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FROMDistribution authorized to U.S. Gov't.agencies only; Test and Evaluation; Jul1982. Other requests shall be referred toCommander, U.S. Army Medical Research andDevelopment Command, Attn: SGRD-RMS, FortDetrick, Frederick, MD 21701-5012.

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USAMRDC, MCMR-RMI-S [70-1Y] ltr, 19 Jul1996

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* 'lDEPARTMENT OF THE ARMY

'~~~ ~U S ARiMY MEDICAL RESEARCH AND NIATPIE. QA, ~ 'FORT (DETHI w( PREDERICK. MP~ 1702 50 12

SMEMORANDUIAI FOR Administrator, Defense Technical information

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1. The U.S. Arm~y Medical Research and Materiel Command, hasreexami.ned the need for the limited distribution statement ontechnical reports. Request the limited distribution statementfor the following accession nu.moers be changed to "Approved forpub.lic re.Lease; distribution unlimited," and that copies of thesereports be released to the National Technical informationService.

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*02. The point of contact for this request is Me. Virginia Milier,DSN 343-7327.

FOR THE COMMANDER:

-COW&*SR. PAY !1Leutenant Colonel, MSDeputy Chief of Staff for-

~nZormaL ion ~ijanagemenc

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A PROPOSAL TO BUILD A LABORATORYBLAST oVtiRaPSSURE TLST SIMULATOR;Subtitles The Oevelopment of a WaterJet !mpactor

Final Report

(byo0

Jams .- Y. YuUdvard J. Veael

July 1952

@ Supported by-U. S, Ars fedical Research and Development Comanad

Fort Derick, Frederick, Marylad 21701

Contract No. DAND17-81-C-1059

11011 Torraysys Roed

Ram Diego, California 92121 0

iatrtibuiim limited to U8 Qergnest &owcl*@ oslyg tootwed ewolustlen (July I1). Other requests for thledocemat moet be referred to Owmder, US Any Nedicallmeeoreb and Develo eent Cosid, AM3$ UUD-lI, FortOstrick, Frederick, Nsa71md 21701-5012.

The findings to tiAm report ae sot eo be cous:msd as w officisal epartusscof the Any position unless so designsted by other sathorsed documents.

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REPORT DOCUMAENTATION PAGE 39*ogZ c cPL97Mo woRM_...._ _ .4

'U im.a (wed 4400 0 TWS9 Of R•CPQNT a P3ftOO CO¥IvZOA PROPOSAL. TO BUILD A LABORATORY FiGal ReportILAST OVZIPRESSURK TEST SIMULATOR; April 1981-harah 1982Subtitlet The Development of a Water .r emRoRWINone. me'oR nutdoc -Jet Impactor J520-62-22287

T. AUTNOM(j 4. GNT~MAT'FT ON GRANT NuIdla81s)

James .- Y T74C-05zduard J. Vaseel" •

&-0ps"POIil OMANI AINION MAMN ANDMAOI. In. ADn4Aa iLSM£.T,1 ifoJjc T.'ASK',JAYCOR •A* .t,,IT W a' uem11011 Torrayana Road

Sau Diego, California 92121 62777A.39162777AS7S.M.3.C

IL. CSJTeO1P6LN OPPICI MANU ANso Ase, Sa IL 49PORT OATS SU.S. AMy Madical Research and Development Comivan July 1982fort Dett:idt IL, OWM61 00• Pu -Frederick, MD 21701 go

___ __ ___ __ ___ __ ___ _,__,,____ 9•I& MONnTOINO V WArN9S & AOO3MSS(#i 4000inu -M. C40MM•dMI OfOtW Is. SECURITV C•AI• (of Nb Iwomo)

Unclassif led

So %2&SIFICA1N OOW GRAING

ellyrSTIUTION VITGTEMET retia *4PWQ)

Distribution limited to US Government agencies only; testand evaluation (July 1982). Other requests for thisdocuent muet be referred to Comander, US Army MedicalResearch and Development Command, ATTM: SGROD-IU, Fort •Detrick, Frederick, Maryland 21701-5012.

IT. ImSr~isu TION STATELNSHT (fL l* 4e4~ weVed to at"4k& so, to kI erN b" A~)

4 ~ . SUPftEMENTARY MOTES

so. okEy "nR$ (G.MA4o G 14W. "*w" I9* 4"06"" Gaw Idd..IU1 AV Ia"# amr)

$laet overpressure SJet impact '

Pulmonary and gastrointestinal tract injury Is,

IL ONIACI j1~o- M~ MVW N HOOA 8" t~wfp AVbd4 Nink t

q In order to establish a damage risk criteria (DOC) on pulonary andgastroincestinal injury for the operating crew vho fira havy artillery,direct imforeaz.on that links the critical blast overpreseure paramters &Adthe degree of injury is necessary. Although field tests can be perforaed toprovide the data, they are not muable to speedy post-mrte analyses a"d /sophisticaced instrumentatiou. A laboratory tast facility that is capable of /generating the equivalent blast oelrpreesure signal vill serve the parpoce aW ,

D *mf 3 -r a,

W , t14.5 E,40w u w /

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CUM"? CI.AMPICATCOM OF Turns PAOKMNWhAa. 0. 5.h.

20. A&STLC (coiat'd)

greatly facilitate the test procedure. Xt will also help to provide a onmist-romment for systematic and controlled axperiments to quantify the relationahipbhetwen blast and Injury.

Nowever, for varioug reasons, msot Conventional approache* in generatingthe blast overpressure or its equivalent are not suitable for a laboratorlsetting. The idea of using a jet impactor to generate the Impact signal wasconceived. This report sumearisee the process of the development of such anapparatus. The first part focuses oan the proof of the f rmuciple and identLfi-cation of key elements and parameters. The second part is mainly devoted tothe desi6n and development of the prototype System.

The system develqped in this project is able to deliver a peak pressureof 25 pei over OO In.' target area. It has arise time of about I me, nd theshots can be repeated at four shou per mimnte for as infinite m er sashots, After a series of calibration tests, the unit was delivered to theWalter Seed Army Institute of Research for animal impact cente.

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11.el Report

Jsams. le-Y, YUSdvezd J. Vogel

July 1982

lUpported by

U. 3. Azwr Medical Monarch and Devel~opment ComandFort Detriek, Frederick, lftrylastd 21701

Contract lb. "MITS1-81-C-1059

JAYCOR11011 Torrteans load

Son Dieoe, Calitormia 92121'

98extrbutles lwmted tuse GW e~vemt $peuctes *sly$ testsed afaluatim (July 19204 Other requests for tugs4omweme meet be referred to Ciembodr, US Army NsdicalkseereI =Ad Developmest Caued, A~Us SCAD-hI, FortOstrio~h, Frederfak, Wery1amd 21701501I2.

The fielldap to this report anr not to be construed asan ea 1f-Icial Departmentof the Army position waeoss so desipated by othar owthorlsed documents.

I0,

�Jin order to establish adamage risk criteria (NC) on pulmonary and

astroin:esrinal injury for the operating crew who fire heavy artillery. Idirect let orma�ioa that links the critical blast overpreesure parameters andthe degree of injury is necessary. Althou�,h field tests can be performed toprovide the data, they are not amenable to speedy post-mortem analyses andsophisticated in�tr�amsntatiom. A laboratory test facility that is capable ofgenerating the equivalent blast overpressur. signal would serve the purpoasand greatly facilitate the test procedure. It would also help to p,:ovide an Senvirowinsat for eyst.matic and controlled experiments to quantify the rela-tienahip between blast and injary.

