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RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER RPS1-B
TRANSMITTAL LETTER TO:
HOLDERS OF COMPONENT MAINTENANCE MANUAL 25-60-03, REVISION 15
REVISION NO. 16, DATED AUGUST 2009 HIGHLIGHTS The pages that have been added or revised are outlined below together with the highlights of the revision. CHAPTER/SECTION AND PAGE NO. Page T-1 Page RR-1 Page LEP-1
Page Intro-1 Entire Document
WAS 6416 Parkland Dr. Suite B T-1 Jul 2007 RR-1 Jul 2007 LEP-1 Jul 2007 Intro-1 Jul 2006 6416 Parkland Dr. Suite B Old Logo
Copyright 2004 by: Radiant Power Corp., a HEICO Company
IS NOW 7135 16th Street, Suite 101 Added: 16 Aug 2009 T-1 Aug 2009 RR-1 Aug 2009 LEP-1 Aug 2009 Intro-1 Aug 2009 7135 16th Street, Suite 101 New Logo
25-60-03
Highlights-1 Aug 2009
RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER RPS1-B
THIS PAGE INTENTIONALLY LEFT BLANK
Copyright 2004 by: Radiant Power Corp., a HEICO Company
25-60-03
Highlights-2 Aug 2009
RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER RPS1-B
RADIANT POWER CORP. 7135 16th STREET. SUITE 101 SARASOTA, FL
34243
(FORMERLY DERLAN INC.)
Component Maintenance Manual With Illustrated Parts List
Battery Power Supply Part Number: RPS1-B
THIS MANUAL CONTAINS PROPRIETARY INFORMATION OF RADIANT POWER CORP., AND IS TENDERED SUBJECT TO THE CONDITION THAT NO COPY OR OTHER REPRODUTION BE MADE IN WHOLE OR IN PART, AND THAT NO OTHER USE BE MADE OF SUCH INFORMATION WITHOUT EXPRESS WRITTEN PERMISSION OF RADIANT POWER CORP.
Copyright 2004 by: Radiant Power Corp., a HEICO Company
REVISION 16
25-60-03
T-1 Aug 2009
RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER RPS1-B
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Copyright 2004 by: Radiant Power Corp., a HEICO Company
25-60-03
T-2 Aug 2009
RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER RPS1-B
RECORD OF REVISIONS REVISION NUMBER 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
REVISION DATE Mar 1/87 Feb 12/88 Jan 2/90 Feb 1/94 Feb 1/97 Oct 15/97 Feb 1/00 Dec 18/00 Sep 26/02 Jan 2003 Jan 2004 Mar 2006 Jun 2006 Jul 2006 Jul 2007 Aug 2009
DATE FILED
BY
Copyright 2004 by: Radiant Power Corp., a HEICO Company
REVISION NUMBER
REVISION DATE
DATE FILED
25-60-03
BY
Page RR-1 Aug 2009
RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER RPS1-B
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Copyright 2004 by: Radiant Power Corp., a HEICO Company
25-60-03
Page RR-2 Aug 2009
RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER RPS1-B
RECORD OF TEMPORARY REVISIONS REVISION NUMBER
REVISION DATE
DATE FILED
BY
Copyright 2004 by: Radiant Power Corp., a HEICO Company
REVISION NUMBER
REVISION DATE
DATE FILED
25-60-03
BY
Page TR-1 Aug 2009
RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER RPS1-B
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Copyright 2004 by: Radiant Power Corp., a HEICO Company
25-60-03
Page TR-2 Aug 2009
RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER RPS1-B
SERVICE BULLETIN LIST SERVICE BULLETIN SB-004 RPS1-B-33
ISSUE DATE OCT 24/86 NOV 24/86
DATE FILED JAN 20/87 JAN 20/87
BY
SERVICE BULLETIN
ISSUE DATE
DATE FILED
BY
DERLAN DERLAN
Copyright 2004 by: Radiant Power Corp., a HEICO Company
25-60-03
Page SB-1 Aug 2009
RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER RPS1-B
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Copyright 2004 by: Radiant Power Corp., a HEICO Company
25-60-03
Page SB-2 Aug 2009
RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER RPS1-B
LIST OF EFFECTIVE PAGES Subject
Page
Date
Subject
Page
Date
Title Page
T-1 T-2
Aug 2009 Aug 2009
Testing and Fault Isolation
Record of Revisions
RR-1 RR-2
Aug 2009 Aug 2009
Record of Temporary Revisions
TR-1 TR-2
Aug 2009 Aug 2009
Service Bulletin List
SB-1 SB-2
Aug 2009 Aug 2009
List of Effective Pages
LEP-1 LEP-2
Aug 2009 Aug 2009
Table of Contents
TC-1 TC-2
Aug 2009 Aug 2009
Introduction
Intro-1 Intro-2 Intro-3 Intro-4
Aug 2009 Aug 2009 Aug 2009 Aug 2009
101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119 120 121 122 123 124
Aug 2009 Aug 2009 Aug 2009 Aug 2009 Aug 2009 Aug 2009 Aug 2009 Aug 2009 Aug 2009 Aug 2009 Aug 2009 Aug 2009 Aug 2009 Aug 2009 Aug 2009 Aug 2009 Aug 2009 Aug 2009 Aug 2009 Aug 2009 Aug 2009 Aug 2009 Aug 2009 Aug 2009
Description and Operation
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24
Aug 2009 Aug 2009 Aug 2009 Aug 2009 Aug 2009 Aug 2009 Aug 2009 Aug 2009 Aug 2009 Aug 2009 Aug 2009 Aug 2009 Aug 2009 Aug 2009 Aug 2009 Aug 2009 Aug 2009 Aug 2009 Aug 2009 Aug 2009 Aug 2009 Aug 2009 Aug 2009 Aug 2009
Disassembly
301 302 303 304 305 306 307 308
