24-30-02_PS-835_RevB-5

Emergency Power Supply ®

JET Model PS-835 Part Number 501-1228-( )

Component Maintenance Manual

This manual contains maintenance instructions for the PS-835 Emergency Power Supply. This information is supplemented and kept current by changes or revisions, service letters and service bulletins.

24-30-02 L-3 Communications Avionics Systems 5353 52nd Street, S.E. Grand Rapids, MI 49512-9704, USA www.as.l-3com.com

TP-329 (Revision B, Change 5) March 13, 2009

Foreword This manual provides information intended for use by persons who, in accordance with current regulatory requirements, are qualified to install or repair this equipment. Installation requirements may vary, depending on the particularities of each aircraft, and this manual is intended as a guideline for that purpose. If further information is required, please contact: L-3 Communications Avionics Systems Attn: Field Service Engineering 5353 52nd Street, S.E.

Grand Rapids, MI USA 49512-9704 Telephone: (800) 453-0288 or (616) 949-6600 Fax: (616) 977-6898 www.as.l-3com.com

We welcome your comments concerning this manual. Although every effort has been made to keep it free of errors, some may occur. When reporting a specific problem, please describe it briefly and include the manual part number, the paragraph/figure/table number, and the page number. Send your comments to:

L-3 Communications Avionics Systems Attn: Technical Publications 5353 52nd Street, S.E. Grand Rapids, MI USA 49512-9704 Telephone: (800) 453-0288 or (616) 949-6600 Fax: (616) 977-6898

WARNING

INFORMATION SUBJECT TO EXPORT CONTROL LAWS

This technical data is controlled under the Export Administration Regulations and may not be exported to a foreign person, either in the United States or abroad without the proper authorization of the U.S. Department of Commerce. [9E991]

© Copyright 2005 thru 2009 L-3 Communications Avionics Systems (Formally Goodrich Avionics Systems, Inc)

Trademarks

JET® is a trademark of L-3 Communications Avionics Systems, Inc.

24-30-02 TP-329 Revision B, Change 5

Forward - Page A March 13, 2009

Record Of Revisions Assigned To:

Rev. No.

Insertion Date

Location:

By

Rev. No.

Insertion Date

By

Rev. No.

Insertion Date

By

Retain this record in the front of this manual. Upon receipt of a revision, insert the revised pages in this manual, enter the revision number, date of insertion and initials on this record of revisions.


Record of Revisions - Page i March 31, 2005

L-3 Avionics Systems Component Maintenance Manual Model PS-835( ) // 501-1228-( )

This page intentionally left blank.


Record of Revisions - Page ii March 31, 2005


List of Effective Pages Dates of srcinal and changed pages are: Original ........................................................................................................................................Circa 1984 Reissue .......................................................................................................................... September 01/1995 Revision 1 ....................................................................................................................... March 31/1996 Revision A ......................................................................................................................... March 30/2002 Change 1 .....................................................................................................................February 28/2003 Revision B .....................................................................................................................February 28/2004 Change 1 ........................................................................................................................ March 31, 2005 Change 2 ...................................................................................................................... February 3, 2006 Change 3 .......................................................................................................................August 29, 2007 Change 4 ...................................................................................................................... January 24, 2008 Change 5 ........................................................................................................................ March 13, 2009 Revision and Changes

Revisions are used to correct major volumes of text or sections of a manual. Manuals at new revision incorporate all previous changes as well as any new changes or updates. Destroy old revisions when new revision is received. Changes are used to correct minor volumes of text or sections of a manual. A vertical line in the outer margins of the page indicates the portion of the text affected by the change. Changes to illustrations (other than diagrams and schematics) are identified with a miniature pointing hand. Shading is used to highlight the area of diagrams and schematics containing a change. INSERT LATEST CHANGED PAGES DESTROY SUPERSEDED PAGES. Those responsible for maintaining this publication should ensure that all previous changes have been received and incorporated. Use the Publication Index located on the Avionics Systems, web site [www.as.l-3com.com] to verify revision and changes to manuals.


List of Effective Pages - Page iii March 13, 2009


Revision Highlights

Revision B, Change 1 Add note to page 102 explaining the use of J1-10 during the Constant-Voltage Charging Method. Correct pin location on page 104, made corrections to Figure 103, added and corrected information for Capacity Testing starting on page 111, inserted new Figure 104, Corrected Figure 105, corrected test steps on page 117. Revision B, Change 2 Added SB501-1228-15 to Figure 1 (pg.4). Updated Figure 7 (pg.11). Updated information in Testing and Fault Isolation with that of SL-80P (pg.102, 103, 104, 105, 106). In Repair section incorporated replacement instructions (taken from SL-84B) for battery cells and packs (pg.601). Also consolidated repair section removing pages 605 and 606. In Assembly section added battery cell and pack replacement information (pg.702). Added replacement statement to figure-item 2-5 in IPL (pg1013). Revision B, Change 3 Added "Note" to various test procedures to ensure test switch was returned to normal. Updated general information to match changes made to installation manual. Updated special tools and equipment information. Added Scotch Grip 847 to consumable list (replaces Vulcabond). Added standoff insulators to assembly instructions. Corrected various typo's and error's to figure callouts. Revision B, Change 4 Changed Test and Fault Isolation section to more closely match procedures in other documentation. Revision B, Change 5 Incorporated new model PS-835G (501-1228-07) to the following pages: Pg 1: Update General information para. Pg 5: Add G model to Figure 2. Pg 7: Add G model to Figure 4. Pg 11: Add G model to Figure 7. Pg 19/20: Update caption of Figure 10. Pg 105: Add G model to step 6) & 8). Pg 107: Add G model to Figure 101. Pg 113 thru 114: Add G model. Pg 805 -806: Add G model to Figure 802 and data in paragraph for installation kit. Pg 811/812: Add G model to Figure 807. Add G model to Figure 901. Pg 1009 thru 1010, Pg 1013: Add G model to parts list. Made corrections to the following: Pg A: Updated export compliance statement. Pg 103: Correction to paragraph 4.B. Pg 104: Reformatted paragraph 6 to match other publications. Pg 107: Removed Ohmmeter (item 3) and manufacturer/model Genrad Model 1864 from Figure 101. Corrected para. B. 4). Pg 108: Corrected Para. "C. 1)" by replacing call-out of Ohmmeter (Figure 101, Item 3) with DVM (Figure 101, Item 2). Corrected paragraph C. (note). Pg 111: Corrected Para. "e. (2)" by replacing call-out of Ohmmeter (Figure 101, Item 3) with DVM (Figure 101, Item 2). Pg 601: Removed Ohmmeter (item 3) and manufacturer/model Genrad Model 1864 from Figure 602. Pg 901: Removed Ohmmeter (item 3) and manufacturer/model Genrad Model 1864 from Figure 901. Pg 1002 thru 1003: Incorporate new part numbers added to IPL lists. Pg 1009 thru 1010: Corrected Item 70 by adding missing A1 CCA part numbers. Pg 1011/1012: Added part numbers for assembly items not included in early revisions of the manual. Pg 1013: Corrected effectivity codes in item 5. Pg 1015: Added part numbers for assembly items (260, 265, 270, & 275) not included in early revisions of the manual.

TP-329 Revision B, Change 5

24-30-02 List of Effective Pages - Page iv March 13, 2009


Section

Page

Title Page

Date March 13, 2009

Section

Page

Date

Description and

17/18

Operation (cont.)

19/20

February 28/2004 March 13, 2009

21/22

February 28/2004

23/24

February 28/2004

25/26

February 28/2004

101

January 24, 2008

Foreword

A

March 13, 2009

Record of Revisions

i-ii

March 31/2005

List of Effective Pages

iii-vi

102

January 24, 2008

Table of Contents

vii

August 29, 2007

103

March 13, 2009

viii

January 24, 2008

104

March 13, 2009

ix-x

August 29, 2007

105

March 13, 2009

106

January 24, 2008

107

March 13, 2009

Introduction

Testing and Fault Isolation

xi

Service Directives List

xii

List of Figures

xiii

List of Symbols and Abbreviations

March 13, 2009

xiv

August 29, 2007 August 29, 2007

January 24, 2008

August 29, 2007

108

March 13, 2009

109

January 24, 2008

110

January 24, 2008

111

March 13, 2009

112

January 24, 2008

113

March 13, 2009

114

March 13, 2009

Description and

1

March 13, 2009

115

March 13, 2009

Operation

2

February 28/2004

116

January 24, 2008

3

February 28/2004

117

January 24, 2008

4

February 3, 2006

118

January 24, 2008

5

March 13, 2009

119

January 24, 2008

6

February 28/2004

120

January 24, 2008

7

March 13, 2009

8

February 28/2004

Disassembly

301

February 28/2004 February 28/2004

9

August 29, 2007

302

10

February 28/2004

303

February 28/2004

March 13, 2009

304

February 28/2004

401 402


11 12

August 29, 2007

13

February 28/2004

14

February 28/2004

15/16

February 28/2004

Cleaning


List of Effective Pages - Page v March 13, 2009


Section Check

Repair

Page

August 29, 2007

502

August 29, 2007

601

March 13, 2009

603

February 3, 2006

605 606

701 702

Fits and Clearances

Special Tools, Fixtures and Equipment

August 29, 2007

602

604

Assembly

Date

501

February 3, 2006 Removed Removed

August 29, 2007 August 29, 2007

703

February 3, 2006

704

August 29, 2007

705

August 29, 2007

706

February 28/2004

801

February 28/2004

802

February 28/2004

803 804


805

March 13, 2009

806

March 13, 2009

807

February 28/2004

808

February 28/2004

809/ 810

February 28/2004

811/ 812

March 13, 2009

901

March 13, 2009

902

August 29, 2007

Section Illustrated Parts List

Page

Date

1001

February 28/2004

1002

March 13, 2009

1003

March 13, 2009

1004

February 28/2004

1005

February 28/2004

1006

February 28/2004

1007/ 1008

February 28/2004

1009

March 13, 2009

1010

March 13, 2009

1011/ 1012

March 13, 2009

1013

March 13, 2009

1014

February 28/2004

1015

March 13, 2009

1016

February 28/2004

1017

February 28/2004

1018

February 28/2004

1019

February 28/2004

1020

February 28/2004


List of Effective Pages - Page vi March 13, 2009


Table of Contents Section

Page

Record of Revisions ............................................................................................................. List of Effective Pages ......................................................................................................... Table of Contents ................................................................................................................. Introduction..........................................................................................................................

i ii v ix

Service Directives List ......................................................................................................... List of Figures ...................................................................................................................... List of Symbols and Abbreviations......................................................................................

x xi xii

Description and Operation 1. General ................................................................................................................................. 2. Purpose of Equipment.......................................................................................................... 3. Physical Description............................................................................................................. 4. Functional Description......................................................................................................... 5. Continued Airworthiness ..................................................................................................... 6. MOD Status.......................................................................................................................... 7. Environmental Test Qualifications ...................................................................................... 8. Specifications ....................................................................................................................... 9. Affiliated Equipment............................................................................................................ 10. Charge and Discharge Performance..................................................................................... A. General Battery and Cell Information................................................................... B. Battery/Cell Outgassing .......................................................................................

1 1 1 1 2 3 5 7 7 8 8 8

C. Storage Time and Temperature............................................................................. D. Cell Current Discharge Time ................................................................................ E. Cell Voltage Discharge Time................................................................................ 11. Operation.............................................................................................................................. 12. Theory of Operation............................................................................................................. A. Power Input .............................................................................................................. B. Heating Resistor ........................................................................................................... C. Heater Control .............................................................................................................. D. Over-Temperature Protection....................................................................................... E. Battery Voltage Level Detection.................................................................................. F. Test ..............................................................................................................

9 10 11 12 12 12 13 13 13 13 14


Table of Contents - Page vii August 29, 2007


Table of Contents (continued) Section

Page

Testing and Fault Isolation 1 General .............................................................................................................................................. 101 2 Battery Testing ................................................................................................................................ 102 3 Charging Procedures ......................................................................................................................... 102 4 Preflight Checks (Recommended) .................................................................................................... 103 5 Periodic Checks (Required 3 to 6 Months) ....................................................................................... 104 6 Capacity Testing (Required Annually) ............................................................................................. 104 7 Cell Isolation Test ............................................................................................................................. 106 8 Performance Test .............................................................................................................................. 107 9 Battery Monitor CCA Test Procedures ............................................................................................. 116 Disassembly 1. General .............................................................................................................................................. 301 2. Disassembly Procedures .................................................................................................................... 301 3. Repair ................................................................................................................................................. 303 Cleaning 1 General .............................................................................................................................................. 401 2 External Cleaning .............................................................................................................................. 401 3 Internal Cleaning ............................................................................................................................... 401 Check 1 General .............................................................................................................................................. 501 2 On-Aircraft Checks ........................................................................................................................... 501 3 Checks After Repair and During Re-Assembly ................................................................................. 501 4 Inspection After Repair and During Re-Assembly............................................................................. 502 5 Storage ............................................................................................................................................... 502 Repair 1 General ............................................................................................................................................... 601 2 Battery Cell and Pack Replacement ................................................................................................... 601 3 Circuit Card Assembly Repair............................................................................................................ 601 4 Consumable Materials ........................................................................................................................ 601 5 Special Tools ...................................................................................................................................... 602 6 Moisture and Fungus Proofing ........................................................................................................... 603 7 Performance Test................................................................................................................................ 603


Table of Contents - Page viii January 24, 2008


Assembly 1 General…… ....................................................................................................................................... 701 2 Assembly Tools, Fixtures, and Consumables..................................................................................... 701 3 Assembly Procedures ......................................................................................................................... 702 4 Performance Test................................................................................................................................ 705 5 PS-835 Storage ................................................................................................................................... 705 Fits and Clearances 1 General ............................................................................................................................................... 801 2 Emergency Power Supply Location ................................................................................................... 801 3 Pre-Installation Inspection and Preparation ....................................................................................... 801 4 Post Installation Check ....................................................................................................................... 801 5 Affiliated Equipment.......................................................................................................................... 803 6 Installation Kits .................................................................................................................................. 805 7 Interconnect Diagrams ....................................................................................................................... 805 Special Tools, Fixtures, Test Equipment and Consumables 1 General ............................................................................................................................................... 901 2 Load Resistor...................................................................................................................................... 901 3 Connector Alignment Gage................................................................................................................ 901 Illustrated Parts List 1 General ............................................................................................................................................. 1001 2 Numerical Index ............................................................................................................................... 1001 3 Part Reference Designator Index...................................................................................................... 1004

4

Detailed Parts List … ....................................................................................................................... 1005

Service Bulletin Information


Table of Contents - Page ix August 29, 2007


This page intentionally blank.


Table of Contents - Page x August 29, 2007


Introduction This Component Maintenance Manual with Illustrated Parts List has been prepared by the Technical Publications Department of Avionics Systems. It provides information needed to operate, maintain, and repair specific avionics equipment. Block diagrams, schematic diagrams, and exploded views are used and referenced within this manual to present the information. An Illustrated Parts List is included to provide information for ordering replacement parts. Common system maintenance procedures are not presented in the interest of clarity. The bestestablished shop and line practices should be used where no specific procedures are given. When direct current polarities are not defined with a given voltage value, the voltage is assumed to be positive with respect to ground. Abbreviations and symbols used in this manual are defined in the List of Symbols and Abbreviations. All weights and measurements in the manual are in English units, unless otherwise stated. This manual contains all practical information for the Operation, Testing, Disassembly/Assembly, and Service and Repair of all variations of the PS-835( ) Emergency Power Supply. The manual in published according to ATA-100 Specification for Manufacturer’s Technical Data for aviation product manuals, to include style, format and content. The manual is partitioned into sections, with tables, illustrations, and cross-references to information located in other sections. Section

Page Group

Description and Operation

1-98

Testing and Fault Isolation

101-198

Disassembly

301-398

Cleaning

401-498

Check

501-598

Repair

601-698

Assembly

701-798

Fits and Clearances

801-898

Special Tools, Fixtures and Equipment Illustrated Parts List

901-998 1001-1098

Service Letters and Bulletins Comments, corrections, deletions, additions, clarifications or other pertinent information should be directed to the Technical Publications Department, Avionics Systems, 5353 52nd Street S.E., Grand Rapids, Michigan, USA 49512-9704, phone number [1-800-253-9525 or (616) 949-6600]. Avionics Systems maintains this manual to insure correct and current information by means of revision notices, Service Letters and Service Bulletins. Follow the instructions provided with revision notices concerning page replacement and notations to the Record of Changes page (page i). See www.as.l-3com.com for revision levels on all Avionics Systems Technical Publications.


Introduction - Page xi August 29, 2007


Service Directives List Directive Numbers

Service Bulletins SB501-1228-1( ) SB501-1228-2( ) SB501-1228-3( )

SB501-1228-4( SB501-1228-5( )) SB501-1228-6( ) SB501-1228-7 ALERT SB501-1228-8( ) SB501-1228-9( ) SB501-1228-10( ) SB501-1228-11( ) SB501-1228-12( ) SB501-1228-13( ) SB501-1228-14( ) SB501-1228-15( ) Service Letters SL-48( ) SL-59()

SL-64( )) SL-80( SL-84( ) SL-85( ) SL-105() SL-109( )

The Service Bulletins listed above have been incorporated into this manual, in so much as it is possible, at the revision levels current at the publishing date. PS-835 Emergency Power Supplies will exist in the field in various levels of modification, so a complete library to all the Service Bulletins that pertain to the PS-835 at their latest revisions will be necessary. See Description section, chapter 6. MOD Status for detailed descriptions of the associated Service Bulletins.

See www.as.l-3com.com, Service Section, Technical Publications Page for the Publications Index to get up-to-date listing of all Avionics Systems technical publications and directives. Or contact Avionics Systems Customer 1-800-453-0288.


