UNIT AND DIRECT SUPPORT MAINTENANCE MANUAL
(INCLUDING REPAIR PARTS AND SPECIAL TOOLS LIST)
FOR
IMPROVED
CHEMICAL AGENT MONITOR (ICAM)
(NSN 6665-01-357-8502) (EIC:5AB)
WARNING - This document contains export-controlled technical data whose export is restricted by the Army Export Control Act (Title 22, U.S.C., Sec 2751 et seq) or executive order 12470. Violations of these export laws are subject to sever criminal penalties.
DISTRIBUTION STATEMENT C: Distribution authorized to U.S. Government agencies and their contractors to protect technical or operational information. This determination was made on 12 November, 1991. Other requests for this document will be referred to: Tech Director, U.S. Army Edgewood Research, Development and Engineering Center, ATTN: SCBRD-ENL-V, Aberdeen Proving Ground, MD 21010-5423
DESTRUCTION NOTICE - Destroy by any method that will prevent disclosure of contents or reconstruction of the document.
HEADQUARTERS, DEPARTMENT OF THE ARMY
9 JUNE 1998
WARNING
RADIATION HAZARD
NICKEL-63 (Ni-63)
Wipe test must be performed before and after any maintenance or testing of CAM.
Contamination can become airborne by heated air and smoke from fire. Stand upwind of fire to avoid inhalation of possible contamination.
The Chemical Agent Monitor (CAM) contains a beta radiation source in the quantity which requires a Nuclear Regulatory Commission (NRC) license to possess items which contain the source. The CAM contains 10 millicuries of Nickel-63. The Nickel-63 plated cylinder is the source which ionizes chemical agents allowing for their detection.
If the CAM is lost or stolen, notify the NBC Officer/NCO and the local Radiation Protection Officer (RPO) immediately. Lost or stolen CAMs are reportable to the Nuclear Regulatory Commission (NRC) by the license holder. Report must be made through the local RPO to the Armament and Chemical Acquisition and Logistics Activity (ACALA) Safety Office, DSN 793-2965/2995/6228.
The source is totally enclosed and protected by the CAM case. However the CAM is potentially dangerous if broken.
SAFETY PRECAUTIONS
1. Handle the CAM carefully.
2. If CAM case is broken or cracked, inform the NBC Officer/NCO, and if available, the local Radiation Protection Officer (RPO).
3. A CAM damaged beyond the repair capability of direct support should be wrapped in a plastic bag and shipped in original packing container, if available, to depot maintenance for repair. If skin contact is made with any area thought to be contaminated with Nickel-63, wash immediately with nonabrasive soap and water.
4. Follow safety procedures for storage, shipment, and disposal in accordance with this manual, local regulations, AR 710-3 and AR 385-11.
WARNING
LITHIUM SULFUR DIOXIDE BATTERIES: Do not attempt to decontaminate CAM batteries. Dispose of batteries according to TB 43-0130 and local Standing Operating Procedures (SOP).
FLAMMABLE AND CORROSIVE HAZARD
Lithium sulfur dioxide batteries contain lithium, sulfur dioxide and an electrolyte. Sulfur dioxide is an irritant gas. The electrolyte is flammable and highly corrosive. Do not immerse in water or decon solution, crush, or burn batteries. Do not attempt to recharge batteries or store at temperatures above 158°F (70°C). If a battery is mishandled or misused, the lithium may rapidly vent out, carrying with it the sulfur dioxide gas and the electrolyte, and it may heat up. If this happens, stay away until the smell of sulfur is gone. If you have to move the battery, move it outside by using a shovel or long tongs. Wear suitable protection when handling suspect batteries. A rapidly venting battery may create an explosive and corrosive hazard which may cause damage to skin and eyes. If skin or eyes come in contact with the electrolyte, wash thoroughly with generous amounts of water and seek medical attention. Dispose of batteries according to TB 43-0130 and local SOP.
WARNING
DANGER-HIGH VOLTAGE-1000 VOLTS DC
1000 volts DC is present on the Printed Circuit Board (PCB) when monitor case is removed. Danger of electrical shock exists if PCB is touched while CAM is operating.
CAUTION
Do not decontaminate CAM or its accessories with M258A1 or M280 Decontamination Kits. These kits may cause false positives and temporarily render the CAM inoperative.
FIRST AID
For first aid information, refer to FM 1-11.
TECHNICAL MANUAL HEADQUARTERS
No. 3-6665-343-23&P Department of the Army
Washington, DC, 9 June 1998 UNIT AND DIRECT SUPPORT MAINTENANCE MANUAL
(INCLUDING REPAIR PARTS AND SPECIAL TOOLS LIST) FOR
IMPROVED CHEMICAL AGENT MONITOR (ICAM) NSN 6665-01-357-8502 (EIC:5AB)
REPORTING ERRORS AND RECOMMENDING IMPROVEMENTS
You can help improve this manual. If you find any mistakes or know of a way to improve the procedures, please let us know. Mail your letter, DA Form 2028 (Recommended Changes to Publications and Blank Forms), or DA Form 2028-2 located in the back of this manual directly to Technical Director, U.S. Army Edgewood Research, Development and Engineering Center, ATTN: SCBRD-ENL-V, Aberdeen Proving Ground, MD 21010-5423. A reply will be furnished to you.
WARNING - This document contains export-controlled technical data whose export is restricted by the Army Export Control Act (Title 22, U.S.C., Sec 2751 et seq) or Executive Order 12470. Violations of these export laws are subject to severe criminal penalties.
DISTRIBUTION STATEMENT C: Distribution authorized to U.S. Government agencies and their contractors to protect technical or operational information. This determination was made on 12 November 1991. Other requests for this document will be referred to Technical Director, U.S. Army Edgewood Research, Development and Engineering Center, ATTN: SCBRD-ENL-V, Aberdeen Proving Ground, MD 21010-5423
DESTRUCTION NOTICE - Destroy by any method that will prevent disclosure of contents or reconstruction of the document.
TABLE OF CONTENTS Page CHAPTER 1 Section I Section II Section III Section IV
HOW TO USE THIS
MANUAL---
INTRODUCTION---General Information ---Equipment Description and Data ---Repair Parts, Special Tools; Test, Measurement ---and Diagnostic Equipment (TMDE); ---and Support Equipment
Principles of Operation---iii 1-1 1-1 1-4 1-7 1-8
TABLE OF CONTENTS (CONT) CHAPTER 2 Section I Section II Section III Section IV Section V CHAPTER 3 Section I Section II Section III Section IV Section V APPENDIX A APPENDIX B APPENDIX C Section I Section II Group 00 Group 01 Section III Section IV APPENDIX D Section I Section II APPENDIX E Page UNIT MAINTENANCE INSTRUCTIONS ---2-1
Service Upon Receipt ---2-1 Preventive Maintenance Checks and Services (PMCS)---2-3 Unit Troubleshooting---2-4 Unit Maintenance Procedures --- 2-10 Preparation for Storage or Shipment --- 2-10
DIRECT SUPPORT MAINTENANCE INSTRUCTIONS---3-1
Radiological Safety Instructions---3-1 Service Upon Receipt ---3-4 Direct Support Troubleshooting--- 3-20 Direct Support Maintenance Procedures --- 3-78 Preparation for Storage or Shipment --- 3-142
REFERENCES--- A-1 MAINTENANCE ALLOCATION CHART --- B-1 REPAIR PARTS AND SPECIAL TOOLS LIST --- C-1
Introduction --- C-1 Repair Parts List --- C-1-1 Monitor, Chemical Agent (ICAM) --- C-1-1 Monitor Kit, CAM --- C-2-1 0101 Monitor, Chemical Agent --- C-3-1 010101 Module Assembly, Monitor --- C-4-1 01010101 Monitor Assembly --- C-5-1 0101010101 Module, Drift Tube --- C-6-1 010102 Case Assembly, Monitor --- C-7-1 0102 Carrying Case Assembly--- C-8-1 Special Tools List (Not Applicable)
National Stock Number, Part Number, and Reference Designator Indexes --- C-I-1
EXPENDABLE AND DURABLE ITEMS LIST--- D-1
Introduction --- D-1 Expendable and Durable Items List--- D-2
NUCLEAR REGULATORY COMMISSION REQUIREMENTS --- E-1
INDEX --- Index-1 Illus/ Figure C-1 C-2 C-3 C-4 C-5 C-6 C-7 C-8 ii
HOW TO USE THIS MANUAL
This manual contains a number of features that enable the user to locate information easily. The table of contents contains a general list of information sections. A comprehensive cross-referenced index is located at the end of the manual. It will also help the user locate specific information.