INovever, for various reaons, met conventional approaches in generating

the blast overpressure or its equivalent wore not suitable for a laboratory b 0setting. The idea of using a jet lopactor to generate the i�act signal weeconceived. 'This report sumarimes the process of the develo�,meat of ouch anapparatus. Tb. first part focuses am the proof of the principle med identifi-cation of hay elements end parameters. The second pare is mainly devoted tocbs design and development of the prototype system. 2 r

1s * MIODUCTION 9...............,..,.......

2& * l J97 MIA0L0f NDML *...**************.*** 11

2.1 Selection of the Approach *........e.~..s.... 11

2.2 Design Considerations end Provisions e...o...a..a ..s... o1a

W. Development of the Single Volve Jet Impactor ......... 14

2.4 Performiance end Discussions ................. * 23

3.1 Design Conasiderations and Provisions ............ 35

3.2 Quialification of the System Performance ............. 48

3.3 Concluding Remarks a .. ***....e**.**e**** 51

AMMIXI I - LIST OF PARTS AMS VIACOM e.......*...~.. 61

AMMI3 I Z- NGNSIMZINU MMINGS *....................*000..*......... 71

AMSWD Iin - INSTUACION AM5 OKlWIOV WN1A FOIL TU JITUAMrOR **.*.*....c.*.*.*.****.** 79

46b

page

1. Schematic of jet Impactor test setup is............~. 1

2. Single valve jet Impactor teot setup -vertical Impact model ..... 16

3. Diffuser cOon geometry 17

4. Orif ice Piatte 6Oale pattern Of the vertical jet laPectOr ..... 13

3.* Pressure and rise time distribution across a target platefor a 4 In. inasle head ........... ,.......... 22

6. Single valve jet Impactor teot setup ........... ***................ 24

7. Rsaxle head configurationa tested *~............... 25

$a Jet 1upact signal ................. ,....... 26

9. The Impact signal from a critically charged accumulator .......... 29

10. Comparison of the effect of trailing stagnation pressure onchest wall, displacement, chest well velocity, and chest wallacceleration for P.um 3 pai *....................e.............. 30

11. Comparison of the effect of trailing stagnuation pressure anchest wall displacement, chest vail velocity, end cheat wallacceleration for Psa - 10 psi ....... ..... ~................... 31

12. Comparison of the effect of trailing stagnation pressure oncheer wall displacement, cheat wall velocity, and chest wallacceleration forP. - 25 pai .. o..........e ........ *........ 32

13. Comparison of the effect of trailing stagnation pressure onchest vail displacement, chest waU velocity, and chest vallacceleration for Pa M50 psi ................. 33

14. Jet trajectories In the plane bisecting the two orificePlate@ . . . 9~*.... . . .... . 34

13. Orifice plate configuration and bael patters .......... 38

16. ftemie bseadconfiguration ... *.*......*...*... 39

17. Valve mounting Plate 40

iS. The masle heAad rrangemot an the monuting plate ......... 41 F

/

page

19. Impact force vs standoff distance for various line pressures ..... 42

20. Rise time va standoff distance for various line pressures ........ 43

21. Impact pr.essure vs line pressure at optimal standoffdistance .. ,.*..*.. . **............... . *..... **,. *... . 44

22. Impact area per valve as a function of standoff distance ......... 45

23. Accumulator charging system .......................... *........... 47

24. The prototype jet impactor impact signal ........................ 50

25. Pressure disaribution along four perpendicular tar,%tdIametero: 5 - 10 psi; standoff distance - 17" .................. 52

26. Pressure distribution along four perpendicular targetdiameters: j a 15 psi; standoff distance - 16" ................... 53

27o Pressure distribution along four perpendicular target 1diameters: 5 - 25 psi; standoff distance - 15" ................... 54

28. Pressure distribution in terms of r2 : A 10 psi; standoffdistance s 17"............ ........... . ...*,.....*...* 55

29. PresoLre distribution in terms of r2 : * 15 psi; standoffdistance va 16" . 56

30. Pressure distribution in tersm of •: 5 25 psi; standoffdistance o 15" ............................................ 57

31. Typical local• mpact signal as wsasuro• by a force transducerwith a 2 in. target area ........................................ 5'.

32. The prototyp jet Impactor ..................................... 59

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Evidence of pulmonary and gSstrointestinal injuries in animals from

intense blast overpremsure (3OP) and the general distress to the operating

crev of the extended range Mi18 towed howitzer prompted the Army to conduct

detail*4 research work to define a damage risk criteria (DEC) for humane in a

blast avniroumaut. In order to facilitate the clinical test, an on-site appa-

ratus that would generate a siuilar lOP or Its equivalent vad required. In

addition, this apparAtus mast be able to provide certain special features. A

gentral guidelins about these features was provided by flAIl. These include

1. Smaa1 overall dimensions so that it can be iuctalled in & normal sizermoa for aliucal usoge.

I2. Capability of delivering a uuLform pressure, •p to 25 psi, over a

100 in.' target area.

3. Repetition rate of 4 shots per minute for infiC.to umber of shots.

4. Lack of nuseance or hazard to operating personnel and ourroundtngresiderts.

5. Ease of operation and convenience of use.

As a result of these requiretwits, it wae apparent that the conventional

appxoaches womld uot be suitable for this applLcatiou. For example, the

approaches of using gun blast, shock tube and the detour-iou of TNT would not

be appropriate for a clinical laboratory setting. Mechanical Impact with con-

trolled velocity and displacement on iopect to simalate the blast effect wee

used extensively by Cleamdson. However, the apparatus was too large to be used

Indoor& and the repetition rate vas slow. Moreover, it was questionable UwheWthe*r the crushing affect of the mechanical Impact would faithfully repro-

duce the effect of the shock wave. The uncertainties and drswbacks associatedvith the azLsting approaches suggested that an alternative approach was re-

qui red.

Ono of the plausible approaches was to use pulses of high velocity water

jets to hit the target. Since this approach hWJ no shock nolses, wa non-

mechanical, and could be esoily tailored for differeun pressures, it became an

- . . . . , ' aL,,' ' ', .. ' - ,-

. .........

attractive candidate. This report details tbe rationales and procedures of the,,. development of such a jet Impactor system.

" Because this project Involved the development of a new product, consider-

able uncertainties more present. To reduce the risk and minimizse the impact to

the overall program, the project was dividewd Into two phases with the proof-

of-principle an the milestone of the first phase. Once the concept was proved

"to be feasible the next phase would then be continued and a prototype system

desIoned and fabricated. Otherwise It would be terminated and alternatives

This report mummarizes the design concept, the major hurdles, and the

approaches we took to alleviate such hurdles. It is divided, in accordance

with the two phases of the project, into two vejor sections with the next eec-

tics devoted to the conceptual vrif ication and parametric study of a sQl2em

valve system while the section that follows concentrates on the development of

the prototype system. D'etailed. installation and maintonance manual, parts and

vendors lisso, and the engineering drawings are appended for reference.

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6 2. 5Z10C W IS APFWAACM

A typical 3OP signal ham a sharp pressure rise followed by an exponentlal

decay and rarefa,:tion. The objective of this phase was to construct a model

apparatus that would deliver a short pulse of water and generate a signal

similar to that of a 8OP.