Service Directives - Page xii August 29, 2007


List of Figures Figure

Title

Page

1

ServiceBulletinsandModifications

2

Environmental Qualifications

3 5

3

PS-835 Emergency Power Supply

6

4

Specifications

7

5

Cell Storage Time vs. Temperature

9

6 7

Typical Discharge Time for Cells Discharge Curves

10 11

8

Schematic for Models E and F

15/16

9

Schematic for Models E and F

17/19

10

Schematic for Models A through D

19/20

11

Schematic for Models A through D

21/22

12

Schematic for Models C and D

23/24

13

Schematic for Models A and B

25/26

101

Test Equipment and Fixtures

107

102

PS-835 Test Setup Schematic

108

103

Connector Pin Continuity Table

109

104

PS-835 Access Panel

112

105

Individual Cell Monitor LED's

116

106

Circuit Cart Assembly Test Setup

117

401

Modified Acid Brush

402

601

Consumable Materials

601

602

Special Tools and Equipment

602

603

Wire List for Models A, B, C, and D

603

604

Wire List for Models E and F

604

701

Tools and Consumables

701

702

Solder Pad Locations

703

801

Affiliated Equipment

804

802

Typical Interconnections for Models A through

806

803

Typical Interconnections for Models E and F

807

804

Interconnections for AC Indicators

808

805

Interconnections for DC Indicators

806

Installation Drawing for Models E and F

809/810

807

Installation Drawing for Models A through D

811/812

901

Special Tools and Equipment

808

901

IPL 1

Emergency Power Supply

1007/1008

IPL 2

Battery Circuit Card Assembly

1011/1012

IPL 3

Battery Monitor CCA

1017


List of Figures - Page xiii January 24, 2008


List of Symbols and Abbreviations The following is a compilation of abbreviations and symbols used in this manual. Every effort has been made to insure that this list is complete. Wire color symbols are not listed, as they are universal throughout the industry. A

Ampere

AC

Alternating Current

awg

American Wire Gauge

AMP

Ampere

AR

As Required

CH

Chemical Hazard

CCA

Circuit Card Assembly

CCW

Counterclockwise

CW

Clockwise

DC

Direct Current

Hz

Hertz (frequency)

″

inch

lbs

pounds

in-lbs

Inch-Pounds (torque)

Max

maximum

MSDS PWB

Material Safety Data Sheet Printed Wiring Board

RPM

revolutions per minute

UUT

unit under test

Vdc

Volts direct current

Vac

Volts alternating current

±

+ (plus) or – (minus)

°

Angular Degree

F°

Temperature Fahrenheit

C°

Temperature Celsius

Ω

Ohm


Symbols and Abbreviations - Page xiv August 29, 2007


Description and Operation 1.

General This manual provides description and theory of operation for Models PS-835 A through G Emergency Power Supplies, part numbers 501-1228-01 through -06 (respectively). Models C, D, E, F and G are current and Models A and B are considered obsolete, see Service Bulletins and Modifications table Figure 1. Models A, C, and E use 2.5Ah cells and Models B, D, F, and G use 5.0Ah cells.

2.

Model Number

Part Number

A

501-1228-01

B

501-1228-02

C

501-1228-03

D

501-1228-04

E

501-1228-05

F

501-1228-06

G

501-1228-07

Purpose of Equipment The Model PS-835 Emergency Power Supply is designed as a 24 Vdc (nominal) emergency power source for prolonging the operation of a connected standby attitude indicator when the aircraft main power buss has de-energized. The aircraft main power buss provides trickle charging to the PS-835 while the aircraft performs normally. The output of the PS-835 can be subsequently converted using either Avionics Systems Model SI100( ) Static Inverter or the SC-841 Static Converter to provide power for standby indicators of different power requirements. The SI-100 provides outputs of 115 Vac or 5 Vac, 400Hz either at single or three phase alternating current. The SC-841 provides direct current outputs of 2.0 to 6.5 Vdc (user adjustable).

3.

Physical Description The PS-835 Emergency Power Supply is fully enclosed unit, designed to easily mount onto an existing avionics shelf or the optional mounting rack Avionics Systems Model MTG-101 (part number 572-1424-01), with models available with lightning surge protection. The face of the unit provides individual cell monitor LED's, voltage output monitor LED's, battery Heater Operation Monitor LED's, and a battery test switch.

4.

Functional Description A.

Power Input Aircraft 28 Vdc is connected to the emergency power buss through pin 10 of connector J1. The input is diode isolated from the internal batteries and circuits to prevent battery discharge in the event of a short circuit, or battery draw caused by low input from the aircraft main DC buss, such as at engine start.


Description - Page 1 March 13, 2009


B.

Battery Heating Battery heating is provided by an etched foil Heating Resistor (HR1) mounted onto the unit chassis. With 28 Vdc applied to the unit and the temperature is 19 !C (66!F) the green HEATER ON LED (Figure 1, Item 3) will come on showing that the heater is operating. The red LED will come on if the temperature exceeds 55!C. The heating element, also, functions as a test load during the time the power supply is being tested aboard the aircraft. The HEATER ON LED will come on when the TEST SWITCH (Figure 1, Item 4) on the front panel is pressed.

C.

Over-Temperature Protection When the temperature of the power supply exceeds +55!C, the temperature sensor imbedded within the Battery CCA (A1) will cause the OVER 55!C LED (Figure 1, Item 3) to go on. The heating control circuitry would then cease the heating-resistor's operation. The heating circuit will remain inoperable until the temperature of sensor drops low enough to again permit heater operation.

D.

Battery Voltage Level Detection There are four OUTPUT VOLTAGE MONITOR LED's on the front panel of the supply (Figure 3, Item 2). These indicate the state-of-charge of the stored power. The LED's go on when the TEST SWITCH is pressed or when the supply is being charged. The power supply is considered greater than 50% charged when the 24V LED momentarily illuminates when the TEST SWITCH is pressed, and fully discharged when the 20V LED is goes out.

5.

Continued Airworthiness (Maintenance) PS-835 Emergency Power Supplies require periodic checks and scheduled testing. Refer to the Testing and Fault Isolation section of this manual for the following checks: Periodic 3-6 Month Check Annual Capacity Testing A need for maintenance is indicated when unit fails the tests described above or functional monitoring as described below. Functional monitoring is based upon the following: Observation of self-test failure notification (applicable only when unit has self-test capability). Visual observation by the user. This unit has unlimited service life, where service life is defined as that point in time when repair is no longer economical.

24-30-02 TP-329 Revision B

Description - Page 2 February 28/2004


6.

MOD Status The PS-835 Emergency Power Supply is a venerable design that has experienced numerous improvements. This manual offers information in a manner that recognizes the various levels of modification at which a unit may exist in the field. All the schematics (see Figures 8 through 13) and components in the Illustrated Parts Listing that have been affecting by the various modifications applied to PS-835 Emergency Power Supplies are included in this manual. NOTE:

It is highly recommended that SB501-1228-8( ) be applied to all PS-835 model A and B units.

The table below lists all Service Bulletins that pertain to the PS-835 Emergency Power Supply up to the date of this publication.

Service Bulletin

Model and Part Number

MOD #

Purpose

Modification Kits and part required for Modification

SB501-1228-1( )

A-501-1228-01 B-501-1228-02

1

Wiring modification to prevent connector J2 arcing during extreme vibrations.

SB501-1228-2( )

A-501-1228-01 B-501-1228-02

2

Replace Thermal Resistor to reduce shorting possibility.

MOD Kit 504-1637-01

SB501-1228-3( )

B-501-1228-02

3

Add insulation plate to prevent shorting possibility between cell BT12 and chassis.

MOD Kit 504-1638-01

SB501-1228-4( )

A-501-1228-01 B-501-1228-02

3 4

Modify wiring to prevent CCA damage because loss of

MOD Kit 504-1642-01

grounding isolation between battery and chassis. SB501-1228-5( )

A-501-1228-01 B-501-1228-02

4 5

Additional instructions to insure previous MOD's 3 and 4 are properly applied.

(Pervious MOD 3 and 4 instructions failed to instruct soldering wire back onto lug)

SB501-1228-6( )

A-501-1228-01 B-501-1228-02

5 6

Replace and reposition resistors A2R1 and A2R7 on Battery Monitor CCA.

MOD Kit 504-1648-01

SB501-12287ALERT

A-501-1228-01 B-501-1228-02 C-501-1228-03 D-501-1228-04

6 7 1 1

Modify wiring to provide selftesting capability for fuse failure.

SB501-1228-8( )

A-501-1228-01 B-501-1228-02

N/A

Modifies Models A and B into Models C and D to meet DO160A voltage spike test. (Factory only)

MOD Kit 504-1745-01 Re-identifies CCA A2 from 542-1634-01 to 542-1495-01

Figure 1: Service Bulletins and Modifications




Modification Kits and part required for Modification

Model and Part Number

MOD #

Purpose

SB501-1228-9( )

A-501-1228-01 B-501-1228-02 C-501-1228-03 D-501-1228-04

7 8 2 2

Replace Battery Monitor CCA to improve Heater Circuit performance.

Replace CCA A2 part number 542-1495-01 with CCA A2 part number 542-1521-01.

SB501-1228-10( )

A-501-1228-01 B-501-1228-02 C-501-1228-03

Modify wiring to circumvent fuse for emergency operation. Re-identifies Models C and D

MOD Kit 504-1746-01 (All previous MOD's to A, B, C, and D must

D-501-1228-04

into Models E and F.

Service Bulletin

first have been performed)

SB501-1228-11( )

A-501-1228-01 C-501-1228-03 E-501-1228-05

8 3 1

Prevent possible shorting between cells and chassis.

MOD Kit 504-1811-01

SB501-1228-12( )

A-501-1228-01 B-501-1228-02 C-501-1228-03 D-501-1228-04 E-501-1228-05 F-501-1228-06

9 9 4 3 2 1

Prevent possible shorting between cells and chassis.

MOD Kit 504-1839-01

SB501-1228-13( )

A-501-1228-01 B-501-1228-02 C-501-1228-03 D-501-1228-04 E-501-1228-05 F-501-1228-06

10 10 5 4 3 2

Modify wiring to prevent improper charging.

SB501-1228-14( )

D-501-1228-04 Serial No's 8647 and higher.

5

Prevent shorting of cell leads by correcting wire routing and improved soldering of cell terminals.

SB501-1228-15()

A-501-1228-01 B-501-1228-02 C-501-1228-03 D-501-1228-04 E-501-1228-05 F-501-1228-06

11 11 6 6 4 3

To add warning instructions for proper care and maintenance of battery pack to prevent voiding warranty.

Warning Label (p/n 535-1873-01)

Figure 1: Service Bulletins and Modifications (Cont.)




7.

Environmental Test Qualifications The following tests have been conducted to satisfy DO-160A test conditions. Name of Test

Qualified to DO-160A elements:

Low Temperature

Section 4.0 Cat. A2F2

Humidity

Section 6.0 Cat. B

Vibration

Section 8.0 Cat. J

Explosion Voltage Spikes

Section 9.0 Cat. E Section 17 Cat. B for Models A and B (obsolete) Section 17 Cat. A for Models C, D, E, F and G

Temperature Variation

Section 5.0 Cat. B

Magnetic Effect

Section 15

Audio Frequency Conducted Susceptibility

Section 18 Cat. A

Electromagnetic Compatibility

Section 19 Cat. A Section 20 Cat. A Section 21 Cat. A

Figure 2: Environmental Qualifications




1 5

2

4

3

Figure 3: PS-835 Emergency Power Supply

1 2 3 4

Individual Cell Monitor LED's Output Voltage Monitor LED's Battery Heater Operation Monitor LED's Test Switch

5

Individual Cell Dip Switches




8.

Specifications Part Number Certification: RTCA Compliance: Size:

Weight:

501-1228-01, -02, -03, -04, -05, -06, -07 FAA-PMA (for 501-1228-03, -04, -06, -07) Environmental: DO-160A Length: 14.110 max. Height: 7.774 max. Width: 2.400 max. Model A, C, E - 8 lbs. [3.65Kg] Model B, D, F, G - 13 lbs.[6.0Kg]

Power Requirements:

Input: 2824toVdc 30 Vdc, 15 Amp max.max. steady state Output: nominal, 10 Amp Model A, C, E - 2.5 Amp Hour Model B, D, F, G - 5.0 Amp Hour See Figure 6 Current Discharge Times and Figure 7 Voltage Discharge Curves

Operating Altitude

Sea level to 55,000 ft. at 25 !C

Operating Temperature:

-55!C to +70!C

Storage Temperature:

-55!C to +85!C Model A, B, C, D, G: DPXB-13-33S-0001 (Avionics Systems P/N S24140-01) Model E, F: DPXB-13-33S-0019 (Avionics Systems P/N S24140-02) The EPS has unlimited service life.

Connector Type:

Service Life:

Figure 4: Specifications 9.

Affiliated Equipment A.

SI-100 Static Inverter The SI-100 Static Inverter provides for alteration of the PS-835 output for use of equipment that requires alternating current (AC). See Avionics Systems Installation Instructions TP-346 for additional information. The Model SI-100A Static Inverter (Avionics Systems part number 501-1240-01) has 3Ø, 400Hz, 115Vac, 25VA output capability. The Model SI-100B Static Inverter (Avionics Systems part number 501-1240-02) has 1Ø, 400Hz 115Vac, 75VA output capability, or 1Ø, 400Hz, 5Vac, 5VA output capability.

B.

SC-841 Static Converter The SC-841 Static Converter (Avionics Systems part number 501-1318-01) provides for direct current conversion for 2 to 6.5 Vdc, 25 Watt output capability. See Avionics Systems Installation Instructions TP-351 for additional information.

C.

BC-815 Battery Charger The BC-815 Battery Charger (Avionics Systems part number 501-1321-01) provides the capability to charge the PS-835 Emergency Power Supply when not mounted on aircraft. See Installation Avionics Systems Instructions TP-350 for additional information.




D.

MTG-101 Mounting Rack ATR Mounting Rack MTG-101 (Avionics Systems part number 572-1424-01) for use with PS835D when desired.

10. Charge and Discharge Performance A.

General Battery and Cell Information The cells are constructed with thin pure lead plates. The overall chemistry is typical of the traditional lead-acid battery. A unique aspect of the sealed lead-acid cell is that the majority of the oxygen generated within the cell during an overcharge condition is recombined within the cell. The quality of the lead grids used in construction minimize the evolution of hydrogen when overcharging occurs. Each cell has a self-resealing release valve designed to operate in the 50-60 psi range. In normal use, the battery internal cell pressure never exceeds 20 psi. This means that in normal conditions the cell can be operated in a perfect vacuum and still have a sufficient safety margin, so that venting will not occur. NOTE:

Batteries should not be left in a discharged state under any circumstances.

Cells should not be left connected to a load when in a discharged state or their ability to accept a charge will be impaired. The cell may develop shorts or chemical action will create water that will freeze at low temperatures and destroy the cell. B.

Battery/Cell Out-Gassing CAUTION:

SOME OFNOT THE BE TYPES OF GASSES MAY NON-VENTED VENT FROM AAREA. CELL ARE TOXIC AND SHOULD CONTAINED IN ATHAT CLOSED,

CAUTION:

CELL/BATTERY CORROSION IS EVIDENCE OF THE LOSS OF SEAL, LIKELY CAUSED BY OUT GASSING. CELLS MUST BE REPLACED WHEN CORROSION ISAPPARENT.

All lead-acid cells and batteries produce gasses during charging. The amount and type of gas produced depends on state of charge, rate of charge, chemical composition of the electrolyte, and general condition of the battery. Normally, gasses produced are recombined within the cells to form oxides and water. Venting occurs when excessive charge rates are placed on the battery or because of a defective cell (s) which subjects the remaining good cells to excessive charge rates. Venting may also result from battery abuse or neglect. If the odor of rotten eggs becomes apparent in the cockpit, pull the aircraft Emergency Power Supply circuit breaker. The rotten egg odor is evidence that the lead-acid cells vent due to prolonged high rate overcharging. Although the possibility of toxic levels is extremely remote, the precaution of pulling the circuit breaker will prevent increased discomfort from the odor. Venting is an indication that the Power Supply in not controlling the charging process. If venting occurs the factory recommends that the Power Supply be removed from the aircraft, tested according to the procedures listed in this manual, and to replace the defective cell(s).




C.

Storage Time and Temperature NOTE:

Avionics Systems Service Letter SL-64 contains additional information on Lead Acid Battery out-gassing and Service Letter SL-80 contains additional information for Float (Trickle) Charging Emergency Power Supplies during storage.

If a ready condition is required of a power supply being stored, recharge batteries every 4 months for 1 hour at 28 to 30Vdc input. Do not store where temperature may exceed 85!F (29!C). Low storage temperatures on fully charged cells lessen the rate of self-discharge, thus increasing shelf life. There is no danger of damage to cells since they will not freeze even at temperatures of -75! F. On the other hand, high storage temperatures will accelerate selfdischarge of the cells and storage under such conditions is not recommended. Refer to Figure 5.

Figure 5: Cell Storage Time vs. Temperature


Description - Page 9 August 29, 2007


D.

Cell Current Discharge Time The rate of energy being withdrawn from a cell affects the amount of energy that can be obtained over time. For example, at low current rates the energy in a cell lasts longer than at high current rates. The actual hours of service (Amp-hours, or Ah) from fully charged "D" or "X" cells can be determined from Figure 6 below.

Figure 6: Typical Discharge Time for Sealed Lead Acid Cells




E.

Cell Voltage Discharge Time Figure 7 displays typical discharge curves at room temperature. At -55!C an internal heater blanket maintains the cells at no lower than 0!C for the "X'' type cells and 20!C for the "S" type cells. A typical discharge rate with the cells at 0!C reduces the capacity by approximately 15%.

Figure 7: PS-835( ) Discharge Curves




11. Operation A.

Battery Testing The majority of the components installed in the PS-835 operate only during test functions. The exceptions are those associated with the battery heating system, and the over 55!C warning system. NOTE:

Test functions should be performed only with the main buss not providing power to the unit (off or disconnected).

