel signal selector, see 8520C-36 8500C/C+ 4-3
8500C/C+, 8520C 4-13
basic operation 3-1 Allison engines A-1
cold-start 3-1 amplifier, programmable gain,
detailed description 4-2 8500C/C+ 4-3
disassembly 5-48 amplitude, frequency & phase accuracy test,
harness assembly 5-63, 5-65 8500C/C+ 5-10
heater modification B-1 8520C 5-14
illustration 1-3 problems (8520C) 5-34
IPB 5-51, 5-53 problems (8500C/C+) 5-38
parts list 5-70 analog board,
physical description 1-2 8500C/C+ 1-3, 4-2
purpose 1-1 block diagram 4-4
reassembly 5-67 ANALOG FILTER FAILURE 5-29
warm-start 3-1 analog-to-digital converter,
8500C/C+ system, 8500C/C+ 4-3
block diagram 4-1 8520C 4-12
repacking 2-4 anti-alias filter 4-2
storage 2-4 anti-alias filter,
unpacking 2-1 response test, 8500C/C+ 5-12
8520C, anti-aliasing test, problems 5-36
detailed description 4-10 azimuth input, 8520C 4-11
disassembly 5-54
harness assembly 5-63 backlight, problems 5-32
illustration 1-4 BAD DYNAMIC MEMORY 5-29
IPB 5-61 balance test,
parts list 5-73 8500C/C+ system 5-3
physical description 1-7 problems 5-34
reassembly 5-67 BALANCE FREQUENCY
8520C-36 Appendix A 8500C/C+ setup 5-4
8520C-36, balancer/analyzer, see 8500C/C+
C-130 test A-3 battery,
channel pin-outs A-22 8500C/C+ 4-5
disassembly A-22 problems 5-32
IPB A-25 battery, check and replacement 5-46
P-3 test A-11 bins, 8500C/C+ 4-5
parts list A-30 BIT, see Velocimeter BIT
reassembly A-23
test cable fabrication A-20
wiring diagram A-26
A+B and A-B 4-11
8500C/8500C+ System Maintenance Manual I-1

Index
block diagrams, DC adapters 1-9

8500C/C+ system 4-1 DFT 4-6
8500C/C+ digital board 4-7 digital board,
8500C/C+ power supply board 4-10 8500C/C+ 1-2
8520C-36 A-2 8500C/C+ 4-5
analog board 4-4 block diagram 4-7
controller board and quad peak detector 4-11 diode bridge, heater/EL 4-8
heater/EL control board 4-8 disassembly,
BNC test cable, 8500C/C+ 5-48
8500C/C+ 5-2 8520C 5-54
8520C-36 A-20 8520C-36 A-23
Built-In Test, see Velocimeter BIT disk drive 1-3
disk drive,
C-130 nacelle harness, assembly, 8500C/C+ 4-10
wiring diagram A-27 cleaning 5-42
C-130, 8520C-36 test A-3 test 5-9
cable, test, problems 5-35
8520C-36 test A-21 disk 1-9
#11517 schematic (8520C-36) A-29 disk insertion 2-1
cables, DISK INCORRECTLY FORMATTED
8500C/C+ system 1-7 display heater, heater/EL 4-9
fabrication (8500C/C+ test) 5-2 distribution board, 8500C/C+ 1-3, 4-9
illustration 1-5 DRAM, 8500C/C+ 4-6
preliminary connections 2-1 dual sum/difference, 8520C 4-11
schematics (8500C/C+ system) 5-43
test, 8500C/C+ 5-1 EL lamps, heater/EL 4-8
CAGE codes 5-75 EL/heater control board 1-3
calibration test, EL controller, heater/EL 4-9
8500C/C+ 5-10 EPROM,
8520C 5-14 change procedure 5-45
problems (8500C/C+) 5-36 required version 5-3
Calibrator 1-1 EPROM TEST HAS FAILED 5-29
Calibrator, EXCEPTION ERROR 5-28
11A 1-8 exploded parts view, see IPB
11B instructions 5-4
instructions for 60Hz light 5-4 Fast Fourier Transform, see FFT
case, carrying 1-9 FasTrak 1-8
CHANGE soft key 3-1 FasTrak signal, 8520C 4-14
changes to manual 1-1 FFT,
channel crosstalk test 5-38 algorithm 4-6
channel pin-outs, 8520C-36 A-22 specs 1-10
cleaning, filter,
disk drive 5-42 8520C power 1-7
surfaces and cables 5-41 anti-alias, 8500C/C+ 4-2
clock, realtime, 8500C/C+ 4-5 high-pass, 8500C/C+ 4-2
cold-start 3-1 keypanel 4-7
communications controller, 8500C/C+ 4-5 power supply, heater/EL 4-8
controller board, firmware, see EPROM
8520C 1-7, 4-10 floppy disk, see disk
8520C-36 A-1 FSCM, see CAGE codes
block diagram, 8520C 4-11 functional test, 8500C/C+ system 5-3
converter, time-to-frequency, 8500C/C+ 4-6 fuse,
problems 5-30, 5-32
date and time, problems 5-32 replacement (8500C/C+ & 8520C) 5-47
I-2 Chadwick-Helmuth A Business Unit of Honeywell International, Inc.