A ember of ideas were conceived and their pros and cons weighed. it wea

concluded that the approach of using a faot cycling valve to deliver the do-

sitred pulse of vater would be msot desirable and involve the least aount of

developoiant work. When such a valve Is combined with a prop rly desiSned dia-

tributor plate, a bundle of uniformly distributed jets can be delivered to the

target and generate the impact pimsoure over the desired area.

Since time required foT development vas of utmost concern aod this

'* 4 'approach used existing hardware and thus l•s development work, it was chosen

as the candidate approach. The following subsections are centered around the

development of thAs concept.

2.2 a== CANSIMIUAZ NU AMD MMI M4• I.,

The first question to be asked in the design of a test jet Impactor wasthe design capacity: the design pressure and the design flow rate. Once theme

parameters mere determined, tht rest of the system components would fall into

place accordingly.

Since the main objectives of the first phase wore to prove the principle,

learn about the system perforiace, end devwlop a unit that can be used on a

small test ialmal, a syotee that would Impact a 4 in. diameter area was

chosen. Simsa a 25 psa pok iqmact pressure was required, the system pressure

uwa snstimated on the order of a few hundred psi. The exact value depended on

the amfout of discharge and, more Importantly, on the perforance of the

valve.

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Fair an impact signal of 25 psi, 5 as duration, and a 12,5 in.2 coverage,?'•--•area, aa equivalent flow rote of 600 Em a t a lies pressure of 100 psi would

be required. This high flow rate calls for a very large pump-and-motor system,and even at considerably higher line pressure, the site in still prohibitively

large. For a prototype that was eight times larger, the approach would 'hardly

be practical.

To alleviate this difficulty, a high capacity, high discharge rate accu-

Melator was desisged iat,o the system, The large discharge port end high volume

capacity, allowed a large volume to be delivered to a short time and without

"etarving" the systems The high pressure pump would only serve to recharge the

accuoulator to its test setting and would have little effect on the Jetted

water. For this purpose, a positive displacement peump model 430 triplex CAT

pump, was chosen for its high capacity (up to 1000 psi in pressure, 5 gpa in

flow rate) and miniml pressure fluctuation. A 2 1P Ealdor TEIC motor was

selected to drive the pump.

for different impact pressures, different line pressures *are required.

This adjustment was done with a pressure reoulator. For each setting, part of

the flow would be delivered downstream of the regulation and part would be by-

passed hack Into the supply tank. As water fills up the accumulator, its

pressure Increases and thus decresees the pressure difference across the

pressure regulator. This reduction reduces the flow into the accusulator and,: forces more flow into the bypass. to this way, the set pressore is achieved

"soptoticelly.

For esch shot, mater is damped out of t seacumalator, the system pres-sure decreases and the recharge cycle restarts.

The moumt of pressure reductiou In the accusulator affects the enoant of

recharge time and the allowable period between shots. For a large capacity

aceaLator, the amount of voter ejected per shot would only be a small per-

ceatage of the accomlator esM hence lss pressure reduction in the system.

Rollver, a large aW.cuMator LUcreases the volume of the total System and thus

installation difficulty and cost. An Initial estimate based an the amount of

water delivered and the nsainal a€cumuaator air/water volume ratio Indicated

* ' that a 2.5 Sallon accumlator would give a pressure variation of less tlwn 52

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per shot. This capacity was chosen and was also used as the basis of estima-

tion for the later prototype design.

A side benefit of the imetallation of an accumulatir ti a pump system was

that it sialificantly reduced the amount of pressure pulsation caused by the

* cyclic action of the pump; otherwise, a pulsation daaper was recommended by

the manufacturer.

The most critical elemont of the lIpactor system Is undoubtedly the con-

trol valve. In principle, it should have a fast pressure rise, s,%ort duration,

be capable of covering a Urge area with high pressures, and be capable of

being Installed Iu say orientation, To meet thas* requiremunts, wo needed a

large diameter, fast cycling time, high pressure rating valve to deliver the

Impact. However, these features were not umtually inclusive and most of th.A

valves had only we or two of the desirab•e features,

Im Seneral, larle, high pressure valves are bulky and slow, while those

that are fst &ad light are small, but suitable for low pressure, kv• flow Iapplications only. Moreover, the vendors usually do not have the perf ormance

Informati'on needed for this task except in very general tern. The only way to

Squalify the performance of candidate valves was direct in-house calibration.

tn conjunction with the pressure regu•stor, a check valve was installed Sto Insure a one-way flow. This valve kept the water in the system when the

pump was turned off.

a water ta•k with an automatic float sbut-oft valve vwe used as the

supply waeservoir for the pump. It was connected to a tap water outlet. •

To prevent rust formation in the system, mstarials used in the system

mere liamted to brass, stainless steel or plastic. for the cases where thesematerials were not practical. the surfaces in direct contact with water ware

costed with epoxy pant. S

In order to effectively control the valving cycle, a Usadu Universal

Frogromeable Timer was used. This timer has 10 channels with the capability to

control 10 valves. For each channel, pulses of different duratLons and inter-

vals can be indepeodently controlled. .

Use6 time, presure N& iude and pressure distribution mmifon~ty were

the three kUy roquir•meatt of the jet Impactor. Im order to *valuate those

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parameter: accurat:ely, piezoelectric transducers were used for pressure and

of the pressure distribution while the force transducer woo used to moniltor

the total force over the entire target &rem. The outputs, from these trans-

ducers were displayed on a Nicolet digital oscilloscope. Since this scopedisplays the digital Information at each time 31tep, very detailed information

on the impact signal was obtained.

2.3 MUWA01 OV TU hIA V*LVU9 Jif DWACMO

Based on tha above design considerations, the single valve jet impactorwee designed as shown in Figure to and the fabricated setup shown is Figure 2.

The Initial concept assumed that a uniform, jet front, end thus a fastpressure rise, would be achiaeved by using a head reservoir combined with alarge full target area orifice plate. Therefore a 4 in. diffuser cone wasinstalled between the valve and the orifice plate (Figs. 3 end 4) so that auniform flow would be achieved before jotting out. lowever, this arrangementwaa later found not feasible for two reasons: (1) It was not suitable forhorizontal Installation because water would be 4rained out of the cone; and(2) It would uot generate high enough Impact pressure because of its largecone volume and large orifice openings. The large orifice openings preventedtha formation of sufficient backpressure that is essential for high Impactpressura. Thus, instead of the straight jet and diffuser chamber combination,

cominaiou A ortdetailed description of this design will be giveu later.

A sjorconernof the project was the valve cycling times, and much emr-pbass ws Vace anthe impact duration* Since smaller valves activate fast-or, "Ivs as s all 0.5 Inch io diameter were tested. other sises tested

4incloded 11.,ad2Inch.*After cosdrbeaffort was mespeded in "earching end testing, me found

* that only the ASCO sormafly-clo~sd, 1-1I2 lack DC valve posoesse imost of thedesirable characteristics. This valve has a safe working pressure of 230 Vsi

* ~(with a bourt pressera five times higher), has an adequate sine sad dischargeesefficlent, is reasonably priced, and has the smallest overall dimensionsamong comparables valves. Though the response time in relatively slow, 40 an to

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tested. Therefore, thia Va1ve WS2 chosen as the prinary unt.

The results of the valve qualification testa .ni.idated that besldes long

sLgnal durstion, for all the valve sizes all the iMPa4t signals were esak.

Thit latter piwoblem was a more critical one. Effort wAn concentrated on

improving the impact tigual.