Toggling the remote or pressing the unit TEST SWITCH (Figure 3, Item 4) on the power supply front panel bypasses the thermostatic heat control system. That, in-turn, applies the battery voltage to the internal battery heater. While in the TEST mode, the batteries are placed under an approximate 7.5" load. The voltage level detection system will then analyze the battery voltage level and will cause the appropriate OUTPUT VOLTAGE MONITOR LED's to go on. NOTE:

Ensure Test Switch is returned to normal position and all LED's are extinguished.

NOTE:

If the unit TEST SWITCH or Remote Test Switch is depressed at a battery ambient temperature of 55 !C or greater, the unit internal heater will not turn ON to provide a test load for the unit battery. This is not an ideal condition for battery state of charge tests and should not be considered valid.

If the remote test is being performed, the Remote Battery-Voltage Level Lamp will go on, provided the internally-loaded battery voltage level is greater than 24 Vdc. The INDIVIDUAL CELL MONITOR LED's function as GO/NO GO indicators each of the PS-835 lead acid cells. In case of low output capacity, these LED's will indicate which cell or cells have failed. The variation of brightness of the LED's does not indicate cell condition. 12. Theory of Operation All the schematic diagrams are included in this section. Any distinctions between drawing numbers and assembly part numbers that apply to the description of the Theory of Operation are highlighted. The majority of the components installed in the PS-835 operate only during test functions. The exceptions are those associated with the battery heating and over 55! C warning system. NOTE:

Test functions must be performed with no input to J1 connector pin J1-10.

Various MOD level units exist in the field and are distinguished in this description by the various Battery Monitor CCA part numbers that may appear for repair. * Components on Battery Monitor CCA part numbers 542-1364-( ) and 542-1495 ( ). **Components on Battery Monitor CCA part numbers 542-1521-( ), 542-2625-( ) and 542-2635-( ). A.

Power Input Aircraft 28 Vdc is connected to the emergency power buss through J-1 connector pin J1-10 and diode A1CR1. Diode (A1CR1) isolates the internal batteries and circuits in case of a short circuit or low input from the aircraft main DC buss.


Description - Page 12 August 29, 2007


The 28 Vdc input through * A2CR1 (**A2CR6) or the TEST SWITCH (A1S1) provides the operating voltage at pin 4 of A2U1 and U2. B.

Heating Resistor (A1HR1) Heating Resistor (A1HR1) provides heat to the battery cells and functions as the internal 7.5 " nominal test load. When 28 Vdc is applied to J1 connector pin J1-10 and the unit temperature is 19C! (66!F) or less, or when the TEST SWITCH (A1S1) is pressed, A2U2-pin 1 is placed in a high state which turns on HEATER ON LED A2DS17 and transistor * A2Q5 (**A2Q2) allowing current flow through A1HR1, so long as the temperature remains less than 55 C.

C.

Heater Control Temperature Transducer (A1U1) is a temperature sensitive device that varies current flow through potentiometer A2R8, TEMP CONTROL. If the power supply temperature is 19! to 27! C (63! to 81! F) or more current flow through A2R8 is heavy, forcing A2U2-pin 1 into a low output cutting off LEDA2DS17, transistor *A2Q5 (**A2Q2), and heating resistor A1HR1. If the unit temperature should drop to 19 ! C (66! F) or less, the current flow through A2R8 would not be sufficient to hold A2U2- pin 1 in a low state, the high output would turn on LED A2DS17, transistor *A2Q5 (**A2Q2), and heating resistor A1HR1.

D.

Over-Temperature Protection Thermal Resistor A1RT1 is a temperature sensitive device that changes resistance rapidly (to over 1 Megohm) if the temperature of the surface where it is mounted exceeds +55! C (131! F). During normal operation or test, the potential applied to the inverting input pin 6 of * A2U1 (**A2U1-13) is such that *A2U1 output pin 7 (**A2U1-14) is high, turning ON transistor *A2Q6 (**A2Q3). If the temperature exceeds +55! C, Thermal Resistor A1RT1 will change value reducing the conduction current and applying a high positive voltage to the inverting inputs of * A2U1-pin 6 (**A2U1-pin 13). This causes *A2U1-pin 7 (**A2U1-pin 14) to go low, OVER 55! C LED A2DS18 to go on, and turning off transistor *A2Q6 (**A2Q3), thereby preventing heating resistor operation. The circuit will remain in this state until the temperature of Thermal Resistor A1RT1 is low enough to a gain permit conduction.

E.

Battery Voltage Level Detection The outputs of *A2U1-pins 1, 8 and 14 (**pins 1, 7 and 8) and A2U2-pin 8 are normally high due to the voltage applied to the non-inverting inputs by *A2Q7 (**A2Q1), resistor *A2R18 (**A2R21) and the voltage applied to the inverting inputs from voltage divider network resistors *A2R19 through A2R22, A2R24 and A2R25 (**A2R5, A2R6, A2R12, A2R17, A2R22 and A2R23). The potentiometer *A2R25 (**A2R5) is adjusted so that OUTPUT VOLTAGE MONITOR LED DS15 will go out when the voltage at J1 connector pin J1-11 is below 24 Vdc. When this requirement has been met, the remaining OUTPUT VOLTAGE MONITOR LED's will go on or off when their representative voltage levels are present at J1 connector pin J1-11.




F.

Test Depressing the remote or unit TEST SWITCH applies the battery output voltage through J1 connector pins J1 pins 2 and 6 to diode *A2CR4 (**A2CR3), to pin J1-4 of A2U1 and A2U2; through diode *A2CR3 (A2CR4) to diode *A2CR11 (**A2CR2) and resistor *A2R5 (**A2R3) to bypass the heater turn-off system. While the TEST SWITCH is being held, the internal heater A1HR1 is turned on, placing the batteries under an approximate 7.5" load. The voltage level detection system analyzes the battery voltage level at this time and will cause the appropriate LED's (DS13 through DS16) to go on. NOTE:

If unit TEST SWITCH or Remote Test Switch is depressed at a battery ambient temperature of 55! C or greater, the unit internal heater will not turn on to provide a test load for the unit battery.

When a remote test is being performed, the Remote Battery-Voltage Level Lamp will go on, provided the loaded battery voltage level is greater than 24 Vdc. NOTE:

INDIVIDUAL CELL MONITOR LED's (DS1 through DS12) function as GO/NO GO indicators when testing PS-835 lead acid cells. In case of low output capacity, these LED's will indicate which cell or cells have failed. The brightness of the LED's may vary and does not indicate cell condition.




J1 Connector

506-2090B

Figure 8: PS-835 Models E and F Schematic Diagram


Description - Page 9 Description - Page 15/16 February 28/2004


*

* This schematic represents Models E and F after conversion from Models C and D as prompted by SB501-1228-10( ). See Service Bulletin table Figure 1 * Note relocation of Fuse F1

506-1622C

Figure 9: PS-835 Models E and F Schematic Diagram




J1 Connector

This schematic represents Models A, B, C, and D after replacement of A2 CCA 542-1521-01 with 542-2635-01. See Service Bulletin table Figure 1 and SB501-1228-9( ). 506-2086A

Figure 10: PS-835 Models A, B, C, D and G Schematic Diagram


Description - Page 9 Description - Page 19/20 March 13, 2009


This schematic represents Models A, B, C, and D after replacement of A2 CCA 542-1495-01 with 542-1521-01. See Service Bulletin table Figure 1 and SB501-1228-9( ).

506-1512G

Figure 11: PS-835 Models A, B, C, D Schematic Diagram




506-1486E

Figure 12: PS-835 Models C and D Schematic Diagram

This schematic represents Models A and B that have been converted to Model C and D with the re-identification of A2 CCA from 542-136401 to 542-1495-01. See Service Bulletin table Figure 1 and SB5011228-8( ). Models C and D that include the A2 CCA's (542-1495-xx) are obsolete and are no longer supported.




506-1287L

This schematic includes wiring changes prompted by MOD 1 to both Model A and B and MOD 6 for Model A and MOD 7 for Model B. See Service Bulletin table Figure 1. Models A and B that include the A2 CCA (542-1495-01) are obsolete and are no longer supported.

Figure 13: PS-835 Models A and B Schematic Diagram


Description - Page Description - Page 25/269 February 28/2004


Testing and Fault Isolation 1.

General This section of the manual provides the following procedures; bench test, battery charging, periodic testing, performance tests and circuit card tests for the PS-835 Emergency Power Supply. NOTE:

Read these procedures thoroughly before proceeding with any testing.

These instructions will offer reference to supporting Illustrated Parts List illustrations that will appear in parenthesis identifying figure and item number (sample 1-50). In addition, electronic components will include Reference Designator identification in parenthesis indicating the major assembly and component reference number that is listed or identified on the appropriate schematic (sample A1R8). Schematic drawings are located in the Description and Operation section. A.

Battery/Cell Out-gassing (Venting) CAUTION:

SOME OF THE TYPES OF GASSES THAT MAY VENT FROM A CELL ARE TOXIC AND SHOULD NOT BE CONTAINED IN A CLOSED, NON-VENTED AREA.

CAUTION:

CELL/BATTERY CORROSION IS EVIDENCE OF THE LOSS OF SEAL, LIKELY CAUSED BY OUT GASSING. CELLS MUST BE REPLACED WHEN CORROSION IS APPARENT.

All lead-acid cells and batteries produce gasses during charging. The amount and type of gas produced depends on state of charge, rate of charge, chemical composition of the electrolyte, and general condition of the battery. Normally, gasses produced are recombined within the cells to form oxides and water. Venting occurs when excessive charge rates are placed on the battery or because of a defective cell(s), which will subject the remaining good cells to excessive charge rates. Venting may also result from battery abuse or neglect. If the odor of rotten eggs becomes apparent in the cockpit, pull the aircraft Emergency Power Supply circuit breaker. The rotten egg odor is evidence that the lead-acid cells vent due to prolonged high rate overcharging. Although the possibility of toxic levels is extremely remote, the precaution of pulling the circuit breaker will prevent increased discomfort from the odor. Venting is an indication that the Power Supply in not controlling the charging process. If venting occurs, the factory recommends that the Power Supply be removed from the aircraft, and tested to identify and replace defective cell(s). NOTE:

With proper maintenance and periodic testing, the likelihood of any battery developing undetected problems is very remote.


Test & Fault - Page 101 January 24, 2008


2.

Battery Testing NOTE:

Test functions should be performed only with the main buss not providing power to the unit (OFF of disconnected).

Toggling the unit TEST SWITCH (Figure 104, Item 4) on the power supply front panel bypasses the thermostatic heat control system. That, in-turn, applies the battery voltage to the internal battery heater. While in the TEST mode, the batteries are placed under an approximate 7.5Ω load. The voltage level detection system will then analyze the battery voltage level and will cause the appropriate OUTPUT VOLTAGE MONITOR LED's (Figure 104, Item 2) to illuminate. NOTE:


NOTE:

If the unit TEST SWITCH or Remote Test Switch is depressed at a battery ambient temperature of 55°C or greater, the unit internal heater will not turn ON to provide a test load for the unit battery. This is not an ideal condition for battery state of charge tests and should not be considered valid.

If the remote test is being performed, the Remote Battery-Voltage Level Lamp will momentarily illuminate, provided the internally loaded battery voltage level is greater than 24Vdc. NOTE:

After testing, it is possible that the lamp will not illuminate again until the batteries are recharged.

The INDIVIDUAL CELL MONITOR LED's (Figure 104, Item 1) function as GO/NO GO indicators for each of the PS-835 lead acid cells. In case of low output capacity, these LED's will indicate which cell or cells have failed. Any variation of brightness does not indicate cell condition. 3.

Charging Procedures A.

Constant-Voltage Charging Method Locally manufacture a power cable using 16AWG wire and the appropriate mating connector See Figure 101, Item 7 & 8. Include a Diode (15 ADC (min), 50.0 PIV or greater, See Figure 101, Item 6) to prevent battery discharge in case of loss of power from the power source. Using the external power supply (Figure 101, Item 1), apply 29.0 ± 0.5 Vdc (10A ma ximum current limited) to J1 connector pins 11 (+) and 7 (-) and charge the unit for 16 hours. The batteries should reach 80% capacity within 1 hour and full charge at 16 hours. J1 pin 11

PS-835 Power Supply

J1 pin 7 (ground)

NOTE:

+

(16AWG conductors)

Power Supply _

Pin J1-11 is used instead of Pin J1-10 (during the Constant-Voltage Charging Method) because applying power to J1-10 may activate the internal heater blanket.




B.

Constant-Voltage Float (trickle) Charging Method Use the locally manufactured power cable, including the appropriate mating connector and diode, to connect a regulated/constant voltage source (28.5 ± 0.5 Vdc) to the PS-835. This method will provide a long-term constant voltage to maintain the fully charged condition of the PS-835 unit when not in service, without any other maintenance action. NOTE:

C.

The trickle charge method can be maintained indefinitely without damage to the charging batteries.

BC-815 Battery Charger Method Install the BC-815 Battery Charger (Avionics Systems part number 501-1321-01) into the PS835 Emergency Power Supply and charge for no-less-than 23 hours. Charge time depends upon the batteries state-of-charge. Charging for 23 hours will essentially guarantee a full charge. The BC-815 provides a constant charging current of either 0.5 A or 0.25 A, selectable by a switch on the face of the unit. The AMBER LED illuminates when power is applied by placing the ON / OFF switch to ON. When the unit being charged is within 90.0% of full charge, the GREEN LED illuminates indicating that the BC-815 has automatically switched to the trickle charge mode. The charger/battery combination may be operated in this mode indefinitely without damage to the BC-815 or to the batteries being charged.

D.

BC-815 Battery Float (trickle) Charging Method Install the BC-815 Battery Charger (Avionics Systems part number 501-1321-01) into the PS835 Emergency Power Supply. This method will provide a long-term constant voltage to maintain the fully charged condition of the PS-835 unit when not in service, without any other maintenance action. NOTE:

4.

The trickle charge method can be maintained indefinitely without damage to the charging batteries.

Preflight Checks (Recommended) NOTE: This check will indicate an accurate condition of the unit only upon the intial attempt. Repeated checks will not reveal accuratly because stored energy is used each time the TEST SWITCH is depressed. A.

Pre-Flight Check for Aircraft with Remote Test Capability With no power applied to the PS-835 Emergency Power Supply, press and hold for 5 seconds the cockpit remote TEST SWITCH in the TEST position. The remote test lamp must, at least, momentarily illuminate to indicate that the Power Supply is adequately charged. If no illumination of the remote test lamp is apparent for the period that switch is held, the Emergency Power Supply is incapable of providing power in an emergency.

B.

Pre-Flight Check for Aircraft with NO Remote Test Capability Access the Emergency Power Supply. Perform the check as listed in paragraph 5, Periodic Checks.


Test & Fault - Page 103 March 13, 2009


5.

Periodic Checks (Required 3 to 6 Months) With no power applied to the PS-835 Emergency Power Supply, press TEST SWITCH (Figure 104, Item 4) (or remote cockpit test switch) into TEST position for 5 seconds. The PS-835 indicates that it is adequately charged when the VOLTAGE LEVEL 24Vdc LED (Figure 104, Item 2) (or remote test indicator), at least, illuminates momentarily, AND the 20Vdc LED (Figure 104, Item 6) remains lit during the test. NOTE:


If the VOLTAGE LEVEL 24Vdc LED does not, at least, momentarily illuminate while the 20Vdc LED is illuminated, the Emergency Power Supply is incapable of providing power in an emergency. Proceed to Fault Isolation Test, Step 7. 6.

Capacity Testing (Required Annually) NOTE:

A.

The PS-835 Emergency Power Supply must have completed a full charge prior to any discharge testing.

Capacity Test

1)

Press and hold TEST SWITCH (Figure 104, Item 4) and observe the OUTPUT VOLTAGE MONITOR LED's (Figure 104, Item 2). NOTE:

B.


2)

If the 24VDC OUTPUT VOLTAGE MONITOR LED comes on, proceed with either Discharge Test procedures.

3)

If OUTPUT VOLTAGE MONITOR LED's do not come on, check Fuse A1F1 (IPL Figure 2, Item 90) and replace if blown. Perform step 7. Cell Isolation Test if fuse is not blown.

Preferred Discharge Test Method (Load Resistor) 1)

Prepare for test by first constructing an X-Y graft similar to the one in Figure 7. If possible, use pre-printed graft paper to create a record of the discharge period along the Xaxis and voltage readings along the Y-axis.

2)

Position all INDIVIDUAL CELL DIP SWITCHES Figure ( 104, Item 5) to the ON position. a.

If the INDIVIDUAL CELL MONITOR LED DS12 (DS1 for models E and F) is the only LED not illuminated, proceed to step 7. Cell Isolation Test.

3)

Connect Digital Voltmeter (Figure 101, Item 2) leads to J1 connector pins 11 (+) and 7 (-).

4)

Connect the Load Resistor (Figure 101, Item 4) across J1 connector pins 11 (+) and 7 (-) and start timing the discharge period with the stopwatch now.

5)

Monitor and plot voltage values at 10-minute intervals.




6)

At 48 minutes (Model’s B, D, F and G) and 20 minutes (Model’s A, C and E), note voltage on Digital Voltmeter. This voltage must be greater than 20.0 Vdc. a.

All INDIVIDUAL CELL MONITOR LED’s (Figure 104, Item 1) must remain on.

b.

Any LED that does go OFF will represent a defective individual cell, which must be replaced.

7)

Remove the Load Resistor from J1 connector pins 11 (+) and 7 (-).

8)

Position all INDIVIDUAL CELL DIP SWITCHES (Figure 104, Item 5) to the OFF position.

9)

Compare the voltage vs. time plot created during this test to that of curve identified as typical for the External Load test method on the chart in Figure 7.

10) If the plot reveals a discharge curve that meets or exceeds the MINIMUM ACCEPTABLE DISCHARGE CURVE, the unit is considered satisfactory. 11) If unit discharge plot is satisfactory and no other failures were revealed, perform either of the Charging Procedures listed in Step 2 within 2 hours of completion of the discharge test. Return the unit into service or storage as required. C.

Alternate Discharge Test Method (Internal Heater Element (HR1) as Load) 1)

Prepare for test by first constructing an X-Y graft similar to the one at Figure 7. If possible, use pre-printed graft paper to create a record of the discharge period along the Xaxis and voltage reading along the Y-axis.