Aug 2009 Aug 2009 Aug 2009 Aug 2009 Aug 2009 Aug 2009 Aug 2009 Aug 2009
Cleaning
401 402
Aug 2009 Aug 2009
Check
501 502 503 504
Aug 2009 Aug 2009 Aug 2009 Aug 2009
Repair
601 602 603 604 605 606 607 608
Aug 2009 Aug 2009 Aug 2009 Aug 2009 Aug 2009 Aug 2009 Aug 2009 Aug 2009
Copyright 2004 by: Radiant Power Corp., a HEICO Company
25-60-03
Page LEP-1 Aug 2009
RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER RPS1-B Subject
Page
Date
Assembly (including Storage)
701 702 703 704 705 706 707 708 709 710 711 712 713 714
Aug 2009 Aug 2009 Aug 2009 Aug 2009 Aug 2009 Aug 2009 Aug 2009 Aug 2009 Aug 2009 Aug 2009 Aug 2009 Aug 2009 Aug 2009 Aug 2009
Special Tools, Fixtures, and Equipment
901 902
Aug 2009 Aug 2009
Illustrated Parts List
1001 1002 1003 1004 1005 1006 1007 1008 1009 1010 1011 1012 1013 1014 1015 1016 1017 1018 1019 1020
Aug 2009 Aug 2009 Aug 2009 Aug 2009 Aug 2009 Aug 2009 Aug 2009 Aug 2009 Aug 2009 Aug 2009 Aug 2009 Aug 2009 Aug 2009 Aug 2009 Aug 2009 Aug 2009 Aug 2009 Aug 2009 Aug 2009 Aug 2009
Copyright 2004 by: Radiant Power Corp., a HEICO Company
Subject
Page
25-60-03
Date
Page LEP-2 Aug 2009
RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER RPS1-B
TABLE OF CONTENTS Subject
Page
Description and Operation Testing and Fault Isolation Automatic Test Requirements Disassembly Cleaning Check Repair Assembly (Including Storage) Fits and Clearances Special Tools, Fixtures, and Equipment Illustrated Parts List
1 101 Not Applicable 301 401 501 601 701 Not Applicable 901 1001
LIST OF FIGURES Figure 1 2 3 4 101 102 103 104 105 106 601 701 702 IPL 1 IPL 2 IPL 3
Page Battery Power Supply General Aircraft Interface Diagram Circuit Schematic Aircraft-Specific Jumper and Operation Truth Table Bench Test Setup Fuse Location Fuse Bending Battery Discharge Battery Charge Battery Housing Analyzer Clinch Nut Installation Resistor R1/R2 Wiring Diagram Battery Connection Diagram Battery Power Supply Electronics Assembly Regulator PCB Assembly A2
3 5 6 10 108 109 110 119 120 121 606 704 708 1008 1014 1018
LIST OF TABLES Table 1 101 102 103 301 401 501 601 602
Page Technical Properties Test Equipment and Materials Control Logic Test Requirements Fault Isolation Procedures Disassembly Materials Cleaning Materials Check Procedures Repair Tools and Materials Connect J1 Wire List
Copyright 2004 by: Radiant Power Corp., a HEICO Company
9 101 107 111 303 401 501 603 606
25-60-03
Page TC-1 Aug 2009
RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER RPS1-B
LIST OF TABLES Figure 701 702 703 901 1001
Page Assembly Tools and Materials Storage Materials Assembly Wire List Special Tools, Fixtures, and Equipment Manufacturer Names and Addresses EQUIPMENT DESIGNATOR INDEX NUMERICAL INDEX PARTS LIST PARTS LIST PARTS LIST
Copyright 2004 by: Radiant Power Corp., a HEICO Company
713 713 714 901 1002 1005 1006 1011 1015 1019
25-60-03
Page TC-2 Aug 2009
RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER RPS1-B
INTRODUCTION 1.
Scope This Component Maintenance Manual (CMM) contains maintenance instructions and lists replacement parts to assist qualified repair personnel in off-aircraft maintenance of Battery Power Supply, (BPS) part number RPS1-B. The BPS is made by Radiant Power Corp. of Sarasota, Florida. NOTE: This CMM covers maintenance of the RPS1-B configuration only. Contact Radiant Power Corp. for maintenance of the earlier configurations given below: Part Number RPS1 RPS1-A
Serial Numbers 0001 through 0016 0017 through 0052
Two electrically identical but physically different logic PCB assemblies are used in the RPS1-B configuration depending on the serial number. Both variations are covered in this CMM.
2.
Part Number
Serial Numbers
11-0041-1 11-0041-2
0626 and subsequent 0053 through 0625
IPL Figure-item Number 2-15 2-15A
Product Support Services Repair and overhaul services, replacement parts, technical documentation, and other product support services are available from Radiant Power Corp. Please contact our Sales Department at: Radiant Power Corp. 7135 16th Street. Suite 101 Sarasota, FL. 34243 USA
3.
Telephone: FAX:
(941) 739-3200 (941) 739-3201
Usage Guide A.
Refer to the Table of Contents to find the necessary maintenance procedures or other data. This CMM is written to ATA 100, Revision 30 and AECMA Simplified English. (1) Description and Operation describes the purpose, primary components, and technical properties of the BPS battery pack. (2) Testing and Fault Isolation contains bench test and fault isolation procedures. (3) Disassembly contains procedures to disassemble the BPS battery pack for repair or part replacement. (4) Cleaning contains procedures to clean the BPS battery pack.
