IN64302
December 2008
Applicable additional manuals:
IN64235
UNDERWIN
Aerospace Group IN64108
Conveyance Systems Division IN64702
Carter® Brand SU64235
Ground Fueling Equipment FBO OPERATIONS
MODELS 6404
Carter now offers an under
airfield, FBO, use with a ne
for strainer checking, with
Installation Instructions break. The underwing noz
utilizes the Carter Unisex C
Digital Manifold with Digital Hydrant Control
Model 64302
6404
Underwing Nozzle
Unisex Coupling
and Dust Caps for
671 W. 17th St., Costa
BACK
IN64302 December 2008
Table of Contents
Page
1.0 Scope....................................................................................................... 3
2.0 Equipment Supplied by Customer ........................................................... 3
3.0 General Description................................................................................. 3
4.0 Installation................................................................................................ 4
5.0 Illustrations............................................................................................... 5
Figure 1.................................................................................................... 6
2
IN64302 December 2008
Installation Instructions
Carter ® Model 64302
Digital Manifold
1.0 Scope
These installation instructions have been such an installation which might be dictated
developed for use in mounting the 64302 by other authorities which have jurisdiction
solenoid manifold assembly on any hydrant over the use of the vehicle. The
servicer vehicle for use in controlling Carter responsibility for proper final installation
Models 64702, 64802, 64804 and 64902 configuration is that of the OEM. Consult
hydrant couplers and a fuel operated with the local airport authority or corporate
hydrant pit valve such as the 60554. These authority for further information.
instructions do not cover all requirements for
2.0 Equipment Supplied by Customer
The following is a listing of the required • Hose and fittings to connect between
equipment supplied by the customer on the the 64302 and hydrant pit valve being
refueling vehicle. The digital system needs operated by the 64302.
to interface with all of the items below:
• An accumulator to be utilized as the
• Mounting hardware needed to affix the fluid power source for the 64302. It is
64302 to the vehicle. recommended that an accumulator with a
minimum volume of 2.5 cubic feet be
• Wire to connect solenoids A thru D to
utilized. An accumulator of lesser volume
the Digital II control panel.
can be used, especially if the hydrant
• Hose and fittings to connect between system pressure is never lower than 90 psi.
the 64302 and hydrant coupler being The amount of volume used provides a
operated by the 64302. capability to operate longer at lower
pressures. If a smaller accumulator is used,
contact Carter prior to proceeding.
3.0 General Description
3.1 The 64302 is an assembly of two solenoid wetting of the system. If these orifices
valves mounted to a manifold block to become blocked, it will adversely affect
constitute a pilot to operate a pressure performance of the pressure control valve.
control coupler such as Carter Model 64802
3.1 One hose, or other suitable conduit, will be
digital coupler and an additional solenoid to
utilized to connect the center passage of the
operate the hydrant pit valve. Solenoid valve
manifold to the control cavity of the pressure
“A” is a normally closed (N/C) valve and
control coupler.
solenoid “B” is normally open (N/O) with
solenoid “C” being a normally closed (N/C) 3.1 Two wires will be connected to each of the
valve which works to control surge. Solenoid four solenoid valves of the manifold
“D” is a 3-way normally closed valve (N/C) assembly (eight (8) wires total) to connect
to control the hydrant pit. them to the 64235 digital control module.
3.1 The manifold block is equipped with two 3.1 The 64302 can be mounted at any
fittings with two orifice screws labeled “A” convenient location on the refueling vehicle
and “B” located next to each other on one in any orientation. However, it is best, if
side of the manifold block. These are factory possible, to mount the assembly with the
installed orifices which are critical to the valves upright and the manifold on the
function of the digital system. Do not bottom.
tamper with these two fittings, or the
orifices with in them, in any way other 3.1 An accumulator must be used to store fluid
than as stated within this document. power to be utilized as the source of inlet
Take great care to keep these orifices pressure for the 64302 manifold block.
clean at all times, especially during first
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IN64302 December 2008
4.0 Installation
4.1 Mounting 64302 on the Vehicle: 4.3.4 Also connect the fuel reservoir portion of the
accumulator to the inlet of the manifold
4.1.1 The Manifold Assembly can be mounted to
block used to control the digital coupler.
the refueling vehicle by utilizing the two
holes drilled through the face of the manifold 4.3.5 Pre-charge the gas end of the accumulator
block. with 60 psi of air (or nitrogen) pressure.
4.2 Solenoid Connections 4.4 Manifold Fluid Connections
4.2.1 Solenoids “A”, “B” and “D” can be connected 4.4.1 There are eight ports on the manifold block,
to the Digital II control module by pulling the each a female 1/4 NPT. Five of these fluid
female connectors and screws from the ports will have to be connected to other fluid
block and connecting 18 gauge sources on the vehicle.
