M2A3 BFV Master Gunner's Course Sustainment and Diagnostics Student Guide PDF

M2A3 BFV Master Gunner’s Course Sustainment and Diagnostics SUSTAINMENT AND DIAGNOSTICS (S&D) S&D-4-E- 1 M2A3 BFV Master Gunner’s Course Sustainment and Diagnostics Terminal Learning Objective ACTION Maintain a M2A3/M3A3 Bradley Fighting Vehicle (BFV). CONDITIONS Given classroom instruction, student guide, TM 9-2350-438-10 fully operational M2A3 BFV, and a M2A3 desktop trainer. STANDARDS Maintain a M2A3/M3A3 BFV through sustainment and diagnostics on a BFV IAW student guide, TM 9-2350-438-10 S&D-4-E- 2 M2A3 BFV Master Gunner’s Course Sustainment and Diagnostics Learning Step Activity 1 ACTION Describe the component functions of the Power Management/Distribution Subsystem (PMDS) CONDITIONS Given classroom instruction, student guide, TM 9-2350-438-10 (31 MAY 2018) fully operational M2A3 BFV, and a M2A3 desktop trainer. STANDARDS Student will describe the component functions of the PMDS IAW the student guide, TM 9-2350-438-10 (31 MAY 2018) Engine Compartment Components Reduced White Smoke Engine (600-HP) 400 Ampere Generator Transmission Electronic Control – Electronic Controlled Braking (TEC-ECB) Interface Assembly S&D-4-E- 3 M2A3 BFV Master Gunner’s Course Sustainment and Diagnostics Learning Step/Activity 1: Describe the component functions of the (PMDS) a. Reduced White-Smoke Engine: The M2A3/M3A3 is equipped with a reduced white-smoke engine. After engine start the Step Timing Control (STC) will cut in within 25 sec. The white smoke will be reduced and the sound of the engine will change. b. 400 Ampere Generator: The generator provides the electrical current and voltage regulated +28 VDC output to charge the turret reserve, two turret electronics, and four hull batteries. c. TEC Transmission – Electronic Controlled Braking: The transmission is commonly referred to as “TEC” (transmission electronic control). 1) The TEC system consists of a Transmission, Interface Assembly (IA), Interface Cable, Electronics Assembly (EA), and the Bradley Shift Tower (BST). The transmission is controlled by the EA, which is housed beneath the shift tower. One of the signals the EA processes is the position of the gear selector, which is transmitted S&D-4-E- 4 M2A3 BFV Master Gunner’s Course Sustainment and Diagnostics 1. Learning Step/Activity 1: Describe the component functions of the (PMDS) electronically to the transmission through the interface cable to the IA which is on the top of the transmission. 2) The principal improvement in the A3 transmission is improved braking capabilities. The transmission has three forward ranges. When the throttle is returned to idle and the transmission is in second or third range, the brake coolant valve opens, flooding the brake assemblies with oil. This action provides a dynamic braking effect, which decreases vehicle acceleration without the driver applying the brakes. The brake pedal can still be used in all ranges to quickly stop the vehicle. S&D-4-E- 5 M2A3 BFV Master Gunner’s Course Sustainment and Diagnostics 1. Learning Step/Activity 1: Describe the component functions of the (PMDS) Bradley Shift Tower Bradley Shift Tower (BST) Electronic Assembly (EA) Engine Start 1. Master Power 2. Engine Accessory 3. Fuel Cut- off S&D-4-E- 6 M2A3 BFV Master Gunner’s Course Sustainment and Diagnostics 1. Learning Step/Activity 1: Describe the component functions of the (PMDS) d. Bradley Shift Tower: The BST is on the driver’s right side on the wall. The Electronics Assembly (EA) is attached under the Bradley Shift Tower. The (EA) monitors and transmits the lever position from the (BST) to the transmission through the Interface Cable (IC) to the Interface Assembly (IA). The (IA) is attached to the top of the transmission. e. Start the Engine: 1) Master Power to ON. 2) Check the light on the top of the BST and ensure that it is flashing. If it is not flashing contact maintenance. 3) Move the Engine Accessory to the ON position. The engine and transmission low oil light will flash until engine is started. 4) Push the fuel cut off handle in. 5) Push the handle on the BST to the right to start the engine. 6) After engine start, check the engine and transmission gauge on the Drivers Tactical Display (DTD). 7) Check light on the top of the BST to ensure the light turns off within 22 seconds. If the light is still on contact maintenance. S&D-4-E- 7 M2A3 BFV Master Gunner’s Course Sustainment and Diagnostics 1. Learning Step/Activity 1: Describe the component functions of the (PMDS) Vehicle and Turret Batteries Viewgraph 24-VDC Turret Turret Electronics Hull Batteries (4) Reserve Battery Batteries (2) Digital Vehicle Distribution Box (DVDB) DVDB Degraded Drivers Emergency Turret Switch Shutdown Switch S&D-4-E- 8 M2A3 BFV Master Gunner’s Course Sustainment and Diagnostics 1. Learning Step/Activity 1: Describe the component functions of the (PMDS) f. Hull Batteries: The Hull Batteries provide storage of +24vdc electrical power for vehicle starting and power when the engine is not running. Hull Batteries will also provide power in the event of instantaneous high current loads caused by Turret Drive and Weapons Drive movement. There are six 12-volt batteries in the hull, two mounted on the left sponson behind the driver and four beneath the driver. The two sponson- mounted batteries are referred to as the Turret Electronic Batteries. g. Turret Reserve Battery: The Turret Reserve Battery is a single 24vdc Battery. The primary role is to assist in preventing surges and drops in power during turret and gun firing operations. h. Digital Vehicle Distribution Box: The primary function of the DVDB is to distribute power and provide circuit breaker protection to hull electrical subsystems. The DVDB adds the capability to store test programs that are used for the hull embedded diagnostics. S&D-4-E- 9 M2A3 BFV Master Gunner’s Course Sustainment and Diagnostics 1. Learning Step/Activity 1: Describe the component functions of the (PMDS) The DVDB contains additional circuit card assemblies that supply RS422 communication for the Squad Leader’s and Driver’s Tactical Displays, and MIL-STD-1553 hull communication. It incorporates a Controller Area Network (CAN) bus for communication with Remote Power Controller (RPC) and Solid State Power Controller (SSPC) circuit card assemblies (CCA). The DVDB provides RS232 bus for serial communications and a Universal Serial Bus (USB) that will be used to extract diagnostic information. The DVDB also provides power and data interfaces for the DTD and DVE. It transfers digital compass data to the DTD. The DVDB additionally enables pass through wiring for the TURRET POWER ON Indicator, the Cargo and Driver’s Hatch Switches, and power for the LAUNCHER UP indicator. S&D-4-E- 10 M2A3 BFV Master Gunner’s Course Sustainment and Diagnostics 1. Learning Step/Activity 1: Describe the component functions of the (PMDS) The DVDB distributes power to the following LRU’s and electrical systems: Cold Start Distribution Box Smoke Generator Solenoid Ramp Pump Motor and Door Switch Hull Ventilation Fans Bilge Pumps (4) Fire Suppression System Winterization Kit (when installed) Emergency Shutdown Switch Fuel Pumps (4) Engine Sensors Driver’s Instrument Panel Gages Hull Dome Lights and Exterior Lights Gas Particulate Filter Unit Pre-cleaner and Hull System Personnel Heater Hydraulic Engine Access Door Slave Start System S&D-4-E- 11 M2A3 BFV Master Gunner’s Course Sustainment and Diagnostics 1. Learning Step/Activity 1: Describe the component functions of the (PMDS) Hull Power Box (HPB) Turret Power Box (TPB) S&D-4-E-12 M2A3 BFV Master Gunner’s Course Sustainment and Diagnostics 1. Learning Step/Activity 1: Describe the component functions of the (PMDS) i. Hull Power Box (HPB): The Hull Power Box (HPB) controls, distributes, protects, and isolates power to all Power Control Modules (PCM)s. It receives power directly from the two turret electronics batteries through an isolation circuit from the generator and the other four hull batteries. The HPB ensures the PCMs are isolated from unregulated power through the use of the isolation circuit. It has a NORMAL/OVERRIDE switch in the event the turret power switch is inoperable. The Normal/Override switch enables the activation of the turret when in the Override position. This is achieved by bypassing the System Control Box (SCB) which will result in the inability to arm and fire the weapon systems or select turret drive. Placing the NORMAL/OVERRIDE switch in the OVERRIDE position disables the Emergency Shutdown switches located on the Digital Vehicle Distribution Box (DVDB) and System Control Box (SCB). j. Turret Power Box (TPB): The Turret Power Box (TPB) protects and distributes high current turret loads not controlled by PCM#1 and PCM#2. The TPB receives power from the hull batteries, generator, and