Test Code: NYT-1992 - C

R a i l V e h i c l e S ys t e m s
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NYT-1992-C
Rev 01: 03/16/2018 - en
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Test Code
Individual Test Rack
LD1000 Air Dryer - FMI Rework
Test Code Doc.-No.: NYT-1992-C
Revision: 01: 03/16/2018 - en
Contact Address
New York Air Brake

748 Starbuck Avenue
Watertown, NY 13601
USA
Phone: +1 315 786 5200
Fax: +1 315 786 5676
www.nyab.com
Confidentiality
The information in this document and the document itself, in

whole or in part, in any form ("Information") is proprietary and/or
confidential property of New York Air Brake, a Knorr
Brake company, and its affiliates and its successors and as-
signees, who retain and reserve all right, title and interest in this
Information in whole or in part and in all forms. This Information
is provided to the original recipient only for confidential use, with
the understanding that it will not be used in any manner detri-
mental to the interests of New York Air Brake, and subject to
return on request. Reproduction, transmission, distribution or
publication of this Information in any form, in whole or in part, for
any purpose without prior written permission of New York Air
Brake is strictly prohibited. © Copyright New York Air Brake. All
rights reserved. CONFIDENTIAL
Revision History
Rev Date Name Para. Description of Change

01 3/16/2018 R. Umstead All Production release
Copyright 2018© Knorr-Bremse AG. All rights reserved, including industrial property rights applications.
Knorr-Bremse AG retains any power of disposal, such as copying and transferring.
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Table of Contents
A GENERAL INFORMATION 4
A.1 Introduction 4
A.2 Technical Changes 5
A.3 Target Group for this Document 5
A.4 Reference Documents 6
A.5 Danger, Warning, Caution, and Notice Messages 7
B TEST RACK SET-UP 8

B.1 Configuration 8
B.2 Settings 8
B.3 Calibration 8
B.4 Rack Setup 9
C LD1000 Component Identification 10
1 Leak Test 11
1.1 Powered Off Leak Test 11
2 Function Test 12
2.1 Setup 12
2.2 Verify Power-Up Sequence 12
3 Shutdown and Preparation for Shipment 13

3.1 De-Pressurize the UUT 13
4 Failure Analysis 14
4.1 Failure Investigation 14
5 SUPPORTING INFORMATION 15
5.1 Abbreviations and Acronyms 15
5.2 Air Dryer Pneumatic Test Schematic: 16
5.3 Check Sheet: LD1000 Air Dryer – FMI Rework 17
The original document was issued in English language.
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A GENERAL INFORMATION
A.1 Introduction
LD1000 air dryers manufactured in 2017 by Parker were made with EPDM valve diaphragms rather than the
specified NBR. EDPM degrades rapidly in the presence of oil. FMI-949 addresses the defect by recalling
and reworking all affected dryers. The LD1000 valve block assembly, which includes the defective dia-
phragms, will be remanufactured and fully tested by Parker. The remanufactured valve blocks will be fitted
to the desiccant stage of the dryer.
This test procedure verifies that the assembly of the two previously tested sub-assemblies is correct and
leak free. Note that the desiccant stage was initially tested as part of the complete LD1000 FAT (factory
acceptance test). The LD1000 valve block sub-assembly testing at Parker verifies full valve block function-
ality equivalent to that done at FAT, including inlet, outlet, and drain valves, heater, sensors, wiring, and
controller.
A.1.1 Applicable Valve Portions:
NOTE:
P/N’s in the shaded regions of the table rep-
resent P/N’s that are not currently supported
by this test program.
P/N Power
791105 72VDC
Table 1-1
The test procedure and sequence of tests of this specification

must be followed as outlined. If, however, it becomes neces-
sary or expedient to deviate from the procedure prescribed, it
can only be done after permission is obtained from NYAB Engi-
neering Department.
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Revision: 01: 03/16/2018 - en
The test procedure includes test outcomes that are identified as

RESULTS or OBSERVATIONS requirements.
 RESULT is a test measurement specific to the function-
al operation of the UUT and identifies a specific UUT
pass or failure criteria.
 OBSERVATION is a test set-up measurement to verify
the test rack or unit under test is appropriately condi-
tioned for the forthcoming test measurement and does
not depict a UUT pass or failure criteria.
The test procedure includes operator interactions that are identi-

fied as VISUAL PROMPT or AUDIABLE SIGNAL requirements.
 VISUAL PROMPT is a visual instructional message
posted to the operator on the Main Operating Screen.
 AUDIABLE SIGNAL is an audible tone enunciated to
the operator.
A.2 Technical Changes

New York Air Brake reserves the right to change the equipment or this document at any time without giving
special notice.
A.3 Target Group for this Document

