CAESAR Maintenance Notes

2/10/2024

• Re-Installed TTRL Temp Amp in Radome Environmental Box.
• Calibrated RTF1.
• Checked Drain Lines - no moisture accumulation at this time.
• Checked Butanol level in RAF CN - Good, no need to fill.
• Cleaned all Radiometer Optics - Heimanns (Top and Bottom) and IR/VIS (Top and Bottom).
• Cleaned VCSEL mirrors.
• Cleaned Down Camera Window.
• Cleaned Probe Optics - CDP x2, 2D-S, HVPS, 2D-C.
• Re-Seated SATCOM box in Overhead. Will test the next time the plane is on the ramp. Visual inspection of connectors was good.
• Installed a temporary Ethernet cable from a computer in the MARLi bench to the right bulkhead. This will likely be added permanently (for the project) so MARLi can be used to help detect icing conditions in flight.
• CFDC group reported no sample flow from the CVI Inlet. Used compressed air to blow from inside the cabin out through the inlet. Did not notice any debris exit the inlet, but this fixed this issue. CFDC reconnected their inlet line and reported good flow at their instrument.
• Added D-Rings to the floor next to ADS seat and behind L-5 seat.
• Placed extra bungee cords on the plane back by the Lav.
• Found only one spare headset to replace the one that broke during TF01. More should be purchased.

2/27/2024

• Offloaded ferry equipment from cabin.
• Removed D-Rings from R-7/L-7 positions, then installed seats.
• Cleaned glass on IRT, IRB, VIST, VISB, RSTB, RSTB1, RSTT, CDP (x2), 2D-S, HVPS, and down looking camera.
• Performed functional test of 2D-S and HVPS. Both are good.
• DSM325 Temp at -2500 deg C determined to be a non issue. This is to be expected anytime the temp sensor in the DSM falls below 0 deg C.
• Mike Reeves removed plug from SDI blower.
• CVI inlet cover removed.
• Josh fixed an analog cabling issue going to DSM319 A1. Cables secured.
• Reattached inlet line to CSU HIMIL on left bulkhead.
• PHIPS probe removed for troubleshooting. Will remain off until further notice. Canister capped.
• Sufficient butanol in the RAF CN for RF01.

3/1/2024

• Removed WCCN from L-1 Rack. Will remain off for RF03.
• Purged 2D-S and HVPS. Went from ~ 20% RH to ~ 7.3% RH with 30 mins 5 SLPM.
• Cleaned glass on IRT, IRB, VIST, VISB, RSTB, RSTB1, RSTT, CDP (x2), 2D-S, HVPS.
• Cleaned 2D-C mirrors.
• Cleaned VCSEL.
• Removed and modified HOLODEC hard drive box to help with overheating problem. (R-6)
• Cleaned connections on 2D-C USB cable and DSM. Secured USB cable with zip ties.
• Blew out DPT and DPB. No moisture found.
• Inspected pressure lines in Radome. Small amount of water in ADIFR Top drain line. Drained.
• Swapped primary dry air cylinder for CVI.

Strange occurrence with acserver late in the day. Seemed to lose all UDP variables when a user walked between the R-1 rack and the FS245 bulkhead. Likely just a coincidence. Janine looked into the problem... She can provide details. It took a long time to get data back and we were unable to reproduce the error. Stopping data_acq and restarting with a new file name finally fixed the data feed.

I noticed the loss of all UDP data in the hangar at RAF a couple times.  Unclear what is going on.  But the GPS is the most obvious way to notice this.  If GG* goes nan, dig in right away.  We'll look into a work around until we can solve the issue.

3/4/2024

• Moved ferrite filter on 2D-C USB cable closer to DSM connector. Cleaned contacts on all USB junctions.
• CVI Inlet showed indications of contamination. Tried cleaning with cotton swabs - no clear results.
• Cleaned all cabin windows, inside and out.
• Removed DSM325 chassis ground lead for 2D-C testing. Secured for next flight.

3/6/2024

• Unpacked / organized air shipment.

• Checked butanol level - ok

• Performed calibrations on both CDP probes.

• 2D-C diode voltages = 3.5, 2.7, 1.9

• Cleaned 2D-C mirrors.

• Applied heat sink compound to 2D-C tip heater cartridges.

• Cleaned glass on IRT, VIST, RSTT

• Cleaned glass on IRB, VISB, RSTB, RSTB1

• Cleaned HVPS windows.

• Cleaned DPT / DPB mirrors and blew out flags. Ground tested - good.

• Installed PHIPS and user tested.

• Installed Point to Point internet between OPS Center and aircraft. Functions well. To be removed before flight.

• CVI inlet contamination traced to loose valve on control box. Tightening fittings believed to have solved the problem.