Chapter 1 contains introductory information. Topics of special importance include equipment description and data, location and description of major components, safety, and principles of operation.
Chapter 2 contains information at the unit maintenance level. Topics of special importance include service upon receipt, preventive maintenance checks and services, troubleshooting, maintenance procedures and preparation for storage or shipment.
Chapter 3 contains information at the direct support maintenance level. Topics of special importance include radiological safety instructions, service upon receipt, troubleshooting, maintenance, and preparation for storage or shipment.
When a CAM arrives at Direct Support for repair, use the information in Chapter 3 to test, troubleshoot, repair and retest the CAM. Use the following steps as a guide:
1. Get the equipment required for testing and troubleshooting a CAM. This equipment is listed in para 3-12. Then prepare the Diagnostic Test Set (for use in testing and troubleshooting the CAM) as instructed in para 3-14.
2. Perform the operational check of the CAM presented in para 3-15. If you come to a part of the operational check that cannot be accomplished, refer to the symptom for the problem. (Para 3-11 lists possible symptoms that could occur during the operational check.) Turn to the page in the manual for troubleshooting the symptom.
3. Follow the troubleshooting logic tree for the symptom. The tree will refer you to a maintenance procedure or to further testing. Further testing consists of more detailed tests: cell test, leak test, pump test, and waveform test.
4. Turn to the maintenance procedure and perform the indicated maintenance action. The procedure begins with an initial setup: a listing of the tools and materials needed to complete the task, and the equipment condition prior to performance of the maintenance task. The equipment conditions are a list of the maintenance tasks that must be accomplished before the present task is started. Do the equipment condition tasks first.
5. The specific maintenance task is then performed. The task usually consists of removal and installation procedures. Once the specific task is completed, return to the beginning of the task at the equipment conditions listing. Reverse the order of equipment condition steps to place the CAM back into a fully assembled condition.
6. Return again to the troubleshooting tree for further direction in trouble analysis or additional testing. Tasks in the troubleshooting tree end by performing the operational check to see that the CAM has been completely returned to operational status.
7. Perform wipe test before returning to user (para 3-7).
A Repair Parts and Special Tools List (RPSTL) that lists and authorizes spares and repair parts, tools, special tools, Test, Measurement and Diagnostic Equipment (TMDE), and support equipment required for
performance of maintenance of the CAM is supplied in Appendix C. Refer to page C-1 for detailed information on using the RPSTL.
1. Carrying Case Assembly 2. Carrying Harness Assembly 3. Battery Cap Assembly
4. Environmental Cap 5. Buzzer
6. Chemical Agent Monitor 7. Nozzle Protective Cap
Improved Chemical Agent Monitor (CAM)
CHAPTER 1 INTRODUCTION
Section I. GENERAL INFORMATION 1-1. SCOPE.
NOTE
The monitor, page 1-0 item 6, will show an NSN on the case; however, the monitor itself is not stocked, stored, or issued. To obtain a new monitor the next higher assembly must be requisitioned. (See system NSN on the front of this manual.)
a. Type of Manual. Unit and Direct Support Maintenance including Repair Parts and Special Tools List. b. Model Number and Equipment Name. No model number; Improved Chemical Agent Monitor (ICAM). c. Purpose of Equipment. Used by ground forces to search out clean areas, to search and locate
contamination on personnel, equipment, ships' structures, aircraft and land vehicles, buildings and terrain, and to monitor the boundaries of collective protection. The CAM responds to nerve and mustard agent vapors down to the lowest concentrations that could affect personnel over a short period.
d. Special Limitations on Equipment. The CAM is a monitor. It is not a detector; therefore, it can become
contaminated and overloaded. The CAM only reports conditions at the front of the inlet nozzle. It is only a point monitor and cannot give a realistic assessment of the vapor hazard over an area from one position. Maintenance must be performed in a clean work area and rubber gloves worn to avoid contaminating CAM.
1-2. MAINTENANCE FORMS, RECORDS, AND REPORTS.
a. Maintenance. Department of the Army forms and procedures used for equipment maintenance will be
those prescribed by DA PAM 738-750, The Army Maintenance Management System (TAMMS) as contained in the Maintenance Management Update.
b. Testing and Tracking. For Department of Army procedures for tracking and wipe testing the cell (a
component of the CAM) through its life cycle, refer to AR 710-3, Chapter 3.
c. Shipments/Receipts. When transporting a CAM, refer to AR 385-11. Also see para 3-62 and 3-63. d. Report of Packaging and Handling Deficiencies. Fill out and forward SF 364 (Report of Discrepancy)
as prescribed in AR 735-11-2.
e. Discrepancy In Shipment Report. Fill out and forward Discrepancy in Shipment Report (SF 361) as
prescribed in AR 55-38.
f. Radiological Accident Reports, RCS DD-SD (AR) 1168. Fill out and forward as prescribed in AR
385-40.
1-3. DESTRUCTION OF ARMY MATERIEL TO PREVENT ENEMY USE.
1-4. PREPARATION FOR STORAGE OR SHIPMENT.
Refer to para 3-62 and 3-63 for special instructions concerning storage or shipment.
1-5. NOMENCLATURE CROSS-REFERENCE LIST.
Common Name Battery Cap Assembly Connector Assembly Display Assembly Environmental Cap Long and Short Pillar Nozzle Seal
Official Nomenclature Retainer Battery Connector Receptacle Optoelectronic Display Protective Dust Cap Threaded Standoff Spacer Sleeve 1-6. LIST OF ABBREVIATIONS. AC A/D CAM DC DC-DC DMM DTS EHT G H IMS LCD LED NRC PCB RAM Vdc °C °F Alternating Current Analog/Digital
Chemical Agent Monitor Direct Current
Direct Current to Direct Current Digital Multimeter
Diagnostic Test Set Extra High Tension Nerve Agent Mustard Agent
Ion Mobility Spectrometry Liquid Crystal Display Light Emitting Diode
Nuclear Regulatory Commission Printed Circuit Board
Random Access Memory Volts Direct Current
Degrees Centigrade (Celsius) Degrees Fahrenheit
1-7. REPORTING EQUIPMENT IMPROVEMENT RECOMMENDATIONS (EIR).
If your CAM needs improvement, let us know. Send us a SF 368 (Product Quality Deficiency Report). You, the user, are the only one who can tell us what you do not like about your equipment. Let us know why you do not like the design or performance. Mail it to the address specified in DA PAM 738-750. A reply will be furnished to you.
1-8. SAFETY, CARE, AND HANDLING.
a. Rules and Regulations. The CAM contains a radioactive source which is controlled by the U.S. Nuclear
Regulatory Commission (NRC) under Title 10 Code of Federal Regulations. AR 385-11 and 700-64 implement NRC regulations. Army-wide possession and use of the CAM is authorized by an NRC Byproduct Materials License issued to the Armament and Chemical Acquisition and Logistics Activity, Attn: AMSTA-AC-SF, Rock Island, IL 61299-7630. The license is issued on the basis of statements concerning procedures established for the life-cycle control of the CAM. The CAM units are issued to Army activities through the Armament and Chemical Acquisition and Logistics Activity National Inventory Control Point, (AMSTA-AC-CTC-D). The serial numbers of the CAM and drift tube module are tracked by AR 710-3, Chapter 4, Section 2. Please notify your Cell Serialization Surety Officer (CSSO) to process the serial number transactions with the DOD Central Registry.
b. Wipe test. The wipe test (para 3-7) must be performed upon receipt and before and after all maintenance
and testing is complete.
c. Posting Requirements. Federal law requires certain notices, instructions, and standards be made
available to all users of items which contain licensed radioactive material. In lieu of posting this information, pages are attached at the back of this technical manual for reference. These pages contain instructions about Title 10 Code of Federal Regulations, NRC Form 3 (Notice to Employees) and Public Law 93-438.
d. Repair/Disposition. Unserviceable CAM will be returned to depot. e. Emergency Procedures.
NOTE
In any emergency event, radioactive contamination must be considered to be present until determined otherwise.
(1) Fire. In a fire emergency, the basic concern is possible airborne contamination carried out of the flames by the heated air and in the smoke. Firefighters should fight the fire from upwind, and wear portable air systems, if available. After the fire has been extinguished, debris must be surveyed for the presence of equipment containing Nickel-63 sources. The RADIAC meter AN/VDR-2 (with the beta window open) is suitable for detecting the location of the Nickel-63 sources. Wipes must be taken and evaluated to determine contamination location.
(2) Equipment Destruction. In an equipment destruction emergency, parts of the equipment must be retrieved, and surveys for possible contamination must be done.