This test specification is intended for use by the test developer and trained test technicians
Test developers who:

a. Have the skill, experience, safety awareness and professional ability to;
Develop air brake product test procedures and programs
Have the complete working knowledge of specified test rack
Have the general understanding of the unit under test
Test technicians who:

a. Have the skill, experience, safety awareness and professional ability to;
Test air brake products
Operate specified test rack
b. Have read and understand this document in its entirety
c. Are familiar with the safety codes and accident prevention regulations for these activities
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CAUTION
IF IT IS NECESSARY TO PARTIALLY OR COMPLETELY DIS-
ASSEMBLE THE VALVE DURING THE COURSE OF THE TEST,
ADEQUATE RETEST OF THE VALVE MUST BE PERFORMED
IN ORDER TO INSURE PROPER LEAKAGE AND FUNCTION OF
THE VALVE PORTION.
A.4 Reference Documents
Doc. ID Doc. No Title
1 FMI-949-1 HARDWARE UPGRADE
2 792301 INSTL DWG, AIR DRYER
Table 1-2
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A.5 Danger, Warning, Caution, and Notice Messages
The symbols indicate that important personal safety information follows. Carefully read and under-
stand each safety related text message and apply the message to the operation and maintenance of the
system as defined in the safety alert message.
The following are definitions associated with the different safety alert message categories.
The words DANGER, WARNING, and CAUTION are used to identify levels of hazard seriousness for the
safety of the personnel and the equipment.
The word DANGER is used to signify an immediate safety hazard and is used in the following manner:
DANGER
INDICATES AN IMMINENTLY HAZARDOUS SITUATION, WHICH IF NOT
AVOIDED, WILL RESULT IN DEATH OR SERIOUS INJURY. THIS WORD
IS TO BE LIMITED TO THE MOST EXTREME SITUATIONS.
The word WARNING is used to signify safety hazards or unsafe practices and is used throughout this
manual in the following manner:
WARNING
FAILURE TO COMPLY WITH THESE INSTRUCTIONS MAY
LEAD TO IRREVERSIBLE PHYSICAL INJURIES WHICH MAY
HAVE FATAL CONSEQUENCES.
The word CAUTION just like the word WARNING is used to signify safety hazards or unsafe practice in ad-
dition to equipment damage and is used in the following manner:
CAUTION
FAILURE TO COMPLY WITH THESE INSTRUCTIONS MAY
LEAD TO PERSONAL INJURIES AND/OR TO DAMAGE TO THE
UNIT OR THE ENVIRONMENT.
The NOTE (NOTICE) messages are used in the following manner:
NOTE
Notes do not contain any messages relevant to safety.
Notes contain useful hints and additional information used to highlight
suggestions which will result in enhanced installation, reliability, or
operation.
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B TEST RACK SET-UP
HIGH PRESSURE AIR IS PRESENT IN THE TEST RACK AND

ASSEMBLY BEING TESTED. PRESSURE WILL VENT FROM
COCKS AND/OR VALVE EXHAUST PORTS WHEN TEST
RACK VALVES ARE MANIPULATED OR WHEN CONTROL
DEVICES ARE OPERATED. TO MINIMIZE THE RISK OF
PERSONAL INJURY FROM PRESSURE EXHAUSTING, EN-
SURE THAT ALL PERSONS STAND CLEAR OF THE EX-
HAUST PATH AND THAT HEARING PROTECTION AND EYE
PROTECTION ARE WORN AT ALL TIMES.
B.1 Configuration
 2-way Ball Valve – quantity 2
 Pressure Sensor – 150 psi full scale, 0.15 psi accuracy
 Input Power – 72 Vdc, 5A
B.2 Settings
 The test rack pressure settings shall be as indicated below:
Source Setting
Supply Pressure Maintained at 150 psi minimum
Regulator #1 130 psi +/- 1 psi, > 20 scfm flow
capacity
Table B-1
B.3 Calibration
CAUTION
BEFORE ANY COMPONENTS ARE TESTED ON THE TEST
RACK, THE FOLLOWING TESTS MUST HAVE BEEN SUC-
CESSFULLY COMPLETED.
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B.4 Rack Setup
See Section 5.2 - Air Dryer Pneumatic Test Schematic for refer-
ence during Test Rack Setup.
1. Connect the inlet air hose, valve 1, and the pressure indicator to the LD1000 inlet flange (ref.
# 9) using a PN 731061 Ring Gasket and four ½” GR5 bolts. Torque to 50 ft-lbs in a
cross pattern.
2. Connect valve 2 to the LD1000 outlet flange (ref. # 10) using a PN 731061 Ring Gasket and
four ½” GR5 bolts. Torque to 50 ft-lbs in a cross pattern.
3. Connect the 72VDC power supply to the power connector (ref. #8).
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C LD1000 Component Identification
Utilize the component identification labels (#1 through #16) to

identify reference locations of test for Sections 1 Leak Test,
Section 2 Function Test, Section 3 Shutdown and Preparation
for Shipment and Section 4 Failure Analysis.
Ref Description Ref Description