2)

Remove cover PS-835cells. Emergency Power Supply and place a small cooling fan in position to coolfrom the battery

3)

Position all INDIVIDUAL CELL DIP SWITCHES (Figure 104, Item 5) to the ON position. a.

If the INDIVIDUAL CELL MONITOR LED DS12 (DS1 for models E and F) is the only LED not lit, proceed to Fault Isolation Test, Step 7.

4)

Connect Digital Voltmeter (Figure 101, Item 2) leads to J1 connector pins 11 (+) and 7 (-).

5)

Place a jumper wire between J1 connector pins 11 and 2.

6)

Start timing the discharge period with the stopwatch now.

7)

Monitor and plot voltage values at 10-minute intervals.

8)

At 48 minutes (Model’s B, D, F and G) and 20 minutes (Model’s A, C and E), note voltage on Digital Voltmeter. This voltage must be greater than 20.0 Vdc. a.

All INDIVIDUAL CELL MONITOR LED’s (Figure 104, Item 1) must remain on.

b.

Any LED that goes OFF will represent a defective individual cell, which must be replaced.




9)

Position all INDIVIDUAL CELL DIP SWITCHES (Figure 104, Item 5) to the OFF position.

10) Compare the voltage vs. time plot created during this test to that of curve identified as typical for the Internal Load Test Method on the chart in Figure 7. 11) If the plot reveals a discharge curve that exceeds the MINIMUM ACCEPTABLE DISCHARGE CURVE, the unit is considered satisfactory. 12) Remove Jumper Wire, Voltmeter leads and reinstall cover 13) If the unit discharge plot is satisfactory and no other failures were revealed, perform either of the Charging Procedures listed in Step 2 within 2 hours of the completion of the discharge test. Return the unit into service or storage as required. 7.

Cell Isolation Test NOTE:

No power should be applied to PS-835 Emergency Power Supply during test.

CAUTION:

THIS TEST PROCEDURE IS APPROPRIATE ONLY FOR THOSE UNITS THAT CONTAIN BATTERY MONITOR CCA (A2) PART NUMBERS 542-1521-01, 542-2625-01, OR 542-2635-01. ALL OLDER VERSIONS MUST BE MODIFIED UP TO ANY ONE OF THESE VERSIONS USING THE SERVICE BULLETIN MODIFICATIONS FOR THESE TESTS TO BE APPLICABLE. SEE SERVICE BULLETIN AND MODIFICATIONS TABLE FIGURE 1, DESCRIPTION SECTION, PAGE 4.

A.

Press and hold TEST SWITCH (Figure 104, Item 4). If no OUTPUT VOLTAGE MONITOR LED's come on: NOTE:


1)

Position all INDIVIDUAL CELL DIP SWITCHES to the ON position.

2)

Press and hold TEST SWITCH (Figure 104, Item 4) and observe the INDIVIDUAL CELL MONITOR LED's (Figure 104, Item 1). a.

If all INDIVIDUAL CELL MONITOR LED’s come on except DS12, the unit is damaged and requires repair at an authorized repair station.

b.

If all INDIVIDUAL CELL MONITOR LED’s are on, there exists a low-battery voltage condition. Perform the Charging Procedures of Step 2.




8.

Performance Test This test is required before a unit can re-enter service after a repair action has been performed on the unit. A.

Recommended Test Equipment Figure 101 provides a list of recommended test equipment needed to accomplish the test and charging requirements for the Model PS-835 Emergency Power Supply. See Special Tools, Fixture, and Equipment section, Figure 901 for detailed listing. NOTE:

Item

Equivalent equipment may be used for all listed items. Description

Manufacturer - Model / Part No.

1

DC Power Supply 0-30 Vdc 20 amp capacity

2

Digital Voltmeter (DVM)

Fluke Model 8050A

3

Delete

Delete

4

Load Resistor 7Ω ±1% 150 watt (minimum), Ceramic wire wrap

WireMasters, Inc. 136 Alpha Drive, Franklin, TN 37064. Cage Code: 0FVD7 Tel: 800-635-5342 (Part Number WM910053 …300 watt version)

5

Stopwatch

Meyland Corp. Model 202A

6

Isolation Diode 15 Amp, 50 Volt PIV

WireMasters, Inc. (Part Number WM1N3208)

7

Mating Connector for PS-835 A to D, & G P/N: DPXB-13-33S-0001

8

Mating Connector for PS-835 E and F

P/N: DPXB-13-33S-0019

9

BC-815 Battery Charger (used in place of DC power supply)

Avionics Systems Part No. 501-1321-01

Hewlett Packard Model 6291

Figure 101: Test Equipment and Fixtures B.

Test Setup and Conditions 1)

Establish a Test Setup stations based on schematics Figure 102 and Figure 106 using the test equipment listed in Test Equipment and Fixtures Figure 101.

2)

All tests must be performed at laboratory ambient temperature (room temperature), humidity, and atmospheric pressure.

3)

All power source settings and load values must be within ±2% of the values cited in the instructions. Time measurements must be within +10% of the specified limits.

4)

The Battery Monitor CCA (A2) MUST be correctly calibrated before unit Charging Procedures and Performance Test Procedures can be performed. See step 8.-C.-C.3) Battery Monitor CCA Calibration Procedure.

5)

Unit must have completed the full charge process within 24 hours before running tests.

6)

Open (OFF) all Test Setup switches before energizing the External Power Supply.

7)

Position Test Setup switch S5 to INPUT.




Figure 102: PS-835 Test Setup Schematic C.

Performance Tests Procedures Before returning a PS-835 Emergency Power Supply to operation the following performance test must be performed to insure operation of the unit according to srcinal specifications. NOTE: 1)

The Battery Monitor CCA (A2) MUST be correctly calibrated before performing these procedures. See step 8.-C.-3) Battery Monitor CCA Calibration Procedure.

Continuity Test Remove unit Cover (1-5) and disconnect any external power source from unit. CAUTION:

DO NOT MEASURE J1 CONNECTOR PIN 11 TO PIN 7 OR PIN 12 (GROUND) ON ALL MODELS AND PIN 9 TO PIN 7 OR PIN 12 (GROUND) ON MODELS E & F.

Use the DVM (Figure 101, Item 2) to measure the resistance for the pin combinations listed below. Record any results that fail to equal the required results listed in the Correct Results column.




Connector Pins From (+)

To ( - )

Correct Results

All Models J1-1

J1-7

Open

J1-1

J2-2

Short

J1-2

J1-7

33KΩ min.

J1-3

J1-7

Open

J1-3

J2-7

Short

J1-4

J1-7

Open

J1-4

J2-15

Short

J1-5

J2-8

Short

J1-5

J1-7

Open

J1-6

J1-7

1MΩ min.

J1-8

J1-7

Open

J1-10

J1-7

20KΩ min.

J1-11

J1-7

CAUTION: DO NOT MEASURE

J1-11

J2-9

Short

J1-12

J1-7

Short

J1-12

J2-5

Short

J1-12

J2-13

Short

J1-12

Chassis

Short

J2-8

J2-3

Short

J3-2

J3-5

40-100 Ω (see step 5. d.(3))

J3-24

J3-25

7.4±0.5 Ω

J1-9

J1-7

Open

J1-9 or J1-13

J1-4 or J1-9 or J1-11

Short

J1-1

J1-5

Open

J1-1

J1-11

Open

J1-1

J2-1

Open

J1-3

J1-5

Open

J1-5

J1-13

Open

J1-9

J1-7

Open

J1-12

J1-13

Open

J1-9

J1-7 or J1-12

CAUTION: DO NOT MEASURE

J1-11

J1-9

Short (through F1 fuse)

J1-13

J2-4 or J2-11

Short

Model A and B

Model C & D

Model E & F

Figure 103: Connector Pin Continuity Table




2)

Voltage Test Use the Digital Voltmeter (Figure 101, Item 2) independent leads to measure the voltage between J1 connector pin J1-11 and the chassis of the unit. The voltage must be 25Vdc (nominal).

3)

Battery Monitor CCA Calibration Procedure NOTE:

The Battery Monitor CCA MUST be correctly calibrated to insure successful Battery Charging and Capacity Testing Procedures.

NOTE:

If calibration cannot be successfully achieved, remove the Battery Monitor CCA and perform the Battery Monitor CCA Test Procedures, Step 8.

a.

Check Transducer (A1U1) (2-210) ensure that it is not grounded. Repair if necessary before proceeding with calibration.

b.

Check Thermo Resistor (A1RT1) (2-215) to ensure that it is adequately grounded to the unit chassis. Repair if necessary before proceeding with calibration.

c.

Battery Heater Adjustment (Perform only if Battery Monitor CCA not previously calibrated) (1) Set External Power Supply to 28 to 30Vdc, open Test Setup switch S4 to prevent application of load to J1 connector pin J1-11, close Test Setup switch S3 to apply power to J1 connector pin J1-10. (2) Find Temperature Control resistor (A2R8) located on the Battery Monitor CCA (A2) and adjust resistor to so to discover the resistor setting that turns ON the HEATER ON LED at the current room temperature. (3) From that point, rotate the resistor adjustment 2 complete turns clockwise to establish the approximate 20°C Heater setting. WARNING:

ADHESIVE (F-900 TORQUE SEAL) HAS BEEN IDENTIFIED AS HAVING A DEGREE OF HAZARD IN HEALTH, FLAMMABILITY, AND REACTIVITY. CONSULT THE APPLICABLE MATERIAL SAFETY DATA SHEET PRIOR TO USE OR ASSOCIATION WITH THIS PRODUCT.

(4) Apply Torque Seal (Figure 701 Item 11) to resistor A2R8 screw head.




d.

Front Panel Battery and Cell Monitor (1) Position all INDIVIDUAL CELL DIP SWITCHES (Figure 3, item 5) to ON and confirm that each INDIVIDUAL CELL MONITOR LED goes ON. (2) Change the External Power Supply setting to 18-19 Vdc, press and hold TEST SWITCH (Figure 3, Item 4) and observe to confirm that the INDIVIDUAL CELL MONITOR LED's remain ON. Release the TEST SWITCH. (3) Change the External Power Supply setting to 28Vdc and confirm that the all BATTERY VOLTAGE MONITOR LED's remain ON. (4) Re-position all INDIVIDUAL CELL DIP SWITCHES to OFF.

e.

Battery Temperature Protection (1) Open (OFF) Test Setup switch S3 to eliminate power to the unit. (2) Use the DVM (Figure 101, Item 2) to measure the resistance value of the Thermo Resistor (A1RT1), applying the Ohmmeter probes between J3 connector pins 2 and 5. Resistance must be 40-100Ω. (3) Replace the Thermo Resistor (A1RT1) if resistance is not between 40-100Ω.

f.

Heater and Control Performance (1) Change External Power Supply to 30 Vdc and close (ON) Test Setup switches S2 and S3. (2) Observe BATTERY HEATER OPERATION MONITOR LED's (Figure 1, Item 3). Within 30 minutes, the OVER 55°C LED must go ON and the HEATER ON LED must go OFF. (3) Open (OFF) Test Setup switch S3 to remove external power supply to unit. (4) Re-install the unit Cover.




4)

Capacity Testing Battery Capacity Testing is Required Annually of all aircraft using a PS-835 Emergency Power Supply. Capacity testing may be performed by the following methods at the discretion of the technician.

Test • • •

Method

Preference

External Load

Constant Voltage

Preferred

Internal Load

Constant Voltage

Alternate

Automatic Discharge

Constant Current

Alternate

NOTE:

Prior to performing test, the power supply must be at full capacity.

Figure 104: PS-835 Access Panel




a.

External Load Method (1) Position all INDIVIDUAL CELL DIP SWITCHES (Figure 104, Item 5) to the ON position. NOTE:

If the INDIVIDUAL CELL MONITOR LED DS12 (DS1 for models E and F) is the only LED not illuminated, proceed to test paragraph 7 [Cell Isolation Test].

(2) Connect Digital Voltmeter [DVM] (Figure 101, Item 2) leads to J1 connector pins 11 (+) and 7 (-). (3) Connect the Load Resistor (Figure 101, Item 4) across J1 connector pins 11 (+) and 7 (-), and start timing the discharge period with the stopwatch (Figure 101, Item 4). NOTE:

• •

During the test All INDIVIDUAL CELL MONITOR LED’s (Figure 104, Item 1) must remain on. Any LED that does go OFF will represent a defective individual cell, which must be replaced. For Models B, D, F and G record the output voltage at 48 minutes. For Models A, C and E record the output voltage at 20 minutes.

(4) The recorded voltage must be greater than 20.0 Vdc. • •

A unit that fails to meet the minimum acceptable voltage will require service. A unit that meets the minimum acceptable voltage proceeds to the Recharging Procedures Paragraph.

CAUTION:

RECHARGE THE PS-835 WITHIN 2 HOURS AFTER DISCHARGING TO REDUCE THE POSSIBILITY OF DAMAGE TO BATTERY CELLS.

(5) Remove the Load Resistor and DVM from J1 connector pins 11 (+) and 7 (-). (6) Position all INDIVIDUAL CELL DIP SWITCHES (Figure 104, Item 5) to the OFF position.




b.

Internal Load Method The internal load method uses the batteries heater blanket to discharge the batteries. Before conducting this test remove the power supply cover and place a small fan near the unit (to dissipate heat). (1) Position all INDIVIDUAL CELL DIP SWITCHES (Figure 104, Item 5) to the ON position. NOTE:


(2) Connect Digital Voltmeter [DVM] (Figure 101, Item 2) leads to J1 connector pins 11 (+) and 7 (-). (3) Connect a jumper to J1 connector pins 11 (24/28Vdc out) and 2 (remote test switch), and start timing the discharge period with the stopwatch (Figure 101, Item 4). NOTE:

• •

During the test All INDIVIDUAL CELL MONITOR LED’s (Figure 104, Item 1) must remain on. Any LED that does go OFF will represent a defective individual cell, which must be replaced.

For Models B, D, F and G record the output voltage at 48 minutes. For Models A, C and E record the output voltage at 20 minutes.

(4) The recorded voltage (on DVM) must be greater than 20.0 Vdc. CAUTION:


(5) Remove the jumper from J1 connector pins 11 and 2 and the DVM from J1 connector pin 11 and 7. (6) Position all INDIVIDUAL CELL DIP SWITCHES (Figure 104, Item 5) to the OFF position.




c.

Automatic Discharge Method The Automatic Discharge Method can only be used when a automatic constant-current battery analyzer is used. (1) Position all INDIVIDUAL CELL DIP SWITCHES (Figure 104, Item 5) to the ON position. NOTE:


(2) Connect unit under test to test equipment and apply power. •

Models B, D, F and G will sustain a constant-current discharge of 3.3 Amps for 48 minutes to not less then 20.0 Vdc.

•

Models A, C and E will sustain a constant-current discharge of 1.5 Amps for 48 minutes to not less then 20.0 Vdc

(3) A unit that fails to meet the minimum acceptable voltage will require service. A unit that meets the minimum acceptable voltage proceeds to the Recharging Procedures Paragraph. CAUTION:


(4) Remove the unit from test equipment. (5) Position all INDIVIDUAL CELL DIP SWITCHES (Figure 104, Item 5) to the OFF position. d.

Cell Isolation Test NOTE:

No power should be applied to PS-835 Emergency Power Supply during test.

(1) Press and hold TEST SWITCH (Figure 104, Item 4). If no OUTPUT VOLTAGE MONITOR LED's come on: NOTE:


a)

Position all INDIVIDUAL CELL DIP SWITCHES (Figure 104, Item 4) to the ON position.

b)

Press and hold TEST SWITCH (Figure 104, Item 4) and observe the INDIVIDUAL CELL MONITOR LED's (Figure 104, Item 1). •

•

If allunit INDIVIDUAL CELL MONITOR the is damaged and requires repair. LED’s come on except DS12, If all INDIVIDUAL CELL MONITOR LED’s are on, there exist a lowbattery voltage condition. Perform the Charging Procedures of Step 2.




9.

Battery Monitor CCA Test Procedures This test procedure includes the calibration process to establish the correct voltage values that illuminate the monitor LED's. The correct calibration of this Battery Monitor CCA is essential for the successful completion of the unit Charging Procedures and Performance Test. Construct the CCA Test Setup station according to the wiring schematic in Figure 105. CAUTION:

THIS TEST PROCEDURE IS APPROPRIATE ONLY FOR BATTERY MONITOR CCA PART NUMBERS 542-1521-01, 542-2625-01, OR 542-2635-01. ALL OLDER VERSIONS MUST BE MODIFIED UP TO ANY ONE OF THESE VERSIONS USING THE SERVICE BULLETIN MODIFICATIONS. SEE SERVICE BULLETIN AND MODIFICATIONS TABLE FIGURE 1, DESCRIPTION SECTION, PAGE 3.

A.

INDIVIDUAL CELL MONITOR LED Test 1)

Position all INDIVIDUAL CELL DIP SWITCHES to ON.

2)

Set External Power Supply to 1.8 Vdc and apply across each LED pin-couple (see table below) on P3 connector pins to confirm that each INDIVIDUAL CELL MONITOR LED goes ON. Pin numbers progress from pin 1 to pin 26 starting from the top of P3 connector when the CCA is viewed as oriented in Figure 104.

Figure 105: Individual Cell Monitor LED's




Figure 106: Circuit Card Assembly Test Setup




B.

Battery Monitor CCA Performance Test (542-1521-xx, 542-2625-xx, 542-2635-xx) NOTE:

Obsolete Battery Monitor CCA's 542-1495-xx and 542-1364-xx have no Performance Tests available. See Service Bulletin and Modification table, Figure 1.

1)

Connect the Battery Monitor CCA (A2) to the CCA Test Setup connector J3.

2)

Open (OFF) switches SW2, SW3, and SW6 and close (ON) switch SW4. Position switch S1 to OFF.

3)

Energize and set the External Power Supply to 28 Vdc.

4)

Turn switch S1 to position 1.