(3) Accident Response in General. (a) Remove injured and spectators. (b) Establish exclusion area.
(c) Determine extent of radiation with AN/VDR-2 (or equivalent). (d) Notify authorities (NBC NCO or officer, and, if available, local RPO).
1-9. CORROSION PREVENTION AND CONTROL (CPC).
a. Corrosion Prevention and Control (CPC) of Army Materiel is a continuing concern. It is important that any corrosion problems with this item be reported so that the problem can be corrected and improvements can be made to prevent the problem in future items.
1-9. CORROSION PREVENTION AND CONTROL (CPC) (CONT).
b. While corrosion is typically associated with rusting of metals, it can also include deterioration of materials such as rubber and plastic. Unusual cracking, softening, swelling, or breaking of these materials may be a corrosion problem.
c. Such problems should be reported using SF 368 (Quality Deficiency Report). Mail it to the address specified in DA PAM 738-750.
Use of key words such as corrosion, rust, deterioration, or cracking will assure that the information is identified as a CPC problem.
1-10. CALIBRATION.
The CAM does not require calibration.
Section II. EQUIPMENT DESCRIPTION AND DATA 1-11. EQUIPMENT CHARACTERISTICS, CAPABILITIES, AND FEATURES.
a. Portable, hand-held instrument designed to determine and indicate the hazard from nerve or mustard agent vapor present in the air.
b. Held in either hand while dressed in any level of nuclear, biological, and chemical (NBC) and environmental protective clothing.
c. Used to search out clean areas, to search for and locate contamination on personnel, equipment, ship's structures, aircraft and land vehicles, buildings and terrain, and to monitor the boundaries of collective protection.
d. Responds to nerve and mustard agent vapors down to the lowest concentrations that could affect personnel over a short period.
e. Operates on one battery. Battery life varies with frequency of use and with temperature. At 68°F (20°C), a fresh battery will last at least 12 hours.
f. Can be operated on an external power supply. g. Easy to operate: only two controls.
h. Relative vapor hazard level indicated on a Liquid Crystal Display (LCD).
1-12. LOCATION AND DESCRIPTION OF MAJOR COMPONENTS.
a. Nozzle Protective Cap (1). Protects nozzle assembly and ensures that clean air is sampled when CAM
is started.
b. Nozzle Assembly (2). Chemical agent vapors are drawn in through this inlet for analysis by the CAM. A
heater wire is wound around the tubular section of the molding. Nozzle assembly is secured to CAM with a special bayonet type locking ring. A special tool from the diagnostic test set is used to remove it from the CAM.
c. Case-Front End (3). Provides a common attachment point for the nozzle protective cap, nozzle
assembly, nozzle holder assembly, and drift tube module.
d. Display Assembly (4). Display is a liquid crystal device back-lit by light emitting diodes (LEDs). Display
shows operating status and hazard level, and aids in indicating a malfunction. The ON/OFF and G/H mode switches are part of the assembly. The mode switch controls the polarity of the cell to enable the cell to handle either positive nerve agent ions or negative mustard agent ions. Two sealed rubber pads cover the switch push-buttons.
e. Battery Contact Assembly (5). Provides spring loaded contact to mate with the battery terminals and
interconnect battery power to the CAM.
f. Case Assembly (6). Houses display assembly and battery contact assembly. Case assembly fits over
the monitor module assembly.
1-12. LOCATION AND DESCRIPTION OF MAJOR COMPONENTS (CONT).
h. Locknut (8). Locknut is removed to gain access to the internal parts of the CAM. It also acts as a
retainer for the disc that contains the serial number of the drift tube module and CAM lot number.
i. Environmental Cap Assembly (9). Consists of a tether-bayonet fitting cap protecting the connector
assembly. Provides storage for nozzle protective cap during operation.
j. Connector Assembly (10). Provides diagnostic electronic connections for use during maintenance. k. Sieve Pack Assembly (11). A molecular sieve which filters the CAM recirculatory air.
I. Pump Assembly (12). Consists of two silicone rubber diaphragm pumps driven by a DC motor and yoke
mechanism.
m. Drift Tube Module (13). Consists of a cell assembly, manifold assembly, and membrane assembly. The
cell assembly, which contains the radioactive source, is in the form of a stack of components held together with stainless steel rods and a retaining clip. Two of the rods are drilled with holes to provide airflow paths for the drift and source regions of the cell; the rods also link the return airflow through the molecular sieve assembly and pump assembly. A membrane assembly is located at the forward end of the cell assembly. The membrane assembly is a thin silicone rubber layer that forms a division between the outside air and the controlled environment inside the analysis section of the CAM. The membrane permits chemical agent vapor molecules to permeate the cell assembly. Membrane is heated to about 250°F (120°C). The serial number of the drift tube module is located on a disc near the locknut (8) on the end of the CAM. The serial number is also etched on the manifold block assembly of the drift tube module.
n. Printed Circuit Board (PCB) (14). A printed circuit board that contains the microprocessor.
o. Monitor Module Assembly (15). Consists of a locknut, sieve pack assembly, pump assembly, drift tube
module and printed circuit board.
p. Confidence Sample (16). Used to test the CAM for its ability to detect G and H. The end with a round
cross-section is marked G and contains nerve agent simulant. The ribbed end is marked H and contains mustard agent simulant. Housed in carrying harness pocket.
q. Buzzer (17). Attaches to electrical connector and provides an audible alarm when CAM displays two or
more bars.
Section III. REPAIR PARTS; TOOLS; SPECIAL TOOLS; TEST MEASUREMENT AND DIAGNOSTIC EQUIPMENT (TMDE); AND SUPPORT EQUIPMENT
1-13. COMMON TOOLS AND EQUIPMENT.
For authorized common tools and equipment, refer to the Modified Table of Organization and Equipment (MTOE) applicable to your unit.
1-14. SPECIAL TOOLS, TMDE, AND SUPPORT EQUIPMENT.
Special tools and TMDE are listed in the Maintenance Allocation Chart in Appendix B of this manual. Support equipment is not needed. Additionally authorized items are listed in TM 3-6665-343-10.
1-15. REPAIR PARTS.
Repair parts are listed and illustrated in the Repair Parts and Special Tools List in Appendix C of this manual.
Section IV. PRINCIPLES OF OPERATION 1-16. INTRODUCTION.
The CAM samples air in the immediate vicinity of the nozzle for the presence of G or H chemical agents. Air sample conditions a short distance away from the CAM may be quite different, and a change in wind direction could quickly bring a hazardous level of agent vapor to a previously safe area.
An internal motor/pump assembly (sample pump) continually draws air in through the nozzle assembly. The air is then passed over a heated membrane assembly before being exhausted back into the atmosphere via an exhaust vent at the side of the nozzle assembly. Any agent vapor present in the air permeates the membrane assembly and the cell assembly. In the cell assembly, the vapor molecules are electrically charged (ionized) by a weak radioactive source in order that the vapor molecules can be detected. These charged particles are used to produce an electronic signal by means of a process called Ion Mobility Spectrometry (IMS).
Agent ions in the cell assembly are swept towards a collector electrode which produces an electrical impulse for each ion received. The current produced by this electrode is analyzed by a microprocessor which drives the display assembly. From the characteristics of this signal, CAM determines the concentration of the nerve or mustard agent present and indicates the vapor hazard by displaying a number of bars on the display assembly.
The closed cell assembly system air is circulated by a recirculating pump through molecular sieves which keep the system dry and chemically clean. The G/H mode push button switch reverses the voltages in the cell assembly to suit nerve or mustard agent vapor which have opposite charges when ionized. Acetone vapor is introduced into the closed circulatory system to stabilize the response of the CAM in the nerve agent mode.
Principles of Operation
The CAM has two operating modes, selectable by means of the G/H mode push-button switch: in the G mode, CAM monitors for nerve agents; in the H mode, CAM monitors for mustard agents. The selected mode is indicated on the display assembly by a G or H. An ON/OFF push-button switch applies 6 Vdc battery power to the CAM. Heater
controllers and heaters keep the temperature of the nozzle, membrane, and cell constant for agent detection. A DC-DC converter changes 6 Vdc input to positive or negative 1 kv for cell operation. An analog-to-digital converter changes the varying cell analog output to digital for processing in the microprocessor. The microprocessor output is shown on the liquid crystal display.
THREE DOTS
The three dots on the far right of the display are used normally only as a diagnostic indication.