As a first stop, changes In ifice plate design were made. By systematl-

cally reducing the orifice else, increasing the masher of Jets end at the sametime varying the plate thickness, optiasal geometry was achieved. By reducing

the hole slie, less flow escaped immaturely from the cavity and a higher backpressure was created. This higbar back pressure produced soam mwre powerful

Jets. Nevertheless, the improvement was still not sufficient.

SAdditional improvements were achieved through the change in standoff dia-

tace umuch stronger signal. were found to result at certain optimm stand-

offs* Wben we combined tho optimal distance with the optimal orifice diameter

a threefold improvement in total impact strength was achieved. As an example

of the d~velipment procedure the results of this met of tests are given In 0Table 1.

The uniformity of pressure distribution at the target was measured along

two perpendicular diameters. An shown in Figure 5, though the distribution was

uniform the sag.-tude was too low.

During this period, a changeover from vertical to borisontal Impact was

made. This was roqktred becaoe in cll"cal tests, sheep will be tested In

standing position. It was found that when a #heep ins laid an its side, it

tends to tens* up and cause different pulmonary stresses compared to tbhe in

the normal standing position. Thus, in order to generate the data In a more

matural state, tivia Impact ams be horizontal.

.On of the m•in concerns of developing a horisontal unit was bow to keep

the water in the cavity behbid the orifice plate, Ve believed (incorrectly)

that a full covity was essential to achieve the highest Impact force. The

larp vlule tco reservoir was abotdoned and nosules with long apect ratios

(length to diameter) were desigred and triad. A umber of other Idmas wera

also ready to be tested. imewer, ve found that the signal would not

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deteriorate when the cavity was not full. As a matter of fact, for certain Scavity mixes and orifice plates, an empty cavity generated evon stronger

signale. This was an important discovery; it eliminated one of the major con-

cerns and freed us for more direct pursuit of signal improvement.

The horizontal single valve Impactor setup is shown in Figure 6. An ex- U

tonsive series of tests was conducted using this setup. The parameters tested

include the nozxle head geometry (Figure 7). cavity sixes, and valve sizes and

brae•s.

The valve cycling time was uso a critical paranster. Though * would Slike to operate the valve in as short a duration as possible, there was a

threshold value under which the valve would not fully open and this resulted

in a lower magnitude signal.

Thrc•rSh an extensive series of tests the design parameters were system&t- S

ica2ly optimsed to produce the right combination of orifice plate geometry,

nmber of jets, cavity sixe, standoff distance and valve cycling time, and an

impact force of 325 the was finally achieved! As shown in Figure 8, this sig-

nal had a rise time of about 1 se, and a min lobe duration of about 4 ms.

Though there was a trailing pressure caused by the slow valve closure, nueri-

Cal modeling shows that it contributed Little to total chest wall signals (use

Section 2.4). The critical paraasiters that contributed to the high impulse

were therefore iused in the design of the large prototype system.

Instead of fixed noszles, It was decided that a desirable festure on thb

prototype Impactor would be to have the nmsales atter.hc•. to the ends of flex4-

ble hoses. This feature would allow freedom is arranging the nossles In avariety of patterns and Senerate different blast loading conditions. To imple-maen this idea and to assure its feasibility a section of the designed hose

was purchased and Installed ahead of the single valve Impactor nossle for

test. Since there was no observable effect on the Impact signal, flexible ae-

tension hoses were designed into the prototype system.

2.4 MYONOM A M DI•CUS=CE

A typical impact signal generated by the single' valve model .'a shown in

ligsre 8. It has a rise tim of 1 m, a peak force of 325 lb, a main lobe of

A me duration, and it can be generated at a rate of four shots per minute. In

L .. ,,,.

41

(b) Valvo and wnsisl head assembly dec.1

Floure 6. $Isola valve jet Impactor tent *e:tmp

24

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short, this system saiAlfle most of the design features. The only objectionIs the trailing pressure after the main impulse.

As we mentioned before, the ASCO valve 4iaa a minimum cycling time of

roughly 120 so (40 - to open and 80 ms to close). This cycling time creates a

total signal duration on the order of about 80 me. Further reduction in

cycling time would cause the valve to open only partially and reduce the meg-

nitude of the impact signal. Cutting cycling time is apparently not an ac-

ceptable approach to reducing the duration of the signal.

A mnmber of other idMe uere tried to alleviate this problem. In general,

they are based on two concepts: relieve the driving pressure or cut off the

water supply after the main Impulse.

The pressure could be relieved either upstream or downstream of the con-

trol valve. Because the cavity eise between the valv and the orifice plate

was small, only a small valve (1/2 in.) could be installed downstream of the

control valve, The amount of relief was not ýenoush to be effective. When a

large valve was used In conjunction with a large cavity, the increased cavity

volume reduced the siga. magnitude. Another alternative was to install a

bypass valve upstream oa.' the main q±trol valve. This reduced the signal

duration slightly but it also reduced the magnitude of the impact signal.

Two ways to cut off the water supply were tried: one wes to install an

extra valve in series with the control valve, and the other was to critically

charge the accumulator so that only the amount of water to be expelled per

shot was kept in the accumulator. The fokmr method required -a uormally-openvalve so that it cut off the supply at the peak of the valve opening of thefirst valve. However, It was found that the second valve would not close any

sooner and it also reduced the signal magnitude due to the additional flow re-

s:triction ispoed by this secood volveý The latter method allowed no fluid to

be left in the accumulator at the end of the shot sad thus terminated the

signal without magnitude reduction (Figure 9). However, as the accumulator

dampa out it. contents iL also causes the valve inside the accumulator to

hammer at the seat. Continued impact was suspected of potentially causing

significant damege to the accumulator. In addition, since the volume control

of the water contest in the accumulator was very sensitive to the setting of

the pressure regulator, which has a resolution on the order of the pressure

27

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! differential between the bladder prassure aud the lini pressure, Identical

shot* were hard to achieve. A differential pressure gauge setup between line

and accumulator would be able to solve this problem.

To quantify the exact effect due to the trailing stagnation pressure, ou-

usricl calculations were perfotrmed. Since In =at caue, the "hoops" wre on

the order of I1Z of the peak value, a simplified profile with a rime time of

1 as thea fall to 10Z peak value at 5 us and remaining constant for 80 w we

used for the calculation. The results for the cases of both with and without

the hump sre compared in terms of chest well acceleration, chest well veloci-

ty, and cheat wall displacement for peak pressures of 3, 10, 25 end 50 pal. As / -

shows In Figures 10 to 13, the differences tetween each set of test c€Ad4tioo*

wera within 2 to 4 percent. This v,,'iation to so small that it is unlikely to

have any Influence oa injury.

Sloce the jet Impactor model was able to capture all the essential fea- .

tures we specified earlier, the adopted approach was shown to be a vlabla one.

Without further delay and upon the approval of WtAI the next phase of the

project, fabrication of the prototype impactor, proceeded.

21

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The demign conslderatio.s of the prototype system, the specific system

components, sad the system performance are given in this section. S

3.1 DIU= CMOSI UO8U AM 0IOV UU

As we learned earlier, the heart of tOe jet Impactor is the nozole/cou-

tr-l valve system. Since the odmom aahievable impact force for each valve to

about 325 lb, an elght-valve system would be required to generate the speci-

fled loading of 2500 lb. To cover the 100 in. 2 target, these valves were

arranged in an 8 inch valve circle. This was the most compact arrangepuat for

the eight ASCO valve.. Since each valve has an outlet area of 1.77 in. 2

(1-1/2" diameter), the jet stream must be fUaed out to cover its share of the

target (12.5 in. 2 ). Moreover, the jets from aLl the valves =ast hit the target

simultaneously to achieve the best rise time.