5)

Measure and record voltage at J3 connector pin J3-8 (TP 1). Voltage must be 12.6 ±7% Vdc.

6)

Adjust resistor A2R13 CW so that Test Setup LED CR1 just goes OFF. WARNING:

7)


Apply Digital Voltmeter test lead to J3 connector pin J3-25 (TP 2) and Set External Power Supply to 24± 0.01 Vdc. Adjust CW resistor A2R5 until OUTPUT MONITOR LED DS15 and Test Setup LED CR3 just goes OFF. a.

Apply Torque Seal (Figure 701 Item 11) to resistor A2R5 screw head.

8)

Increase External Power Supply (measured at TP 2) to 28 Vdc. INDIVIDUAL CELL MONITOR LED's DS13 through DS16 and Test Setup LED CR3 must go ON.

9)

Gradually decrease External Power Supply to 19.8 Vdc, observe and record voltage values that each LED, DS13 through DS16 and TestSetup LED CR3, go OFF. LED's must go OFF at: LED DS13 DS14 DS15 CR3 (TP 2) DS16

Voltage 27± 0.27 Vdc 25± 0.25 Vdc 24± 0.10 Vdc 24± 0.10 Vdc 20± 0.20 Vdc

10) Close (ON) Test Setup switch SW3, observe and confirm that HEATER ON LED DS17 is still OFF. Apply the Digital Voltmeter test lead to pin 19 (TP 3) and set the External Power Supply to 26.07± 0.01 Vdc.




11) Slowly adjust resistor A2R13 CCW until Test Setup LED CR1 goes ON. a.

It is easy to overshoot the adjustment, that is to continue rotation to some degree after the Test Setup LED CR1 goes ON. In that case, back-up the adjustment (CW) about a full rotation. Quickly toggle the Test Setup switch S6 close/open (ON/OFF) to reset the circuit.

b.

Repeat the slow and deliberate adjustment of resistor A2R13 CCW until Test Setup LED CR1 goes on.

c.

Raise the input voltage at J3 connector pin J3-19 (slow and deliberate to avoid overshoot) to 27.75± 0.01 Vdc. Test Setup LED CR1 must turn OFF at or before reaching this voltage. WARNING:

d.


Apply Torque Seal (Figure 701 Item 11) to resistor A2R13 screw head.

12) Open (OFF) Test Setup switch SW3, close (ON) SW6, and adjust External Power Supply to 28 Vdc as measured at J3 connector pin J3-19 (TP 3). 13) Adjust resistor A2R8 CCW until HEATER ON INDICATOR LED DS17 goes ON, then close (ON) the Test Setup switch SW3 which must result in cell HEATER ON INDICATOR LED DS17 to go OFF. 14) Close (ON) switch SW2 and apply Digital V oltmeter lead to pin 24 (TP 4). With switch SW3 still closed (ON) the voltage reading at pin 24 (TP 4) must be 28 Vdc. Open (OFF) switch SW3 and voltage reading must be less than 2.5 Vdc. 15) Apply, again, the Digital Voltmeter lead to J3 connector pin J3-19 (TP3). Open (OFF) Test Setup switch SW3, close (ON) SW6, and adjust External Power Supply to 26 Vdc. 16) Adjust resistor A2R8 CCW and confirm that HEATER ON INDICATOR LED DS17 remains OFF. 17) Close (ON) switch SW2 and apply Digital Voltmeter lead to pin 24 (TP 4). Close (ON) switch SW3, voltage reading at J3 connector pin J3-24 (TP 4) must be 26 Vdc. Open (OFF) switch SW3 and voltage reading must continue to be 26 Vdc. 18) Return External Power Supply to 28 Vdc and open (OFF) Test Setup switch SW3. Open (OFF) Test Setup switch SW4, observe and confirm the OVER 55 ° LED DS18 goes ON and Test Setup LED CR2 goes OFF. 19) Apply the Digital Voltmeter lead to J3 connector pin J3-19 (TP 3) and adjust External Power Supply to 28 Vdc. Close (ON) Test Setup switches SW2, SW3, and SW4. Place Test Setup switch SW1 to position 2. Apply Digital Voltmeter lead to pin 24(TP 4). Open (OFF) Test Setup switch SW4. The Digital Voltmeter must read 28 Vdc.




20) Place Test Setup switch SW1 to position 3. The Digital Voltmeter must read 28 Vdc. WARNING:


21) Apply Torque Seal (Figure 701 Item 11) to resistor A2R8 screw head. C.

Post Test Procedures Return the Battery Monitor CCA into the unit and perform the Test Procedures for the LRU. Perform the Charging Procedures and Capacity Test Procedures as required to return the unit to service.




Disassembly 1.

General CAUTION:

READ ALL THE INFORMATION IN THIS SECTION BEFORE ANY ATTEMPT TO DISASSEMBLE THIS UNIT.

Disassembly procedures are listed in descending order to allow for successive accessibility to subassemblies and components. These procedures are intended to cover most aspects of disassembly. De-soldering of components and wires, and the replacement of items such as switches, fasteners, and other simple operations are not covered explicitly. Technicians working on avionics equipment of this type should have adequate knowledge of avionics shop practices before attempting any repairs. Whenever a disassembly procedure involves disconnecting wires from components and/or connector J1, it is best to tag, mark, or identify the wires that are cut, de-soldered, or otherwise removed. If wires are cut, do so in a manner that provides an adequate wire for re-connections. Disassemble the PS-835 Emergency Power Supply only to the level necessary to repair the unit as revealed in the procedures of the Fault Isolation and Test section. Any disassembly of the PS-835 for repair or cleaning will require functional testing after reassembly and before installation. See the Testing and Fault Isolation section for functional test procedures and wiring diagrams. WARNING:

SEVERE (3RD DEGREE) BURNS AND MELTED METAL PARTS CAN RESULT THROUGH IMPROPER HANDLING OF THELRU AND SUBASSEMBLIES. THE BATTERIES CONTAINED WITHIN THE PS-835 ARE CAPABLE OF PRODUCING AND SUSTAINING LARGE CURRENTS (OVER 50 AMPS) FOR SEVERAL MINUTES. REMOVE ALL JEWELRY WHEN WORKING ON THIS EQUIPMENT.

Place the PS-835 on a stable, flat surface with appropriate lighting. Anticipate placing fasteners and other small components into containers to prevent loss. NOTE:

2.

Components and assemblies listed in these instructions include IPL Figure and Item numbers in parenthesis. Use the Illustrated Parts List section to assist in the disassembly process.

Disassembly Procedures A.

Cover Removal 1)

Remove Screws (1-10), Washers (1-15 and 1-20), and Nuts (1-25) from rear of Cover Assembly (1-5).

2)

Grasp Front Panel Handle (1-55) while holding Cover Assembly (1-5), separate cover from unit by pulling cover rearward.


Disassembly - Page 301 February 28/2004


B.

Front Panel Removal WARNING:

C.

1)

Remove Screws (1-50 and 1-40) and Washer (1-45) from Front Panel (1-30).

2)

Separate Front Panel (1-30) from Battery CCA (A1) (1-70).

Battery Monitor Circuit Card Assembly (A2) (CCA) Removal 1)

D.

E.

USE SPECIAL CARE TO RETRIEVE THE WASHER (1-45) ASSOCIATED WITH FRONT PANEL ASSEMBLY. RE-ASSEMBLY WITHOUT THE WASHER IN PLACE WILL CAUSE SHORTING THAT WILL DESTROY THE UNIT AND INJURE BYSTANDERS.

Grasp the Battery Monitor CCA (A2) by the edges and pull straight out from Connector (J3) (2-23)

Cell Removal CAUTION:

CELLS ARE CHARGED AND HAVE THE ABILITY TO INDUCE SHOCK OR BURNS WHEN MISHANDLED.

CAUTION:

CELL/BATTERY CORROSION IS EVIDENCE OF THE LOSS OF SEAL, LIKELY CAUSED BY OUT GASSING. CELLS MUST BE REPLACED WHEN CORROSION IS APPARENT.

1)

Clip all Tie-Down Straps (2-6) from the backside of the Battery CCA (A1) (1-70).

2)

Pull the first (closest to Front Panel) vertical 4-cell group from Battery CCA and clip all cell wires just above the cell terminals.

3)

Repeat for the next vertical 4-cell group.

4)

Pull out the last vertical 4-cell group.

5)

Clip all the wires just above the cell terminals except the red wire (positive) on cell BT1 for models E and F, or the black wire (negative) for cell BT12 for models C and D. (See IPL Figure 1 Note A)

6)

De-solder and remove that wire not clipped from the cell.

7)

Cut and/or shave RTV material that secures the 4-cell groups away from their associated Insulator Plates (2-10). Save the Insulator Plates and discard cells.

8)

De-solder and remove all those clipped cell wires from the solder pads located on the back of the Battery CCA (A1).

Heater Element (HR1) Removal 1)

De-solder and remove Heater Element wires (white) from terminals on reverse side of Battery CCA (A1) (1-70) (see Figure 702).

2)

Peel Heater Element (HR1) (2-45) from Battery CCA Chassis.

3)

Remove excess adhesive from chassis.




F.

Battery CCA (A1) Disassembly NOTE:

3.

De-solder, clip, or otherwise disconnect wires from terminals to the degree necessary to proceed with disassembly. Remember to mark or tag wires and terminal to ensure for proper re-assembly.

1)

Remove Screws (2-20 and 2-25), Washers (2-30 and 2-35), and Nut (2-40).

2)

Separate Inverter Assembly Support (2-15) form Battery CCA (A1) (1-70).

3)

Remove Screws (2-150 and 2-160), Washers (2-155 and 2-165)

4)

Separate Battery PWB (2-145) from Battery CCA Chassis.

Repair See Repair section for instructions and guidance for repair of those issues identified in the Performance Test of the Fault and Isolation section. See Assembly section for re-assembly instructions and guidance.








Cleaning 1.

General The PS-835, like any avionics equipment, will accumulate dust and dirt during service. Avionics Systems has taken precautions to allow cleaning the equipment with environmentally friendly solutions and chemicals. Procedures and suggested cleaning agents are described in this section.

2.

External Cleaning CAUTION:

WATER MAY MIGRATE OR LEAK INTO THE CELL THROUGH THE CELL VENT CAUSING A CHEMICAL CHANGE IN THE CELL RESULTING IN SHORTENED SERVICE LIFE, EVEN THOUGH THE BATTERY CELLS ARE SUPPOSEDLY SEALED.DO NOT IMMERSE THEPOWER SUPPLIES IN A WATER BATH.

The outside surfaces and flat metal parts may be cleaned with a damp cloth containing a mild solution of ordinary household cleaner (following manufacturer's instructions on cleaner container) and water. Dirt and grime caught in metal corners or around screws or other fasteners may be removed with a modified acid brush (bristles removed to 1/3 of the normal length as shown in Figure 401) and a solution of cleaner and water. Dry the unit after cleaning before reinstallation and use. NOTE: 3.

Water in connectors can be removed using low pressure compressed air.

Internal Cleaning CAUTION:

CELL/BATTERY CORROSION IS EVIDENCE OF THE LOSS OF SEAL, LIKELY CAUSED BY OUT GASSING. CELLS MUST BE REPLACED WHEN CORROSION ISAPPARENT.

WARNING:

ISOPROPYL ALCOHOL HAS BEEN IDENTIFIED AS HAVING A DEGREE OF HAZARD IN HEALTH AND FLAMMABILITY. CONSULT THE APPLICABLE MATERIAL SAFETYDATA SHEET PRIOR TO USE OR ASSOCIATION WITH THIS PRODUCT.

With exception to the circuit card assemblies (CCAs), the internal surfaces of the assembly may be cleaned following the processes for external cleaning above. CCAs can be cleansed using Isopropyl Alcohol and a modified acid brush. Allow CCA to dry before use. Remove dust and dirt with a low-pressure jet of clean, dry air. If necessary, use the brush depicted in Figure 401 to loosen hardened dirt and embedded dust balls.


Cleaning - Page 401 February 28/2004


Figure 401: Modified Acid Brush


Cleaning - Page 402 February 28/2004


Check 1.

General This section provides avionics service personnel necessary guidance for inspections to the PS-835 Emergency Power Supply, which will assist in identifying shortcomings that may result in failure of the unit operate.

2.

On Aircraft Checks A.

Pull aircraft circuit breaker to remove power from PS-835 Emergency Power Supply.

B.

Place TEST SWITCH (cockpit remote test switch for aircraft so equipped) into the TEST position.

C.

View Output Voltage Monitor LED's (cockpit remote test lamp for aircraft so equipped). Output Voltage Monitor LED for 24VDC (or the cockpit remote test lamp) must illuminate momentarily to indicate that the unit is adequately charged.

D.

Release the TEST SWITCH and reset the aircraft circuit breaker. NOTE:

3.


Checks After Repair and During Re-assembly A.

Perform disassembly according to the Disassembly section. While in progress of disassembly, check: 1)

Transistors, high-wattage resistors and surrounding areas for overheating.

2)

For burned, broken, or shorted parts, components, and hardware.

3)

Connector and terminal posts for bent, broken, or damaged pins, screws (heads and threads), and casings for breakage and cracking.

4)

Inspect all wiring for being excessively tight or loose, chafing, fraying, burned insulation, and breakage. Wiring insulated with Teflon should be checked closely for insulation coldflowing and bare conductors. This phenomenon would be most evident at wire bends and places where wire bundles are secured or tied. Being able to see actual wire through the insulation does not necessarily mean the wire needs replacement. An insulation breakdown test will determine if replacement is warranted.

5)

Inspect all soldered connections, even those not unsoldered during disassembly, for broken or pitted solder, cold joints, and solder quality.

Deficiencies found during inspection should be corrected when repairing a defective unit, or performed as a preventive maintenance measure to preclude future problems. Repair defects in accordance with the Repair section of this manual.


24-30-02 Checks - Page 501 August 29, 2007


4.

Inspection After Repair and During Assembly A.

Perform re-assembly according to Reassembly section. While in progress of unit re-assembly check: 1)

Sufficient service loop exists between interconnected subassemblies.

2)

All screws in terminal posts and CCAs are tight (not stripped).

3)

Screws attaching subassemblies to chassis are tight (not stripped).

4)

External hardware and nuts securing front panel to chassis are tight.

5)

Appropriate modifications have been incorporated and mod numbers marked off accordingly on modification plate.

6)

Connector J1 is properly covered for storage or handling.

After assembly, perform unit performance test according to Testing and Fault Isolation section. 5.

PS-835 Storage NOTE:

A.

Service Letter SL-64 contains additional information on Lead Acid Battery outgassing and Service Letter SL-80 contains additional information for Float Charging Emergency Power Supplies during storage.

If a ready condition is required of a power supply being stored, recharge batteries every 4 months for 1 hour at 28 to 30Vdc input. Do not store where temperature may exceed 85 F (29 C). See Figure 5 for storage lengths of non-ready conditions. °

°


24-30-02 Checks - Page 502 August 29, 2007


Repair 1.

General Repair of the PS-835 Emergency Power Supply should be accomplished by a qualified technician at an authorized service center. Figure 601 provides a list of consumable materials.

2.

Battery Cell and Pack Replacement NOTE:

Refer to SL-84( ) for instructions concerning the replacement of nickel cadmium

(NiCad) battery cells and packs; and lead-acid cells. When replacing cells within a pack the cells must be the same part number and vendor as the cells being replaced. Avionics Systems recommends that when any pack has more than 4 defective cells, all 12 cells should be replaced. 3.

Circuit Card Assembly (CCA) Repair Avionics Systems exercises stringent circuit board manufacturing processes and soldering requirements. To provide for best circuit board repair results, match these requirements in the CCA repair process. Avionics Systems uses industry standards IPC-A-610B and ANSI/J-STD-001 (for class 2 applications) for soldering practices and workmanship standards.

4.

Consumable Materials This table lists the tools, fixtures, and consumable materials necessary to correctly assembly the PS835 Emergency Power Supply. Those products listed that are considered chemical hazards are marked with a CH symbol. Material Safety Data Sheets should be on hand to determine the best means to safely handle these products. Part Number

ACETONE CH

Description and Vendor Information

Intended Use

Dow Corning

Pre-solder cleaning

SOLDER WICK, PLATO-WICK or equivalent

De-solder

R or RMA

FLUX CH

Pre-solder preparation

SN63WRMA

SOLDER-025"DIA.

Wire connections and component installations

#340

HEATSINK COMPOUNDCH - Dow Corning

MS3368-3-9C

CELL TIE-DOWN STRAPS

Battery Monitor CCA transistors

Q2 and Q3

Cells secured to Battery CCA (A1)

MS3367-4-9

TIE-DOWN STRAP

Wire Bundles

1425 (clear)

ADHESIVE EPOXY TWO-PART FLEXIBLE CH Devcon

Securing Transistor Q1 to Battery Monitor CCA

732 RTV

ADHESIVE SILICONE RUBBERCH - Stabond Corp

Secure Cells and Insulator Plates

VULCABOND V36

ADHESIVE RUBBER BASECH - Stabond Corp

Secure Insulator Plates

SCOTCHGRIP-847

ADHESIVE RUBBER BASE CH - 3M Co.