turret battery, and distributes that S&D-4-E- 13 M2A3 BFV Master Gunner’s Course Sustainment and Diagnostics 1. Learning Step/Activity 1: Describe the component functions of the (PMDS) power to various loads within the turret. It provides power to the Turret Drive System, 25mm Gun Motor, Sear Solenoid, and Feed Select Solenoid, Palm Switches, Turret Cooling Fan Temperature Sensors, Cooling and Exhaust Fans, Turret Lights, and the Diagnostic/Training Power Receptacle. Power Control Modules (PCMs) GUNNERS SIGHT CONTROL PANEL (GSCP) NOTE: PCM’s 1 & 2 are interchangeable with one another, but they must be reprogrammed; PCM 3 is only interchangeable with another PCM 3 due to the CCA for the Appliqué Computer Processing Unit. The PCM’s can only be interchanged or replaced by authorized maintenance personnel. S&D-4-E-14 M2A3 BFV Master Gunner’s Course Sustainment and Diagnostics 1. Learning Step/Activity 1: Describe the component functions of the (PMDS) k. Power Control Modules: The Power Control module (PCM) distributes power to electronic components within the vehicle. There are two PCMs in the turret and one in the Hull, PCM1, PCM2, and PCM3 respectively. The PCMs provide the following capabilities: 1) Load Switching 2) No Load Status 3) On/Off Status 4) Overload Protection 5) Short circuit Protection 6) Grnd/Open outputs 7) 28 Volt/Open inputs 8) Built-In Test 9) Mil-Std 1553 Data Bus Interface 10) On Board Reprogramming NOTE: In the event of a channel failure in PCM’s 1 or 2 the turret can still be operated in a degraded mode. S&D-4-E- 15 M2A3 BFV Master Gunner’s Course Sustainment and Diagnostics 1. Learning Step/Activity 1: Describe the component functions of the (PMDS) Turret Processor Unit (TPU) l. Turret Processor Unit (TPU): The TPU is the Primary Mission Computer. Once power-up is complete the TPU takes over as the Bus Controller (Provides the communication network from the TPU to all other Line Replaceable Units (LRU)s. The TPU houses the Fire Control Processor card which gives the fire control system super elevation corrections and Kinematic lead. The TPU also stores information in its Volatile and Non- volatile memory such as Fire Control, Navigation, and all built (BIT) in test data from Test Management Diagnostic Equipment (TMDE). S&D-4-E- 16 M2A3 BFV Master Gunner’s Course Sustainment and Diagnostics 1. Learning Step/Activity 1: Describe the component functions of the (PMDS) Slip Ring (SLR) M. Slip Ring (SLR): Provides interconnection for power, signal, video signal, and CBRN air connection between hull and turret. S&D-4-E-17 M2A3 BFV Master Gunner’s Course Sustainment and Diagnostics Learning Step Activity 2 ACTION Describe the PMDS mode of operation and types of Built-In tests. CONDITIONS Given classroom instruction, student guide, TM 9-2350-438-10 (31 MAY 2018) fully operational M2A3 BFV, and a M2A3 desktop trainer. STANDARDS Description will include: Identification of the modes of operation Description of the built in tests for the embedded diagnostic system. Power Up Sequence Power Down Sequence Controlled Power Down Uncontrolled Power Down Silent Watch State S&D-4-E-18 M2A3 BFV Master Gunner’s Course Sustainment and Diagnostics Learning Step/Activity 2: Modes of Operation and Types of BIT’s. a. Operation of the PMDS: The Power Management/Distribution Subsystem (PMDS) is a series of LRU’s that manages, operates, monitors, and protects the electrical power distribution in the A3 BFV. The PMDS also provides electrical power that is isolated from the weapon systems, turret drives, and Vehicle starting/charging system. The operation modes of the PMDS includes the following: Power Up Sequence Power Down Sequence Controlled Power Down Uncontrolled Power Down Silent Watch State 1) Power Up Sequence: Turning ON the TURRET POWER switch located on the SCB enables power through the HPB to the PCMs and the TPB, and on to their associated LRUs, including the TPU. The TPU runs an internal SBIT and assumes the role of Bus Controller. SBIT then continues with the start up built in test. 2) Controlled Power Down: Moving the TURRET POWER switch to the OFF position starts the Power Down Sequence in an S&D-4-E- 19 M2A3 BFV Master Gunner’s Course Sustainment and Diagnostics Learning Step/Activity 2: Modes of Operation and Types of BIT’s. orderly fashion. The Power Down Sequence provides the signal and time that allows turret subsystems to store critical data into memory before losing electrical power. This process is referred to as Controlled Power Down, and will be displayed on a CTD popup screen. 3) Uncontrolled Power Down: Uncontrolled Power Down is caused by an unknown/and or unexpected failure of turret or vehicle power, Emergency Shutdown and data deletion. Subsystems might not have stored critical data in memory. During subsequent power up, the vehicle may not be able to re-establish a known safe configuration. In some cases, previously stored data may be cleared or zeroed. For example, boresight parameters, which had previously been entered and saved, may be zeroed causing a potentially unsafe condition. If an Uncontrolled Power Down has occurred, ensure environmental parameters, boresight parameters, and navigation parameters are correctly set before continuing with the mission. S&D-4-E- 20 M2A3 BFV Master Gunner’s Course Sustainment and Diagnostics Learning Step/Activity 2: Modes of Operation and Types of BIT’s. Emergency Turret Shutdown Switch Emergency Turret Data Deletion Switch Shutdown Switch Data Deletion Switch S&D-4-E- 21 M2A3 BFV Master Gunner’s Course Sustainment and Diagnostics Learning Step/Activity 2: Modes of Operation and Types of BIT’s. 4) Emergency Turret Power Shutdown Switch: This switch enables the GNR or BC to positively shut down turret power in the event of an emergency or erratic operation 5) Data Deletion Switch: The Data Deletion Switch eliminates all data stored in the TPU, the INU data to include BIT, boresight and alignment constants and DAGR encryption keys and coordinates. DO NOT use this switch unless directed to do so by your instructor. S&D-4-E- 22 M2A3 BFV Master Gunner’s Course Sustainment and Diagnostics Learning Step/Activity 2: Modes of Operation and Types of BIT’s. 6) Silent Watch State: Silent Watch is a low power / low signature A3 system state (Fire Control Mode of Operation ) which provides a surveillance capability while minimizing the acoustic, thermal, and electromagnetic emissions. After the A3 has read and saved navigation data, it will shut down power to the following LRUs: Position Interface Box (PIB) Eye safe Laser Rangefinder (ELRF) Gun Control Unit (GCU) Global Positioning System (GPS) Inertial Navigation Unit (INU) Gas Particulate Filter Unit (GPFU) and Heaters Turret Drive Control Unit (TDCU) IBAS Defogger EPLRS TDS Drive power MRE Heater Squad Leader’s Display (SLD) Driver's Displays Drivers Viewer Enhancer (DVE) if used Silent Watch mode initialization includes placing the system into a safe mode, reducing the signature and setting of the S&D-4-E- 23 M2A3 BFV Master Gunner’s Course Sustainment and Diagnostics Learning Step/Activity 2: Modes of Operation and Types of BIT’s. CIV and the Biocular Display Units for operation. Both the Commander’s and Gunner’s sights displays the video image of the selected CIV sensor (TV or FLIR). The Fire Control subsystem displays "Silent Watch" in the IBAS's and CIV's Biocular displays. Voice radio transmissions and some digital transmissions are not inhibited. The commander has to make sure that he is not transmitting accidentally. SILENT WATCH provides the operator interface to the control elements on the CHS, GHS, SCB, CSCP, GSCP, CDET, and CTD screens just as in the COMBAT state. Accessibility to maintenance and Fire Control screens is inhibited. Soft keys that normally (in COMBAT state) call up screens and their underlying functionality that are not available in the SILENT WATCH state, are grayed out and are disabled. All screens that can be called up display an overlay that indicates the SILENT WATCH state is active. Background BIT (BBIT) runs just as in the COMBAT state, except that it does not report or display failure messages for failures that occur because an LRU is in Standby due to SILENT WATCH state. Fire Control operates in a surveillance mode only. The CIV is used for the surveillance function. The CIV's Day- TV or S&D-4-E- 24 M2A3 BFV Master Gunner’s Course Sustainment and Diagnostics Learning Step/Activity 2: Modes of Operation and Types of BIT’s. FLIR video image is displayed on both the Commander's and Gunner's Biocular displays. Since the CIV video image needs to be displayed on the gunner's Biocular display also, IBAS power is not turned off. Both the gunner and the commander are able to control the functions of the CIV. The commander continues to stow and unstow the CIV. The Fire Control