Copyright 2004 by: Radiant Power Corp., a HEICO Company
25-60-03
Page Intro-1 Aug 2009
RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER RPS1-B (5) Check contains procedures to check parts for damage. (6) Repair contains procedures to refinish and rework parts to serviceable condition. (7) Assembly contains procedures to reassemble and store the BPS battery pack. (8) Illustrated Parts List contains the information necessary to order replacement parts. An equipment designator index, a numerical index, and exploded-view drawings are provided to help find and identify the parts. The introduction to the IPL gives more data. B.
The recommended tools and materials are given in each section. Equivalent items can be used.
C.
WARNINGS, CAUTIONS and NOTES (1) WARNINGS are provided before potentially dangerous procedures, materials, methods, and processes which must be followed precisely to avoid injury. (2) CAUTIONS are provided before procedures, materials, methods, and processes which must be followed precisely to avoid equipment damage. (3) NOTES are provided after applicable procedure steps when necessary to highlight or clarify information.
4.
General Safety Precautions The following general safety precautions must be observed during all phases of operation, service, and repair of the battery/pack. ELECTROSTATIC DISCHARGE
All Integrated Circuits (ICs), surface mounted devices, and many semiconductors are susceptible to Electrostatic Discharge (ESD). Careless handling during repair can drastically decrease the component life. Follow the PCB handling procedures given in REPAIR to avoid ESD damage.
GROUNDING
Connect equipment and personnel to electrical ground to minimize shock hazards. When handling PCB assemblies, place them on a grounded workbench.
EXPLOSIVE ENVIRONMENT
Do not operate the battery/ pack in the presence of flammable gas or fumes.
LIVE CIRCUITS
The battery/ pack contains high voltage electrical circuits. Do not service the unit with the power on. To avoid injury, always disconnect power and discharge the circuits before maintenance.
Copyright 2004 by: Radiant Power Corp., a HEICO Company
25-60-03
Page Intro-2 Aug 2009
RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER RPS1-B DO NOT SERVICE OR ADJUST ALONE
Only qualified maintenance personnel are authorized to replace or adjust internal components of the battery/ pack. Maintenance personnel must be familiar with high voltage equipment safety guidelines. Another person capable of providing first aid and resuscitation must be present.
DO NOT SUBSTITUTE PARTS OR MODIFY EQUIPMENT
Do not alter or add to the mechanical or electrical design of the battery/ pack. Design changes and additions can alter safety characteristics and create a hazard. Any design alterations or additions will void the warranty. Do not install substitute parts or do any unauthorized modifications to the equipment.
SHOCK
To prevent electrical discharge, do not expose the equipment to rain or high humidity. Visually check for pinched, out of place, or frayed wiring during maintenance. Components and/or wiring that appear to have overheated or are otherwise damaged should be replaced with components that meet the original specifications. Do a safety check of the entire unit before returning the equipment for operation.
5.
Verification Dates Procedure
6.
Date
Testing/Fault Isolation
Jan 15/87
Disassembly
Jan 15/87
Assembly
Jan 15/87
Revision Service Revised pages will be issued when necessary to correct errors or to add new configurations. The revised part of the page will be identified by a change bar or capital R in the left margin.
Copyright 2004 by: Radiant Power Corp., a HEICO Company
25-60-03
Page Intro-3 Aug 2009
RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER RPS1-B
7.
Abbreviations and Unit Symbols Abbreviations and unit symbols used in this manual are defined below. All weights and measurements are given first in English standard units followed by the metric equivalent in parentheses. Assy ATA AWG BPS C C CAGE cm CMM D DC EFF ESD F F F GND Fig. Hz IC IPL J K kg
Assembly Air Transport Association American Wire Gage Battery Power Supply degree Celsius Capacitor Commercial And Government Entity centimeter Component Maintenance Manual Diode Direct Current Effectivity Electrostatic Discharge Farad Fuse degree Fahrenheit Ground Figure Hertz Integrated Circuit Illustrated Parts List Jack Kilo kilogram (1 kg = 2.205 lb.)
Copyright 2004 by: Radiant Power Corp., a HEICO Company
kPag kiloPascal - gage (1 kPag 0. 145 psig) lb. pound LRU Line Replaceable Unit M Mega MEK Methyl-Ethyl-Ketone mm Millimeter N-m Newton-meter (torque) NHA Next Higher Assembly NIST National Institute of Standards and Technology No. Number PCB Printed Circuit Board P/N Part Number psig pounds per square inch - gage Q Transistor R Resistor RF Reference SB Service Bulletin SCD Source Control Drawing SIT Select In Test SPST Single Pole, Single Throw SW Switch UUT Unit Under Test V Vendor VDC Voltage, Direct Current W Watt
25-60-03
Page Intro-4 Aug 2009
RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER RPS1-B
DESCRIPTION AND OPERATION 1.
Purpose The Battery Power Supply (BPS) provides direct current (DC) power to operate the escape track lights.
2.
Primary Components A.
The primary components of the BPS are shown in Figure 1.
B.
The BPS consists of a battery holder assembly and an electronics assembly mounted on an aluminum chassis. The battery holder assembly and the electronics assembly are separate, fully contained modules that can be independently removed for repair or replacement.
C.