Index
Goertzel Discrete operation, basic 3-1

Fourier Transform, see DFT optical probe 1-8
graphics module 1-2 overload detector, 8500C/C+ 4--3
harness assembly,
8500C/C+ 1-3, 5-57, 5-59 P-3 nacelle harness,
8520C 1-7, 5-63, 5-65 wiring diagram A-28
heater control board 1-3 P-3, 8520C-36 test A-11
heater modification B-1 paper, printer 1-9
heater/EL control board, parts list,
8500C/C+ 4-8 8500C/C+ 5-70
block diagram 4-8 8520C 5-73
high-pass filter, 8500C/C+ 4-2 8520C-36 A-30
peak detect and hold, 8520C 4-12
illustrated parts breakdown, see IPB periodic inspection, 8500C/C+ system 5-3
inspection, 8500C/C+ system 5-3, 5-44 phase shift,
interrupters 1-9 signal generator output 5-11
IPB, phase measurement,
8500C/C+ 5-51, 5-53 C-H convention Appendix C
8520C 5-61 Photocell Processor 1-9
8520C-36 A-25 photocell, see optical probe
pickup, see magnetic pickup
Keypanel, 8500C/C+ 4-7 pilot light,
keypanel filter 4-7 problems (8500C/C+) 5-30
troubleshooting
LCD, flowchart (8500C/C+) 5-39
8500C/C+ 4-6 power light,
problems 5-30 problems (8520C) 5-31
leading particulars 1-7 troubleshooting
flowchart (8520C) 5-40
magnetic pickup 1-9 power supply,
maintenance, routine 5-1 8500C/C+ 1-3
manuals 1-7 8520C 1-7
memory, power supply board,
8500C/C+ 4-6 8500C/C+ 4-9
problems 5-31 (8500C/C+) block diagram 4-10
microcontroller, 8520C 4-12 8520C 4-13
microprocessor, 8500C/C+ 4-6 printer,
MORE KEYS soft key 3-1 paper removal 2-2
8520C-36 A-1 paper loading 2-2
analog board 4-2 problems 5-32
multiplexers, printer assembly, 8500C/C+ 1-3, 4-
2:1 8520C 4-11 10
4:1 8520C 4-12 printer board, 8500C/C+ 1-3, 4-9
mux board, 8520C-36 printer, problems 5-32
publications 1-7
nacelle harness, pulse detector,
C-130 A-3 8500C/C+ 4-5
P-3 A-11 8520C 4-13
noise and spurious signals test,
8500C/C+, 5-12 quad peak detector board,
problems 5-36 8520C 1-7, 4-13
noise generator, analog board 4-2 block diagram, 8520C 4-13
NVRAM, 8500C/C+ 4-6
realtime clock, 8500C/C+ 4-5
8500C/8500C+ System Maintenance Manual I-3