1 Upper Manifold 9 Dryer Inlet
2 Lower Manifold 10 Dryer Outlet
3 Valve Block (LRU) 11 Humidity Indicator
4 Desiccant Filled Columns 12 Dryer Lifting point (Eyebolt not supplied)
5 Water Separator Chamber 13 Condensate Discharge Port
6 General Purpose Coalescer Chamber (Grade AO) 14 Purge Exhaust Port
7 High Efficiency Coalescer Chamber (Grade AA) 15 Coalescing Filter Access Cover
8 Power Connector 16 Identification Plate
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1 Leak Test
Section B.4 Rack Setup steps should be completed prior to

performing all the subsequent tests.
1.1 Powered Off Leak Test
1.1.1 Power OFF, Valve 1 OPEN, Valve 2 CLOSED
1.1.2 Pressurize the UUT to line pressure (130 psi ± 1 psi). Wait 1 minute for pressure to stabilize.
1.1.3 Soap the condensate drain valve exhaust port (ref. #13).
 Result: Leak bubble shall be no more than ½” diameter in 30 seconds.
1.1.4 Soap the Purge Exhaust Port (ref. #14).
 Result: Leak bubble shall be no more than ½” diameter in 30 seconds.
1.1.5 Soap the Humidity Indicator (ref. #11)
 Result: No leakage allowed.
1.1.6 Power OFF, Valve 1 CLOSED , Valve 2 CLOSED
1.1.7 Close Valve 1, to bottle air pressure in the UUT. Starting at 130 psi ± 1 psi:
 Result: Pressure decay shall be no more than 2 psi in 5 minutes.
If the UUT failed the test, then investigate root cause per Sec-
tion 4.1 Failure Investigation, Table 4-1.
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2 Function Test
Section B.4 Rack Setup steps should be completed prior to

performing all the subsequent tests.
2.1 Setup
2.1.1 Power ON, Valve 1 OPEN, Valve 2 CLOSED
 Electrical connector: VEAM CIR06F-16S-1S-F80
2.2 Verify Power-Up Sequence
2.2.1 UUT Circuit A Purge

 Result: Strong initial blast of air from Purge Exhaust Port (ref. #14), followed by
steady blow for a total of approximately 110 seconds, followed by 10 seconds
of repressurization. (2 minute cycle)
2.2.2 UUT Circuit B Purge

 Result: Strong initial blast of air from Purge Exhaust Port (ref. #14), followed by
steady blow for a total of approximately 110 seconds, followed by 10 seconds
of repressurization. (2 minute cycle)
2.2.3 Condensate Drain Valve

 Result: Cycles 2 seconds every 2 minutes
After the power up sequence, the interval between subse-

quent purges is variable and is dependent on outlet air quali-
ty. The on-line cycle (between purges) may range from 2
minutes to 60 minutes.
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2.2.4 Verify On-Line Extension

 Result: Measure time between subsequent purges until on-line interval is greater than 4
minutes.
3 Shutdown and Preparation for Shipment
3.1 De-Pressurize the UUT
3.1.1 Power OFF, Valve 1 CLOSED, Valve 2 Open
3.1.2 Remove the test devices
3.1.3 Cover the LD1000 Inlet and Outlet ports with the supplied protective sheets
3.1.4 Apply a shipping cover to the VV1000T electrical connector.
3.1.5 Verify that Mod-Strike 3 is marked on the Identification Plate (ref. #16)
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4 Failure Analysis
4.1 Failure Investigation
4.1.1 If the UUT failed the test, then investigate root cause:
Test # If Then Action

2 Condensate Valve Leak >.5” in 30 Drain Valve is defec- Replace the Drain
seconds tive Valve
3 Purge Exhaust Leak >.5” in 30 One of the exhaust Replace the Valve
seconds valves is defective Block Assembly
4 Humidity Indicator is leaking Verify torque Tighten to 50 Nm
**RCA needed
5 Pressure decay is > 2 psi in 5 Soap valve Replace interface
minutes and 2, 3, and 4 are tight block/desiccant inter- seals if leak is found.
face. ** RCA needed
6a-6c Defect in the Power Up Sequence Valve block is defec- Replace the Valve
tive Block Assembly
6d If the interval between purges is 2 Either the desiccant Verify the Humidity
minutes for 10 consecutive purg- is over saturated or Sensor reading.
es, ie no extension, the cycle extension **RCA needed
has a defect.
Table 4-1
** if the suggested action does not resolve the test issue, contact NYAB for direction.
Eric Wright Bill Gaudette Grant Helmerci

Chief Engineer Field Service Specialist Manager Supplier Quality
(315) 786-5307 (315) 786-5238 (315) 786-5426
eric.wright@nyab.com William.gaudette@nyab.com Grant.helmerci@nyab.com
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5 SUPPORTING INFORMATION
5.1 Abbreviations and Acronyms