If at any time during normal operation the processor loses the Reactant Ion Peak (RIP) (i.e., the RIP, always monitored, does not meet the preset height and position criteria), the three dots will be activated. This would normally happen briefly after a mode change or during excessive dosage of agent or simulant (as they have a greater charge affinity than air). During this period, the unit will still operate normally as the processor is using the last known reference for the RIP (from RAM).
If, however, the processor does not find a RIP again within about 30 minutes of its disappearance (normally this would be caused only by either gross contamination or equipment failure), a fault condition signal is given to the operator. This failure signal comprises all eight bars and the WAIT symbol flashing at a frequency of approximately 2Hz.
CHAPTER 2
UNIT MAINTENANCE INSTRUCTIONS
Section I. SERVICE UPON RECEIPT 2-1. INTRODUCTION.
This section provides the information the unit maintenance technician needs to inspect and service the Chemical Agent Monitor (CAM) before issuing it to the operator.
Table 2-1. Service Upon Receipt – CAM
LOCATION/ITEM ACTION
a. Preparation of work area. (1) Clean the work surface. (2) Cover work surface with paper.
(3) Secure paper to work surface with tape, ensuring all seams are sealed.
b. Open packaging carton (1) from top.
c. Lift the CAM Monitor Kit (2) out of the packaging carton and set it aside until further directed. DO NOT OPEN ANY PACKAGES OR CONTAINERS AT THIS TIME.
CAM
d. Save the empty container for future use.
Table 2-1. Service Upon Receipt - CAM (Cont)
LOCATION/ITEM ACTION
e. Open the CAM Monitor Kit:
(1) Squeeze buckle and pull up on strap (1) to open case lid (2); verify that there are two filtered nozzle package assemblies (3) in the case lid (2). DO NOT OPEN FILTERED NOZZLE PACKAGE ASSEMBLIES UNTIL REQUIRED FOR USE.
(2) Lift carrying harness (4); verify that two filtered nozzle packages (5) are located in the carrying harness. DO NOT OPEN
FILTERED NOZZLE PACKAGE ASSEMBLIES UNTIL REQUIRED FOR USE.
(3) Verify the following items are located in the interior pockets of the carrying case (6): nozzle protective cap (7), packaged carrying harness assembly (8), confidence sample (9), buzzer (10), and strap (11). Remove strap (11) from pocket and attach to rings at ends of carrying case (6).
(4) Remove small handle strap (12) from carrying case (6). (5) Remove large handle strap (13) from carrying case (6). (6) Lift CAM (14) from carrying case (6).
(7) Open monitor polyethylene bag (15) and remove CAM (14). (8) Remove and discard two desiccant bags (16) from CAM (14). f. Inspect the equipment for damage incurred during shipment. If the
equipment has been damaged, report the damage on SF 364, Report of Discrepancy.
g. Check the equipment against the packing slip to see if the shipment is complete. Report all discrepancies in accordance with the
instructions of DA PAM 738-750, The Army Maintenance Management System (TAMMS) Update.
h. Turn in to Direct Support to perform wipe and waveform tests.
i. Install battery (para 3-8 steps d, f, and g only). Perform self-test (para 3-9) and confidence test (para 3-10).
Section II. PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) 2-2. UNIT PROCEDURES.
Your Preventive Maintenance Checks and Services (PMCS) table lists the procedures you are required to perform. The interval column tells you when to do the check or service. The procedures column tells how to do the required PMCS. Carefully follow these instructions.
PREVENTIVE MAINTENANCE CHECKS AND SERVICES FOR CAM
Item Interval Item to Procedure
No. Check/Service
1 Weekly CAM Perform a self-test and a confidence test.
Run the CAM until it passes the confidence test, but at least 30 minutes minimum. Run the CAM at least 5 additional minutes after the display bars clear.
NOTE
This procedure is also operator PMCS. See para 2-2 of TM 3-6665-343-10.
2 Annually* CAM Process transactions IAW AR 710-3 and
return CAM with transactions to Direct Support for wipe test.
* Wipe test to be performed annually or at change in ownership if it has not been performed in the past six months.
NOTE
Before you send the CAM for DS maintenance, monitor it for radiation leaks using a RADIAC set, if available. If a leak is detected, place the CAM in a plastic bag before sending it to DS If a RADIAC is not available, or if CAM is damaged, place the CAM in a plastic bag before sending it to DS.
Section III. UNIT TROUBLESHOOTING 2-3. INTRODUCTION.
Use the following index to locate trouble symptoms. You should perform the test/inspections and corrective actions in the order listed, until the malfunction is corrected. If malfunction is not corrected by listed corrective actions, then forward the CAM to Direct Support (para 2-6).
SYMPTOM INDEX
Troubleshooting Procedure
Symptom Page
1. BACKLIGHT NOT OPERATING ... 2. BL SHOWN ON DISPLAY DURING OPERATION ... 3. DISPLAY DOES NOT COME ON OR DISPLAY DISAPPEARS ... 4. DISPLAY FLASHES ON AND OFF... 5. DOES NOT CHANGE MODE FROM G TO H OR H TO G ... 6. DOES NOT CLEAR DOWN TO ZERO OR ONE BAR IN 2 MINUTES
(OR 5 MINUTES FOR FIVE OR MORE BARS) ... 7. DOES NOT CLEAR DOWN TO ZERO OR ONE BAR BEFORE SHUTDOWN ... 8. DOES NOT RESPOND TO CONFIDENCE SAMPLE (SIMULANT) ... 9. ONE OR MORE DISPLAY INDICATORS DO NOT SHOW DURING SELF-TEST... 10. REMAINS IN SELF-TEST FOR MORE THAN 30 SECONDS ... 11. REMAINS IN WAIT FOR LONGER THAN 2 MINUTES ... 12. BUZZER DOES NOT SOUND WHEN DISPLAY SHOWS TWO BARS OR MORE...
2-5 2-5 2-5 2-5 2-6 2-6 2-7 2-7 2-8 2-8 2-9 2-9
Table 2-3. Unit Troubleshooting
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION 1. BACKLIGHT NOT OPERATING.
Step 1. No test or inspection required; proceed to corrective action. Turn CAM off.
Forward CAM to Direct Support (para 2-6). 2. BL SHOWN ON DISPLAY DURING OPERATION.
Step 1. No test or inspection required; proceed to corrective action. Turn CAM off.
Replace battery.
Forward CAM to Direct Support (para 2-6). 3. DISPLAY DOES NOT COME ON OR DISPLAY DISAPPEARS.
Step 1. No test or inspection required; proceed to corrective action. Turn CAM off.
Remove battery cap assembly. Step 2. Check that battery is present.
Install battery with terminal end toward display. Press ON/OFF push-button switch.
Turn CAM off. Replace battery.
Forward CAM to Direct Support (para 2-6). 4. DISPLAY FLASHES ON AND OFF.
Step 1. No test or inspection required; proceed to corrective action.
Make sure filtered nozzle standoff is removed and protective cap assembly is attached on front of CAM case.
Turn CAM off. Wait 2 seconds. Step 2. Perform self-test (para 3-9).
Look for BL indication after the self-test is complete. Replace battery if necessary.
Table 2-3. Unit Troubleshooting (Cont)
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION 4. DISPLAY FLASHES ON AND OFF (CONT). Let CAM run for 20 minutes. Turn CAM off. Wait 2 seconds.
Step 3. Perform self-test (para 3-9) and confidence test (para 3-10). Forward CAM to Direct Support (para 2-6).
5. DOES NOT CHANGE MODE FROM G TO H OR H TO G.
Step 1. No test or inspection required; proceed to corrective action. Press G/H mode push-button switch.
Step 2. Check that display does not indicate change in mode. Forward CAM to Direct Support (para 2-6).
6. DOES NOT CLEAR DOWN TO ZERO OR ONE BAR IN 2 MINUTES (OR 5 MINUTES FOR FIVE OR MORE BARS).
Step 1. No test or inspection required; proceed to corrective action. Remove the filtered nozzle standoff.
Install nozzle protective cap onto CAM front end (para 3-10, steps h through j). Let CAM run for 15 minutes.
Clean vertical face of case front-end with a cloth dampened with water. Step 2. Repeat self-test (para 3-9) and confidence test (para 3-10).
Table 2-3. Unit Troubleshooting (Cont)
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
7. DOES NOT CLEAR DOWN TO ZERO OR ONE BAR BEFORE SHUTDOWN. Step 1. No test or inspection required; proceed to corrective action.
Make sure CAM runs with protective cap on nozzle for at least 1 hour.
Remove protective cap from CAM nozzle and twist (clockwise) onto CAM environmental cap. Turn CAM off.
Decontaminate the CAM nozzle assembly with a cloth dampened with water. Install protective cap onto nozzle.