system does not report all failures that occur during silent watch because the LRU’s are in a standby mode. Types of Built In Tests (BIT) Startup Built In Test (SBIT) Non-Interactive Built In Test (NBIT) Background Built In Test (BBIT) Interactive Built In Test (IBIT) Fault Isolation Test (FIT) S&D-4-E- 25 M2A3 BFV Master Gunner’s Course Sustainment and Diagnostics Learning Step/Activity 2: Modes of Operation and Types of BIT’s. TPU T=0s: Turret Power Switch On; Turret Drive Switch On: Power to PCMs, TPB and HPB T=0.5s: Power to TPU, GCU, SINCGARS, EPLRS, VIS, PNS, BCIS, SCB T=6.0s: TPU Complete SBIT: Establish Runtime Environment; Initialize 1553; TPU becomes Bus Controller and Commands PCM’s/ TPB to Power Respective LRU’s T=15s: LRU’s Complete SBIT; TPU Collects and Analyzes SBIT Data Extensive Self Testing Minimizes Manual Checks Combat Capable In About 15 Seconds (Basic Test) S&D-4-E- 26 M2A3 BFV Master Gunner’s Course Sustainment and Diagnostics Learning Step/Activity 2: Modes of Operation and Types of BIT’s. b. Built in Test: Essentially, the A3 Bradley Fighting Vehicle System employs five types of Built In Testing to detect faults and determine vehicle readiness: Startup Built In Test (SBIT) Non-Interactive Built In test (NBIT) Background Built In Test (BBIT) Interactive Built In Test (IBIT) Fault Isolation Testing (FIT) c. Startup Sequence: As part of the startup sequence, the Commander’s Tactical Display (CTD) may display these screens in quick succession. The screens that may be displayed: A white and black checkerboard pattern. Vertical columns of alternating white and black lines. A white background with one set of large squares colored red, green and blue, and one set of smaller squares of the same color. The next screen will be divided into thirds. The previous screen will be reduced and displayed in the lower left third of the screen. The upper third will display Black and White horizontal S&D-4-E- 27 M2A3 BFV Master Gunner’s Course Sustainment and Diagnostics Learning Step/Activity 2: Modes of Operation and Types of BIT’s. lines The lower right third will display Black and White vertical lines. The fifth screen is a solid gray screen, and the final screen displays nine vertical colored lines. Start Up Built In Test(SBIT) TURRET POWER SWITCH ON; TURRET DRIVE SWITCH ON; POWER TO PCM’S TPB AND HPB POWER TO TPU, GCU, VAA, VIS, PNS, AND SCB. TPU COMPLETES SBIT (6 SEC); ESTABLISHES RUNTIME ENVIRONMENT; INITIALIZE 1553; TPU BECOMES BUS CONTROLLER AND COMMANDS PCM’S/TPB TO POWER RESPECTIVE LRU’S. LRU’S SBIT; TPU COLLECTS AND ANALYZES SBIT DATA AND STORES IT IN VOLATILE MEMORY. LRU SBIT COMPLETE S&D-4-E- 28 M2A3 BFV Master Gunner’s Course Sustainment and Diagnostics Learning Step/Activity 2: Modes of Operation and Types of BIT’s. A3 Banner Screen d. Startup Built In Test (SBIT): SBIT is executed during the startup sequence. This test is run by the electronic hardware and software components to test them-selves during every power-up cycle. Electronic components with resident software "intelligent” enough to perform SBIT are designed to provide self-tests which can be completed within 15 seconds. When power is applied (TURRET POWER switch to ON), those LRUs able to perform SBIT, including the Turret Processor Unit (TPU) will begin self-test automatically. All SBIT results are stored in volatile memory (results may only be accessed during the current power cycle). S&D-4-E- 29 M2A3 BFV Master Gunner’s Course Sustainment and Diagnostics Learning Step/Activity 2: Modes of Operation and Types of BIT’s. When the TURRET POWER switch is set to on, power is supplied to the Power Control Modules (PCMs), TPB, TPU, Gun Control Unit (GCU), Vehicular Amplified Adapter (VAA) Vehicle Intercommunication System (VIS), Position/Navigation Subsystem (PNS), System Control Box (SCB), IBAS, CTD, CIV, TDS and Battlefield Combat Identification System (BCIS) within 0.5 seconds. The TPU completes SBIT establishing the runtime environment and initializing the 1553B data bus. The TPU becomes the Bus Controller. The LRUs initiate SBIT and then report their status to the TPU. The TPU collects, analyzes and stores SBIT data, and clears the A3 banner screen. While this screen is being displayed, the SBIT results of each device on the 1553B data bus are reported. The SBIT results are saved in a fault register in the TPU. The A3 banner screen also informs the operator when NBIT is abortable. If a critical fault is detected during SBIT, the system is placed in Safe Mode. If this happens the system will not accept or respond to inputs from either of the hand stations or the SCB. Safe mode will be indicated in the Biocular display with a pop-up fault message on the CTD. S&D-4-E- 30 M2A3 BFV Master Gunner’s Course Sustainment and Diagnostics Learning Step/Activity 2: Modes of Operation and Types of BIT’s. Non-Interactive Built In Test (N-BIT) TDS READY; IBAS/CIV DAYSIGHT READY; GPS ONLY READY; DISPLAYS READY; NBIT STARTED. IBAS/CIV GYROS READY NBIT COMPLETE (ALL LRU’S TESTED AND REPORTED STATUS) OR NBIT TIME – OUT (PARTICULAR LRU NOT COMPLETELY TESTED) OR NBIT ABORTED BY CREW. PNS FULLY OPERATIONAL; FLIR’S COOL DOWN COMPLETE S&D-4-E- 31 M2A3 BFV Master Gunner’s Course Sustainment and Diagnostics Learning Step/Activity 2: Modes of Operation and Types of BIT’s. Navigation Setup Screen Self Test Completion Indicator S&D-4-E- 32 M2A3 BFV Master Gunner’s Course Sustainment and Diagnostics Learning Step/Activity 2: Modes of Operation and Types of BIT’s. e. Non-Interactive Built In Test: The CTD displays the Self Test Summary Screen. After SBIT has run, the components will load operations software as necessary. The components will begin executing NBIT, which consists of non-interactive hardware checks, which could not be run during SBIT due to time constraints. Functional checks of the software and I/O is also conducted during NBIT. NBIT is required to finish and report results within 120 seconds (two minutes). NBIT may be aborted if required by Squeezing either the CHS palm switch or a GHS palm switch. This will activate the turret drives, or by selecting a turret weapon system. The NBIT will stop and place the system into a Combat State. If a Loss or Advisory message is displayed selecting CLOSE from the Self-Test screen before Self-Test is complete allows the operator to continue normal login and setup procedures. The Self- Test status is displayed as a percentage in a pop-up screen until it is complete. S&D-4-E- 33 M2A3 BFV Master Gunner’s Course Sustainment and Diagnostics Learning Step/Activity 2: Modes of Operation and Types of BIT’s. When Self-Test is complete, all LRUs will have been polled and the PASS/FAIL results displayed on the Self-Test Screen. NBIT testing is non-intrusive (does not interfere with normal operation) and does not require external test equipment. Once NBIT is complete, the Navigation Setup Screen will be displayed. If, after 120 seconds, NBIT is not complete, a message will be displayed advising the operator that a particular LRU was not completely tested. That particular LRU may or may not function during normal operation. This condition is referred to as NBIT time-out. The operator’s first indication that NBIT was aborted is illumination of the SCB sear indicator. It should be noted that some subsystems require additional time to reach full functionality. Once the Self-Test screen appears, the Turret Drive Subsystem is ready if the TURRET DRIVE power switch has been set to on. The Position/Navigation Subsystem requires additional time (up to 5.5 minutes) to become fully operational, although the GPS mode is available at approximately 61 seconds after power-up. At approximately 61 seconds after power-up, the IBAS and CIV are Day sight ready, though the FLIR systems in both require up to 15 minutes from Startup until cooldown is complete. S&D-4-E- 34 M2A3 BFV Master Gunner’s Course Sustainment and Diagnostics Learning Step/Activity 2: Modes of Operation and Types of BIT’s. Background Built In Test (B-BIT) BEGINS ONCE N-BIT IS COMPLETE OR ABORTED. MONITORS THE HEALTH OF THE SYSTEM. RUNS IN EACH SYSTEM CRITICAL INTELLIGENT COMPONENT. CONTINUOUSLY REPEATED AS A LOW PRIORITY TASK. WILL NOT INTERFERE OR AFFECT OPERATIONAL PERFORMANCE AND REAL-TIME OPERATIONS. BBIT REPORTS FAILURES, LOST FUNCTIONALITY, AND ONLINE STATUS TO THE TPU. THE BUS CONTROLLER (TPU) COLLECTS, ANALYZES AND STORES ALL RESULTS INTO NON-VOLATILE MEMORY. THE TPU WILL TRANSMIT A MALFUNCTION POP-UP AND OR (MAL) COUNTER INCREMENT IF A FAULT IS DETECTED. f. Background Built In Test (BBIT): Background BIT (BBIT) begins executing once NBIT is complete or aborted. BBIT is composed of all of the non-interactive tests, which run to monitor the health of the system. BBIT is continuously repeated as a low priority task. BBIT does not interfere with or affect operational