The battery holder assembly consists of six nickel-cadmium batteries mounted in a lightweight, durable plastic case. The batteries are wired in series and connected to red and black pin sockets J2-1 and J2-2. The pin sockets connect directly to pin contacts J3-1 and J3-2 on regulator PCB assembly A2 when the battery holder assembly is installed in the chassis against the electronics assembly. The battery holder assembly can easily be removed by disengaging two 1/4-turn fasteners and sliding the assembly out of the chassis away from the electronics assembly.
D.
The electronics assembly is made up of logic PCB assembly A1, regulator PCB assembly A2, connector J1, resistors R1 and R2, TEST switch SW1, and transistors Q1 and Q2. A cover assembly provides protection from moisture and handling damage. All electronic components including the solder connections are conformal coated. The cover can easily be removed for maintenance access. The electronics assembly can also be removed from the chassis by removing the mounting screws and sliding the assembly out of the chassis away from the battery holder assembly.
E.
All components except the battery holder assembly are secured by standard attaching hardware. All wire connections are soldered or crimp. The chassis cover assembly and other exposed aluminum components have a chemical film finish for protection from corrosion.
F.
A single 24-pin BACC45FN16-24P or 48-10-R16-24P (Amphenol) electrical connector provides the electrical interface with the aircraft. The connector mates to a BACC45FN16-24S receptacle. The interface circuits are described in Figures 2 through 4 and Table 2.
G.
The BPS is a Line Replaceable Unit (LRU). It mounts against a flat surface with fasteners through the four 0.192/0.203 inch (4.88/5.16 mm) diameter mounting holes in the chassis. It can be removed and replaced on the aircraft in less than 1 minute without the use of special tools.
Copyright 2004 by: Radiant Power Corp., a HEICO Company
25-60-03
Page 1 Aug 2009
RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER RPS1-B 3.
Differences Between Configurations This CMM covers maintenance of the RPS1-B configuration only. Contact Radiant Power Corp. for maintenance of the earlier configurations given below: Part Number RPS1 RPS1-A
Serial Numbers 0001 through 0016 0017 through 0052
Two electrically identical but physically different logic PCB assemblies are used in the RPS1 –B configuration depending on the serial number. Logic variations are covered in this CMM. Part Number 11-0041-1 11-0041-2
4.
Serial Numbers 0626 and subsequent 0053 through 0625
IPL Figure-item Number 2-15 2-15A
Functional Description (Figures 2 and 3) A.
The BPS provides DC power to operate the escape track lights. It charges and maintains the battery holder assembly and outputs 5.7 to 6.7 VDC at connector J1, pins 9, 10 and 11, depending on the presence or absence of 28 VDC at connector J1, pin 2, the jumper configuration of the mating connector, and the status of pins 3, 4, 8, 12, 17, 18 and 24 (open, ground, or +28 VDC).
B.
When 22 to 32 VDC from the aircraft electrical system is present at connector J1, pin 2, transistor Q1 and charging circuits on regulator PCB assembly A2 provide 300 to 375 milliamperes constant charging current to the six-cell battery pack.
C.
Pushing TEST switch SW1 mounted on the BPS will turn on the escape track lights. The test switch is provided to confirm circuit continuity, the condition of the escape track lights, and function of the BPS. It does not assure adequate battery capacity in an emergency.
D.
The logic circuits on logic PCB assembly A1 include a low battery cutoff circuit and a slow turn-on feature. The low battery cutoff circuit senses battery voltage and automatically turns the BPS off when the voltage drops to 4.8 VDC minimum (5.4 VDC nominal). This avoids deep discharging of the batteries, a condition that can result in cell reversal and permanent battery damage.
E.
The slow turn-on circuit made up of resistor/capacitor combinations at the input of comparator U1 ramp-up the turn-on signal from the logic circuits to the regulator circuits. This limits the lamp inrush current to prolong the life of the escape track lights.
F.
The regulator circuits on regulator PCB assembly A2 maintain the output voltage across the escape track lights to between 5.7 and 6.7 VDC at a load of 7.0 Amperes. This is accomplished by comparing the output voltage sensed at the collector of transistor Q2 to the 2.5 VDC turn-on signal from the logic circuits. The resultant error signal is then amplified and used to drive regulator output transistor Q3. Excessive current through drive transistor Q3 will cause transistor Q6 to conduct, decreasing the reference voltage and the excessive current.
Copyright 2004 by: Radiant Power Corp., a HEICO Company
25-60-03
Page 2 Aug 2009
RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER RPS1-B
5.
G.
The batteries are high temperature, matched D-size nickel-cadmium cells with higher voltage electrolyte and lower internal resistance than normally available. Each cell is rated 1.25 VDC at 149°F (65°C) and 4 ampere-hours (minimum) when discharged at the one hour or C rate. The cells are connected in series by solder tabs, forming a 7.5 VDC (nominal) battery. The battery pack provides sufficient power to sustain, through the control circuits, a 7 Ampere lamp load at 5.7 to 6.7 VDC for a minimum of 10 minutes. Under worst case conditions, the BPS has enough battery capacity to meet the requirements of FAR 25.812 .Paragraph (i) [emergency illuminate system].
H.
Fuses F1 through F3 limit the output voltage at pins 9 through 11 of connector J1 to 5 Amperes.
Operation A.
To charge the BPS, continuously apply 22 to 32 VDC (28 VDC nominal) voltage across pins 2(+) and 1(-) and jumper pin 5 to pin 6 of connector J1. A fully discharged battery pack will charge from 0% of full capacity to 100% in less than 16 hours at 77°F (25°C).
NOTE: Figure 2 gives a general aircraft interface diagram for the BPS. Refer to Figure 4 for aircraft-specific jumper configuration data and operation truth tables.