To satisfy the coverage requirement, a direct solution wou for each valve

to cover a sector equal to ona-eighth of the circle. Simultameous jet arrival, S 0however, was not as straightforward to achieve. Since all the jets Initiated

from the 1-1/2 in. diameter valve need to cover a 45" sector uniformly, a 45"

nozzle pattern yes a natural choice. Within this region, each jet had its own

inclination for hitting its designated target. Because the target to 12 inches

in dismster and the valve circle is 8 inches, the jet patterns were skewed.

Figure 14 shows the different jet traveling distances and jet eagles along the

blsctlng diameter of two orifice plates.

Since ."be proseure In the cavity behind the orifice plate was the sam

for all the jets, all would have the me velocities. Tbm. for different

traveling distances, they would have different arrival times at the target,

and consequently longer preceure rise times.

To compensate for this effect, we seded to slow down the jets that

travel shorter distanceo. This can be achieved by inreasing the nosula

resistance either by •mllor eosale diameter or by longer nossle length. Aware

that we were at the thmheold pert ormence of the orifice plate and too much

35 3

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resistance would decrease the impact pressure, we chose to use variable uoxle 0length@ to balance the jet velocity. This was achieved by contouring the crt-

fice plate in a cone shape so that the length decreaseQ from the center toward

the periphery. Through this arrangement, all the jet@ will be modulated In

proportion to theiv Inclinations so that they will arrive at the target plate

close to the same Instant and this luprove the magnitude and rise time of the

impact signal.

Another consideration was thc jet density, Obviously, the higher the den-

city the less spiky the pressure distribution. However, because of the limited

aiso of the valve, orifice spacing was limited. The jet density we decigned

has a jet-to-jet distanco of about 0.5 inch on the target for the 16 inch

standoff distance.

ased on these considerations, a mmber of orifice plates were designed

and teated. The final choice wao based on the best performance in signal rise S~Stime and impact force. HLgh speed movies were used to help the selection. The

final design of the orifice plate Is shown in Figure 15. The valve arrangement

pattern on the valve support plate Is given in Figures 16 to 18.

The corresponding jet impact force of the single valve versus the stand- ,!*

off distance for various lina pressures is show In Figure 19, and the corre-

sponding 1ignal rise tins is shown in Figure 20. From theme figures, the

optimal mtandoff distances for the vrrious lins praisures can be sumnsrised as

shown In Figure 21. For any target Impact pressure, the required system pres-

sure and target standoff can be read off directly. For example, in order to Sachieve an Impact pressure of 17 psi, it ir necessary to use a line pressure

of 185 pei and a standoff distance of 15.7 inches. Since the jets are fanning

eat from the nousle head, the coverage area Increases with standoff distance.

?te exact Impact pressure should therefore be calculated bused on the total

area coverage by the jets. The area coverago of a single valve for different

stan4off distances is shams in Figure 22.

The diJmensious of the system were specified as such that neither the unit

as a whole nor Ums separated parts should be larger thsp 4 ft wide, 8 ft long

and 6 ft high. This provision wee required so that there would be no problem

in moving through doors or hallways. In addition, we designed the system in

much a way that its major componeints were all Installed on a heavy duty cart

37

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for ease of position adjustment. The valve supporting frame anig the calibra-(

tion target mounting frame were dwidgned a. two separate units to allow

troedon in standoff distance adjustment. Th. supporting plates for both trainee

can be adjusted to different Impact heigbtes.

A 15 H 3? laldr TKPC motor was used to drive a Moedel Nto. 2520 CAT pump.

This jnim has rated capacities of 25 gpa and 700 psi. Both the motor and the

pump were mounted on the lower shelf of the heavy duty service cart * A 1/2 In.

aluminum plate wae used to reinforce the lower shelf to reduce the amouat of

vibrcation. The pump supplied water to a reservoir which wae connected to the

facr 5-gallon xydrodyne accumualators. This arrangement allows a feet charge

end dis charge rate of the accumulators.* The 20 gallon totciA capacity was

necessary to main~tain a pressure drop Use than 5% for each shot.

As In the mingle vaive watup, a check valve and a pressure regulator were

provided to serve the sane functions.* A pressure gauge was mountad on top of

the task reservoir to monitor the system pressure, and a bleed valve wes in-

stalled to vent thei air accimulated ini the systemn during initial PAWp-Up.

Originally, the accumulator*s needed to be chArged separately. This was

modified by connecting their chargin~g ports together so that a common air

I) valve could be used (Figure 23). This provision simplified the tehAraing pror-

Case and helped to equalize the pressures of the accuasulators.

As mentioned earlier, it wee desirable to have flexible hase" designed

Into the system no that diffevent valve patterno for ditforent Impact tests

could he made. To meet this requirement, eight 2-ft long VPlexonics stsIl.uless

steel hoes@ were used to connect the valvaes with the reaervair tank.

The mounting plates for both the target plate aod the valve/nosele eye-.

teos were made of 6061T aluminum plAte. For tho valve/nousle plate, eight

preclise mounting bo?.es were drilled to fix the locations o. the valvas. A

1-1/20 Alimamter short nipple we threaded Into e&ac valve and then fad through

the emouting bole, Each wait was then locked In place by a lock nat.

Once the valves were fixed in place, orifice plates waire binatced. Dor-agese each orifice plate had Its own, designed orientation, freedom of adjust-

smis was designed Into the system for proper alignment. The orifice plates

were designed such that they could be rotated at the ond of the pip* zipples. /

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NeAon-jar-type rings were used to fix tile orif ice plates in place. The largo

ring opening. allow all the jets to pass through freely. The exact orientationof the orifice plates were adjusted before completely tightening down the "Jar

rings." This was achieved by aligning tha bisecting lines of the orifice

plates with the guiding grooves an the mounting plate.

The target plate was mounted on a steel channel support frame. The centerwas aligned with the canter of the valve group. Parallelism and exact distance

between the two were fixed by four Unistruts mounted on the sides of the two

support frames. This arrangement a' fi kasps the targeit in place during cali-bration, shots.

The impact load wee measaured by a force transducer, coater. unted behinda target plete. Three gui41ng bolts hold the target p1 ita to the mounting

plate. These bolte were used to atnImixe the amount of tilting nf the target

plate during the ahote.* OIL Impregnat~ed brass bushings were used to _.iide themovement of the bolts. Becaumse of the bushings' low friction, little re-

sistance was generated between the bolts end the bushings. This alluws theforcze transducer to absorb and meamure all the Impact loading delivered by the

jets. Rubber washers were Inserted between the nuts and the wounting plat* to

minimize the amount of target pltat vibration Induced by the impact.

A 2 x 1.5 x 1.5 ft plastic took wasn used as the water supply reservoir.Top water was connected to the tank as the source. A float valve was used to

control the water level in the tank. A screen filter was Instolled at the

inlet of the suction pipe to prevent debris from getting into the system. The

1W-timer visa used to synchrouims the opexatiou of the valves.S

3.2 (PMWIAI CTOM SVTW INATOCA=U

After the systam wes fabricate6, a comp~lets system shakedown &and calibra-

tics was made. Thom objectives were tu evaluate the system performance and to

identi fy and eliminate aay trouble spot so that a ral~ialwle system would beachieved. 09A of the key factors that dictated the porfowmeuce of~ the sYstem

was the synchronization of the valves. It was crucial that all eight valvesopen sivultaosw~emly son that tho jeto would arrive at the txrget at the mseso

time. Any mst ifrsi wksld resa*lt In delayad rise tit* and reduced Impact..