performance or real-time operations. It reports failures, lost functionality, and on- line status the TPU. S&D-4-E- 35 M2A3 BFV Master Gunner’s Course Sustainment and Diagnostics Learning Step/Activity 2: Modes of Operation and Types of BIT’s. The TPU, as the Bus Controller collects and analyzes results. If a fault is detected a malfunction Advisory pop-up will display on the CTD and or the MAL indicator on the status bar will increase its counter increments. BBIT results are saved in the Non-Volatile memory at controlled power down. Interactive Built In Test (I-BIT) IS USED BY THE OPERATOR AND MAINTAINER AS ANOTHER MEANS OF FAULT DETECTION. IT ALLOWS THE OPERATOR OR MAINTAINER TO INITIATE TESTS FROM THE CTD. COLLECTS, ANALYSES, AND STORES RESULTS IN THE NON- VOLATILE MEMORY OF THE TPU. THE RESULTS ARE THEN DISPLAYED ON THE CTD (I.E. PASS OR FAIL). DOES NOT REQUIRE THE USE OF TEST MEASUREMENT DIAGNOSTIC EQUIPMENT (TMDE). INTERFERES WITH NORMAL OPERATION. g. Interactive Built In Test (IBIT): Interactive BIT (IBIT) is used by the operator as another means of fault detection. During a Readiness Test, the maintenance software requires that the operator push specific buttons or manipulate the controls (i.e. depress the CHS S&D-4-E- 36 M2A3 BFV Master Gunner’s Course Sustainment and Diagnostics Learning Step/Activity 2: Modes of Operation and Types of BIT’s. palm switch). This allows the health of the system to be checked. The results are then displayed on the CTD and inform the operator or maintainer of subsystem status (i.e. Pass or Fail). Like SBIT, NBIT and BBIT, IBIT does not require the use of Test Measurement and Diagnostic Equipment (TMDE). IBIT does, however, interfere with normal operations, in that it requires operator input and response. During IBIT the system is not in a combat state. The operator is limited to the Readiness Test for IBIT. If NBIT times-out, the operator may invoke the Readiness Test to determine the operational readiness of the system. The Readiness Test is accessed as follows: SETUP MISSION CHKLIST READINESS TEST or MAINTENANCE READINESS TEST. The Readiness Test is abortable without powering down the turret. Other extensions of IBIT are available to the maintainer to detect faults. These tests include Target Acquisition Tests, Weapons Controls Tests, Turret/Weapon Drive Tests, Controls and Displays Tests, PNS Commo Tests, Power/Data Bus Management Tests, Position Sensors and Interlocks Tests, Power Unit Performance Tests, and Maintenance Tests. S&D-4-E- 37 M2A3 BFV Master Gunner’s Course Sustainment and Diagnostics Learning Step/Activity 2: Modes of Operation and Types of BIT’s. Fault Isolation Test (FIT) IS ONLY USED BY MAINTAINERS. A MAINTANER CAN FAULTS AND SYMPTOMS IN THE VEHICLE DIAGNOSTIC MANAGEMENT SYSTEM (VDMS) REQUIRES THE USE OF TEST MEASUREMENT AND DIAGNOSTIC EQUIPMENT (TMDE). ISOLATES FAILED MISSION CRITICAL COMPONENTS 95% OF THE TIME. ISOLATES FAILED NON-MISSION CRITICAL COMPONENTS 90% OF THE TIME. h. Fault Isolation Test (FIT): Only trained maintainers are to diagnose faults and symptoms in the Built-in Vehicle Diagnostic Management System of the A3 using the Fault Isolation Test (FIT). FIT requires the use of Test Measurement and Diagnostic Equipment. FIT isolates failed mission critical components 95% of the time and failed non-mission critical components 90%of the time. NOTE: Entering FIT can be intrusive and destructive. S&D-4-E- 38 M2A3 BFV Master Gunner’s Course Sustainment and Diagnostics Learning Step Activity 3 ACTION Describe the Failure Handling Process and fault notification. CONDITIONS Given classroom instruction, student guide, TM 9-2350-438-10 (31 MAY 2018) fully operational M2A3 BFV, and a M2A3 desktop trainer. STANDARDS Student will describe the Failure Handling Process and fault notifications IAW the student guide. Learning Step/Activity 3: Describe the Failure Handling Process a. Failure Handling Process: Failure Handling detects critical failures and disables the affected functionality. The remaining systems will continue operation without the failed functionality. 1) Critical failures are limited only to those which compromise system safety, (i.e. weapon firing or turret motion functions or those which may cause more system degradation if not handled properly). 2) Safe Mode: When losses of functionality are considered critical, the failure handling process automatically transitions the fire control system into Safe Mode. In Safe Mode, the Turret Drive System power is inhibited and the system overrides a Safe to Fire condition to Not Safe to Fire condition for all weapons (weapon selection is inhibited). S&D-4-E- 39 M2A3 BFV Master Gunner’s Course Sustainment and Diagnostics Learning Step/Activity 3: Describe the Failure Handling Process When a pop-up failure-handling message is displayed on the CTD, the Commander must acknowledge the message (by pressing the CLOSE soft-key) and the system may be returned to the condition before the pop-up was displayed, out of safe mode, with the impacted or lost functionality not available. Example: Gun power track pop-up message comes up. The commander closes the pop-up but you will not get TDS, WPN control or IBAS until the commander goes into Gun Power track in the CTD and then the vehicle will be in a degraded mode. Exception to Safe Mode: An exception to this process is when the system is operating in Degraded Gun Mode (Degraded Gun Mode switch on the SCB is ON). Safe Mode will not be fully initiated because in this mode, the gun is “hot”, and only the Turret Drive System will be inhibited. 4) Failure Handling Messages: Some LOSS messages do not automatically put the system into Safe Mode and no ADVISORY message will put the system into Safe Mode. S&D-4-E- 40 M2A3 BFV Master Gunner’s Course Sustainment and Diagnostics Learning Step/Activity 3: Describe the Failure Handling Process Failure Handling Messages S&D-4-E- 41 M2A3 BFV Master Gunner’s Course Sustainment and Diagnostics Learning Step/Activity 3: Describe the Failure Handling Process Accessing Malfunction Advisory Malfunction Advisory List (MAL) S&D-4-E- 42 M2A3 BFV Master Gunner’s Course Sustainment and Diagnostics Learning Step/Activity 3: Describe the Failure Handling Process b. Accessing the MAL: The Commander can select this screen using the status bar “MAL” indicator, or select SETUP MAL ADVSY soft-keys. 1) This screen identifies each loss of mission capability (LOSS) and separates each loss with a semi-colon (;). In this illustration the WEAPON CONTROL mission capability, identifies five losses separated by semi-colons. If an advisory (ADVSY) is provided, it will also be displayed. An ADVSY may be displayed without a corresponding LOSS message. This screen further identifies whether malfunctions (MALF [faults]) have been detected which do not signify a loss of mission capability and which subsequently will not appear either as pop-ups nor increment the MAL indicator on the status bar. A scroll bar is provided to navigate through the MAL. 2) Each of the mission capabilities listed, (i.e., SAFETY SENSOR & INTERLOCK, WEAPON CONTROL, FIRE CONTROL, etc., will S&D-4-E- 43 M2A3 BFV Master Gunner’s Course Sustainment and Diagnostics Learning Step/Activity 3: Describe the Failure Handling Process also have its status displayed. The following are the status terms and their meanings: a) GO. The system (mission capability) is fully functional and ready for use. b) DEGRADED. Some functions are not available and you will be operating in a degraded mode. When the mission capability is completely degraded (the whole weapon system faulty for example), the DEGRADED status changes to NOGO. c) IN PROGRESS. The mission capability is undergoing BIT. d) ABORT NBIT. If NBIT was interrupted (aborted) during startup, the system tells you that it is unknown whether the system is GO or whether there is some degradation of mission capabilities. e) VERIFY. If a fault was not corrected during the previous power up cycle, the system retains that information in a fault log which may be accessed only by Unit Level Maintenance personnel. With this status, you may still have full functionality. S&D-4-E- 44 M2A3 BFV Master Gunner’s Course Sustainment and Diagnostics Learning Step/Activity 3: Describe the Failure Handling Process f) NO GO. The system is fully degraded in at least one area and may only operate in a degraded mode of operation. The MAL Indicator on the status bar increments under the following conditions: When the Mission Capability Status is either NOGO, DEGRADED, or VERIFY. When a mission capability has one or more than one LOSS. S&D-4-E- 45 M2A3 BFV Master Gunner’s Course Sustainment and Diagnostics Learning Step/Activity 3: Describe the Failure Handling Process Failure Handling Scenario c. Failure Handling Notification and Response: When the failure handling process detects