Turn CAM on. The number of bars displayed should decrease with the cap on. If number of bars increases, the nozzle protective cap is contaminated.
If CAM does not clear within 15 minutes, replace nozzle protective cap. Turn CAM on and let run for an additional 15 minutes.
Forward CAM to Direct Support (para 2-6).
8. DOES NOT RESPOND TO CONFIDENCE SAMPLE (SIMULANT).
Step 1. No test or inspection required; proceed to corrective action.
Make sure CAM runs for at least 15 minutes. CAM may require an extra warm-up period if it has been in storage.
Wait 10 seconds and repeat the 1 second exposure. This can be done up to five times.
Run CAM 5 minutes.
Step 2. Repeat confidence test (para 3-10) using another confidence sample, if available. Remove filtered nozzle standoff.
Install nozzle protective cap onto CAM front end (para 3-10, steps h through j). Turn CAM off. Wait 2 seconds.
Step 3. Perform self-test (para 3-9).
Let CAM operate for 1 hour. (Disregard display during the hour.) Turn CAM off. Wait 2 seconds.
Table 2-3. Unit Troubleshooting (Cont)
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
8. DOES NOT RESPOND TO CONFIDENCE SAMPLE (SIMULANT)(CONT). Step 4. Repeat self-test (para 3-9) and confidence test (para 3-10).
Remove filtered nozzle standoff; install nozzle protective cap onto CAM front end (para 3-10, steps h through j).
Turn CAM on. Let CAM run 30 minutes. Turn CAM off. Wait 2 seconds.
Step 5. Repeat self-test (para 3-9) and confidence test (para 3-10). Forward CAM to Direct Support (para 2-6).
9. ONE OR MORE DISPLAY INDICATORS DO NOT SHOW DURING SELF-TEST.
NOTE
Either G or H mode show on the display, never both at the same time. Step 1. No test or inspection required; proceed to corrective action.
Turn CAM off. Wait 2 seconds. Step 2. Repeat self-test (para 3-9).
Forward CAM to Direct Support (para 2-6). 10. REMAINS IN SELF-TEST FOR MORE THAN 30 SECONDS.
Step 1. No test or inspection required; proceed to corrective action. Turn CAM off. Wait 2 seconds.
Step 2. Repeat self-test (para 3-9).
Forward CAM to Direct Support (para 2-6).
Table 2-3. Unit Troubleshooting (Cont)
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
11. REMAINS IN WAIT FOR LONGER THAN 2 MINUTES.
Step 1. No test or inspection required; proceed to corrective action. Turn CAM off. Wait 2 seconds.
Step 2. Repeat self-test (para 3-9). Let CAM run up to 30 minutes.
If CAM remains in WAIT again, let CAM run another 30 minutes. Turn CAM off. Wait 2 seconds.
Step 3. Repeat self-test (para 3-9).
If CAM does not clear within 2 minutes, replace nozzle protective cap assembly. Turn CAM on. Let CAM run for up to 30 minutes.
Forward CAM to Direct Support (para 2-6).
12. BUZZER DOES NOT SOUND WHEN DISPLAY SHOWS TWO BARS OR MORE. Step 1. Replace the buzzer battery.
Step 2. Repeat confidence test (para 3-10). Forward CAM to Direct Support (para 2-6).
Section IV. UNIT MAINTENANCE PROCEDURES 2-4. INTRODUCTION.
Unit maintenance is limited to inspection and fault verification.
Section V. PREPARATION FOR STORAGE OR SHIPMENT 2-5. STORAGE.
a. Remove battery from CAM. Store battery separately from CAM. Install and turn (clockwise) battery cap on CAM. b. Store CAM in rooms/areas/sections designated for storage of radioactive materials which are free from the danger of flooding, outside the danger radius of flammables or explosives, and secured against unauthorized removal.
c. Post the area with CAUTION - RADIOACTIVE MATERIAL signs as required.
d. The signs shall be yellow with magenta letters and radiation symbol at least 8 inches by 10 inches. Post signs on outside of lockable containers.
e. Storage of a single CAM must be in a secure area; the area does not need to be marked. f. Process transactions as required by AR 710-3.
2-6. SHIPMENT.
a. Remove battery from CAM. Install and turn (clockwise) battery cap on CAM. b. Place CAM in carrying case assembly and return to Direct Support.
CHAPTER 3
DIRECT SUPPORT MAINTENANCE INSTRUCTIONS Section I. RADIOLOGICAL SAFETY INSTRUCTIONS
WARNING
RADIATION HAZARD
NICKEL-63 (Ni-63)
Wipe test must be performed before and after any maintenance or testing of Chemical Agent Monitor (CAM).
CAUTION
To avoid contamination of equipment DO NOT: Smoke, eat, or drink in work area. Use aftershave or perfume.
Use cleaning agents, floor wax sprays, adhesives, paint, or similar items. Use insect or skin repellents.
Handle internal parts without wearing rubber gloves.
NOTE
CAM performance may be affected by EMI when attached to the DTS. Avoid performing maintenance tasks near equipment emitting high electromagnetic radiation.
3-1. WORK AREA. INITIAL SETUP Tools/Equipment
RADIAC Set AN/VDR-2 (or equivalent)
Materials/Parts
Paper (Item 5, App D) Tape (Item 8, App D) Gloves (Item 4, App D) Plastic Bag (Item 1, App D) Wipe Test Kit (Item 10, App D) Ball Point Pen (Item 6, App D) Soap (Item 7, App D)
3-1. WORK AREA (CONT).
a. Preparation of Work Area.
(1) Clean the work surface. (2) Cover work surface with paper.
(3) Secure paper to work surface with tape, insuring all seams are sealed.
b. Work Area Cleanup and Decontamination. NOTE
Work area must be wiped and the wipe surveyed with AN/VDR-2, or equivalent, for presence of Nickel-63 contamination at conclusion of work EACH day that maintenance operations are performed. Surveys must be documented.
(1) Record wipe test information IAW para 3-7. a. Identify the area (e.g., Bldg 51) on the form. Set aside vial and form.
(2) Wear disposable gloves.
(3) Fold paper inward to hold in contamination and place in plastic bag.
(4) Take a wipe test of the area with a moistened wipe test filter from the wipe test kit (Item 10, App D). Evaluate the wipe test filter with AN/VDR-2, or equivalent. It should read no more than twice background. If the reading is higher, stop cleanup and contact the RPO.
(5) Dispose of gloves in plastic bag. Seal bag.
(6) Using a ball point pen, mark: "RADIOACTIVE MATERIAL Ni-63" on a piece of tape and apply the tape to the plastic bag. Set aside bag pending lab results of wipe test.
(7) Place the wipe test filter in the prepared vial. Send this wipe test for evaluation to the Rock Island Laboratory identified in para 3-7, along with the CAM wipes.
(8) Wash hands for 2 minutes with soap at conclusion of maintenance or testing of CAM and at conclusion of any work area cleanup operations.
(9) Dispose of bag as regular or radioactive waste, depending upon lab test results.
3-2.
ACCOUNTABILITY.
For instructions on completing necessary transactions, contact your Cell Serialization Surety Officer (CSSO) in accordance with AR 710-3, Chapter 4, Section 2. A transaction is required for each of the following:
a. Inventory loss.
c. Receipt. d. Shipment. e. Demilitarization. f. Wipe test result.
g. Removal of a drift tube module from CAM. h. Insertion of a drift tube module into CAM.
3-3. FIRE AND EXPLOSION EMERGENCIES. a. Fire Emergencies.
WARNING
RADIATION HAZARD
NICKEL-63 (Ni-63)
Contamination can become airborne by heated air and smoke from fire. Stand upwind of fire to avoid inhalation of possible contamination.
(1) Notify all personnel to evacuate area or building and to stand upwind of heat and smoke.
(2) Notify fire department of fire and possible hazards, and that self-contained breathing apparatus should be worn.
(3) Turn off all ventilation equipment. (4) Close all doors and windows.
(5) Notify your NBC NCO or Officer, or RPO.
b. Explosion Emergencies.
(1) Care for injured (FM 21-11).
(2) Notify your NBC NCO or Officer, or RPO. (3) Notify medical team.
(4) Cordon off area.
Section II. SERVICE UPON RECEIPT
3-4.
INTRODUCTION.
This section describes unpacking, checking unpacked equipment, wipe test, assembly and preparation of CAM for use, self-test, and confidence test.
3-5. UNPACKING.
a. Preparation of Work Area. (1) Clean the work surface. (2) Cover work surface with paper.