To synchronize the valve operation, eight transducers would be required

to mouit.r the jet arrival time of the eight valves. The average time-delays

for each would then be corrected by adjusting the corresponding activation

time on the control card of the UP-timer. This was a preferred approach. How-

ever, because of time and budgetary constraints this approach was not a4opted

during the development phase. Instead, an alternative approach was used.

If the jets from two different valves do not arrive at the single force

transducer tacget plate at the same instant, two distlnct Impact signals will

be generated. By measuring the time delay between the two peaks and adjusting

the control card accordingly, the delay between then can be eliminated. Using

the same valve as a reference, we could therefore eliminate the time delays Sfor all the valves. This was the approach we used. Though there were varia-

tions among shot*, a half doxen to a dosen shots usually result in a good

averaga value. A sample output of an eight valve impact signal is shown in

Figure 24. .lThe major defects of this approach were that it was a time-consuming pro-

cess, and the results obtained from a pair of valves might be different frou

those when all eight valves were firing. In addition, using two valves tendedto create unsymmetrical loading that night damage the target transducer and

Impair the system. We therefore recomnd the use of eight transducers to time

the eight valves.

To calibrate the uniformity of the Impact pressure, two smell target

plates were designed and fabricated as sensor probes. One had an area of 5

a.2 nd the othaet had an area of 2 in. 2 The smaller target wea used to mea-

sure the distribution of the higher pressure shots to achieve a "point-like" T

measurement without much swearing effect. The larger me was used fur low

pressure cmoditiona to Increase the sign l-tn-nolis ratio.

The aperiments wxa% conducted by firing all eight valves sinimtamously 5

while the force was measured at the sensor target. The target was mounted ou a

uiftlng plate which wan Inserted in a Unistrut for ease of transalation. The

target wu slid along the UnIstrut to traverse across the diameter of the im-

pact a•ra. For ebch test pressure, data at every inch across four perpendicu-

lar diameters were taken. At each location, five hate w•e re md to get tbe

average value. The results for the 10, 15 mA 25 psi tests are shown in

049

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Figures 25, 26,* and 27. These results wer~e also plotted In terms of distance

squared to si~mulate the area coverage of fect and are shown in Figures 28 to30. An shown, there to a low pressure region near the target center caused

primarily by ttbe relatively spar.e jet deusity at the apex of the orifice

plate. The presoure distributiouna over the roost of the target are relatively

unifoarm.

Sample local Impact signals are shown In figure 31.* These are the outputfrots a 2 in.2 sensor target. They all exhibit short rise times and short dura-tions, Implying that locally they are very similar to the bleast overpressUresignal.

3.3 CONCLUDING XONMS

After an intensive system life test and modification ond/ot replacement,of all. troublesome parts, the prototype impactor as shown In Vigure 32 alongwith this parts and vendors list, enginseeing drawings and a detailed instatla-tion and operation manual as shown in the appendices were delivered to UIMIRto be used for pulmonary injury study.

To achieve the designed Impact effect it Is essenhtial that all the 'valvesdeliver, the impact to the target sminltaneously, In ordar to achieve the syn-chronized valve operation the vast direct approach would be to hive eightIndividual sanoors at the target to measure the jet arrival time and make theproper correction accordingly. Presently, WWRl personnel are fabricating sucha calibraitIca target. Since there might be mome variation among startups, Itwould be worthwhile to make smes periodical calibrations to ensure the properresults.

Irrespective of the straightforwardness of the procedure In synchronizingthe valves, it is still preferable to use as few valves as possible when thetest condi1tions so warranted. Such would be the cose for low prossasre tests,for example, It would be desirable to use juet four 'valves for proessues lostthen 10 pai and two 'valves for pressures Less than 5 psi. in both casses neworifice plates would be reqniired.

The relatively low Impact pressure near the center of the target area canbe Improved by some simple modification of the orifice plate. A TOW judiciallyadded snsooue at the alpex region will achieve this objective.

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As Ln any now product develtpment there are always hur4les end atumbling

1mlocke during the p-oceavi, which are also exatly what makee the oxpersnrAi

challenging and rewardLqn. Suk was the ca** In the jet impactor developkeant.

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Coie-Palmet7425 Worth Oak PST"h AV**Chicao.o ML E6064

SOO-323-434 0 oir 312447-7600

p~tnua tank Cat OC4323-4 3 , 30 1l, 4x1" !"

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HydrodYfl IndusttlOiesm.

S6 ~~~S oll4W2 Ave* G1$

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714-292 -6 " ? - --- 16-234 -D00

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Igistlear Inst•'uwnt Corp.

75 John Glenu DriveAeshewt, NY 1O6120

71A-,691-3100 Mr. Mike Murphy

1. Low impedance Piezotrofi Type 21134 pressure trcusducer (0-200 psi).

Low Impedance plieoto, Type 21113 pressure transducer (0-5300 ps).

2. Transducer cable 1514A2.

3 iPlesotrom couple: Type 5116.

4. Model 2I3A flush mounting ndapter for preosure transiacsr.

5. Yomc transducer Model 92273 (0-5000).

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1k1anter-CarrP. 0. sox 54960Los Angeles, CA 90054

213-945-2811

laetr Suply Teak

1. Polypropylene float No. 9775K12.

2. Uress float rod No. 2754K3.

3. Brass float valve No. 4652122 (1/2").S

4. auction screec No. 9877063 (1-1/4" pipe .s1e).

Orifice Plate

5. 1" union No. 4725116 (to hold orifice plate in place).

6. Brae lockout No. 45571•8. S

Notor

7. Cant iron pulley No. 6209R117, bore size 1-11/16".

8. 1 sectlo V-belt No. 6187K142.

Other

9. Broke check valve (1") No. 9770035,

10. Stailules steel nipplee, elbows, tee., unions, bushings.

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WeNlon-Duen, Inc.7818 Wilteruon CourtSan Diego, CA 92111

714-268-4140

1. Flexonle. aeries 401M stainless steel hose. 1-1/2" diameter, 24" long, male

pipe fittings on bEh en4s.

2. internal svivle/externol pipe No. 2105-24-24S.

3. Hydraulic hose 02781-16-36W/4722-16-16S. 1" diameter, 36" long, male pipefittings on Noth ends.

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14

PcM Piesatrouces3425 Walden AvenueD.epev, NY 14043

1. Quartx force tronsducer Type 20LMQS (5,000#).

2. Qcartx force xIoS Nu.del #2024 (1.0,0000).

S. CoauIa2 cable 002ZC10.

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I Valvate Associates Automatic Switch Co.'ii15925 a Mi ots Ave,. 6 Watseammln Ave,ftramouut, CA "Q72 •loomfiald. NJ 07003

I 714-761-3644 201-703-2M04

1. ASCO 2-way solenoid valve, 1-1/2", N.C., 24 VOC 08210356.

2, Cpbre part kit #168-503.