Battery Power Supply Figure 1
Copyright 2004 by: Radiant Power Corp., a HEICO Company
25-60-03
Page 3 Aug 2009
RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER RPS1-B
6.
B.
Set the pilot/attendant aircraft switches to the proper positions for the aircraft type to discharge the BPS. The BPS will output 5.7 to 6.7 VDC at connector J1, pins 9, 10 and 11, depending on the presence or absence of 28 VDC at connector J1, pin 2, the jumper configuration of the mating connector, and the status of pins 3, 4, 8, 12, 17, 18 and 24 (open, ground, or +28 VDC). Refer to Figure 4.
C.
Push TEST switch SW1 on the BPS to turn on the escape track lights. A successful test will indicate that the BPS is functioning properly and is connected correctly in the circuit, and the escape track lights are functioning properly. The test will also show that the BPS is charged sufficiently to turn on the lights, but it will not show adequate battery capacity for the 10 minutes duration requirements of FAR 25.812.
Technical Properties Technical properties of the BPS are given in Table 1.
7.
Truth Tables and Jumper Connections Refer to Figure 4 for aircraft-specific jumper configuration data and operation truth tables. Figure 2 gives a general aircraft interface diagram.
Copyright 2004 by: Radiant Power Corp., a HEICO Company
25-60-03
Page 4 Aug 2009
RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER RPS1-B
General Aircraft Interface Diagram Figure 2
Copyright 2004 by: Radiant Power Corp., a HEICO Company
25-60-03
Page 5 Aug 2009
RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER RPS1-B
Circuit Schematic Figure 3 (Sheet 1 of 3)
Copyright 2004 by: Radiant Power Corp., a HEICO Company
25-60-03
Page 6 Aug 2009
RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER RPS1-B
Circuit Schematic Figure 3 (Sheet 2 of 3)
Copyright 2004 by: Radiant Power Corp., a HEICO Company
25-60-03
Page 7 Aug 2009
RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER RPS1-B
Circuit Schematic Figure 3 (Sheet 3 of 3)
Copyright 2004 by: Radiant Power Corp., a HEICO Company
25-60-03
Page 8 Aug 2009
RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER RPS1-B Technical Properties Table 1 Property Description Manufacturer Nomenclature Part Number Radiant Power Corp. Functional Properties Input Power Output Power Voltage Escape Track Lights Full Charge Battery Voltage Low Battery Cutoff Voltage Current Output Charging Charging Time Battery Pack Data Number of Batteries Battery Type Rating Fully-Charged Voltage Insulation Resistance Removal and Replacement Time Electrical Connector Mating Connector Dimensions and Weight Overall Dimensions Height Width Overall Between Mounting Hole Centerlines Length Overall Between Mounting Hole Centerlines Diameter of Mounting Holes (4 Places) Weight Battery Holder Assembly Battery Charger Assembly
Copyright 2004 by: Radiant Power Corp., a HEICO Company
Specification Radiant Power Corp. Battery Power Supply (BPS) RPS1-B 22.0 to 29.5 VDC (28 VDC nominal)
5.7 to 6.7 VDC for 15 minutes 7.5 VDC nominal 4.8 VDC minimum (5.4 VDC nominal) Limited to 5 Amperes by Fuses F1, F2 and F3(40 or 40A) 300 to 375 milliamperes at 22 to 32 VDC input voltage Charge from 0% of full capacity to 100% in less than 16 hours at 77°F (25°C) 6 connected in series Nickel-Cadmium 4 ampere-hours 1.25 VDC at 149°F (65°C) 100 megohms minimum at 500 VDC 1 minutes maximum with no special tools BACC45FT16-24P or 48-10-R16-24P (Amphenol) BACC45FT16-24S
2.0 inches (5.1 cm) maximum 3.5 inches (8.9 cm) maximum 2.700 ±0.010 inches (6.858 ±0.025 cm) 2.600 ±0.010 inches (6.604 ±0.025 cm) 11.0 inches (27.9 cm) maximum 10.100 ±0.010 inches (25.654 ±0.025 cm) 10.020 ±0.010 inches (25.451 ±0.025 cm) 0. 1975 ±0.0055 inch (5.0165 ±0.1397mm) 2.3 lbs (1.0 kg) maximum 1.0 lbs (0.5 kg) maximum 3.3 lbs (1.5 kg) maximum
25-60-03