a loss of mission capability in the system, the crew will be notified in the following ways. 1) A blue-bordered pop-up message is displayed on the CTD advising the Commander of the loss of a specific mission capability (identified as LOSS). When a failure-handling message is displayed, all available soft-keys will be replaced S&D-4-E- 46 M2A3 BFV Master Gunner’s Course Sustainment and Diagnostics Learning Step/Activity 3: Describe the Failure Handling Process by only one soft-key: CLOSE. The Commander must acknowledge the message by selecting the CLOSE soft-key. Upon closing, the soft-keys that were present prior to generation of the pop-up message will reappear. When this message is acknowledged (pressing the CLOSE soft-key), another pop-up message is sometimes displayed (not in all cases) providing an advisory (ADVSY), which offers additional information to the Commander. These screens appear on top of all other screens. A Failure Handling ADVSY may pop up without an accompanying LOSS pop-up. 2) An audible signal “BEEP, CHECK DISPLAY” is provided through the Vehicle Intercommunications System (VIS) whenever a LOSS pop-up message is displayed which places the system in SAFE MODE. 3) In some cases, when a failure handling pop-up is displayed, the system automatically activates a light on the SCB annunciator panel. S&D-4-E- 47 M2A3 BFV Master Gunner’s Course Sustainment and Diagnostics Learning Step/Activity 3: Describe the Failure Handling Process d. Typical Failure Handling Scenario: When the system software detects a failure, the functionality associated with that failure is immediately disabled. The system then determines whether the failure is mission critical and if so, places the system in Safe Mode. Whenever the Safe Mode is initiated, there will be a corresponding “Safe Mode” displayed on the IBAS and CIV symbology in their respective mode fields (even when the system is in Degraded Gun Mode). If the Safe Mode is initiated, there will be a corresponding LOSS pop-up screen advising the Commander of the functionality lost. See LOSS messages (page 39) for which do and do not require safe mode.. Some LOSS’s (and ADVSRY’s) are displayed without “Safe Mode” being required. While the Failure handling process identifies losses of functionality, the diagnostics system of the Vehicle Diagnostic and Management System (VDMS) identifies “Faults”. Faults are identified by VDMS independently of the Failure Handling process; however faults related to losses of functionality may be identified concurrently with Failure Handling. As with LOSS’s and S&D-4-E- 48 M2A3 BFV Master Gunner’s Course Sustainment and Diagnostics Learning Step/Activity 3: Describe the Failure Handling Process ADVSY’s, faults will be listed on the Malfunction Advisory List (MAL) (Figure 1). These faults are transparent to the crew and can only be acknowledged (seen) by accessing the MAL. LOSS’s and ADVSY’s are always listed on the MAL. However, Faults and ADVSYS do not increment the “MAL” Indicator on the screen Status Bar. Some LOSS's will also activate one of the annunciator indicators on the SCB (see Table 2) or the CIV ON/STOW Switch on the CSCP. Upon pressing the CLOSE soft-key (which is the only soft-key available when a failure handling message is displayed), if the system was placed in Safe Mode, the system will come out of Safe Mode, returning to its previous state within the limits of the new disabled functionality. When loss of Power Track is indicated the following actions must be taken: 1) Close all Pop-ups 2) Stow CIV 3) Go into CTD and set Gun Power Track. Depending on non-operational components, there are further steps that must be taken (i.e. manual mode, back-up sight). S&D-4-E- 49 M2A3 BFV Master Gunner’s Course Sustainment and Diagnostics Learning Step/Activity 3: Describe the Failure Handling Process e. Annunciator Light Activation: LOSS’s that activate annunciator lights on the SCB and on the CSCP are shown in Table 2. NOTE: When the INU is failed, failure handling displays a Loss Popup “Loss: External Target Handoff”. Operators need to recognize this message as indicating that location calculations in the FBCB2 messages cannot be generated automatically from the “Use Lase” soft-key. Table 2. The Flashing “M” S&D-4-E- 50 M2A3 BFV Master Gunner’s Course Sustainment and Diagnostics Learning Step/Activity 3: Describe the Failure Handling Process f. The Flashing “M”: The flashing “M” in both the IBAS and CIV sights symbology indicates a safety-related fault (in general). Whenever the flashing “M” appears in the IBAS Biocular display it indicates that either the P-Head or TOW system has been lost. Either of these will have a corresponding Failure Handling message pop-up on the CTD (LOSS if the P- head, ADVSRY if the TOW). The loss of the TOW system will also light the TOW MALF annunciator on the System Control Box (SCB).Two other conditions will result in the flashing “M” in the IBAS Biocular display: 25mm malfunction Feeder malfunction Either of these malfunctions will also cause the GUN MALF indicator on the SCB to light. Flashing “M” indicates mission critical faults (safety) g. The Flashing “M” in the CIV: The flashing “M” in the CIV symbology indicates that either of the following has occurred: 25mm malfunction Feeder malfunction Either of these malfunctions will also cause the GUN MALF indicator on the SCB to light. S&D-4-E- 51 M2A3 BFV Master Gunner’s Course Sustainment and Diagnostics Learning Step Activity 4 ACTION Identify the embedded Mission Checklists and Readiness Tests. CONDITIONS Given classroom instruction, student guide, and a M2A3 desktop trainer. STANDARDS Answer all questions correctly when questioned by the instructor. 1. Learning Step/Activity 4: Identify Mission Checklists and Readiness Tests In previous versions of the Bradley, the crew conducted Preventive Maintenance Checks and Services by following procedures in the technical manual. While this remains true for the A3, the crew can additionally use checklists, which are automated and embedded within the software the software to identify faults within the system and reliably demonstrate the readiness of the vehicle. On the second page of the Pre-Mission Checklist, Item 18, you are S&D-4-E- 52 M2A3 BFV Master Gunner’s Course Sustainment and Diagnostics Learning Step/Activity 4: Identify Mission Checklists and Readiness Tests directed to “Perform Readiness Test”. However, the Readiness Test may be conducted at any time. Accessing Mission Checklists S&D-4-E- 53 M2A3 BFV Master Gunner’s Course Sustainment and Diagnostics Learning Step/Activity 4: Identify Mission Checklists and Readiness Tests Selecting Mission Checklists a. Accessing Mission Checklists: The Mission Checklists may be selected by following the path SETUP MISSION CHKLIST. b. Mission Checklist Start Page: Selecting MISSION CHKLIST opens the Mission Checklist Start Page. The Mission Checklist S&D-4-E- 54 M2A3 BFV Master Gunner’s Course Sustainment and Diagnostics Learning Step/Activity 4: Identify Mission Checklists and Readiness Tests Start Page gives you the option of selecting either Pre-Mission Checklist, During Mission Checklist or Post Mission Checklist. When the checklist(s) have been used, the Clear Mission Checklist Memory is selectable. Pre-Mission Checklist S&D-4-E- 55 M2A3 BFV Master Gunner’s Course Sustainment and Diagnostics Learning Step/Activity 4: Identify Mission Checklists and Readiness Tests c. Example of Mission Checklist: Selecting PRE-MISSION CHECKLIST by using the up and down arrow key and pressing the ENTER Soft key, provides you with the first screen of the Pre- Mission Checklist. This checklist consists of a database that includes descriptions of actions to be performed, or vehicle configurations to be verified, and checked-off prior to the start of a mission. The checklist does not have the capability of affecting the mission capability or functionality of the vehicle. The first numbered item and first checkbox are highlighted. The Commander may move from field to field by using the right or left arrow soft-key, keyboard arrow keys, CTD arrow keys or by clicking on them with the cursor. The selected checkbox is filled or cleared when the CHECK/CLEAR Soft key is pressed. Pressing the up or down arrow keys will highlight the next action. Pressing the NEXT PAGE Soft key, cycles to the next page in the list. Pressing the NEXT PAGE Soft key, while on the last page, cycles to the first page of the list. Pressing the PREVIOUS Soft key from any page of the checklist returns to the Mission Checklist S&D-4-E- 56 M2A3 BFV Master Gunner’s Course Sustainment and Diagnostics Learning Step/Activity 4: Identify Mission Checklists and Readiness Tests Start Page. Items which are not affected by cycling TURRET POWER are stored in non-volatile memory at power down and can be recalled in a