Index
reassembly, test,
8500C/C+ 5-67 amplitude, frequency & phase accuracy
8520C 5-67 (8520C) 5-14
8520C-36 A-23 anti-alias filter response (8500C/C+) 5-12
reboot, see cold-start calibration (8500C/C+) 5-10
repair, calibration (8520C) 5-14
8500C/C+ system 5-41 channel crosstalk (8520C) 5-17
minor procedures 5-41 disk drive 5-9
reset, see cold-start functional (8500C/C+ system) 5-3
resolution, timer 4-5 noise and spurious signals (8500C/C+) 5-12
retro-reflective tape 1-9 spectrum accuracy (8500C/C+ system) 5-18
scale 1-9 spectrum 5-7
scheduled maintenance 5-1 track 5-8
schematic, #11517 cable (8520C-36) A-29 test cables,
schematics, 8500C/C+ 5-1
8500C/C+ system cables 5-43 fabrication (8500C/C+) 5-2
8500C/C+ test cables 5-2 fabrication (8520C-36) A-21
8520C-36 test cable A-21 test equipment 5-1
short light, 8520C 5-32 8520C-36 A-1
short circuit lamp, 8520C 4-12 timing controller, 8500C/C+ 4-5
SHOW/HIDE soft key 3-1 track test,
signal generator, 8500C/C+ system 5-8
H-P 5-1 problems 5-35
phase shift 5-11 track and hold, 8500C/C+ 4-3
setup 5-10 tracker, signal, 8520C 4-13
signal selector, see 8520C tracker, optical, see FasTrak
signal selector (8520CS) Appendix D troubleshooting flowchart,
signal selector, 36-channel, see 8520C-36 8500C/C+ pilot light 5-39
softkeys 3-1 8520C power light 5-40
specifications, system 1-10 troubleshooting guide 5-27
spectrum analyzer, H-P 5-2
spectrum test, problems 5-34 Unpacking, 8500C/C+ system 2-1
spectrum accuracy test,
8500C/C+ system 5-17 Velocimeter BIT 4-12
8520C-36 A-20 8520C 4-13
problems 5-37 Velocimeter input, 8520C 4-11
spectrum analyzer, setup 5-10 vibration analysis 1-2
spectrum functional test, 8500C/C+ system 5-7
static, precautions 5-45 warm-start 3-1
Strobex 1-9 wiring diagram,
8500C/C+, see harness assembly
T-56 A-1 8520C, see harness assembly
tape, retroreflective 1-9 8520C-36 A-26
test, C-130 nacelle harness A-27
8520C-36 Appendix A P-3 nacelle harness A-28
amplitude, frequency & phase accuracy
(8500C/C+) 5-10
I-4 Chadwick-Helmuth A Business Unit of Honeywell International, Inc.

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This document contains technology under

The export jurisdiction of the U.S. Department

Model 8500C/C+ Balancer/Analyzer System

Manual No. 10902-4

ii Chadwick-Helmuth A Business of Honeywell International, Inc.

Potential for damage to equipment.

Potential for minor, moderate, or serious injury.

Maintenance and Operation References

8500C/8500C+ System Maintenance Manual iii

iv Chadwick-Helmuth A Business Unit of Honeywell International, Inc.

Chapter 1. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Chapter 2. 8500C/C+ Handling And Installation . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Chapter 3. 8500C/C+ Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Chapter 4. System Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

8500C/8500C+ System Maintenance Manual v

4.2.2 8520C Signal Selector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

Chapter 5. Maintenance And Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

vi Chadwick-Helmuth A Business Unit of Honeywell International, Inc.

5.7.4.2 Battery Pack Replacement (Figure 5-17). . . . . . . . . . . . . . . . . . . . . . . 5-49

Appendix A. 8520C-36 Signal Selector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1

Appendix B. 8500C Heater Modification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-1

Appendix C. Chadwick-Helmuth Phase Measurement Convention. . . . . . . . . C-1

Appendix D. 8520CS Signal Selector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-1

8500C/8500C+ System Maintenance Manual vii

D.7 Maintenance and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-16

viii Chadwick-Helmuth A Business Unit of Honeywell International, Inc.

8500C/8500C+ System Maintenance Manual ix

Figure 5-15. EPROM Locations on Digital Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-48

x Chadwick-Helmuth A Business Unit of Honeywell International, Inc.

8500C/8500C+ System Maintenance Manual xi

xii Chadwick-Helmuth A Business Unit of Honeywell International, Inc.

Section 1.1 About This Manual............................................................................................1-1

1.1 About This Manual

1.1.1 Purpose and Function

1.2 System Purpose And Function

8500C/8500C+ System Maintenance Manual 1-1

1.3 System Physical Description

1.3.1 8500C/C+ Balancer/Analyzer (Figure 1-1)

1.3.1.1 Balancer/Analyzer Assembly

1.3.1.2 Printer/Disk Drive Assembly

1-2 Chadwick-Helmuth A Business Unit of Honeywell International, Inc.

The 8500C/C+ printer/disk drive assembly is composed of the following items:

Figure 1-1. 8500C/C+ Balance/Analyzer

8500C/8500C+ System Maintenance Manual 1-3

Figure 1-2. 8520C Signal Selector

1-4 Chadwick-Helmuth A Business Unit of Honeywell International, Inc.

Figure 1-3. System Cables

8500C/8500C+ System Maintenance Manual 1-5

Figure 1-4. System Accessories (not to scale)

1-6 Chadwick-Helmuth A Business Unit of Honeywell International, Inc.

1.3.2 8520C Signal Selector (Figure 1-2)

1.4 Leading Particulars

1.5 Related Publications

Table 1-1. 8500C/C+ Balancer/Analyzer System, Major Components

Part No. Nomenclature Purpose Qty.

8500C/8500C+ System Maintenance Manual 1-7

Table 1-2. System Interconnect Cables

Part No. Nomenclature Purpose Qty.

Table 1-3. Basic System Accessories 1