3. Coll #74-073-5-".

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Spris.1t~d NJ07061

Z0k-*67-6100

2. OptIon "C" surfacie uaunted barackr-t Interfisce.

3. Teledyne part 9 6a3-2 aolid state relay.

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Zemare3946 S. Washington Blvd. pLos Angeles, CA 90040

21,3-721-5598

1. CAT pump Nodel 2520.

2. Pulley ausembly No. 30269.

1 3. Shaft protector No. 26516.

4• 4. lotinting rail Mo. 30268.

5. CAT o11, 21 oa bottle.

Other

6. laldor 717C 3 phase aotor Hf333T-9T (15 UP).

7. VITA pressure gauge Type 2130 4" glycerine filled, 0-400 psi.

U. Spring systems pressure regul•tor 06819-1/2-HSS-700.

Accaulator Chargins System

0 4 9. Gaugs has& assembly 9A768-236.

10. Char•ging hose (2 x 1/5' NVYT) 2' loi, 1768-214-2.

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INSTALZLATIN ND 3 ;=AI MANUAL

VOR TS JITWACT.

INOTALLATION A19D OPERATION UANUAL

PON Tax

Jill IMPACTOR

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1, ?k-vZRAL INFORMATION

2. INSTALLATION

3. INTIAT, START-UP

4. TROUBLESHOOTING

5. NORMAL OPERATION PROCEDUIR

6. MAIITENANCE

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1.1 This manual contains Infor:nation for the Installation, start-up, opera-

tion, and tr•obleshootigu of the jet impactor devolped by JAYCOR under Con-tract WiRAIR-DAMDIT-81-1059 for the U. S. Ar%y Tilvision of Wediclne, WalterRead Army Institute of Research.

1.2 The jet inmpactor was developed to simulate blast ov'r rnsure signalsbetween 3 psi and 25 psi on target areas approximately 100 Ina.

1.3 Tho jet impactor vas designed to be semi-aobile and has a flexible headassembly which can be targeted at various heights off the floor to accomodatedifferent also test subjects. Specific principles of operation and parlor-sancu characteristics will be contained in tho final report.

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2. DSSTALLATION

2.1 Initial InapectrIo1.fore shipment, this assembly was operational and found to be free of

mechanical and electrical defects. As each crate is unpacked, inspect for anydamage that my have occurred In transit. Save all packing materials untilInspection is completed. It damaga is found, file a claim with the carrierImmediately. JAYCOR should be notified as soon as possible.

2.2 Nchamical COechThis check should confirm that there are no broken knobs or connectors,

that all finished surfaces are free of dents and scratches and that meters andgauges are not scratched or cracked.

2.3 Slectrical CheckAll electrical components should be checked according to their respec-

tive check-out procedures in the appropriate operating and service manualsfound in the appendix of this document.

2.4 Assembly and InstallationThe jet impactor is shipped ready for permanent field operation. After

assembly it is necesealj only to connect the motor to a 230 volt 3-phase powersource, the power supply and timer to a 115 volt AC source and the water tankto a water supply. The assembly procedure is done in six stages: impactor

SF $ core assembly, accumulator, impactor nozzle head support structure, nozzlehead assembly, water tank and calibration targct support structure assemly.The final assembled unit is shown in Figure 1.

2.5 Assembly of the Impactor should begin vwth the unpaecking of Crate 11which contains all the smell components, gauges, transducers, target plates,0-rings, and bolts necessary for assembly and calibration.

2.6 Crate #4 which contains the impactor core assembly should be positionednear the final installatton site and uncrated. This assembly contains thepump, motor and pressure chamber of the Impactor, These are wounted on a cnrtwhich has wheels for relative easy movement of Och jet impactor. Inspect the"core assembly for damage. Remove the tape covering or holding the four accu-mulator O-rings on the top of the assembly. Clean the 0-rings of all dirt orgrit and apply a even coat of silicon grease. Rleinstall the 0-rings in theO-ting seats.

2.7 Open Crates #2 and 13 containing the four Hydrodyne Accumulators. ast-move all protective tape from the accumulator openings and clean each mett.isurface with a mild solvent to remove any adhesive residue. Each accumulatoris marked near the edge of the meting surface with a series of dots corre-sponding to similar dot patterns on the corn ••a•embly unit. Katching each dotpattern will insure proper installation of each accumulator and perfect holealignment of mounting bolts. (Note: An overhead hoist using nylon straps isvery useful for accumulator installation. Each accumulator weighs approxi-mately 250 lbs.) Start all four machina belts in each accumulator beforefinal torquing is accomplished. le sure two washers are used for each bolt

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and all are fully tightened. After ll accamulators are installed, the impac-tor can still be moved, but should be accelerated and decelerated slowly and

(•) snoothly to prevent rock"'ng of the accumulators which could result in damageto the core assemlly structure.

2.8 Crate 91 containa the pressure gauge/charging assembly, and charginghose for the accuoulators. This 3 hoss/l gauge assembly is installed on thetop of the four accumulators after rtmoving the protective screw caps (silverand yellow). No teflon tape is needed for installation. The 2 ft cable sec-tions should be coiled towards the center of the four accueulatora as shown inFigure 2. The 10 ft charging hose Is used to charge the accumulators from abottled N2 source.

2.9 A pressure gauge from Crate 01 should be inutalled using teflon tape toone of the ports on top of the pressure chamber. A petcock with tygon tubingfor pressure relief should I* installed in the remaining pressure chamberport. Hove the core unit to thbo final installation position. The unit isdesigned to shoot froe right to left from the operator's viewpoint.

2.10 Crate 06 contains the DC power supply, the valve tiner, inlet pipe as-semblies, calibration stand-off distance struts and the nozzle head supportframe. Remove The nozzle head support fraes and place approximately 3 ft infrout of the prcasurI chauber.

2.11 Locate the large pressure chamber 0-rin8 in Crate 01. Clean, garase,and install it in the pressure chamber O-ring groove.

2.12 Carefully unpack the nogule heed asseubly from Crate 95. (Notes Mhenlifting the assembly be sure It is evenly supported along all the flexibleboes section so as aot to induce undue stresses which could result in potqn-tital 1aki.) Use sfL 5/16' bex bolts from Crate 01 to attach the head aesea-bly to the frame vhil, resting the pressure chamber mounting plate on the cartedge. Is sure the "W"' of the noasle support plate is in an upright position.

2.13 Kate the pressure chamber plate to the pressure chamber and Install theproper bolts from Crate 01. U sure to fully tighten all bolts and compresslock rincs to prevent haumrit. of belts during pressurisation of system.After initial tact run. re-tighten all bolts.

2.14 Connest the prewIred relay plqel asuembly to the back of the program-mablet UVP-TM from Crate 96 as dh .a n Figuve 3. First coexect the relaybracket weram. Next plug in relay coomactoc plug. Finally, plug red andblack pins into respective recoyptore. Couiert power cord to IP-TDO1 and con-sect to 113 volt source. Notice that the relay panel has 10 relays. Thefirst eight relays are currenrly wired to valves 01-03 respoctivaly. Relays9 oand 010 are not currently being used. These are open channels for spares

o •r future growth. Sach valvi relay has a channel color assigned according tothe color code attached to the wiring harness. Color coded "pigtails" havebeen attached to each positive (red) wire going to each valve to help identifythe relay number end TWI~h channel assigned to that valve. For example,Channel 3 is red and valwv number 3 is attached to the red 'pigtailed" ve-lay. Channel Identification is essential for valve synchronization. Theblack wire gSing to each valvm is a common megative ground (). Therefore any

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black wire can be attached to !ny valve Hovever, only each valve's assignedpositive (+) "pigtail" colored wire can be attached to each specific valve.2.15 Unpack the DC power supply from Crate 06. (Note: This paver supply hasbeen converted to operate an 115 volt. input current.) Refer to Section Iof the Hiewlett Packard Operating and Service Hanual for the Turn-On CheckoutProcedure. This most be done before any load is connected to the power sup-ply. Section 3-8. 3-12 of the HP manual must be accomplished for proper oper-ation of all eight valves. Sot the current limit according to Section 3-8 at12.0 AIPS. Set the "Overvoltage Trip" point ia section 3-12 at 26.2 volt@.Turn off power witch.