checked state. Readiness Test Setup Screen S&D-4-E- 57 M2A3 BFV Master Gunner’s Course Sustainment and Diagnostics Learning Step/Activity 4: Identify Mission Checklists and Readiness Tests Readiness Test S&D-4-E- 58 M2A3 BFV Master Gunner’s Course Sustainment and Diagnostics Learning Step/Activity 4: Identify Mission Checklists and Readiness Tests Readiness Test Warnings Readiness Test Fault Detected S&D-4-E- 59 M2A3 BFV Master Gunner’s Course Sustainment and Diagnostics Learning Step/Activity 4: Identify Mission Checklists and Readiness Tests d. Readiness Test: There is a READINESS TEST Soft key at the bottom of the Pre-Mission Checklist screens. Selecting the READINESS TEST soft-key starts the Readiness Test. The Readiness Test consists of an automated sequence which checks the integrity of selected vehicle functions. Failure conditions detected during the course of running the Readiness Test will not automatically branch to diagnostic or fault isolation software. Testing is thorough and continues even after faults are detected, so long as safety and the validity of subsequent tests do not dictate otherwise. Entering the Readiness Test presents the operator with the Readiness Test Setup screen. This screen instructs the operator to establish initial conditions before beginning the test. It is important to establish initial conditions and to follow instructions exactly, as the test assumes these conditions have been established, and may possibly result in an erroneous fault situation if environmental parameters are exceeded. Pressing the CANCEL Soft key cancels the Readiness Test. The up and down arrow Soft keys, scroll up or down the current screen. Using either the keyboard or CTD S&D-4-E- 60 M2A3 BFV Master Gunner’s Course Sustainment and Diagnostics Learning Step/Activity 4: Identify Mission Checklists and Readiness Tests up and down arrow keys has the same effect. To continue with the test (once initial conditions have been established), press the CONTINUE Soft key. Follow instructions exactly as they appear on the screen. For example, if the Commander is prompted to have the engine started, and then asks if the BATTERY gauge on the Driver’s Instrument Panel reads in the green area, he must perform the task required and respond with YES or NO soft-keys provided when the system asks the operator a question. Successful completion of the Readiness Test is not intended to take the place of normal Preventive Maintenance Checks and Services (PMCS). Rather, it is intended to add to the PMCS, as well as provide the crew with a quick method of verifying the integrity of critical sub-systems. e. Completed Test Soft keys. When the test is completed, the following soft-keys are available: TEST MENU FAULT SUMMARY MAIN Select MAIN: this returns you to the PRE-MISSION CHECKLIST screen. S&D-4-E- 61 M2A3 BFV Master Gunner’s Course Sustainment and Diagnostics Learning Step/Activity 4: Identify Mission Checklists and Readiness Tests Accessing Power Management Status f. Power Management: The crew has the ability to reset circuit breakers by using the CTD. Failure of a specific LRU or subsystem may be caused by a circuit breaker in a PCM or the TPB being in a “tripped” state. When a load trips, you see “Tripped” momentarily, then failed, to verify the state of the PCM/TPB circuit breakers, the operator may follow the path: SETUP POWER MGMT. S&D-4-E- 62 M2A3 BFV Master Gunner’s Course Sustainment and Diagnostics Learning Step/Activity 4: Identify Mission Checklists and Readiness Tests Tripped Condition for Power Management Go Condition for Power Management S&D-4-E- 63 M2A3 BFV Master Gunner’s Course Sustainment and Diagnostics Learning Step/Activity 4: Identify Mission Checklists and Readiness Tests If the Power Management Status has detected one or more failed (tripped) circuit breakers, the message “EQUIPMENT CIRCUIT BREAKERS – FAIL” is displayed, followed by a listing of the failed circuit breaker(s). The operator is also prompted to SELECT RESET TO TURN ON BREAKERS. The operator may only reset ALL failed circuit breakers; not individual breakers. To reset all circuit breakers, select the RESET Soft key. To exit the screen, press the PREVIOUS Soft key. Upon entering the Power Management Status screen, the operator is presented with one of two situations. Either all circuit breakers have passed, or one or more have failed. If the Power Management Status is good, the message “EQUIPMENT CIRCUIT BREAKERS – PASS” is displayed. S&D-4-E- 64 M2A3 BFV Master Gunner’s Course Sustainment and Diagnostics Learning Step Activity 5 ACTION Explain the Vehicle Diagnostic Management System Architecture CONDITIONS Given classroom instruction, student guide, TM 9-2350-438-10 fully operational M2A3 BFV, and a M2A3 desktop trainer. STANDARDS Explanation will include: Function of VDMS, when it should be used, and how to troubleshoot through hands on performance. VDMS Vehicle Diagnostic Management System S&D-4-E- 65 M2A3 BFV Master Gunner’s Course Sustainment and Diagnostics Learning Step/Activity 5: M2A3 VDMS Architecture 1. Define M2A3 VDMS Architecture. The on-board diagnostics capability utilizes built-in test (BIT) residing in various LRUs and software known as the Vehicle Diagnostics Management System (VDMS). The VDMS software program is stored in the TPU. There are five types of BIT: Startup BIT (SBIT), Non-interactive BIT (NBIT), Background BIT (BBIT), Interactive BIT (IBIT), and Fault Isolation Test (FIT). SBIT executes within the first 6 seconds of power-up. Immediately following the completion of SBIT, NBIT starts. NBIT tests the remaining items not covered by SBIT due to the 6 second limitation. NBIT can take up to 120 seconds to complete. At the completion of NBIT, the system displays the test results on the startup screen and is ready for normal operation. BBIT (for S&D-4-E- 66 M2A3 BFV Master Gunner’s Course Sustainment and Diagnostics Learning Step/Activity 5: M2A3 VDMS Architecture mission critical LRUs only) begins and remains operational for as long as turret power is applied. IBIT is used during initial maintenance troubleshooting. When IBIT cannot fault isolate to a single LRU or requires the aid of external test equipment, IBIT then invokes FIT. SBIT, NBIT, and BBIT are fully automated and test results are presented to the crew. Unlike the crew, who only use SBIT, NBIT, and BBIT, the Maintainer uses all five types of BIT. The IBIT and FIT diagnostics tests are step-by-step, screen driven procedures. The maintainer navigates the screen menus under the MAINTENANCE section to locate the diagnostic tests. IBIT and FIT both have two types of tests: 2. ISOLATE and VERIFY. The ISOLATION test is used to isolate an unknown problem. After performing the repair or replacement task, the Maintainer must perform the VERIFY test to ensure the problem has been corrected. Some IBIT and FIT tests require the aid of an external device such as Bradley Automated Diagnostic System (BRADS). S&D-4-E- 67 M2A3 BFV Master Gunner’s Course Sustainment and Diagnostics Learning Step/Activity 5: M2A3 VDMS Architecture 3. Interactive Built In Test (IBIT). Interactive BIT (IBIT) is used by the maintainer as another means of fault detection. It allows the operator or maintainer to initiate tests from the CTD for purposes of determining and displaying the operational status of the system/subsystems. To invoke IBIT, the maintainer selects from the Main Screen the path: MAINTENANCE DIAGNOSTICS S&D-4-E- 68 M2A3 BFV Master Gunner’s Course Sustainment and Diagnostics Learning Step/Activity 5: M2A3 VDMS Architecture The CTD will display either the Vehicle Tests Menu if no faults exist or the Fault Summary if faults exist. Refer to above Figure. 4. Vehicle Tests Menu The Vehicle Tests Menu presents the maintainer with a list of system level tests that can be currently run, based upon system status. This menu may not present all tests for selection based upon the current fault status of the vehicle. Restrictive faults for a given test are defined within the test. This list includes: TARGET ACQUISITION WEAPON CONTROLS TURRET/WEAPON DRIVES CONTROLS & DISPLAYS POS/NAV & COMMUNICATIONS POWER/DATA BUS MANAGEMENT POSITION SENSORS & INTERLOCKS MAINTENANCE TASKS S&D-4-E- 69 M2A3 BFV Master Gunner’s Course Sustainment and Diagnostics Learning Step/Activity 5: M2A3 VDMS Architecture Refer to above Figure. By selecting one of these items, the maintainer can choose to run either the complete system test or to test a subsystem or component of the subsystem. For example, if the maintainer chooses WEAPONS CONTROLS TESTS from the VEHICLE TESTS Menu, he can select to run either the WEAPON CONTROL COMPLETE TEST or any of the following subtests: 25MM GUN TEST TOW LAUNCH – TRACKING TEST S&D-4-E- 70 M2A3 BFV Master Gunner’s Course Sustainment and Diagnostics Learning Step/Activity 5: M2A3 VDMS Architecture 7.62MM GUN TEST LOW AMMO TEST FANS TEST GRENADES TEST Like the VEHICLE TESTS Menu, depending upon the current fault status of the vehicle, not all tests may be available. Once initiated by the operator or mechanic, IBIT directs the subsystems to run tests and collects, analyzes, and stores results. The results are then displayed on the CTD and inform the operator or mechanic of the subsystem’s status (i.e. Pass or Fail) upon completion. Like SBIT, NBIT and BBIT, IBIT does not require the use of TMDE. IBIT does however interfere with normal operations, in that it requires operator input and response. 