(recommended) insulated wires to the
4.4.2 The two fittings marked “A” and “B” located
solenoids then securing lid, screws and
on either side of the port marked “coupler”
female connectors.
have factory installed orifices within them
4.2.2 Solenoid “A” (slightly shorter of the two) which are critical to the function of the digital
should be wired to the terminals numbered valve system. Do not tamper with these
41 and 42 on the control board for Digital II. two fittings, or the orifices with in them,
in any way other than as stated within
4.2.3 Solenoid “B” (slightly taller of the two)
this document. Take great care to keep
should be wired to the terminals numbered
these orifices clean at all times,
39 and 40 on the control board for Digital II.
including during first wetting of the
4.2.3 Solenoid “D” should be wired to the battery system.
“hot side” and the terminal numbered 36 on
4.4.3 Connect the high pressure source, such as
the control board for Digital II.
an accumulator used in conjunction with the
4.2.4 Solenoid “C” has a length of wire extending coupler to the port marked “accumulator” on
from the housing that will need to be the manifold block. Use a 1/4” or 3/8” inside
connected to another piece of wire of diameter hose, tube or pipe for this
suitable length fro connection to the digital II application.
control board. Solenoid “C” should be wired
4.4.4 Connect the port marked “accumulator pre-
to the terminals numbered 37 and 38.
charge” on the manifold block to the
4.3 Accumulator accumulator hand pump. Use a 1/4” or 3/8”
inside diameter hose, tube or pipe for this
4.3.1 Any 2.5 gallon bladder accumulator can be application.
utilized for the fluid power source for the
manifold block used to control the digital 4.4.5 Connect the low pressure point to the port
coupler. Follow the manufacturer’s marked “recovery tank”. Use a 1/4” or 3/8”
instructions for mounting the accumulator on inside diameter hose, tube or pipe for this
your vehicle. application. NOTE: The hose or conduit
selected for this purpose must be free
4.3.2 Connect a line to the fuel reservoir portion of flowing. Any major resistance to flow in this
the accumulator from a high pressure line will adversely affect the operation of the
source on the vehicle. This line will be used 64302. Free flow of fluid in this line is
to charge the accumulator with fuel imperative.
pressure.
4.4.6 Connect the hose or conduit which carries
4.3.3 Install a check valve in this line which will fluid to the pressure control coupler to the
allow flow from the vehicle plumbing into the port on the manifold block marked “coupler”.
accumulator but not allow flow from the Use a 1/4” or 3/8” inside diameter hose,
accumulator back into the plumbing. The tube or pipe for this application. If using
result is that fuel pressure will be applied to hose, it must be a braid reinforced hose
the inlet of the manifold block from the suitable for 300 psi service or some other
accumulator and it will become re-charged very stiff conduit. For best results, use the
whenever the pressure in the vehicle is stiffest (least inflatable) hose you can.
greater than the pressure within the (Good results have been accomplished with
accumulator. the ¼” DAYCO 6L2 hose.) The hoses can
be no longer than 60 feet. The other end of
the hose or conduit is connected to the
4
IN64302 December 2008
control cavity of the pressure control 4.5.3 Use the hand pump to ensure the
coupler. accumulator has at least 80 psi of fuel
pressure. Remove the fuel command line
[Link] When making this connection, use free
from the coupler and press the rapid bleed
flowing fittings which will not restrict flow
valve button on the 64302 catching the fuel
through this conduit. Any major resistance
emitted from the control line in a suitable
to flow in this line will adversely affect the
container. Release the button and place a
operation of the coupler. Free flow of fluid
finger over the end of the command line to
in this line is imperative.
minimize further ingestion of air. Reconnect
4.4.7 Connect the hose or conduit which carries the line to the coupler.
fluid to the fuel operated hydrant pit valve to
4.5.4 Using the hand pump recharge the
the port on the manifold block marked
accumulator to 80 psi fuel pressure. Loosen
“hydrant”. The other end of the hose or
the bleed plug on the top of the hydrant
conduit is connected to pilot on the hydrant
coupler and press the rapid bleed button on
pit valve.
the 64302 again. When the residual air is
4.5 Air Bleeding bled, tighten the bleed plug on the coupler.
Repeat this step if necessary until satisfied
4.5.1 Once the physical installation is complete that all the air is removed from the control
and the vehicle is filled with fuel, upon first line and from the control cavity of the
pressurization, the hoses and/or tubes that coupler.
connect the 64302 manifold assembly to the
digital coupler and its internal cavity must be The unit is ready for testing and setup of the
bled of air. digital control system. Refer to manual
SU64235 for instructions.
4.5.2 The 64302 is equipped with a rapid bleed
valve feature to assist in bleeding trapped
air from the coupler command line.
5.0 Illustrations
See following page.
5
6
IN64302
Figure 1
64302 Connection Schematic
December 2008
Aerospace Group
Conveyance Systems Division
9650 Jeronimo Rd
Irvine, CA 92618
Ph (949) 452-9500
Fax (949) 452-9992