Page 9 Aug 2009
RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER RPS1-B BOEING 727/737 AIRCRAFT INTERCONNECT CHART BPS Connector Pin (J1-)
Aircraft Connector Pin for Emergency Packs
Jumper Wires
1
Pin 1 (28 VDC Return)
Pin 1 to Pins 12,17 and 18
2
Pin 2 (+28 VDC Essential Buss)
Pin 5 to Pin 6
3
Pin 3
Pin 13 to Pin 21
4
Pin 4
Pin 14 to Pin 20
7
Aircraft Ground
Pin 15 to Pin 16
9
Output (Load)
Pin 19 to Pin 23
10
Output (Load)
11
Output (Load)
OPERATION TRUTH TABLE Pin J1-2 Voltage (Input Power)
Pin J1-3 Status
Pin J1-4 Status
Lights Status
Pilot Switch Position
Attendant Switch Position
+28 VDC
OPEN
+28 VDC
OFF
OFF
NORMAL
0 VDC
OPEN
+28 VDC
OFF
OFF
NORMAL
+28 VDC
+28 VDC
OPEN
OFF
ARMED
NORMAL
0 VDC
+28 VDC
OPEN
ON
ARMED
NORMAL
0 VDC
+28 VDC
OPEN
ON
ON
NORMAL
0 VDC
+28 VDC
+28 VDC
ON
OFF
ON
Aircraft-Specific Jumper and Operation Truth Table Figure 4 (Sheet 1 of 15)
Copyright 2004 by: Radiant Power Corp., a HEICO Company
25-60-03
Page 10 Aug 2009
RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER RPS1-B INTERCONNECT CHART BPS Connector Pin (J1-)
Aircraft Connector Pin for Emergency Packs
Jumper Wires
1
Pin 5 (28 VDC Return)
Pin 1 to Pins 18
2
Pin 2 (+28 VDC Essential Buss)
Pin 5 to Pin 6
3
Pin 3
Pin 13 to Pin 15
4
Pin 4
Pin 16 to Pin 22
7
Aircraft Ground
Pin 19 to Pin 21
9
Output (Load)
Pin 20 to Pin 23
10
Output (Load)
11
Output (Load)
OPERATION TRUTH TABLE Pin J1-2 Voltage (Input Power)
Pin J1-3 Status
Pin J1-4 Status
Lights Status
0 VDC
GROUND
GROUND
OFF
+28 VDC
GROUND
GROUND
OFF
0 VDC
OPEN
GROUND
ON
+28 VDC
OPEN
GROUND
ON
0 VDC
GROUND
OPEN
ON
+28 VDC
GROUND
OPEN
OFF
0 VDC
OPEN
OPEN
ON
+28 VDC
OPEN
OPEN
OFF
Aircraft-Specific Jumper and Operation Truth Table Figure 4 (Sheet 2 of 15)
Copyright 2004 by: Radiant Power Corp., a HEICO Company
25-60-03
Page 11 Aug 2009
RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER RPS1-B BAC 111 AIRCRAFT INTERCONNECT CHART BPS Connector Pin (J1-)
Aircraft Connector Pin for Emergency Packs
Jumper Wires
1
Pin 5 (28 VDC Return)
Pin 1 to Pins 12, 17 and 18
2
Pin 2 (+28 VDC Essential Buss)
Pin 5 to Pin 6
3
Pin 3
Pin 13 to Pin 21
4
Pin 4
Pin 16 to Pin 22
7
Aircraft Ground
Pin 19 to Pin 23
9
Output (Load)
10
Output (Load)
11
Output (Load)
OPERATION TRUTH TABLE Pin J1-2 Voltage (Input Power)
Pin J1-3 Status
Pin J1-4 Status
Lights Status
Pilot Switch Position
Attendant Switch Position
OPEN OPEN OPEN OPEN +28 VDC OPEN OPEN OPEN OPEN OPEN +28 VDC* OPEN
OPEN +28 VDC +28 VDC +28 VDC +28 VDC 0 VDC +28 VDC +28 VDC +28 VDC +28 VDC OPEN +28 VDC
+28 VDC OPEN OPEN OPEN OPEN OPEN OPEN OPEN OPEN OPEN +28 VDC OPEN
OFF ON ON ON OFF ON ON ON ON ON OFF ON
OFF OFF ARMED ARMED ARMED ARMED ON ON ON ON OFF OFF
NORMAL ON NORMAL ON NORMAL ON NORMAL ON NORMAL ON NORMAL ON
* IN THIS CONDITION, REMOVE VOLTAGE FROM PIN 2 THEN PIN 4. THE LIGHTS SHOULD REMAIN EXTINGUISHED (PARKED AIRCRAFT). Aircraft-Specific Jumper and Operation Truth Table Figure 4 (Sheet 3 of 15)
Copyright 2004 by: Radiant Power Corp., a HEICO Company
25-60-03
Page 12 Aug 2009
RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER RPS1-B YS-11A AIRCRAFT INTERCONNECT CHART BPS Connector Pin (J1-)
Aircraft Connector Pin for Emergency Packs
Jumper Wires
1
Pin 5 (28 VDC Return)
Pin 1 to Pins 17 and 18
4
Pin 4
Pin 5 to Pin 6
7
Aircraft Ground
Pin 19 to Pin 23
9
Output (Load)
10
Output (Load)
11
Output (Load)
24
Pins 2 and 3
OPERATION TRUTH TABLE Pin J1-4 Status
Pin J1-24 Status
Lights Status
Pilot Switch Position
Attendant Switch Position
+28 VDC
0 VDC
OFF
OFF
OFF
0 VDC
+28 VDC
OFF
ARMED
ON
0 VDC
0 VDC
ON
ARMED
ON
0 VDC
0 VDC
OFF
OFF
OFF
Aircraft-Specific Jumper and Operation Truth Table Figure 4 (Sheet 4 of 15)
Copyright 2004 by: Radiant Power Corp., a HEICO Company
25-60-03
Page 13 Aug 2009
RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER RPS1-B DC-8 AIRCRAFT INTERCONNECT CHART BPS Connector Pin (J1-)