5. Fault Isolation Test (FIT). The maintainer also has the ability to conduct Fault Isolation Testing (FIT) on the M2A3/M3A3 when faults exist. At the conclusion of a system (or subsystem) test, if a fault has been detected, the maintainer can choose to isolate the S&D-4-E- 71 M2A3 BFV Master Gunner’s Course Sustainment and Diagnostics Learning Step/Activity 5: M2A3 VDMS Architecture fault. FIT is considered intrusive, and may require the employment of TMDE. Once entered, FIT may require a complete system shutdown to abort/cancel/exit. Entering FIT is limited to maintainers only, as turret and weapon systems may operate erratically, sometimes outside operational safety limits. To conduct fault isolation, select the ISOLATE Soft key at the bottom of the Vehicle Fault Summary. Remember, if a fault is not active (was not detected during the current power cycle), you should verify presence of the fault first by selecting the VERIFY Soft key at the bottom of the Vehicle Fault Summary. Fault isolation can only be conducted on faults, which the diagnostic software knows to exist. Figure DIAG-9 Malfunction Advisory List (MAL) Indicator S&D-4-E- 72 M2A3 BFV Master Gunner’s Course Sustainment and Diagnostics Learning Step/Activity 5: M2A3 VDMS Architecture Figure DIAG-10 Malfunction Advisory List 6. Accessing the Malfunction Advisory List. Refer to Figure DIAG-9. During the course of power up and operation, SBIT, NBIT and in some cases BBIT, will store losses of functionality, malfunctions, and certain advisories into the Malfunction Advisory List. When preparing to perform diagnostics, the mechanic should consult the Malfunction Advisory List first. Listed failure conditions can provide clues, which may assist in diagnosing the vehicle. The MAL S&D-4-E- 73 M2A3 BFV Master Gunner’s Course Sustainment and Diagnostics Learning Step/Activity 5: M2A3 VDMS Architecture Indicator is located at the top of each screen to the far left of the status bar, and indicates the number of functional area losses. The A3 will recognize losses in the following functional areas: Safety Sensors and Interlocks Weapon Control Fire Control Turret Drive Gunner’s Sight Commander’s Sight Communication Navigation 7. Malfunction Advisory List. Refer to Figure DIAG-10. To review the Malfunction Advisory List, place the X-Cursor over the MAL Indicator and select by pressing in on the Commander’s Hand station (CHS) Cursor Controller. The Malfunction Advisory List will appear, and may be navigated using either the é or ê Soft keys, scroll bars, or the CDET Arrow keys. This screen is important because all malfunctions causing a loss of functionality can be S&D-4-E- 74 M2A3 BFV Master Gunner’s Course Sustainment and Diagnostics Learning Step/Activity 5: M2A3 VDMS Architecture recalled. This information is vital to the maintainer for troubleshooting purposes. To review the Malfunction Advisory List via Soft key selection, select the path SETUP MALF ADVSY from the Main Screen. Figure DIAG-12. Vehicle Fault Summary S&D-4-E- 75 M2A3 BFV Master Gunner’s Course Sustainment and Diagnostics Learning Step/Activity 5: M2A3 VDMS Architecture 8. Accessing the Vehicle Fault Summary. Refer to Figure DIAG-12. The Vehicle Fault Summary provides the maintainer with a snapshot of faults which are active (have been encountered during the current power cycle) or inactive (were detected and stored during a previous power cycle and have not been repaired/adjusted/verified/ cleared). Reviewing this list can provide valuable clues to the maintainer when performing diagnostics. The Vehicle Fault Summary can be accessed in the following ways. If no faults are active during the current power cycle, the maintainer may select: MAINTENANCE DIAGNOSTICS FAULT SUMMARY If faults are currently active, the Vehicle Fault Summary will be displayed by selecting the path: MAINTENANCE DIAGNOSTICS S&D-4-E- 76 M2A3 BFV Master Gunner’s Course Sustainment and Diagnostics Learning Step/Activity 5: M2A3 VDMS Architecture 9. Accessing Vehicle Tests. Refer to Figure DIAG-13 Accessing the Vehicle Tests Menu can be accomplished in several ways. The most direct method for the maintainer is by selecting the path: MAINTENANCE DIAGNOSTICS from the Main Screen. If no faults are present, the maintainer will be presented with the Vehicle Tests Menu. If no faults are present, the Vehicle Tests Menu will display a list of all major test categories. If faults exist, the maintainer will be sent to the Vehicle Fault Summary. Additionally, the presence of certain faults may reduce the number of systems-level tests displayed, due to safety or the fact that tests run in the presence of certain faults may not provide accurate diagnostics or isolation. Refer to Figure DIAG-14. At the bottom of the Vehicle Fault Summary, the operator has the choice of selecting the Vehicle Tests Soft key. Selecting Vehicle Tests will transition the display to the Vehicle Tests Menu, which will display those test categories which may be run, based on the current S&D-4-E- 77 M2A3 BFV Master Gunner’s Course Sustainment and Diagnostics Learning Step/Activity 5: M2A3 VDMS Architecture equipment fault status. Those tests which, if run, may cause damage or injury, or produce potentially invalid results, will not be displayed. Troubleshooting Procedures with VDMS. Initiate Troubleshooting Method. 10. Identify and Verify Fault. The maintainer should still receive an Equipment Inspection and Maintenance Worksheet, DA Form 5988E or 2404, with a description of the fault. He must still verify that the fault exists, but he is facilitated by the non-volatile memory storage of existing faults. When verifying the existence of a fault, the maintainer must allow SBIT and NBIT to complete. Next, he should open the Malfunction Advisory List and identify conditions that exist which may share commonality with the fault reported. Not all faults will induce a BIT failure, so the maintainer must be alert to deviations from normal operation. In our example, the maintainer would be presented with a Malfunction Advisory List similar to the one depicted here. The maintainer should also check the system awareness screens. S&D-4-E- 78 M2A3 BFV Master Gunner’s Course Sustainment and Diagnostics Learning Step/Activity 5: M2A3 VDMS Architecture Figure DIAG-15. Vehicle Versions List Figure DIAG-16. Check Fault Summary S&D-4-E- 79 M2A3 BFV Master Gunner’s Course Sustainment and Diagnostics Learning Step/Activity 5: M2A3 VDMS Architecture Refer to Figure DIAG-15 11. CHECK VVID Check the VVID to compare the expected with the reported software and hardware. Equal signs denote that reported and expected data must be identical. If problems are identified the maintainer halts the process and reprograms the vehicle using the Software Loader/Verifier (SL/V). After verifying the download was successful return to the process at this point and verify the Vehicle Version is correct. Refer to Figure DIAG-16 12. CHECK FAULT SUMMARY The maintainer verifies if the fault is active or inactive. Inactive means that the fault was recorded into the fault register during a previous power cycle and has not been encountered or detected during the current power cycle.. Active means that the fault was recorded into the fault register during current power cycle. S&D-4-E- 80 M2A3 BFV Master Gunner’s Course Sustainment and Diagnostics Learning Step/Activity 5: M2A3 VDMS Architecture Figure DIAG-17 Vehicle Tests by Subsystem Refer to Figure DIAG-17 13. Sectionalize. If a fault is not recorded in either the Malfunction Advisory List or the Fault Summary, or Vehicle Version, the maintainer must correctly select the system or subsystem(s), which may be affected by the fault. To do this (in the absence of recorded faults) the maintainer must select the path. From the Main Screen select MAINTENANCE DIAGNOSTICS. S&D-4-E- 81 M2A3 BFV Master Gunner’s Course Sustainment and Diagnostics Learning Step/Activity 5: M2A3 VDMS Architecture Figure DIAG-18 Target Acquisition Tests Figure DIAG-19 Weapon Control Tests S&D-4-E- 82 M2A3 BFV Master Gunner’s Course Sustainment and Diagnostics Learning Step/Activity 5: M2A3 VDMS Architecture After selecting the subsystem you will receive a list of options to troubleshoot a