2.16 Connect the red power vires from the UP-'ZXNIE relays to the EC PowerSupply positive (+) output bar uwI•g two terminals to each free screw oan the(+) power bus bar. Now connect the two terminals each of the black ground-wire. to each free screw of the negative (-) power bus bar. See Figure 4 forproper installation. a

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Figure 4 i~'7Proper Installation requires that the black terminals come off towards the topof the bar and the red terminals come off towards the bottom of the bus bar toelilinete the possibility of shorting between bus bars.The UP-TZIMt and DC Power Supply may be stacked. Since both units arefan-cooled they must be instelle~d with sufficient space for cooling air toreach their sides. These units should be used In an area where the ambienttemperature does not exceed 55"C.

2.17 Attach the stainless steel inlet water pipe to the pump using teflontape for sealant. Slide the moter tank from Crate 97 into position and attachthe fill shut-off float to the fill valve. Connect the water supply hose.screw the plastic feed pipe filter section into the stainless steel inlet pipeasmembly as shown In Figure S.2.18 Attach the pressure regulator with the by-pass port pointing aft amshan In Figure 6.

2.19 Install the by-pass stainless pipe section and support ad showu in Fi8-ure 7. Attach the clear plastic by-pass section.2.20 Before hooking pomr to the pump motor, loosen the brass belt tensionadjustment ocrme on the pump and clacken the belts enough to remove thee.Once the belt. are removed, the motor can be itired and tested for proper rota-tion direction to prevent demsge to the pump.

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2.21 Vire the motor to the 230 Volts, 3-phass input as described on the motorfor "Low Voltage" hookup. Moke connections as to local code and Install anynecessary wire brackets or hold downise Check for proper rotation of the 6 .)motor. If motor turns in wrong direction, wtitch any pair of wires and tcstit again.

2.22 Once propsr connection and rotation is established, reinstall and adjustbelts. A properly adjusted belt should have less than 1/2' depression dia-taose.

2.23 Unpack the target support frame from Crate P7. Attach the plexiglas.splash shi.ld to the target support frame. Attach the four stead-off distancecalibration struts between the target support fraom and the nozzle head sup-port frat'& as (lovn In Figure 1. Set stand-off dist.nca acrording to the cal-Ibratir" curve for different impact pressures.

2.24 Install a calibration transducer* or transducer array.* Attach trans-ducer cable(s) to N-eso*ron Coupler input connector and attach black piesatronoutput cable to an oscilloscope. Turn on Piazotron coupler. Sias voltageslicld reQd 12 volts.

2.25 The jet Impactor assembly Is now complete.

4 1'

GA single for" ring and target plates of 2 In. 2 $ 5 IU.2 OW 113 in.2 areprovided. A pressure transducer Is slso provided. User my elect to use anarray of transducers.

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3. INITIAL S T-W

3.1 Refer to the pump section in the Service Manuae. Appendix for proper ad-justment of the automatic oilers on the pump.

3.2 Refer to the UP-TIHER section for the procedure involved in programming Sthe timer. Although the valves should bt reeynchronixed before each a 74bro-tion teots the timing card supplied in the pack can be used for the initialstart-up tesot Set the timer on 0201100 see* cycle duration. Turn on timerpower. Pull out TIMt drawer. Push in control knob and rotate to "PROGRAM."Push "RESET." Place timing card in drawer. Be careful of proper corner orl-e*tation key. Carefully slide drawer in amoothly. Watch channel lights Slowand turn off as push is complete. Rotate control knob to "SINGLE."

3.3 Charge acktuulators to OOZ of the desired line pressure. (Notes *ccu-nulator valves are open when rotated clockwise down into stem and are closedby baciinS valve steme counterclockwise out of stoms.)

3.4 Turn on pump motor, looses loc.k nut on regulator and rotate regulatoradjustment control until chamber pressure gauge holds at the deslred pres-sure.** Lock ad~ustmont nut. Bleed any compressed air from chamber usingpetcock relief valve.

3.3 Turvi power suppiy power on. be sure 24 volts is Indicated output.

3.6 To fire impactor, quickly depress and release "START" switch on the UP- S 0TIDMR. If swtch is depressed too long, multiple valve firings w•ll resultand also may cause the valves to stick op4n. Note that the first firing mycontain some compressed air. Bleed air from proesure chamber again and re-charge system to the desired line pressure. Blow orifice plates clean ofentrained water with compressed air supply. This insures similar chamber con-"ditions for all valves. A series of 5 or 6 shots my be needed before system"WAINS" up #nd begins repeatable operation.

'I

-M6100 se "- 200 mec cycle duration or 2 maecluait. 60 units 120 meec Svalve shot time. Note: When I 00 sec are used me lights in elapsed time /are visible.

Oftote: Never pressurize system beyond 250 pai. Valves are not rated above250 psi.

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40.4. TW0UBLIiOTf DIG

4.1 Problems System Leaks

Remedy: The impactor Is designed for relatively easy disassembly atvarious points in the system. Swivel connections are providedat the valve/flexible hoe interfaces and at the pump flexiblebome/preasure regulator interface. Also a union is providedbetween the pressure chamber and check valve. Loosen leakingsection, retape with teflon tape and reassemble section.

4.2 Problem: Loeks at OwifIce Piate

Remedys A large leak at an orifice plate may reduce that specificvalve's performance. Hold valve secure and loosen stainless"Wmason jar" retaining ring. Remove ring and orifice plate.Replace or reseat 0-ring onto brass nipple. Retape teflon ontobrass nipple. Reinstall orifice plate and retaining ring.Align orifice plate properly whila tightening. It Is importantto tighten the orifice plate securely against the brass nipple0-ring seat for proper seal. If retaining ring begins totighten but the orifice plate appears loose, slightly loosenretaining ring and begin to tighten again until proper seatingis attained. IMPORTANT NOTE: If retaining ring is not tight-ened and fully seated, It my cause the orifice plate and theretaining ring to be "shot off" the brass nipple causing damag& * Oto callbrztion plate or injury to test subject.

4.3 Problems Oil In Water Sapply

Remodyi Oil slick in the w.6ter supply is caused by improper adjustmentof the automatic oilers on the pump bearings section. Refer tothe pump section of the service manuals for proper adjustmentprocedures.

4.4 Problems Valve sticks "ea. System cannot be preasuriad.

Momadys This usually occurs if a valve has malfunctioned or It my4 occur if the operator has cycled the valvts when the system

pressure Is xero. One solution to this problem can be attainedby cycling the charging system en and off a few times in quicksuccession. The pressure pulses my close the valve. If thisdoes not solve the problem, then the solenoid section of themalfusnctionina valve wuat ho removed and reinstalled.

Valve Removal Procidure:

I. Bleod system pressure

2. Removw solenoid retaining bolts from valve housing.

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