(3) Secure paper to work surface with tape, insuring all seams are sealed. b. Open packaging carton (1) from top.
c. Lift the CAM Monitor Kit (2) out of the packaging carton and set it aside until further directed: DO NOT OPEN ANY PACKAGES OR CONTAINERS AT THIS TIME.
e. Open the CAM Monitor Kit:
(1) Pull up on strap (1) to open case lid (2); verify that there are two filtered nozzle package assemblies (3) in the case lid (2). DO NOT OPEN FILTERED NOZZLE PACKAGE ASSEMBLIES UNTIL REQUIRED FOR USE.
(2) Lift carrying harness (4); verify that two filtered nozzle packages (5) are located in the carrying harness. DO NOT OPEN FILTERED NOZZLE PACKAGE ASSEMBLIES UNTIL REQUIRED FOR USE.
(3) Verify the following items are located in the interior pockets of the carrying case (6): nozzle protective cap (7), packaged carrying harness assembly (8), confidence sample (9), buzzer (10), and strap (11). Remove strap (11) from pocket and attach to rings at ends of carrying case (6).
(4) Remove small handle strap (12) from carrying case (6). (5) Remove large handle strap (13) from carrying case (6). (6) Lift CAM (14) from carrying case (6).
(7) Open monitor polyethylene bag (15); remove CAM (14). (8) Remove and discard two desiccant bags (16) from CAM (14).
3-6. CHECKING UNPACKED EQUIPMENT.
a. Inspection. Inspect the equipment for damage incurred during shipment. If the equipment has been
damaged, report the damage on SF 364, Report of Discrepancy.
b. Check the equipment against the packing slip to see if the shipment is complete. Report all discrepancies in
accordance with the instructions of DA PAM 738-750, The Army Maintenance Management System (TAMMS) Update.
3-7. WIPE TEST.
WARNING
Do not lick envelopes to seal them or ingestion of Nickel-63 may result.
NOTE
Perform wipe test annually or at change in ownership if it has not been performed in the past six months.
a. Recording Information.
(1) If needed, make additional copies of the RIA Wipe Test Request Form that is supplied in the wipe test kit (Item 10, App D).
(2) Record the following information on the Wipe Test Request Form: complete mailing address, POC, DSN or commercial phone and fax numbers, date wipes were taken, and reporting activity DODAAC. Use a ball-point pen (Item 6, App D).
(3) Using the felt marker provided in the kit, assign a number to the top of the cap of the plastic vial.
NOTE
Do not mark on the side of the plastic vial or the wipe test may not be readable.
(4) Mark the same number in the column marked "VIAL NO." on the Wipe Test Request Form along with the corresponding owning activity DODAAC. Indicate an A for annual wipe or M for maintenance wipe. b. Wipe Test Procedures.
NOTE
To avoid mixing up samples, perform each wipe test after recording each CAM's serial number on the Wipe Test Request Form.
(1) Wear disposable gloves.
(2) Twist (counterclockwise) and remove environmental cap (1) from CAM (2). Let environmental cap hang on its tether (3).
(3) Record the CAM serial number from the side of the CAM (4) and the drift tube module serial number from the disc on the end of the CAM (view A) on the same line of the Wipe Test Request Form that the vial number is recorded on.
(4) Moisten a wipe test filter with 2 or 3 drops of water from the kit or clean tap water.
(5) Wipe the exterior of the CAM (2) around the nozzle protective cap assembly (5), along the case seal and around the environmental cap(1).
(6) Using a RADIAC set, AN/VDR-2 (or equivalent) check the wipe test filter for contamination as follows:
NOTE
Perform the following procedures in an area that is free from all radiation, except for normal background radiation.
* This is a manufacturer number (it will vary) VIEW A
(a) Adjust AN/VDR-2 (or equivalent) to measure 0 to 0.5 mR/hr. (b) Open the beta shield of the probe of the AN/VDR-2 (or equivalent).
(c) Place wipe test filter approximately 1/4 in. in front of the probe and note the indication. DO NOT TOUCH THE PROBE WITH THE WIPE TEST FILTER.
WARNING
Any sustained reading of the AN/VDR-2 (or equivalent meter) that is twice background may indicate Nickel-63 contamination. If the reading is over twice background, discontinue use of the CAM, place it in a plastic bag and store it in a secure radioactive material storage area until the wipe test is analyzed by the laboratory, to verify that Nickel-63 contamination is present. Notify your RPO, and have supply personnel coordinate shipment with the ACALA item manager, DSN 793-5961/5916. If the sustained reading is less than twice background level, the CAM may be returned to use. The wipe test will be verified by the laboratory stated in step (9).
(7) Place wipe test filter into the plastic vial and screw the cap on the vial.
3-7. WIPE TEST (CONT).
WARNING
Do not lick packaging envelopes to seal them or ingestion of Ni-63 may result.
(8) Place the numbered vial(s) along with the Wipe Test Request Form in the pre-addressed packaging envelope provided or other sturdy packaging. Seal the package. Mark the envelope: MAIL ROOM - DO NOT OPEN.
(9) Mail samples to the following address: Commander, Rock Island Arsenal
Radiation Test Lab/Radiation Wipe Test Samples ATTN: SIORI-SEL/RIA RPO
Rodman Ave. Bldg 210, Room 407 Rock Island, IL 61299-5000
(10) Results of the wipe test evaluated by the laboratory will be sent to the address entered on the Wipe Test Request Form.
(11) The CAM can be used immediately after wipe testing unless leakage of Nickel-63 is suspected or an accident has occurred.
(12) Proceed with work area cleanup and Decontamination (para 3-1b) or Direct Support troubleshooting (para 3-11) as appropriate.
3-8.
ASSEMBLY AND PREPARATION OF CAM FOR USE.
a. Assemble carrying harness to CAM:
(1) If not already buckled, remove twists from carrying harness (1) and fasten buckle (2).
(2) Place small handle strap (3) around forward part of handle (4); snap the end (5) of the carrying harness that contains filtered nozzle package assembly (6) to the small handle strap (3).
(3) Place large handle strap (7) around rear section of handle (4) as shown. Snap end (8) of carrying harness to large handle strap (7).
b. Remove vapor proof barrier (1) from confidence sample (2). Place confidence sample (2) in carrying harness pocket (3).
c. Twist (counterclockwise) and remove battery cap assembly (1) from monitor case assembly (2). d. Pull desiccant bag (3) from CAM (4) and discard.
3-8. ASSEMBLY AND PREPARATION OF CAM FOR USE (CONT).
e. Install battery (1) into CAM. Ensure that terminal end of battery is inserted first.
NOTE
If the CAM makes a humming sound and/or if the display shows an indication when the battery cap assembly is installed in the next step, press the ON/OFF (2) push-button switch one time.
f. Install and turn (clockwise) battery cap assembly (3) onto CAM.
g. Perform self-test (para 3-9). If CAM fails self-test, refer to troubleshooting (para 3-11).
h. Remove battery. Prepare DTS for use (para 3-14). Perform waveform test (para 3-61). Let CAM run until it reaches peak heights (step m) of 2 volts in each mode, up to 8 hours.
i. Perform confidence test (para 3-10). If CAM fails confidence test, refer to troubleshooting (para 3-11). j. Let CAM run at least 2 hours. Disconnect CAM from DTS.
WARNING
FLAMMABLE AND CORROSIVE HAZARD
Lithium-sulfur dioxide batteries contain lithium, sulfur dioxide and an electrolyte. Sulfur dioxide is an irritant gas. The electrolyte is flammable and highly corrosive. Do not immerse in water or decon solution, crush, or burn batteries. Do not attempt to recharge batteries or store at temperatures above 158°F (70°C). If a battery is mishandled or misused, the lithium may rapidly vent out, carrying with it the sulfur dioxide gas and the electrolyte, and it may heat up. If this happens, stay away until the smell of sulfur is gone. If you have to move the battery, move it outside by using a shovel or long tongs. Wear suitable protection when handling suspect batteries. A rapidly venting battery may create an explosive and corrosive hazard which may cause damage to skin and eyes. If the skin or eyes come in contact with the electrolyte, wash thoroughly with generous amounts of water, and seek medical
attention. Dispose of batteries according to TB 43-0130 and local SOP.
3-8. ASSEMBLY AND PREPARATION OF CAM FOR USE (CONT).
k. Place CAM (1) into carrying case (2).
I. Close lid (3) of carrying case (4). Slide hand along hook-and-loop fastener (5) to seal carrying case closed. m. Clip cover buckle (6) into case buckle (7).