Preferred Alternate for Vulcabond V36

F-900 Torque SealGreen

SEALING LOCKING AND RETAINING COMPOUND CH

Secure Adjustable Resistor Screw

1A34 or 1B31

HUMISEAL CH

Sealing CCAs against environmental conditions

Figure 601: Consumable Materials


Repair - Page 601 August 29, 2007


Part Number

50-0210

Description and Vendor Information

Intended Use

SLEEVING 26 AWG NATURAL

Insulation of bare leads and wires

M23053/5-103-0

INSULATION SLEEVING


M23053/5-105-0

INSULATION SLEEVING ELECTRICAL HEAT SHRINK


M16878/4BFB2

WIRE RED 22 AWG W11

Internal and interconnecting wiring

M16878/4BGB3

WIRE ORN 20 AWG W9


M16878/4BGB4

WIRE YEL 20 AWG W1


M16878/4BGB5

WIRE GRN 20 AWG W2


M16878/4BGB6

WIRE BLU 20 AWG W12


M16878/4BGB7

WIRE VIO 20 AWG W3


M16878/4BGB8

WIRE GRAY 20 AWG W13


M16878/4BGB9

WIRE WHT 20 AWG W4


M16878/4BHB1

WIRE BRN 18 AWG W50


M16878/4BHB0

WIRE BLK 18 AWG W17 W21 W19 W23 W24 W25 W28 W29 W33 W34 W38 W39 W44 W48 W49 W5 W7 W15


M16878/4BHB2

WIRE RED 18 AWG W10 W14 W18 W20 W22 W26 W27 W30 W32 W35 W37 W40 W41 W45 W46 W47


QQW343H20S1T

WIRE 20 AWG TIN COAT W43


(see Wiring List Figures 603 and 604)

Figure 601: Consumable Materials (cont.) 5.

Special Tools NOTE:

Equivalent equipment may be used for all listed items.

Item

Description

Characteristic Required

1

DC Power Supply

0-40 Vdc 20amp capacity Hewlett Packard Model 6291*

2


Fluke Model 8050A*

3

Delete

Delete

4

Load Resistor

7Ω ±1% 150 watt or greater * (WireMasters, Inc. 136 Alpha Drive, Franklin, TN 37064. Cage Code: 0FVD7)*

5

Stopwatch

Meyland Corp. Model 202A*

6



7

Adjustable Tension Installation Tool

Thomas & Bretts Co.* Cat. No. WT-199

Figure602: Special Tools and Equipment


Repair - Page 602 March 13, 2009


6.

Moisture and Fungus Proofing WARNING:

A.

COATING MATERIAL FROM HUMISEAL 1A34, AND HUMISEAL 1B31 HAVE BEEN IDENTIFIED AS HAVING A DEGREE OF HAZARD IN HEATH AND FLAMMABILITY. CONSULT THE APPLICABLE MATERIAL SAFETY DATA SHEET PRIOR TO USE OR ASSOCIATION WITH THIS PRODUCT.

Prepare coating HUMISEAL 1A34 or HUMISEAL 1B31 in accordance with manufacturer's instructions on product. Prepare only enough coating to accomplish the task. The srcinal CCAs are coated at the factory with Paraxylene C. This coating may be repaired by applying HUMISEAL 1A34 to the areas of the CCA where repair was accomplished. HUMISEAL 1A34 may be used on all CCAs, but is expressly used for military qualified units. HUMISEAL 1B31 is the preferred alternate coating if 1A34 is unavailable for CCAs not

qualified for military use. It is unnecessary and inadvisable to re-coat the entire CCA. 7.

Performance Test Perform the tests cited in Testing and Fault Isolation section before returning unit into service or storage.

Wire Number

From

To

Wire Number

From

To

W1

A1E1

J1 pin 1

W23

BT12 neg

AF1-2

W2

A1E2

J1 pin 2

W11

CR1 ANODE

A1E12

W3

A1E3

J1 pin 4

W10

CR1 ANODE

J1 pin 10

W4

A1E4

J1 pin 6

W15

E18

J1 pin 11

W5

A1E7

J1 pin 7

W42

E18

A1-22

W43

A1E7

A1E9

W1

J1 pin 1

A1E1

W6

A1E7

XF1-1

W2

J1 pin 2

A1E2

W16

A1E8

A1-24

W12

J1 pin 3

A1E14

W43

A1E9

A1E7

W3

J1 pin 4

A1E3

W7

A1E9

J1 pin 12

W13

J1 pin 5

A1E15

W44

A1E9

A1E19

W4

J1 pin 6

A1E4

W8

A1E10

J1 pin 9

W5

J1 pin 7

A1E7

W9

A1E11

J1 pin 13

W8

J1 pin 9

A1E10

W11

A1E12

CR1 ANODE

W10

J1 pin 10

CR1 ANODE

A12

A1E14

J1 pin 3

W15

J1 pin 11

E18

W13

A1E15

J1 pin 5

W7

J1 pin 12

A1E9

W44

A1E19

A1E9

W9

J1 pin 13

A1E11

W42

A1-22

E18

W6

XF1-1

A1E7

W16

A1-24

A1E8

W23

XF1-2

B12 neg

W14

BT1 pos

A1-22

Figure 603: Wire List for PS-835 A, B, C, and D


Repair - Page 603 February 3, 2006


Wire Number

From

To

Wire Number

From

To

W1

A1E1

J1 pin 1

W11

CR1 ANODE

A1E12

W2

A1E2

J1 pin 2

W10

CR1 ANODE

J1 pin 10

W3

A1E3

J1 pin 4

W15

E18

J1 pin 11

W4

A1E4

J1 pin 6

W50

E18

XF1-1

W5

A1E7

J1 pin 7

W1

J1 pin 1

A1E1

W43

A1E7

A1E9

W2

J1 pin 2

A1E2

W49

A1E7

A1 pin 24

W12

J1 pin 3

A1E14

W43

A1E9

A1E7

W3

J1 pin 4

A1E3

W7

A1E9

J1 pin 12

W13

J1 pin 5

A1E15

W44

A1E9

A1E19

W4

J1 pin 6

A1E4

W9

A1E11

J1 pin 13

W5

J1 pin 7

A1E7

W11

A1E12

CR1 ANODE

W46

J1 pin 9

XF1-2

W12

A1E14

J1 pin 3

W10

J1 pin 10

CR1 ANODE

W13

A1E15

J1 pin 5

W15

J1 pin 11

E18

W44

A1E19

A1E9

W7

J1 pin 12

A1E9

W45

A1-22

XF1-1

W9

J1 pin 13

A1E11

W48

A1-24

BT12 neg

W50

XF1-1

E18

W49

A1-24

A1E7

W45

XF1-1

A1-22

W47

BT1 pos

XF1-2

W47

XF1-2

BT1 pos

W48

BT12 neg

A1-24

W46

XF1-2

J1 pin 9

Figure 604: Wire List for PS-835 E and F


Repair - Page 604 February 3, 2006


Assembly 1.

General Assembly procedures are listed in ascension order, starting at the lowest level of assembly. These procedures are intended to cover most aspects of assembly. Soldering of components and wires, and the replacement of items such as switches, fasteners, and other simple operations are not covered explicitly. Technicians working on avionics equipment of this type should have adequate knowledge of avionics shop practices before attempting any repairs. CAUTION:

READ AND UNDERSTAND ASSEMBLY OF THIS UNIT. ALL THE INFORMATION IN THIS SECTION BEFORE ATTEMPTING

NOTE:

Detailed assembly procedures for the Battery Pack(s) are listed in the Repair section. Testing procedures are found in the Testing and Fault Isolation section of this manual.

Disassembly section procedures included encouragement to tag and/or mark wires at disconnection. If no wire marking was performed at disassembly, take time to identify wires and appropriate connection points before starting re-assembly process. See Description and Operation section for Schematic Diagrams.

2.

WARNING:

SEVERE (3RD DEGREE) BURNS AND MELTED METAL PARTS CAN RESULT THROUGH IMPROPER HANDLING OF THELRU AND SUBASSEMBLIES. THE BATTERIES CONTAINED WITHIN THE PS-835 ARE CAPABLE OF PRODUCING AND SUSTAINING LARGE CURRENTS (OVER 50 AMPS) FOR SEVERAL MINUTES. REMOVE ALL JEWELRY WHEN WORKING ON THIS EQUIPMENT.

NOTE:

Place the PS-835 assemblies and components on a stable, flat surface with appropriate lighting. Take special note that storage batteries contained in the PS-835 are charged and capable of inflicting burns and shocks. Do not proceed with assembly without reading this entire section.

Assembly Tools, Fixtures and Consumables This table lists the tools, fixtures, and consumable materials necessary to correctly assembly the PS835 Emergency Power Supply. Those products listed that are considered chemical hazards are marked with a CH symbol. Material Safety Data Sheets should be on hand to determine the best means to safely handle these products. Item #

Tools and Consumable Materials

Part Number

Source

Consumables:

1.

Acetone CH

Allied Fibris & Plst

2.

Solder Wick

PLATO-WICK or equivalent

3.

Flux CH

R or RMA

4.

Solder-025"dia.

SN63WRMA

5.

HEATSINK COMPOUND CH

#340

6.

TIE DOWN STRAP

MS3367-4-9

7.

ADHESIVE EPOXY TWO-PART FLEXIBLE CH

514-1247-01

Dow Corning

Figure 701: Tools and Consumables


Assembly - Page 701 August 29, 2007


Item #

Tools and Consumable Materials

Part Number

Source

8.

CELL TIE DOWN STRAPS

P/N 566-1115-01 MS3368-3-9C

9.

ADHESIVE SILICONE RUBBERCH

732 RTV

Stabond Corp

10.

ADHESIVE RUBBER BASE-CH

VULCABOND V36

Stabond Corp

SCOTCHGRIP-847

ADHESIVE RUBBER BASE Preferred Alternate for CH - 3M Co. Vulcabond V36

11.

SEALING LOCKING AND RETAINING COMPOUND CH

F-900 Torque Seal- Green

Organic Products Co.

12.

INSULATING COMPOUND CH

1A34 or 1B31

HUMISEAL

13.

Miscellaneous Hand/Shop Tools: Screwdrivers (Phillips and Standard), Wire Cutters, Needle Nose Pliers, Applicator Brush, Cotton Swab, Toothpick, Kim wipe, Nut Driver (various sizes), Bench Vise, Solder Iron and associated tools. See Consumable Materials (Figure 601) and Wiring Lists (Figures 603 and 604) for wire information.

Figure 701: Tools and Consumables (Cont.) 3.

Assembly Procedures A.

B.

Heater Element (HR1) Assembly WARNING:

ADHESIVE (VULCABOND V-36) HAS BEEN IDENTIFIED AS HAVING A DEGREE OF HAZARD IN HEALTH, FLAMMABILITY, AND REACTIVITY. CONSULT THE APPLICABLE MATERIAL SAFETY DATA SHEET PRIOR TO USE OR ASSOCIATION WITH THIS PRODUCT.

WARNING:

ADHESIVE (SCOTCHGRIP-847) HAS BEEN IDENTIFIED AS HAVING A DEGREE OF HAZARD IN HEALTH, AND FLAMMABILITY. CONSULT THE APPLICABLE MSDS PRIOR TO USE OR ASSOCIATION WITH THIS PRODUCT.

1)

Apply Vulcabond (Scotchgrip 847) adhesive (Figure 701 Item 10) uniformly to Battery CCA Chassis.

2)

Place Heater Element (HR1) (2-45) onto Battery CCA Chassis.

3)

Solder Heater Element (HR1) wires onto Battery CCA solder pads #18 and #19 (see Figure 702).

Cell Installation (All cells replaced assumed) NOTE:

Refer to SL-84( ) for instructions concerning the replacement of nickel cadmium (NiCad) battery cells and packs; and lead-acid cells.

CAUTION:

WHEN REPLACING CELLS WITHIN A PACK THE CELLS MUST BE THE SAME PART NUMBER AND VENDOR AS THE CELLS BEING REPLACED. AVIONICS SYSTEMS RECOMMENDS THAT WHEN ANY PACK HAS MORE THAN 4 DEFECTIVE CELLS, ALL 12 CELLS SHOULD BE REPLACED.

1)

Prepare cells by: a.

For models C and D, de-solder and remove the pre-installed black (negative) wire from one of the cells. This cell now becomes BT12. See IPL Figure 1 Note A for cell BT12 location.

b.

For models E and F, de-solder and remove the pre-installed red (positive) wire from one of the cells. This cell now becomes BT1. See IPL Figure 1 NoteA for cell BT1.




c.

For models C and D, solder the black (negative) wire that passes through the rear vertical chassis member access hole and is attached to Fuse Holder (XF1) to the negative (-) terminal of cell BT12.

d.

For models E and F, solder the red (positive) wire that passes through the rear vertical chassis member access hole and is attached to the Fuse Holder (XF1) to the positive (+) terminal of cell BT1.

2)

Mount Insulator Plate (2-10) onto the inside surface, notch facing Heater Element, of the Rear Vertical Chassis Member (see IPL Figure 2 Note A) using Vulcabond (Figure 701 Item 10).

3)

Mount the initial cell (BT1 or BT12) into position and secure it to the Battery CCA (A1) with a Tie-Down Strap (2-6).

4)

Solder the black wire of cell BT1 for models C and D, or red wire of cell BT12 for models E and F, onto the appropriate Battery CCA solder pad on reverse side of Battery CCA (A1).

5)

Mount cells (BT2-BT4) (see IPL Figure 1 Note A), aligned with positive (+) terminals down, onto Battery CCA(A1) by securing them with Tie-Down Straps (2-6). Solder the cell wires to the appropriate solder pads on the reverse side of the Battery CCA (A1).

Tie-Down Strap holes are numbered to correspond to cell ref. designator numbers. Example: BT12

Cell solder pads are located adjacent to cell Tie-Down Strap holes. Pad polarity designated on board Example: BT7

Figure 702: Solder Pad Locations

Heater Element (HR1) solder pad location


Assembly - Page 703 February 3/2006


WARNING:

ADHESIVE (VULCABOND V-36) HAS BEEN IDENTIFIED AS HAVING A DEGREE OF HAZARD IN HEALTH, FLAMMABILITY, AND REACTIVITY. CONSULT THE APPLICABLE MATERIAL SAFETY DATA SHEET PRIOR TO USE OR ASSOCIATION WITH THIS PRODUCT.

6)

Mount an Insulator Plate (2-10) onto the bottom surfaces of the just-mounted cells using Vulcabond (Figure 701 Item 10).

7)

Mount the next 4-cell row of cells (see IPL Figure 1 Note A), aligned with positive (+) terminals down, by securing them with Tie-Down Straps (2-6). Solder the cell wires to the appropriate solder pads on the reverse side of the Battery CCA (A1).

8)

Mount an Insulator Plate (2-10) onto the bottom surfaces of the just-mounted cells (see IPL Figure 1 Note A) using Vulcabond (Figure 701 Item 10).

9)

Mount the next 4-cell row of cells (see IPL Figure 1 Note A), aligned with positive (+) terminals down, by securing them with Tie-Down Straps (2-6). Solder the cell wires to the appropriate solder pads on the reverse side of the Battery CCA (A1). WARNING:

SILICONE RUBBER ADHESIVE (DOW 732 RTV) HAS BEEN IDENTIFIED AS HAVING A DEGREE OF HAZARD IN HEALTH AND FLAMMABILITY. CONSULT THE APPLICABLE MATERIAL SAFETY DATA SHEET PRIOR TO USE OR ASSOCIATION WITH THIS PRODUCT.

10) Apply RTV (Figure 701 Item 9) fillets to Cell Insulator Plate locations (see IPL Figure 1 Note A). C.

Battery Monitor CCA (A2) Installation WARNING:

D.

HEAT SINK COMPOND (#340) HAS BEEN IDENTIFIED AS HAVING A DEGREE OF HAZARD IN HEALTH, FLAMMABILITY, AND REACTIVITY. CONSULT THE APPLICABLE MATERIAL SAFETY DATA SHEET PRIOR TO USE OR ASSOCIATION WITH THIS PRODUCT.

1)

Apply Heatsink Compound (Figure 701 Item 5) to Transistors Q2 and Q3.

2)

Align pins of Battery Monitor CCA Connector (P3) to the mounting holes of Battery CCA Connector (J3) (2-230) and insert CCA into the connector.

3)

When replacing LED Diodes (3-195) place 1 or 2, as needed, Insulator Standoff's (3-240) between CCA and LED.

Front Panel Installation 1)

Insert Screws (1-50 and 1-40) into the appropriate mounting holes in the Front Panel (1-30). CAUTION:

2)

USE SPECIAL CARE WHEN PLACING WASHER (1-45) ASSOCIATED WITH FRONT PANEL ASSEMBLY. RE-ASSEMBLY WITHOUT THE WASHER IN PLACEWILL CAUSE SHORTING THAT WILL DESTROY THE UNIT AND INJURE BYSTANDERS.

Align Front Panel Screws to Battery CCA (A1) and Battery Monitor CCA (A2) mounting holes, place Washer (1-45) onto screws while inserting screws into place, and drive screws tight.




E.

4.

Cover Installation 1)

Insert Battery CCA (A1) into the opening of the Cover (1-5).

2)

Place Screws (1-10) and Washers (1-15) through Cover and Battery CCA holes. Mount Washers (1-15 and 1-20) onto Screws and tighten.

Performance Test Perform those procedures listed in the Fault Isolation and Testing section before entering unit back into service.

5.

PS-835 Storage NOTE:

A.

Avionics Services Service Letter SL-64 contains additional information on Lead Acid Battery out-gassing and Service Letter SL-108 contains additional information for Float Charging Emergency Power Supplies during storage.

If a ready condition is required of a power supply being stored, recharge batteries every 4 months for 1 hour at 28 to 30Vdc input. Do not store where temperature may exceed 85 F (29 C). See Figure 5 for storage lengths of non-ready conditions. °

TP-329 Revision B

°

24-30-02 Assembly - Page 705 February 28/2004



TP-329 Revision B

24-30-02 Assembly - Page 706 February 28/2004


Fits and Clearances 1.

General The installation information provided is for “typical” install situations, not including information for specific aircraft. Additional information may be obtained from the srcinal aircraft manufacturer.

2.

Emergency Power Supply Location The following steps provide general requirements for locating the Emergency Power Supply in an aircraft.

3.

4.

A.

The Emergency Power Supply provides limited direct-current power and 115Vac (when in combination with Static Inverter Model SI-100) to the aircraft emergency bus equipment in case of primary power failure. Therefore, the supply should be located in the general area of aircraft AC and DC busses.

B.

Ensure that space requirements for the supply match space available for the installation being considered. 1)

The Emergency Power Supply should be accessible for inspection, maintenance, or removal.

2)

The installation area should be free from excessive vibration and heat.

C.

Consider the relative distance to associated equipment. Keep connecting cables as short as possible.

D.