Aircraft Connector Pin for Emergency Packs
Jumper Wires
1
Pin 9 (28 VDC Return)
Pin 1 to Pins 12, 17 and 18
2
Pin 8 (+28 VDC Essential Buss)
Pin 2 to Pin 4
3
Pin 6
Pin 5 to Pin 6
7
Aircraft Ground
Pin 13 to Pin 15
9
Output (Load)
Pin 19 to Pin 21
10
Output (Load)
Pin 22 to Pin 23
11
Output (Load)
24
Pins 10
OPERATION TRUTH TABLE Pin J1-2 Voltage (Input Power)
Pin J1-3 Status
Pin J1-24 Status
Lights Status
Aircraft Switch Position
+28 VDC
0 VDC
0 VDC
OFF
OFF
0 VDC
+28 VDC
+28 VDC
OFF
ARMED
0 VDC
+28 VDC
0 VDC
ON
ON
0 VDC
0 VDC
0 VDC
OFF
OFF (PARKED AIRCRAFT)
Aircraft-Specific Jumper and Operation Truth Table Figure 4 (Sheet 5 of 15)
Copyright 2004 by: Radiant Power Corp., a HEICO Company
25-60-03
Page 14 Aug 2009
RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER RPS1-B DC-9 AIRCRAFT INTERCONNECT CHART BPS Connector Pin (J1-)
Aircraft Connector Pin for Emergency Packs
Jumper Wires
1
Pin 3 (28 VDC Return)
Pin 1 to Pins 17, 18 and 21
2
Pin 4 (+28 VDC Essential Buss)
Pin 5 to Pin 6
4
Pin 2
Pin 13 to Pin 14
7
Aircraft Ground
Pin 19 to Pin 23
9
Output (Load)
10
Output (Load)
11
Output (Load)
24
Pins 7
OPERATION TRUTH TABLE Condition*
Pin J1-2 Voltage (Input Power)
Pin J1-4 Status
Pin J1-24 Status
Lights Status
Aircraft Switch Position
1
+28 VDC
+28 VDC
OPEN
OFF
OFF
2
OPEN
OPEN
+28 VDC
OFF
ARMED
3
OPEN
OPEN
OPEN
ON
ARMED
4
OPEN
OPEN
OPEN
ON
ON
* TO PARK THE AIRCRAFT, GO TO CONDITION 1 AND OPEN VOLTAGE ON PIN 2 BEFORE PIN 4. THE LIGHTS WILL REMAIN OFF. Aircraft-Specific Jumper and Operation Truth Table Figure 4 (Sheet 6 of 15)
Copyright 2004 by: Radiant Power Corp., a HEICO Company
25-60-03
Page 15 Aug 2009
RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER RPS1-B DC-10 AIRCRAFT INTERCONNECT CHART BPS Connector Pin (J1-)
Aircraft Connector Pin for Emergency Packs
Jumper Wires
1
Pin T (28 VDC Return)
Pin 1 to Pins 12 and 17
2
Pin K (+28 VDC Essential Buss)
Pin 3 to Pin 16
3
Pin U
Pin 5 to Pin 6
4
Pin V
Pin 19 to Pin 21
7
Pin G (Aircraft Ground)
Pin 22 to Pin 23
9
Output (Load)
10
Output (Load)
11
Output (Load)
18
Pin E
OPERATION TRUTH TABLE Step 1 2* 3 4 5 6 7
Pin J1-2 Voltage
Pin J1-3 Status
Pin J1-4 Status
Pin J1-18 Status
Lights Status
Pilot Switch Position
+28 VDC 0 VDC 0 VDC +28 VDC 0 VDC 0 VDC
OPEN OPEN OPEN +28 VDC +28 VDC OPEN
+28 VDC +28 VDC OPEN OPEN OPEN OPEN
GROUND GROUND GROUND GROUND GROUND GROUND OPEN
OFF OFF OFF OFF ON ON ON
OFF OFF OFF ARMED ARMED ARMED ON
Remarks
Parked Aircraft Power Failure Cabin Switch ON
* TO PARK THE AIRCRAFT, DO STEP 2 THEN STEP 3. Aircraft-Specific Jumper and Operation Truth Table Figure 4 (Sheet 7 of 15)
Copyright 2004 by: Radiant Power Corp., a HEICO Company
25-60-03
Page 16 Aug 2009
RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER RPS1-B A-300 AIRCRAFT INTERCONNECT CHART BPS Connector Pin (J1-)
Aircraft Connector Pin for Emergency Packs
Jumper Wires
1
Pin E (28 VDC Return)
Pin 1 to Pin 18
2
Pin B (+28 VDC Essential Buss)
Pin 5 to Pin 6
4
Pin D
Pin 14 to Pins 20 and 23
7
Aircraft Ground
Pin 15 to Pin 16
9
Output (Load)
Pin 19 to Pin 21
10
Output (Load)
11
Output (Load)
OPERATION TRUTH TABLE Pin J1-2 Voltage (Input Power)
Pin J1-4 Status
Lights Status
Aircraft Switch Position
0 VDC
GROUND
OFF
OFF
+28 VDC
GROUND
OFF
OFF
+28 VDC
OPEN
OFF
ARMED
0 VDC
OPEN
ON
ARMED
0 VDC
OPEN
ON
ON
Aircraft-Specific Jumper and Operation Truth Table Figure 4 (Sheet 8 of 15)
Copyright 2004 by: Radiant Power Corp., a HEICO Company
25-60-03
Page 17 Aug 2009
RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER RPS1-B A-310 AIRCRAFT INTERCONNECT CHART BPS Connector Pin (J1-)
Aircraft Connector Pin for Emergency Packs
Jumper Wires
1
Ground (DC Return)
Pin 5 to Pin 6
2
Pin V
Pin 13 to Pins 14 and 23
3
Pin B
Pin 15 to Pin 16
4
Pin A
Pin 18 to Pin 20
7
Aircraft Ground
Pin 19 to Pin 21
9
Output (Load)
10