3-9. SELF-TEST.
a. Ensure that nozzle protective cap assembly (1) is in position on CAM (2).
b. Press ON/OFF push-button switch (3) and observe the display for the following indications (1) through (8); if indications are not shown, refer to troubleshooting section (para 3-11).
(1) H mode (4) is shown; if G mode is shown, press G/H mode push-button switch (5). Verify H mode is shown.
(2) Markers A and B (6) are shown. (3) All eight bars (7) are shown. (4) Three vertical dots (8) are shown. (5) BL (9) is shown.
(6) WAIT (10) is shown.
3-9. SELF-TEST (CONT).
(7) Display clears from self-test after 30 seconds (H mode, WAIT, and A and B markers remain).
NOTE
Self-test is now complete. (8) Display clears from WAIT mode within 2 minutes.
NOTE
In very cold conditions, the battery may not immediately reach operating level (BL may not go out). If BL is still displayed after 5 minutes, repeat step b.
An extended warm up period may be necessary if a CAM has been in storage 30 days or longer. Allow CAM to run until it will pass confidence test (para 3-10), but not more than 72 hours.
3-10. CONFIDENCE TEST.
CAUTION
Nozzle protective cap must be stored on environmental cap when not on the front of the CAM.
Do not touch the nozzle assembly or the new filtered nozzle standoff; touching could contaminate them.
Remove and install nozzle protective cap and nozzle standoffs as quickly as possible to avoid dust or other contamination from entering the CAM protective cap or nozzle.
a. Twist (counterclockwise) and remove nozzle protective cap (1) from front of CAM (2); place nozzle protective cap onto CAM environmental cap (3) and twist clockwise.
3-10. CONFIDENCE TEST (CONT).
b. Place a filtered nozzle standoff onto CAM nozzle assembly, as follows:
(1) Pull one filtered nozzle package assembly (1) from pocket (2) of carrying harness.
(2) Peel back covering (3) from top of filtered nozzle package assembly (1) until one filtered nozzle standoff (4) is exposed.
(3) Press CAM nozzle assembly (5) into exposed filtered nozzle standoff (4) and remove.
(4) Lay covering (3) back in place across top of filtered nozzle package assembly (1). Slide package assembly (1) back into pocket (2) of carrying harness.
c. Remove environmental cap (6) and nozzle protective cap (7) combination by twisting counterclockwise. Install buzzer (9) onto electrical connector by twisting the ring (8) clockwise.
NOTE
Make sure CAM display indicates H Mode.
Your confidence sample may be different in appearance and operation (depending on when it was produced), but will provide the same result.
d. Remove confidence sample from carrying harness and perform H confidence test as follows: (1) Grasp confidence sample (1) with H end valve exposed.
CAUTION
Do not allow the CAM to sample the confidence sample for more than 1 second. Longer than 1 second will saturate the CAM with vapor. It is only necessary that at least three bars show for test verification (do not attempt to have all bars show).
(2) Insert CAM nozzle assembly (2) in H end of confidence sample (1) for 1 second, depressing valve (confidence sample should touch filtered nozzle standoff).
(3) Remove confidence sample (1).
(4) Verify that at least three (3) bars are displayed and buzzer sounds after a few seconds. Three dots may appear momentarily; ignore them. If at least three bars do not appear, wait 10 seconds and repeat the 1 second exposure. You may do this up to five times, waiting at least 10 seconds between each try. If at least three bars still do not appear, refer to troubleshooting symptom 17 (para 3-32). If the buzzer does not sound, refer to troubleshooting symptom 21 (para 3-36).
3-10. CONFIDENCE TEST (CONT).
(5) Wait for display to clear. Display should clear to either zero or one bar within 2 minutes. (If display shows five or more bars, CAM may need approximately 5 minutes to clear.)
e. Press G/H mode push-button switch (1); verify mode changes from H to G (2). WAIT may be displayed for several seconds. When WAIT has disappeared, proceed. The three dots may also appear following the mode change.
f. Perform G confidence test the same as the H confidence test using the G end of the confidence sample. g. Place confidence sample (3) into pocket (4) of carrying harness (5).
h. Remove and discard filtered nozzle standoff (1) from nozzle assembly (2).
i. Twist (counterclockwise) and remove nozzle protective cap assembly (3) from environmental cap (4). j. Twist and install nozzle protective cap assembly (3) to CAM case front-end (5).
k. Remove buzzer (7) from electrical connector and install environmental cap (4) on electrical connector.
CAUTION
Do not switch CAM off when one or more bars are showing because this action stops the purging of any contaminant remaining; this would extend the warm up time on future use.
NOTE
CAM normally clears down to either zero or one bar within 2 minutes. If CAM is contaminated, it may take at least 1 hour to clear down to zero bars.
I. Observe display (6). If display shows zero bars, press G/H push-button switch to change modes of operation. Observe display (6).
m. Make sure CAM has cleared down to zero bars in both modes. Press ON/OFF push-button switch to turn CAM off. If CAM fails to clear down, in either mode, within 1 hour, refer to troubleshooting (para 3-11).
Section III. DIRECT SUPPORT TROUBLESHOOTING 3-11. INTRODUCTION.
WARNING
RADIATION HAZARD
NICKEL-63 (NI-63)
Wipe test must be performed before and after any maintenance or testing of CAM.
When a CAM is sent to DS for repair, the performance of the CAM is first checked by an operational check. When a fault occurs during the operational check, the maintainer goes to the troubleshooting logic tree for the symptom of the fault.
The troubleshooting logic tree leads the maintainer through step-by-step procedures to determine that there is a malfunction and then to isolate the trouble to the malfunctioning assembly or part. The logic tree will reference tests and maintenance procedures (in section IV) where needed. At any point during the referenced tests that the indications are not as required, the maintainer returns to the logic tree. The logic tree will tell the maintainer what to do if the test has failed.
Once the CAM has been repaired, it is again checked by the operational check to determine that the CAM is ready for a mission.
Use the following index to locate information in this troubleshooting section.
Subject
EQUIPMENT REQUIRED ... CLEAN WORK SURFACE ... PREPARATION OF DIAGNOSTIC TEST SET FOR USE... OPERATIONAL CHECK ... TROUBLESHOOTING SYMPTOMS
1. MECHANICALLY BROKEN PUSH-BUTTON SWITCH OR CRACKED
OR BROKEN DISPLAY ... 2. PUMP NOT RUNNING ... 3. CAM AMPS NOT BETWEEN 3.6 AND 6.0, OR CAM DOES NOT COME ON ... 4. ALL INDICATIONS ARE NOT DISPLAYED DURING SELF-TEST ... 5. DISPLAY DOES NOT COMPLETE SELF-TEST OR BL IS DISPLAYED
WHEN CAM IS POWERED BY DTS ... 6. WAIT IS DISPLAYED LONGER THAN 2 MINUTES ... 7. BL NOT SHOWN WHEN BATT LOW SWITCH IS PRESSED ... 8. NO DISPLAY OR BL DISPLAYED AFTER SELF-TEST WHEN CAM IS
POWERED BY BATTERY ... 9. NOZZLE FLOW IS LESS THAN 200 ml/min ... 10. GATE WIDTH, GATE HEIGHT, OR PULSE WIDTH NOT WITHIN
SPECIFICATION ... 11. NOISE LEVEL IN WAVEFORM TEST IS EXCESSIVE ... 12. SECONDARY PEAKS PRESENT IN WAVEFORM TEST OR CAM WILL NOT
CLEAR DOWN ... 13. DC OFFSET IS GREATER THAN 1V... 14. (G OR H) PEAK HEIGHTS OR RATIO OF TIMES NOT WITHIN
SPECIFICATION ... 15. CELL DOES NOT PASS CELL TEST ... 16. MONITOR MODULE FAILS LEAK TEST ... 17. DOES NOT RESPOND TO CONFIDENCE SAMPLE ... 18. DISPLAY FLASHES ON AND OFF ... 19. DOES NOT CHANGE MODE FROM G TO H OR H TO G ... 20. NO DISPLAY OR BL DISPLAYED AFTER SELF-TEST WHEN CAM IS
POWERED BY DTS ... 21. BUZZER DOES NOT SOUND WHEN DISPLAY SHOWS TWO BARS OR MORE ...
Para 3-12 3-13 3-14 3-15 3-16 3-17 3-18 3-19 3-20 3-21 3-22 3-23 3-24 3-25 3-26 3-27 3-28 3-29 3-30 3-31 3-32 3-33 3-34 3-35 3-36 3-21
3-12. EQUIPMENT REQUIRED.