The cable should not run adjacent to heaters or engine exhausts.

Pre-Installation Inspection And Preparation A.

Check unit for physical damage that may have occurred during shipping and handling.

B.

For new-unit installation, the PS-835 Battery Pack must be charged. See Testing and Fault Isolation section charging procedures.

C.

Units installed after a maintenance action must be tested in accordance with the Performance Test procedures listed inTesting and Fault Isolationsection before installation.

Post Installation Perform either the Preflight or the Periodic Check, see Testing and Fault Isolation section, immediately after installation of the PS-835 Emergency Power Supply.

TP-329 Revision B

24-30-02 Fits and Clearances - Page 801 February 28/2004



TP-329 Revision B



5.

Affiliated Equipment A.

SI-100 Static Inverter The SI-100 Static Inverter provides for alteration of the PS-835 output for use of equipment that requires alternating current (AC). The Model SI-100A Static Inverter (Avionics Systems part number 501-1240-01) has 3Ø, 400Hz, 115Vac, 25VA output capability. The Model SI-100B Static Inverter (Avionics Systems part number 501-1240-02) has 1Ø, 400Hz 115Vac, 75VA output capability, or 1Ø, 400Hz, 5Vac, 5VA output capability.

B.

SC-841 Static Converter The SC-841 Static Converter (Avionics Systems part number 501-1318-01) provides for direct current conversion for 2 to 6.5 Vdc, 25 Watt output capability. See Avionics Systems Installation Instructions TP-351 for additional information.

C.

BC-815 Battery Charger The BC-815 Battery Charger (Avionics Systems part number 501-1321-01) provides the capability to charge the PS-835 Emergency Power Supply when not mounted on aircraft. See Avionics Systems Installation Instructions TP-350 for additional information.

D.

ATR Mounting Rack ATR Mounting Rack (Avionics Systems part number S53001-01) for use with PS-835 in aircraft applications.

E.

Transformer (used with SI-100 Static Inverter) For aircraft applications that require 26Vac output. (Avionics Systems part number 556-200601)

F.

Connector Plug for AC and DC powered Indicators MS3126E10-16S for AC power Indicators, Avionics Systems part number 563-1013-04 for DC powered Indicators.

G.

Mating Connectors Avionics Systems part numbers S24140-02 for PS-835 E and F, S24140-01 for PS-835 A through D. (See Figure 806 and 807)

TP-329 Revision B



Item 1

Item 2

Item 3

Figure 801: Affiliated Equipment

TP-329 Revision B



6.

Installation Kits Kit Part Number 504-1019-01 504-1019-02 504-1019-05 504-1019-06 504-1035-01

7.

PS-835 Including Inverter or Connecting to Indicator units: Model Converter A-D, G SI-100( ) AI-804 or AI-904 AC powered A-D, G SI-100( ) or SC-841 AI-804 or AI-904 DC powered E-F SI-100( ) or SC-841 AI-804 or AI-904 AC powered E-F SI-100( ) or SC-841 AI-804 or AI-904 DC powered A-D, G GH-3000 and GH-3100 ESIS

Interconnect Diagrams A.

Fuse and Circuit Breakers The PS-835 Emergency Power Supply contains internal fuses and circuit breakers to protect the supply against shorting conditions. Additional fuses or breakers may be required to protect aircraft wiring, as determined by the specific loads. The required current-rating of any additional current protection is dependent on the load applied to the units connector J1 Pin 11. All circuits connecting to the output Pin 11 should use current/load appropriate sized wire. Refer to the Typical Installation Interconnect Diagrams (Figures 802 or 803) for additional information. See Specification table, Figure 4 for PS-835 current output information.

B.

Retrofits The older PS-823 Emergency Power Supply can be replaced by the PS-835. The PS-823, when providing 115 Vac output, can be replaced with the PS-835/SI-100 combination to provide 115Vac output, also. In cases where the previous PS-823 provided 26 Vdc output, add the Transformer (Figure 801, Item 2 Avionics Systems part number 556-2006-01) to the PS-835/SI-100 combination. See Figure 801, Item 3 for suggested Transformer location. Tap either phase A or C output leg when using a SI-100A, 3 -phase Static Inverter. Test-switch circuitry of the previous PS-823 setup must be altered as indicated below.

PS-823 (/T) Comparison

PS-835 ()

Test Switch

2

6


EXT 28 Vdc

Test Lamp

Test Switch 28 Vdc

2

6

Test Lamp

24-30-02 Fits and Clearances - Page 805 March 13, 2009


Figure 802: Typical Installation Interconnections for PS-835A through D, and G


24-30-02 Fits and Clearances - Page 806 March 13, 2009


*

(* or Microsemi P/N UES702)

Figure 803: Typical Installation Interconnections for PS-835E and F

TP-329 Revision B



*

*If an existing installation is being converted from a PS-823 to a PS-835 and a Transformer is required, remove wire from power supply mating connector pin 4 and connect to transformer yellow lead.

Figure 804: Interconnections to AC Powered Indicators

Figure 805: Interconnections to DC Powered Indicators

TP-329 Revision B



Connector Keying for PS-835 models E and F See Service Bulleting SB501-1228-10( )

507-1182M

Figure 806: PS-835 Models E and F Installation Drawing TP-329 Revision B

24-30-02 Clearances - Page 801 FitsFits andand Clearances Page 809/810 February 28/2004


Connector Keying for PS-835 models A, B, C, D, and G See Service Bulleting SB501-1228-10( )

507-1182P

Figure 807: PS-835 Models A, B, C, D and G Installation Drawing TP-329 Revision B, Change 5

24-30-02 Clearances - Page 801 FitsFits andand Clearances Page 811/812 March 13, 2009


Special Tools, Fixtures, and Equipment 1.

General This section lists those tools and equipment necessary to successfully repair, calibrate, and install the PS-835 Emergency Power Supplies. In addition, normal avionics shop tools and equipment will be necessary for the repair and service of the unit. NOTE:

Equivalent equipment may be used for all listed items.

Item

Description

Vendor

1

DC Power Supply

Hewlett Packard Model 6291 0-30 Vdc 20amp capacity

2


Fluke Model 8050A

3

Delete

Delete

4

Load Resistor

7Ω ±1% 150 watt or greater * (WireMasters, Inc. 136 Alpha Drive, Franklin, TN 37064. Cage Code: 0FVD7)*

5

Stopwatch

Meyland Corp. Model 202A*

6



7

Mating Connector for PS-835 A to D, &G

P/N: DPXB-13-33S-0001

8

Mating Connector for PS-835 E and F

P/N: DPXB-13-33S-0019

9

BC-815 Battery Charger (used in place of DC power supply)

Avionics Systems Part No. 501-1321-01

10

Connector Alignment Gage**

JF-204A 570-4195-01*

Figure 901: Special Tools and Equipment 2.

Load Resistor The Load Resistor used in both the unit and Battery Monitor CCA Performance Test procedures, see Testing and Fault Isolation section, is necessary to simulate in-flight operation. Any resistance circuit that provides the required 7 ohms resistance and accommodates the power/heat generated from the test will be sufficient for performing the test procedures.


Special Tools Fixtures - Page 901 March 13, 2009


3.

Connector Alignment Gage** The Connector Alignment Gage, listed above, was added as the result of Service Bulletin SB5011228-1A. The service issue concerned the position of J2Connector for correct and successful pin contact to the connector of the Static Inverter SI-100, when used in conjunction with the PS-835 Emergency Power Supply. The J2 Connector, see Figure 801 and 802, position is irrelevant for aircraft applications that do not include the use of the SI-100. Connector position can also be achieved using a ruler with decimal inch graduations.


24-30-02 Special Tools Fixtures - Page 902 August 29, 2007


Illustrated Parts Listing 1.

General The purpose of the Illustrated Parts List is to provide detailed illustrations and parts listings that assist in identification and location of component parts and assemblies for the PS-835 (Part Numbers 501-1228-01 through -06). The illustrations and listing are arranged, also, to assist in the unit's assembly and disassembly. NOTE:

To insure accurate parts reciept, record the information on the Modification Plate, located on the front panel of the PS-835, and be prepared to provide that information when ordering parts.

The Illustrated Parts Listing includes three subsections:   

Numerical Index Part Reference Designator Index Detailed Parts List

The Numerical and Part Reference Designator Index tables are constructed to assist in utilizing the Detailed Part List when component identity is known. 2.

Numerical Index A.

Part Number Column Contains a complete numerical-alpha listing of all part numbers appearing in the Detailed Parts List.

B.

IPL Figure and Item Number Column Lists the Detailed Parts List figure and item number assigned for all parts listed.

C.

Total Required Column Reflects the total quantity for each item number listed.


Illustrated Parts Listing - Page 1001 February 28/2004


Part Number

Fig/ Item

Qty.

1N4751A

3-150

1

1N829A

3-125

1

501-1228

1-1

501-1228-01

1-1

REF

501-1228-02

1-1

REF

501-1228-03

1-1

REF

501-1228-04

1-1

REF

501-1228-05

1-1

REF

501-1228-06

1-1

REF

501-1228-07

1-1

REF

517-1252-01

1-5

1

517-1253-01

2-260

1

518-1371-01

1-30

1

520-1091-02

2-125

1

520-1092-01

2-270

1

520-1121-01

2-15

1

520-1132-01

2-265

1

528-1036-01

3-200

1

535-1257-01

1-80

1

535-1375-01

1-80

1

535-1404-01

1-95

1

535-1818-01

1-95

1

535-1818-03

1-95

1

535-1859-01

1-91

1

535-1873-01

1-96

1

535-1926-01

1-85A

1

535-2198-01

1-90

1

535-2201-01

1-85

1

535-2221-01

1-95

1

535-2222-01

1-95

1

535-2251-01

1-95

1

536-2402-01 536-2594-01

2-145 3-5

1 1

542-1361-01 thru -08

2-1

Part Number

Fig/ Item

Qty.

542-1361-01 thru -8

1-70

542-1361-09

1-70

542-1361-09

2-1

542-1361-10

1-70

542-1361-10

2-1

542-1361-11 542-1361-11

1-70 2-1

1

542-1361-12

1-70

1

542-1361-12

2-1

542-1364-01

1-75

1

542-1495-01

1-75

1

542-1495-02

1-75

1

542-1521-01

1-75

1

542-1521-01

3-1

542-2625-01

1-75

542-2625-01

3-1

542-2635-01

1-75

542-2635-01

3-1

549-1011-06

1-55

1

549-1121-01

2-110

1

549-1159-01

2-215

1

549-1170-01

2-5

12

549-1170-05

2-5

12

549-1170-06

2-5

12

551-1022-11

3-160

1

551-1022-13

3-165

1

551-1022-13

3-165

1

551-1211-04

3-105

1

551-1211-04

3-105

1

551-1211-06

3-25

1

551-1217-14

3-75

1

551-1217-34

3-65

1

551-1300-05

3-10

12

551-1301-01

2-45

1

1

1

1

1

Part Number

Fig/ Item

Qty.

553-1047-01

3-60

1

553-1047-01

3-60

1

553-1060-01

3-135

1

553-1069-01

3-45

1

554-1108-02

3-35

1

554-1108-02

3-35

1

554-1108-02

3-35

1

554-1108-03

3-30

1

554-1108-03

3-30

1

554-1119-01

2-95

1

554-1171-01

3-195

1

554-1171-01

3-195

1

554-1171-01

3-195

1

554-1171-01

3-195

1

554-1171-01

3-195

1

554-1171-01

3-195

1

554-1171-01

3-195

1

554-1171-01

3-195

1

554-1171-01

3-195

1

554-1171-01

3-195

1

554-1171-01

3-195

1

554-1171-01

3-195

1

554-1171-01

3-195

1

560-1303-02

2-60

1

561-1018-01

3-15

1

563-1033-02

2-230

1

563-1033-03

3-20

1

563-1039-02

2-235

1

563-1725-01

1-100

1

568-1566-06

3-205

2

568-1578-04

2-170

568-1578-05 568-1578-06

2-175 2-180

568-1578-07

2-185

568-1578-09

2-170

1


Illustrated Parts Listing - Page 1002 March 13, 2009


Part Number

Fig/ Item

Qty.

Part Number

Fig/ Item

Qty.

Part Number

Fig/ Item

Qty.

568-1578-10

2-175

1

MS24693C3

2-20

2

RN55C1001F

3-115

1

568-1578-11

2-180

1

MS24693C3

2-275

6

RN55C1001F

3-185

1

568-1578-12

2-185

1

MS24693C4

2-85

1

RN55C1002F

3-170

1

569-1137-07

3-210

2

MS24693C5

3-225

2

RN55C1002F

3-170

1

569-1149-20

2-10

4

MS353338-135

2-135

2

RN55C1004F

3-95

1

569-1149-26

2-10

4

MS35338-135

1-20

2

RN55C1050F

3-140

1

569-1152-01

2-105

1

MS35338-135

2-250

2

RN55C1822F

3-145

1

569-1157-01

2-225

46

MS35338-135

2-35

1

RN55C2001F

3-180

569-1901-01

1-35

1

MS35338-135

2-70

4

RN55C3162F

3-155

1

577-1019-01

3-100

1

MS35338-139

2-115

1

RN55C4122F

3-85

1

577-1019-01

3-100

1

MS35649-244

1-25

2

RN55C4532F

3-175

1

577-1048-01

2-210

1

MS35649-244

2-140

2

RN55C4990F

3-190

1

580-1513-02

3-215

2

MS35649-244

2-40

1

RN55C5623F

3-120

1

580-1513-09

3-220

1

MS35649-244

2-75

2

RN55C8250F

3-130

1

JAN1N5618

3-55

1

MS35650-304

1-65

2

RN55C9092F

3-50

1

JANTX1N4148-1

3-40

1

MS35650-3255

2-120

1

S21001-33

2-90

1

JANTX1N4148-1

3-40

1

MS51957-14

1-50

4

S21029-06

2-220

1

JANTX1N4148-1

3-40

1

MS51957-14

2-160

1

S22033-04

2-205

1

JANTX1N4148-1

3-40

1

MS51957-14

2-240

2

S23044-13

3-230

24

JANTX1N4148-1 JANTX1N4148-1

3-40 3-40

1 1

MS51957-14 MS51957-15

2-55 1-10

3 2

S23044-24 S24134-01

3-240 2-50

18 1

JANTX1N4148-1

3-40

1

MS51957-15

2-150

2

S24134-02

2-50

1

JANTX1N4148-1

3-40

1

MS51957-16

2-25

1

S26100-04

2-190

1

JANTX1N4148-1

3-40

1

MS51957-19

1-40

1

S32063-06

2-200

M39003/01-2362

3-110

1

NAS671C4

2-255

1

S32068-01

2-80

1

MS15795-803

2-165

3

NAS671C4

2-65

1

S36002-005

1-45

1

MS15795-803

2-30

1

RLR05C2700GS

3-80

1

S36002-007

2-155

2

MS15795-804

1-15

4

RLR07C2001GS

3-90

1

S43003-07

3-235

2

MS15795-804

2-245

2

RLR07C5601GS

3-70

1

S43003-20

2-100

1

MS24693C271

1-60

2

RN55C1001F

3-115

1

SE12XC07S

2-195

3

MS24693C3

2-130

2

RN55C1001F

3-115

1

SE16XC01S

2-200

14




3.

Part Reference Designator Index A.

Part Reference Designator This column lists all components by their equipment designator in alphanumeric sequence.

B.

IPL Figure Column This column lists Detailed Parts List IPL Figure number.

C.

Item Number This column lists the Detailed Parts List Item Number where all items having equipment designators can be found. Ref. Designator

Fig/ Item

Ref. Designator

Fig/ Item

Ref. Designator

Fig/ Item

A1

1-70

A1J2

2-235

A2CR8

3-40

A1

1-70

A1J3

2-230

A2CR9

3-40

A1

1-70

A1RT1

2-215

A2D18

3-195

A1

2-1

A1S1

2-205

A2DS1

3-195

A1

2-1

A1U1

2-210

A2DS10

3-195

A1

2-1

A1XF1

2-60

A2DS11

3-195

A1

2-1

A2

1-75

A2DS12

3-195

A1

2-1

A2

1-75

A2DS13

3-30

A2

1-75

A2DS14

3-35

A2

1-75

A2DS15

3-35

A2

1-75

A2DS16

3-35

A2

1-75

A2DS17

3-30

A2

3-1

A2DS2

3-195

A1BT1 thru A1BT12

2-5

A1BT1 thru A1BT12

2-5

A1BT1 thru A1BT12

2-5

A1CR1

2-95

A2

3-1

A2DS3

3-195

A1E1

2-200

A2

3-1

A2DS4

3-195

A1E1

2-200

A2C1

3-110

A2DS5

3-195

A1E18

2-110

A2CR1

3-40

A2DS6

3-195

A1E19

2-80

A2CR10

3-40

A2DS7

3-195

A1E7

2-195

A2CR2

3-40

A2DS8

3-195

A1F1

2-90

A2CR3

3-40

A2DS9

3-195

A1F2

2-220

A2CR4

3-40

A2P3

3-20

A1HR1

2-45

A2CR5

3-40

A2Q1

3-135

A1J1

2-50

A2CR6

3-55

A2Q2

3-60

A1J1

2-50

A2CR7

3-40

A2Q3

3-60




Ref. Designator

4.

Fig/ Item

Ref. Designator

Fig/ Item

Ref. Designator

Fig/ Item

A2Q4

3-45

A2R2

3-130

A2RT1

3-10

A2R1

3-115

A2R20

3-80

A2S1

3-15

A2R10

3-120

A2R21

3-170

A2U1

3-100

A2R11

3-85

A2R22

3-180

A2U2

3-100

A2R12

3-115

A2R23

3-170

A2U3

3-105

A2R12

3-185

A2R24

3-115

A2U4

3-105

A2R13

3-165

A2R3

3-70

A2U5

3-25

A2R14

3-145

A2R4

3-50

A2VR1

3-125

A2R15

3-95

A2R5

3-165

A2VR2

3-150

A2R16

3-90

A2R6

3-175

A2R17

3-190

A2R7

3-65

A2R18

3-140

A2R8

3-160

A2R19

3-75

A2R9

3-155

Detailed Parts List The Detailed Parts List consists of illustrations and columnar parts listing of component parts for this equipment. All assemblies, subassemblies, and parts that can be disassembled, repaired or replaced, and reassembled are included. The Detailed Parts List only lists and illustrates those parts attached by means other than welding or riveting, or other generally accepted means of permanent attachment. Each illustration is assigned a figure number commencing with IPL Figure 1 and progressing sequentially from there. Alpha variants A thru Z will be assigned to figure numbers when necessary to add additional figures to show modification or configuration changes, or differences between units. A.