particular part of the subsystem or the complete test. 14. Vehicle Tests Refer to Figure DIAG-18 A. TARGET ACQUISTION (1) IBAS Complete Test IBAS Self Test (2) CIV Complete Test CIV Viewing Test CIV LOS Positioning Test Refer to Figure DIAG-19 B. WEAPON CONTROLS TEST Weapon Control Complete Test 25mm Gun Test TOW Launch-Tracking Test 7.62mm Gun Test Low Ammo Test Fan’s Test Grenades Test S&D-4-E- 83 M2A3 BFV Master Gunner’s Course Sustainment and Diagnostics Learning Step/Activity 5: M2A3 VDMS Architecture Figure DIAG-20 Turret Weapons and Drives Tests Figure DIAG-21 Controls and Displays Tests S&D-4-E- 84 M2A3 BFV Master Gunner’s Course Sustainment and Diagnostics Learning Step/Activity 5: M2A3 VDMS Architecture. Refer to Figure DIAG-20 C. TURRET/WEAPON DRIVES TEST Turret/Weapon Drive Complete Test Gun Elevation Test Turret Traverse Test TOW Left/Elevation Test Refer to Figure DIAG-21 D. CONTROLS & DISPLAYS TEST Controls & Displays Complete Test Turret Controls & Displays Test Hull Controls & Displays Test Commander’s Hand station Test Gunner’s Hand station Test S&D-4-E- 85 M2A3 BFV Master Gunner’s Course Sustainment and Diagnostics Learning Step/Activity 5: M2A3 VDMS Architecture. FIGURE DIAG-22 POS/NAV AND COMMUNICATIONS TESTS Figure DIAG-23 Power and Data Bus Management S&D-4-E- 86 M2A3 BFV Master Gunner’s Course Sustainment and Diagnostics Learning Step/Activity 5: M2A3 VDMS Architecture. Refer to Figure DIAG-22 E. POS/NAV & COMMUNICATIONS TEST POS/NAV Test Communication Complete Test Intercom Test FBCB2 Test Refer to Figure DIAG-23 F. POWER/DATA BUS MANAGEMENT Power Data Bus Management Complete Test Electronics Power Test Interactive Power Test Systems Data Bus Test S&D-4-E- 87 M2A3 BFV Master Gunner’s Course Sustainment and Diagnostics Learning Step/Activity 5: M2A3 VDMS Architecture. Figure DIAG-24 Position Sensors and Interlock Test Figure DIAG-25 Maintenance Tasks S&D-4-E- 88 M2A3 BFV Master Gunner’s Course Sustainment and Diagnostics Learning Step/Activity 5: M2A3 VDMS Architecture. Refer to Figure DIAG-24 G. POSITION SENSORS & INTERLOCKS Sensors & Interlocks Complete Test Position Sensors Test Interlock Switches Test Refer to Figure DIAG-25 H. MAINTENANCE TASKS Gun Elevation POT Adjustment TOW Elevation POT Adjustment Maintenance Support S&D-4-E- 89 M2A3 BFV Master Gunner’s Course Sustainment and Diagnostics Learning Step/Activity 5: M2A3 VDMS Architecture. Figure DIAG-26 Test Selection Figure DIAG-27 Test Procedures S&D-4-E- 90 M2A3 BFV Master Gunner’s Course Sustainment and Diagnostics Learning Step/Activity 5: M2A3 VDMS Architecture. Refer to Figure DIAG-26 and Figure DIAG-27 Use the arrow keys to highlight the test you wish to perform and press the SELECT soft-key. Tests are interactive and requires maintainer input. Care must be give when performing tests. The maintainer needs to pay close attention to the instructions, and perform the task IAW. Figure DIAG-28 Test Results Screen S&D-4-E- 91 M2A3 BFV Master Gunner’s Course Sustainment and Diagnostics Learning Step/Activity 5: M2A3 VDMS Architecture. Figure DIAG-29 Fault Summary Refer to Figure DIAG-28 and Figure DIAG-29 If a fault is detected while running the test, the maintainer will be presented with the Test Results Screen. In this case, we see that the fault was detected again. Under UNIT(S), this screen lists the suspected faulty LRU(s). If troubleshooting an inactive fault, the maintainer should verify the fault’s existence by using the arrow keys to highlight the fault, then select the VERIFY Soft key. The maintainer will then be sent immediately to the system or S&D-4-E- 92 M2A3 BFV Master Gunner’s Course Sustainment and Diagnostics Learning Step/Activity 5: M2A3 VDMS Architecture. Figure DIAG-30 Fault Selection Figure DIAG-31 Fault Isolation S&D-4-E- 93 M2A3 BFV Master Gunner’s Course Sustainment and Diagnostics Learning Step/Activity 5: M2A3 VDMS Architecture. Refer to Figure DIAG-30 and Figure DIAG-31 At this point in the troubleshooting process, the maintainer should return to the VEHICLE FAULT SUMMARY screen. The maintainer would then use the arrow keys, highlight the desired fault and then select the ISOLATE Soft key, to isolate the faulty component. Selecting the fault from the Vehicle Fault Summary and selecting ISOLATE invokes the VDMS Fault-Isolation-Test (FIT) for the selected fault, eliminating the need for the maintainer to determine the best fault isolation method(s) to resolve an ambiguity group. If no further testing is required to localize and isolate the component, the maintainer will be presented with an Unambiguous Fault Isolation Screen, eliminating the need for the maintainer to Sectionalize, Localize, and Isolate as part of his troubleshooting procedures. From this screen the maintainer will receive follow-on instructions for resolving the fault ether with adjust/replacement or further isolation using BRADS. In our example, the maintainer would be presented with an Unambiguous Fault Isolation Screen that states “NO ISOLATION TESTING IS AVAILABLE FOR CODE 43025”. The maintainer would S&D-4-E- 94 M2A3 BFV Master Gunner’s Course Sustainment and Diagnostics Learning Step/Activity 5: M2A3 VDMS Architecture. then replace the faulty Commander’s Hand station. As you can see by this example, Sectionalizing, Localizing and Isolation of the fault was handled by VDMS. If the fault had not been detected during SBIT, NBIT or IBIT, the maintainer would choose the System Level Test most appropriate for the fault from the Vehicle Tests Menu. 15. Localize and Isolate. There are circumstances in which the maintainer must localize the fault. If the fault has not been previously recorded in the fault registry or detected during the current power cycle, the maintainer must select the correct subsystem to test in order to resolve the fault. S&D-4-E- 95 M2A3 BFV Master Gunner’s Course Sustainment and Diagnostics Learning Step/Activity 5: M2A3 VDMS Architecture. Figure DIAG-38. Query Messages Figure DIAG-39. Aborting VDMS S&D-4-E- 96 M2A3 BFV Master Gunner’s Course Sustainment and Diagnostics Learning Step/Activity 5: M2A3 VDMS Architecture. Refer to Figure DIAG-38 16. Query Messages. Earlier we saw one form of error message. When the maintainer was asked if the Driver’s Instrument Panel Battery Voltage was in the green zone, the maintainer was required to answer YES or NO or to abort the test. This is the simplest form of query message. Other query messages may require the maintainer to choose from several possible responses. In this case, the maintainer is instructed to check the Gun Elevation Drive hand wheel operation. Base upon the descriptions embedded in the test step, the maintainer must choose the response which best describes the operation. Each description assumes a familiarity with the equipment. What may seem “Binding” to one person may seem “Normal” to another. Refer to Figure DIAG-39. 17. Aborting a Test. Whenever the ABORT Soft key is pressed, the maintainer may choose to abort the VDMS test or maintenance step currently S&D-4-E- 97 M2A3 BFV Master Gunner’s Course Sustainment and Diagnostics Learning Step/Activity 5: M2A3 VDMS Architecture. displayed. Selecting the ABORT Soft key will present a dialog box that requires the maintainer to confirm his intent to abort. Selecting the CANCEL Soft key, or moving the cursor over the Cancel button within the dialog box and selecting, returns the maintainer to the current step. Selecting the OK Soft key, or moving the cursor over the OK button with the dialog box and selecting, aborts the test or maintenance step. Depending upon the test steps completed thus far, the maintainer may be directed to power down and reconnect any LRUs and cables that were disconnected while running the test or performing the maintenance action. S&D-4-E- 98 M2A3 BFV Master Gunner’s Course Sustainment and Diagnostics Learning Step/Activity 5: M2A3 VDMS Architecture. Figure DIAG-40. Error Termination Refer to Figure DIAG-40. 18. Error Termination. Sometimes, through maintainer error, power surges, operation outside safe parameters, or software error, the software is not able to execute a test or maintenance step. In these cases, the system may “lockup” and a system reboot may be required. To shut down turret power, it may be necessary to move the System S&D-4-E- 99 M2A3 BFV Master Gunner’s Course Sustainment and Diagnostics Learning Step/Activity 5: M2A3 VDMS Architecture. Control Box or Vehicle Distribution Box Emergency Shutdown Switch to ON. In other cases, the maintainer may be presented with an Error Termination Screen, such as the one depicted here. In this case, the maintainer has no CTD input options and is instructed to turn off Turret Power. S&D-4-E-100 M2A3 BFV Master Gunner’s Course Sustainment and Diagnostics INTENTIONALLY LEFT BLANK S&D-4-E- 101

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