Term Description
# Number
A Amperes
ft-lbs Foot Pounds
LRU Line Replaceable Unit
P/N Part number
psi Pounds per square inch (pressure)
Ref. Reference
scfm Standard Cubic Feet per Minute (Flow)
SN Serial Number
UUT Unit under test
V Volts
VDC Voltage Direct Current
Table 5-1
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5.2 Air Dryer Pneumatic Test Schematic:
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Revision: 01: 03/16/2018 - en
5.3 Check Sheet: LD1000 Air Dryer – FMI Rework
Date: P/N: S/N:

Note: Record data in BLACK ink.
TEST NO. 1 – Leak Test:
1.1.3 Drain Valve Exhaust Port Leakage – less than ½” in 30 seconds Pass / Fail
1.1.4 Purge Exhaust Port Leakage – less than ½” in 30 seconds Pass / Fail
1.1.5 Humidity Indicator Leakage – No leakage allowed Pass / Fail
1.1.7 Leakage – less than 2 psi drop in 5 minutes Pass / Fail
TEST NO. 2 – Function Test:
2.2.1 UUT Circuit A Purge – Strong blast, steady blow for approx. 110 seconds,
followed by 10 seconds of repressurization
(2 minute cycle) Pass / Fail
2.2.2 UUT Circuit B Purge - Strong blast, steady blow for approx. 110 seconds,
followed by 10 seconds of repressurization
(2 minute cycle) Pass / Fail
2.2.3 Condensate Drain Valve – Cycles 2 seconds every 2 minutes Pass / Fail
2.2.4 On-Line Extension – Time between subsequent purges till on-line interval is
greater than 4 minutes. Pass / Fail
TESTER:

Test Code: NYT-1992 - C

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R a i l V e h i c l e S ys t e m s

New York Air Brake

The information in this document and the document itself, in

Rev Date Name Para. Description of Change

B TEST RACK SET-UP 8

C LD1000 Component Identification 10

3 Shutdown and Preparation for Shipment 13

The original document was issued in English language.

A.1.1 Applicable Valve Portions:

The test procedure and sequence of tests of this specification

The test procedure includes test outcomes that are identified as

The test procedure includes operator interactions that are identi-

A.2 Technical Changes

A.3 Target Group for this Document

Test developers who:

Test technicians who:

A.4 Reference Documents

Doc. ID Doc. No Title

1 FMI-949-1 HARDWARE UPGRADE

2 792301 INSTL DWG, AIR DRYER

A.5 Danger, Warning, Caution, and Notice Messages

The NOTE (NOTICE) messages are used in the following manner:

B TEST RACK SET-UP

HIGH PRESSURE AIR IS PRESENT IN THE TEST RACK AND

B.4 Rack Setup

C LD1000 Component Identification

Utilize the component identification labels (#1 through #16) to

Ref Description Ref Description

Section B.4 Rack Setup steps should be completed prior to

1.1 Powered Off Leak Test

1.1.1 Power OFF, Valve 1 OPEN, Valve 2 CLOSED

1.1.4 Soap the Purge Exhaust Port (ref. #14).

 Result: Leak bubble shall be no more than ½” diameter in 30 seconds.

1.1.5 Soap the Humidity Indicator (ref. #11)

 Result: No leakage allowed.

1.1.6 Power OFF, Valve 1 CLOSED , Valve 2 CLOSED

Section B.4 Rack Setup steps should be completed prior to

2.1.1 Power ON, Valve 1 OPEN, Valve 2 CLOSED

 Electrical connector: VEAM CIR06F-16S-1S-F80

2.2 Verify Power-Up Sequence

2.2.1 UUT Circuit A Purge

2.2.2 UUT Circuit B Purge

2.2.3 Condensate Drain Valve

After the power up sequence, the interval between subse-

2.2.4 Verify On-Line Extension

3 Shutdown and Preparation for Shipment

3.1 De-Pressurize the UUT

3.1.1 Power OFF, Valve 1 CLOSED, Valve 2 Open

3.1.2 Remove the test devices

3.1.4 Apply a shipping cover to the VV1000T electrical connector.

4.1 Failure Investigation

Test # If Then Action

Eric Wright Bill Gaudette Grant Helmerci

5.1 Abbreviations and Acronyms

5.2 Air Dryer Pneumatic Test Schematic:

5.3 Check Sheet: LD1000 Air Dryer – FMI Rework

Date: P/N: S/N:

TEST NO. 1 – Leak Test:

1.1.5 Humidity Indicator Leakage – No leakage allowed Pass / Fail

1.1.7 Leakage – less than 2 psi drop in 5 minutes Pass / Fail

TEST NO. 2 – Function Test:

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