Figure Number Column This column reflects the assigned Figure number of an illustration.

B.

Item Number Column This column reflects the assigned Item number of an illustration. Items listed but not shown on the illustration are identified with a dash (-) to the left of the item number. Alpha variants A thru Z are assigned to existing item numbers when necessary to add items, to show configuration changes, or multiple sources for component parts.

C.

Part Number Column Part numbers listed are MIL Standard or Goodrich Avionics Systems, Inc. part numbers Goodrich Avionics Systems part numbers consist of a three digit family group, four digit family number, and a two digit variant number.




D.

Nomenclature Column This column contains key and modifying words depicted within Goodrich Avionics Systems, Inc. drawing title description blocks, modification numbers and service bulletin references, part reference designators “if any”, military standards, plus pertinent information relative to that part such as “Matched Parts” or Next Higher Assembly (NHA). Electrostatic discharge sensitive components are identified with bold letters (ESDS).

E.

Units Per Assembly Column Quantities specified in this column are per item number. The letters AR appearing in this column denote selection of parts on an As Required basis. Letters REF refer to an assembly completely assembled on a previous illustration.

F.

Effectivity Code Column This column is used to establish parts compatibility with units or subassemblies that are essentially the same as far as color, marking methods, etc. When no code is listed, parts are usable on all applicable models or assemblies. At the end of each Figure Listing is a Effectivity Code to Part Number cross reference table to assist in unit identification.

G.

How To Use The Detailed Parts List For the following examples, refer to the appropriate lists and indexes within this manual. 1)

2)

3)

Finding the Part Number when only the physical location of the part is known: a.

Use the List of Illustrations to locate assembly page number in which the part is used.

b.

Find the illustration and locate the part on the next higher assembly (e.g., if a part is located on a PC board, the PC board is the next higher assembly). Note the part number.

c.

Refer to the Detailed Parts List for the illustration figure number.

d.

Locate the part item number and the part number in the Part Number column.

Finding the Part Number when only the Part Reference Designator is known: a.

Find the Part Reference designation number in the Part Reference Designator Index.

b.

Refer to the figure and item number column in the Detailed Parts List for part number.

Finding an Illustration for a known Part Number: a.

Locate the known part number in the Numerical Index. Note the figure and item

b.

number. Turn to the Detailed Parts List and locate the figure and index number for a description of the part.

c.

Turn to the illustration and locate the physical position of that part on the assembly.



L-3 Avionics Systems Component Maintenance Manual Model PS-835( ) // 501-1228-( ) 15 4 ea

96 95

85

20 2 ea

25

2 ea

75 (A2)

45

CAUTION! See Assembly section

30 5

35

A Note: Replace Cells in the order for which they are numbered. Arrange Cells to align terminals vertically with positive (+) terminal on bottom. Invert the position of the Tie-Down Straps for the top row of Cells. Apply RTV into the shaded areas. Note location of cellsBT1 and BT12 Disassembly and Assembly wiring instructions.

50 3 ea

BT10

BT11

BT12

BT9

BT8

BT4

BT5

BT6

BT3

BT2

BT1

70 (A1)

BT7

40

60 2 ea 91

65 2 ea

90

IPL Figure 1: PS-835 Emergency Power Supply


Illustrated Illustrated Parts Parts Listing Listing - Page- 1007/1008 Page 1001 February 28/2004


FigItem 1-1

Nomenclature 123456

Part Number

Units/ Assy

Eff. Code

501-1228

Emergency Power Supply

501-1228-07

Model PS-835G (5 Ah Cell units) (Model G is similar to model D, except where indicated)

REF

501-1228-06

Model PS-835F (5 Ah Cell units)

REF

F

501-1228-05

Model PS-835E (2.5 Ah Cell units)

REF

E

501-1228-04

Model PS-835D (5 Ah Cell units)

REF

D

501-1228-03

Model PS-835C (2.5 Ah Cell units)

REF

C

501-1228-02

Model PS-835B (5 Ah Cell units) Obsolete

REF

B

REF

A

501-1228-01

Model PS-835A (2.5 Ah Cell units) Obsolete

5

517-1252-01

•

10

MS51957-15

•

SCREW, MACHINE PAN HEAD

2

15

MS15795-804

•

WASHER, FLAT-METAL ROUND #4

4

20

MS35338-135

•

WASHER, LOCK SPRING

2

25

MS35649-244

•

PLAIN-HEX NUT

2

G

1

COVER ASSEMBLY

ATTACHING PARTS

***

30

518-1371-01

•

FRONT PLATE

1

35

569-1901-01

•

PLATE, OVERLAY

1

ATTACHING PARTS

40

MS51957-19

•


1

45

S36002-005

•

WASHER, FLAT NON-METALLIC

1

50

MS51957-14

•


4

HANDLE

1

***

55

549-1011-06

•

ATTACHING PARTS

60

MS24693C271

•

SCREW, MACHINE FLAT CSK HEAD

2

65

MS35650-304

•

NUT

2

1

F

1

E

***

70

542-1361-12

•

542-1361-11

•

542-1361-10

•

542-1361-09

•

BATTERY CCA (A1) (5 Ah Cell units) See IPL Figure 2 BATTERY CCA (A1) (2.5 Ah Cell units) See IPL Figure 2 BATTERY CCA (A1) (5.0 Ah cells) See IPL Figure 2 BATTERY CCA (A1) (2.5 Ah cells)

542-1361-01 thru -8

•

See IPL Figure 2 BATTERY CCA (A1) *Obsolete

B, D, G A, C A, B

*See Service Bulletins and Modifications table Figure 1.




FigItem 1-75

Nomenclature 123456

Part Number

Units/ Assy

Eff. Code

542-2635-01

•

BATTERY MONITOR CCA(A2) See IPL Figure 3

1

A, B, C, D, E, F, G

542-2625-01

•

BATTERY MONITOR CCA(A2) *Obsolete

1

E,F

542-1521-01

•


1

A, B, C, D

542-1495-01

•


1

C, D

542-1495-02

•


1

C, D

542-1364-01

•


1

A, B


80

535-1375-01

•

PLATE CAUTION

1

E, F, G

535-1257-01

•

PLATE CAUTION Obsolete

1

A, B, C, D

85

535-2201-01

•

85A

535-1926-01

•

90

535-2198-01

•

PLATE, IDENTIFICATION (Mark with unit model, 1 part, and serial numbers. Also, unit weight and appropriate MOD level) PLATE, IDENTIFICATION (Marked with unit model, 1 part no., input power, RCI P/N and appropriate MOD level. Also mark the serial no.) PLATE, IDENTIFICATION SECONDARY (Mark 1 with unit part number and serial number) Mount label on Front Plate just below Handle.

91

535-1859-01

•

PLATE, DESIGNATION

1

95

535-1818-01

•

FAA-PMA ID PLATE

1

535-1818-02

•

FAA-PMA ID PLATE

1

535-1818-03

•

FAA-PMA ID PLATE

1

G

535-2222-01

•

FAA-PMA ID PLATE

1

F

535-1404-01

•

FAA-PMA ID PLATE Obsolete

535-2251-01

•

FAA-PMA ID PLATE, Obsolete

1

B, C

535-2221-01

•

FAA-PMA ID PLATE, Obsolete

1

D

96

535-1873-01

•

WARNING LABEL See Service Bulletin SB501-1228-15

1

100

563-1725-01

•

DUST CAP, ELECTRICAL CONNECTOR

1

G

D

D




FigItem 2-1

Nomenclature 123456

Part Number

Units/ Assy

Eff. Code

542-1361-12

BATTERY CCA (A1) (5.0 Ah cells) See IPL Figure 1 for next higher assembly.

F

542-1361-11

BATTERY CCA (A1) (2.5 Ah cells) See IPL Figure 1 for next higher assembly.

E

542-1361-10

BATTERY CCA (5.0 (A1)Ah cells) *

B, D,

542-1361-09

BATTERY CCA (2.5 (A1)Ah cells) *

A, C

542-1361-01 thru -08

BATTERY CCA (A1) *Obsolete

G

*See Service Bulletins and Modifications table Figure 1. 5

549-1170-05

549-1170-06

•

•

•

549-1170-01

A, C, E

CELL, STORAGE LEAD-ACID 2.0V 2.5 Ah (BT1 thru BT12) [See Repair section for replacement instructions]

12

CELL, STORAGE LEAD ACID 2.0V 2.5 Ah (BT1 thru BT12) (alternate for 549-1170-05) [See Repair section for replacement instructions]

12

CELL, STORAGE, LEAD ACID 5.0 Ah (BT1 thru BT12) [See Repair section for replacement instructions]

12

A, C, E

B, D, F, G

ATTACHING PARTS

6

•

TIE-DOWN STRAP (See Tools and Consumables Table Figure 701, Item 8)

12

***

10

15

569-1149-26 569-1149-20

• •

INSULATOR PLATE INSULATOR PLATE

4 4

520-1121-01

•

SUPPORT, INVERTER ASSEMBLY

1

A, C, E B, D, F, G

ATTACHING PARTS

20

MS24693C3

•


2

25

MS51957-16

•

SCREW

1

30

MS15795-803

•

WASHER, FLAT #4

1

35

MS35338-135

•

WASHER, LOCK SPRING

1

40

MS35649-244

•

NUT, PLAIN-HEX

1

***

45

551-1301-01

•

HEATING ELEMENT (HR1)

1

50

S24134-02

•

CONNECTOR (J1)

1

S24134-01

•

CONNECTOR (J1)

1

E, F A, B, C, D, G

ATTACHING PARTS

55

MS51957-14

•


3

***




FigItem 2-60

Nomenclature 123456

Part Number 560-1303-02

•

Units/ Assy

Eff. Code

1

FUSE BLOCK (XF1)

ATTACHING PARTS

65

NAS671C4

•

NUT, PLAIN HEXAGON

1

70

MS35338-135

•

WASHER, LOCK SPRING

4

75

MS35649-244

•

NUT PLAIN-HEX

2

80

S32068-01

•

TERMINAL LUG (E19)

1

85

MS24693C4

•


1

***

90

S21001-33

•

FUSE, SIZE 3 SLOW (F1)

1

95

554-1119-01

•

DIODE, 100V 90A STUD (CR1)

1

ATTACHING PARTS

100

S43003-20

•

INSULATOR, SEMICONDUCTOR MOUNTING

1

105

569-1152-01

•

WASHER, SHOULDERED NON-METALLIC

1

110

549-1121-01

•

TERMINAL LUG (E18)

1

115

MS35338-139

•

WASHER, LOCK SPRING

1

120

MS356503255

•

NUT, HEX

1

125

520-1091-02

•

ANGLE ASSEMBLY

1

130

MS24693C3

•


2

135

MS353338135

•

WASHER, LOCK SPRING

2

140

MS35649-244

•

NUT

2

PRINTED WIRING BOARD

1

***

145

536-2402-01

•

ATTACHING PARTS

150

MS51957-15

•


2

155

S36002-007

•

WASHER, FLAT NON-METALLIC

2

160

MS51957-14

•


1

165

MS15795-803

•

WASHER, FLAT #4

3

***




FigItem 2-170

175

180

Units/ Assy

568-1578-09

•

SPACER, GAP (self stick version)

568-1578-04

•

SPACER, GAP (replace with 568-1578-09 when necessary)

568-1578-10

•


568-1578-05

•


568-1578-11

•


•


568-1578-12

•


568-1578-07

•


568-1578-06 185

Nomenclature 123456

Part Number

Eff. Code

1

1

*

1

1

*Part of MOD Kit 504-1839-01 Per Service Bulletin SB501-1228-12( )

190

S26100-04

•

PLATE, MODIFICATION

1

•

TERMINAL, TURRET UN-INSULATED (E7, E8, and E9)

3

195

SE12XC07S

200

SE16XC01S

•

TERMINAL, STUD (E1 thru E6 and E10 thru E17)

14

S32063-06

•

TERMINAL, STUD (Obsolete use SE16XC01S)

N/A

205

S22033-04

•

SWITCH, TOGGLE MINIATURE(S1)

1

210

577-1048-01

•

LINEAR TRANSDUCER (U1)

1

•

RESISTOR, THERMAL (RT1) FUSE (F2) (See Service Bulletin SB501-1228-13)

1 1

•

215 220

549-1159-01 S21029-06

225

569-1157-01

•

INSULATOR WASHER SHOULDERED

46

230

563-1033-02

•

CONNECTOR, ELECTRICAL(J3)

1

235

563-1039-02

•

CONNECTOR, ELECTRICAL RIGHT-ANGLE(J2)

1

240

MS51957-14

•

SCREW

2

245

MS15795-804

•

WASHER, FLAT-METAL ROUND #4

2

250

MS35338-135

•

WASHER, LOCK

2

255

NAS671C4

•

NUT, PLAIN HEXAGON

1

FRAME, Base Assembly

1

ATTACHING PARTS

*** 260

517-1253-01

•

ATTACHING PARTS 265

520-1132-01

•

SUPPORT, Plate

1

270

520-1092-01

•

SUPPORT, Angle

1

275

MS24693C3

•


6

***




This page intentionally left blank.




FigItem 3-1

Nomenclature 123456

Part Number

Units/ Assy

Eff. Code

542-2635-01

BATTERY MONITOR CCA(A2) (See IPL Figure 1 for next higher assembly.)

542-2625-01

BATTERY MONITOR CCA (A2) *Obsolete

E, F


A, B, C, E, F

542-1521-01 542-1495-01

BATTERY MONITOR CCA (A2) *Obsolete

1

C, D

542-1495-02 542-1364-01

BATTERY MONITOR CCA (A2) *Obsolete BATTERY MONITOR CCA (A2) *Obsolete

1 1

C, D A, B


5

536-2594-01

•

10

551-1300-05

THERMAL RESISTOR (RT1)

1

15

561-1018-01

•

SWITCH, ROCKER DIP (S1)

1

20

563-1033-03

•

CONNECTOR, ELECTRICAL(P3)

1

25

551-1211-06

•

RESISTOR NETWORK 42.2K 1W 2% SIP8(U5)

1

30

554-1108-03

•

2

35

554-1108-02

•

40

JANTX1N4148-1

•

DIODE, LED GREEN 90MA T1-3/4(DS13 and DS17) DIODE, LED YELLOW 60MA T1-3/4(DS14 ,DS15, DS16) DIODE, FAST 75V 150MA DO-35 (CR1-CR5, CR7CR10)

45

553-1069-01

•

TRANSISTOR (Q4)

1

50

RN55C9092F

•

RESISTOR, 90.9K .1W 1%(R4)

1

55

JAN1N5618

•

DIODE, FAST 600V 1A DO-204AP (CR6)

1

60

553-1047-01

•

TRANSISTOR (Q2,Q3)

2

65

551-1217-34

•

RESISTOR, WIRE WOUND 50Ω 2.2W 1% (R7)

1

70

RLR07C5601GS

•


1

75

551-1217-14

•

RESISTOR, WIRE WOUND 2.00K 2.2W 1%(R19)

1

80

RLR05C2700GS

•

RESISTOR, 270 OHM .125W 2%(R20)

1

85

RN55C4122F

•


1

90

RLR07C2001GS

•


1

95

RN55C1004F

•

RESISTOR, 1 MEG .1W 1%(R15)

1

100

577-1019-01

•

QUAD OP AMP (U1,U2)

2

105

551-1211-04

•

RESISTOR, NETWORK (U3,U4)

2

110

M39003/01-2362

•

CAPACITOR (C1)

1

115

RN55C1001F

•

RESISTOR, 1.00K .1W 1%(R1,R12,R24)

3

120

RN55C5623F

•

RESISTOR, 562K .1W 1%(R10)

1

PRINTED WIRING BOARD

12

3 9




FigItem

Nomenclature 123456

Part Number

Units/ Assy

3-125

1N829A

•

DIODE, 6.2V 250MW 5% DO-34 (VR1)

1

130

RN55C8250F

•


1

135

553-1060-01

•

TRANSISTOR, N-CHANNEL FET(Q1)

1

140

RN55C1050F

•


1

145

RN55C1822F

•


1

150

1N4751A

•

DIODE, 30V 1W 5% DO-204 (VR2)

1

155

RN55C3162F

•


1

160

551-1022-11

•

RESISTOR, VARIABLE(R8)

1

165

551-1022-13

•

RESISTOR, VARIABLE(R13,R5)

2

170

RN55C1002F

•

RESISTOR, 10.0K .1W 1%(R21,R23)

2

175

RN55C4532F

•


1

180

RN55C2001F

•


185

RN55C1001F

•


1

190

RN55C4990F

•


1

195

554-1171-01

•

DIODE, LED RED 5V 7MA T1-3/4(DS1-D12,D18)

13

200

528-1036-01

•

HEATSINK AND NUT ASSY

1

Eff. Code

ATTACHING PARTS

205

568-1566-06

•

SPACER

2

210 215

569-1137-07 580-1513-02

• •

WASHER SHOULDERED NON-METALLIC STANDOFF P.C. BD.

2 2

220

580-1513-09

•

STANDOFF P.C. BD.

1

225

MS24693C5

•

SCREW MACHINE FLAT COUNTERSUNK HEAD

2

***

230

S23044-13

•

INSULATOR STANDOFF

24

235

S43003-07

•

INSULATOR SEMICONDUCTOR MOUNTING

2

240

S23044-24

•

INSULATOR STANDOFF

18







24-30-02_PS-835_RevB-5

Recommend Documents