3/7/2024

• Cleaned VCSEL
• Power and Access

3/9/2024

• Power and Access
• Added extra ferrite core around 2D-C USB junction.
• Changed primary zero-air cylinder for CVI.

3/10/2024

• Power and Access

3/13/2024

Education and Outreach Open House.

• Power and Access.
• Removed ferrite core on 2D-C USB cable.
• RSTT powered on fine this morning. Sprayed all connectors with contact cleaner. Observed today with no dropouts.
• Swapped zero-air cylinder for CVI.
• Fixed damaged dump line at L-1 rack.
• Windows Laptops are not syncing time to timeserver, they are ~ 0.5 seconds offset. In settings, the "Update Now" does not manually fix this. Janine has further information.
• Replaced desiccant, purged, and cleaned HVPS. Tested - good.
• Replaced desiccant, purged, and cleaned 2D-S. Tested - good.
• Cleaned IRT, VIST, RSTT.
• Cleaned IRB, VISB, RSTB, RSTB1.

*When 2D-S probe was pulled for servicing, a set screw was found that had come loose from the laser alignment. The screw was replaced, but not so much that it would affect the alignment of the laser.

3/15/2024

• RF07 scrubbed today due to snowfall.
• Power and Access.

3/17/2024

• Power and Access.
• Blew out all radome pressure lines from transducer fittings toward drain ports. Moisture found in T-fitting of QCR. Moisture also found in drain lines.
• Cleaned IRT, VIST, RSTT.
• Cleaned IRB, VISB, RSTB, RSTB1.
• Cleaned 2D-C mirrors (s/n 003). Tested - good.
• Cleaned both CDP probe windows. Tested - good.
• Cleaned 2D-S windows. Tested - good.
• Cleaned HVPS windows. Tested - good.
• Installed spare 2D-C probe. *S/N 003 removed. S/N 001 installed.
• Changed secondary zero-air cylinder for CVI.

3/18/2024

• Power and Access

3/22/2024

• Power and Access
• Performed CDP Cals
• Cleaned windows on both CDP probes
• Cleaned IRT, VIST, RSTT.
• Cleaned IRB, VISB, RSTB, RSTB1.
• Verified IRS3 is connected to both Control Boxes of Stabilized Platforms. Top Control Box uses twinax cable. Bottom Control Box uses an ARINC specific shielded twisted pair.
• Troubleshot noise issues on Engine 2 Velocimeter. No indication of bad continuity. Cables were secured with zip ties. Will monitor during next flight.

3/23/2024

RF08 scrubbed today due to snowfall.

• Power and Access
• Cleaned windows on 2D-S and HVPS
• Performed functional test on 2D-S and HVPS

3/26/2024

• Troubleshooting of RF08 smoke event. Found blown fuse in parallel cable on RH bus Slave 1 (inverter #8). Swapped out paralleling cable with spare and removed #8 inverter from RH bus circuit. Will continue project operating on 5 of 6 inverters.
• Investigated blown circuit breaker on right wing pod 400Hz. Found 400Hz connector in RW Pod to be loose. Upon further inspection, pin B was misaligned and did not seat into its mating socket causing damage and likely resulting in the popped circuit breaker. 400Hz is not used during CAESAR so the connector was coiled and stowed and the breaker is locked out.
• Power and Access provided for users to assess any damage incurred during RF08 power drop. This time was also utilized to determine the operational health of the power system.

At end of day we believe the power system is mission ready.

4/5/2024

• Power and Access
• Changed out cylinders for CVI, CFDC, and left side N2.
• Removed all probe/instrument covers from being parked on the ramp.
• Reinstalled 2D-S (new desiccant), HVPS (new desiccant), and Holodec.
• Tested Holodec.
• Tested RAF CN and filled butanol.
• Tested VCSEL.
• Tested Dew Point Sensors
• Tested Temp Probes.
• Tested Stabilized Platforms.
• Tested KT.19s.
• Tested K&Z Radiometers.
• Tested CDPs.
• Tested 2D-S.
• Tested HVPS.
• Cleaned glass on - 2D-C, 2D-S, HVPS, CDPs, VIST, IRT, RSTT, VISB, IRB, RSTB, RSTB1.
• Purged 2D-S.
• Purged HVPS.

All instruments are functioning nominally according to the variables available while in the hangar - we are mission ready.

No further research flights will be done due to aircraft issues.

4/6/2024

• Removed seats at R-7 and L-7
• Installed D-Rings at R-7 and L-7
• Removed PHIPS probe
• Capped PHIPS cannister
• Capped left side HIMIL
• Closed valve on RAF CN
• Installed NO containment vessel
• Re-Packed all gray boxes
• Organized majority of items for sea-container shipping, air shipment, and C130 onboard shipping (mech items excluded)