The following equipment is required to troubleshoot the CAM: Tool Kit, Electronic Equipment TK-105/G
Oscilloscope, Dual Trace, AN/USM-488 Multimeter, Digital, AN/PSM-45A (DMM) CAM Diagnostic Test Set
Wrench, Torque (4-120 lb in. 3/8 in. drive) Screwdriver, Torque (10-120 oz in.) Adapter
Socket (30A/F 1/2 in. drive)
Bit, Screwdriver (1/4 in. A/F Hex Shank, cross-tipped) Blade, Screwdriver (1/4 in. A/F Hex Shank)
Bit, Screwdriver (1/4 in. A/F Hex Shank, posidrive) Power Supply
3-13. CLEAN WORK SURFACE.
Clean the work surface (Para 3-1). Place clean paper (Item 5, App D) across the top of the surface.
3-14. PREPARATION OF DIAGNOSTIC TEST SET FOR USE.
a. Release 12 knurled case lid knobs and remove case lid. b. Inspect inside lid knobs and remove case lid.
(1) Container (for soap solution) (1) (2) Chassis assembly (2)
(3) Nozzle extraction tool (3)
(4) Battery contact assembly tool (4) (5) Nozzle flexible hose (5)
(6) Cell flexible hose (6)
(7) Partition (7) with the following items: (a) Battery contact extraction tool (8) (b) H.V. monitor adapter assembly (9)
(c) H.V. leads, test assembly (black and red) (9A) (d) CAM power lead (W1) (10)
(e) Cell heater lead assembly (W5) (11) (f) Display connector (W2) (12)
(g) Main cord set (W3) (13) (h) Cell lead (W4) (14)
(i) Cell assembly to body assembly tool (15) (posidrive screwdriver)
3-14. PREPARATION OF DIAGNOSTIC TEST SET FOR USE (CONT).
c. Using the container of soap solution from the lid of the DTS, remove and fill the bulb (1) of the LEAK TEST flowmeter approximately three-quarters full of solution and replace bulb on flowmeter. Return bottle to lid of DTS for storage.
d. Check that the 115 or 230 switch (2) is switched to proper voltage; if incorrect, remove two screws (3) and shield (4). Set switch to proper voltage. Reinstall shield and two screws.
WARNING
Make sure DTS SUPPLY switch (13) is down (off) to avoid electrical shock. e. Connect main cord set W3 (5) to DTS connector (6) and then to 115 V ac source power. f. Connect W1P1 end of CAM power lead W1 to DTS CAM I/O connector (7).
g. Connect W2P2 end of display connector W2 to DTS 25 PIN connector (8). h. Connect W4P1 end of cell lead W4 to DTS 9 PIN connector (9).
NOTE
The meter indicates arbitrary units of measure - not actual volts or amperes. Therefore, the reading limits specified in the troubleshooting procedures should only be associated with use of the DTS.
i. Connect tubing end of nozzle flexible hose to DTS FLOW LEAK TEST NOZZLE fitting (10). j. Connect one end of cell flexible hose to DTS FLOW LEAK TEST CELL fitting (11).
CAUTION
Avoid using excessive force when removing or installing the bubble flowmeter. It is a fragile piece of glassware.
k. Vigorously squeeze bulb (1) of LEAK TEST flowmeter until bubbles reach the top. I. Set R405 CURRENT switch (12) to NORM.
m. Press DTS SUPPLY switch (13) up to ON.
n. Hold TEST DISPLAY switch (14) to TEST; all display indications should come on. o. Press DTS SUPPLY switch (13) down to OFF.
3-15. OPERATIONAL CHECK.
a. Prepare DTS for use (para 3-14). b. Prepare work area (para 3-1).
3-15. OPERATIONAL CHECK (CONT).
d. Remove CAM environmental cap assembly; let it hang on the tether.
e. Remove battery cap assembly. Ensure battery is removed. Reinstall battery cap assembly. f. Connect W1P2 to CAM connector assembly.
NOTE
The CAM is protected from excessive current draw by the DTS automatic power shut off. To reset the DTS, press the supply switch off and then on again.
g. Press DTS SUPPLY switch (1) up to ON; SUPPLY indicator lamp comes on. If CAM does not come on, press CAM ON/OFF push-button switch.
h. Listen for pump running. If pump is not running, perform troubleshooting symptom 2 (para 3-17). i. On DTS, press CAM AMP switch (2).
j. DTS meter should indicate 3.6 to 6.0 units. If DTS meter does not indicate 3.6 to 6.0 units, perform troubleshooting symptom 3 (para 3-18).
k. Press CAM ON/OFF push-button switch to turn CAM off. Wait 2 seconds. Press ON/OFF push-button switch again to start CAM in self-test.
I. Monitor CAM display for the following indications: (1) All eight bars are shown.
(2) Markers A and B are shown. (3) Three vertical dots are shown. (4) BL is shown.
(5) WAIT is shown. (6) H or G is shown.
(7) If above 6 steps are not indicated, perform troubleshooting symptom 4 (para 3-19). (8) The display partially clears after 30 seconds; H or G, A and B markers, and WAIT remain.
(9) After completion of self-test, press G/H push-button; opposite indication of step 6 above is shown. WAIT should clear within 2 minutes. If it does not clear within 2 minutes, perform troubleshooting symptom 6 (para 3-21).
NOTE
Disregard any bars that may reappear on CAM display for purposes of this test.
m. Press CAM VOLTS switch (3). Press and hold BATT LOW switch (4) until BL shows on CAM display. Wait 2 seconds and then release BATT LOW switch (4). IF BL is not shown on display while BATT LOW switch is pressed refer to troubleshooting symptom 7 (para 3-22).
NOTE
If testing a monitor module assembly, proceed to step w. n. Press CAM ON/OFF push-button switch to turn CAM off.
o. Disconnect CAM power lead W1 from CAM connector assembly. p. Install battery into CAM.
q. Press CAM ON/OFF switch to turn CAM on, if necessary. CAM should complete self-test and BL should not remain lit. If CAM display does not light or BL remains lit after self test refer to troubleshooting symptom 8 (para 3-23).
r. Press CAM ON/OFF switch to turn CAM off. s. Remove battery from CAM.
t. Connect DTS CAM power lead W1 to CAM connector assembly.
u. On DTS, set V2 (5) to NOZZLE INLET FLOW. Let CAM continue to run.
3-15. OPERATIONAL CHECK (CONT).
NOTE
Remove and install nozzle protective cap as quickly as possible to avoid dust or other contamination from entering CAM protective cap.
v. Twist (counterclockwise) and remove nozzle protective cap assembly from front of CAM; place nozzle protective cap assembly onto CAM environmental cap and twist clockwise.
w. Push nozzle end of nozzle flexible hose over CAM nozzle assembly.
x. Read FLOW 2 flowmeter. Reading should be greater than 200 (ml/min). Read flowmeter across top of float. If reading is less than 200, perform troubleshooting symptom 9 (para 3-24).
y. Remove nozzle flexible hose from CAM nozzle assembly. Twist (counterclockwise) and remove nozzle protective cap assembly from CAM environmental cap; place nozzle protective cap assembly onto front of CAM and twist clockwise.
z. Perform waveform test (para 3-61). When a symptom occurs, refer to the appropriate troubleshooting procedure (para 3-11).
aa. Perform confidence test (para 3-10).
ab. Tun off DTS. Remove I/O cable W1 from CAM. Install environmental cap.
ac. Perform wipe test (para 3-7) upon completion of all maintenance, before CAM is returned to user. ad. Remove DTS from use.
(1) Remove all cables/connections attached to the front panel except cell flexible hose (1).
(2) Pull bulb (2) from LEAK TEST flowmeter. Dump out any solution remaining in bulb. Attach bellows to cell flexible hose (1). Set valve V3 (3) to cell LEAK TEST. Squeeze bellows and look for liquid in bubble flowmeter. Continue squeezing bellows until no more liquid enters flowmeter. Remove cell flexible hose from front panel.
3-16. SYMPTOM 1. MECHANICALLY BROKEN PUSH-BUTTON SWITCH OR CRACKED OR BROKEN DISPLAY.
para 3-15 para 3-41
3-17. SYMPTOM 2. PUMP NOT RUNNING. para 3-59 para 3-47 para 3-47 para 3-60 para 3-15 para 3-40 para 3-31
3-18. SYMPTOM 3. CAM AMPS NOT BETWEEN 3.6 AND 6.0 OR CAM DOES NOT COME ON. NOTE
The DTS will shut off power to the CAM if the current is too high. If the meter rises, then drops to zero when the CAM is tugged on, the current is too high. Answer the question below "NO" and proceed to (B).
para 3-40 page 3-33