Output (Load)
11
Output (Load)
-(N/C)
Pin D
OPERATION TRUTH TABLE Pin J1-2 Voltage (Input Power)
Pin J1-3 Status
Pin J1-4 Status
Lights Status
Pilot Switch Position
Attendant Switch Position
+28 VDC
OPEN
OPEN
OFF
OFF
OFF
+28 VDC
OPEN
GROUND
ON
OFF
ON
+28 VDC
GROUND GROUND GROUND
OPEN
OFF
ARMED
OFF
OPEN
ON
ARMED
OFF
GROUND
ON
ON
OFF
0 VDC +28 VDC
Aircraft-Specific Jumper and Operation Truth Table Figure 4 (Sheet 9 of 15)
Copyright 2004 by: Radiant Power Corp., a HEICO Company
25-60-03
Page 18 Aug 2009
RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER RPS1-B BAe-146 AIRCRAFT INTERCONNECT CHART BPS Connector Pin (J1-)
Aircraft Connector Pin for Emergency Packs
Jumper Wires
1
28 VDC Return
Pin 1 to Pins 12 and 17
2
Pin C (+28 VDC Essential Buss)
Pin 2 to Pin 4
3
Pin A
Pin 5 to Pin 6
7
Aircraft Ground
Pin 13 to Pin 21
9
Output (Load)
Pin 18 to Pin 22
10
Output (Load)
Pin 19 to Pin 23
11
Output (Load)
24
Pin B
OPERATION TRUTH TABLE Pin J1-2 Voltage (Input Power)
Pin J1-3 Status
Pin J1-24 Status
Lights Status
Attendant Switch Position
+28 VDC
0 VDC
0 VDC
OFF
OFF
0 VDC
0 VDC
0 VDC
OFF
AIRCRAFT OFF LATCHED
0 VDC
0 VDC
+28 VDC
OFF
ARMED
0 VDC
0 VDC
0 VDC
ON
ARMED
0 VDC
+28 VDC
+28 VDC
ON
ON
Aircraft-Specific Jumper and Operation Truth Table Figure 4 (Sheet 10 of 15)
Copyright 2004 by: Radiant Power Corp., a HEICO Company
25-60-03
Page 19 Aug 2009
RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER RPS1-B F-27J AIRCRAFT INTERCONNECT CHART BPS Connector Pin (J1-)
Aircraft Connector Pin for Emergency Packs
Jumper Wires
1
Pin 5 (28 VDC Return)
Pin 1 to Pins 17 and 18
4
Pin 4
Pin 2 to Pin 4
7
Aircraft Ground
Pin 5 and 6
9
Output (Load)
Pin 12 to Pin 14
10
Output (Load)
Pin 19 to Pin 23
11
Output (Load)
24
Pins 2 and 3
OPERATION TRUTH TABLE Pin J1-4 Status
Pin J1-24 Status
Lights Status
Aircraft Switch Position
+28 VDC
OPEN
OFF
DISARM
OPEN
OPEN
OFF
DISARM (PARKED AIRCRAFT)
OPEN
+28 VDC
OFF
ARMED
OPEN
OPEN
ON
ARMED
OPEN
OPEN
ON
ON
Aircraft-Specific Jumper and Operation Truth Table Figure 4 (Sheet 11 of 15)
Copyright 2004 by: Radiant Power Corp., a HEICO Company
25-60-03
Page 20 Aug 2009
RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER RPS1-B F-28 AIRCRAFT INTERCONNECT CHART BPS Connector Pin (J1-)
Aircraft Connector Pin for Emergency Packs
Jumper Wires
1
Pin B
Pin 1 to Pins 17 and 18
2
Pin J
Pin 5 and 6
4
Pin K
Pin 19 to Pin 23
7
Aircraft Ground
9
Output (Load)
10
Output (Load)
11
Output (Load)
24
Pin A
OPERATION TRUTH TABLE Pin J1-2 Voltage (Input Power)
Pin J1-4 Status
Pin J1-24 Status
Lights Status
Aircraft Switch Position
+28 VDC
+28 VDC
OPEN
OFF
OFF
0 VDC
0 VDC
OPEN
OFF
OFF (PARKED AIRCRAFT)
+28 VDC
OPEN
+28 VDC
OFF
ARMED
0 VDC
OPEN
0 VDC
ON
ARMED
0 VDC
OPEN
0 VDC
ON
ON
Aircraft-Specific Jumper and Operation Truth Table Figure 4 (Sheet 12 of 15)
Copyright 2004 by: Radiant Power Corp., a HEICO Company
25-60-03
Page 21 Aug 2009
RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER RPS1-B FH-227 AIRCRAFT INTERCONNECT CHART BPS Connector Pin (J1-)
Aircraft Connector Pin for Emergency Packs
Jumper Wires
1
Pin 3 (28 VDC Return)
Pin 1 to Pins 17 and 18
4
Pin 2
Pin 2 and 4
7
Aircraft Ground
Pin 5 and 6
9
Output (Load)
Pin 12 to Pin 14
10
Output (Load)
Pin 19 to Pin 23
11
Output (Load)
24
Pin 7
OPERATION TRUTH TABLE Pin J1-4 Voltage (Input Power)
Pin J1-24 Status
Lights Status
Aircraft Switch Position
+28 VDC
OPEN
OFF
OFF
OPEN
OPEN
OFF
OFF (PARKED AIRCRAFT)
OPEN
+28 VDC
OFF
ARMED
OPEN
OPEN
ON
ARMED
OPEN
OPEN
ON
ON
Aircraft-Specific Jumper and Operation Truth Table Figure 4 (Sheet 13 of 15)
Copyright 2004 by: Radiant Power Corp., a HEICO Company
25-60-03
Page 22 Aug 2009
RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER RPS1-B L-1011 AIRCRAFT INTERCONNECT CHART BPS Connector Pin (J1-)
Aircraft Connector Pin for Emergency Packs
Jumper Wires
1
Pin 9 and 11
Pin 1 to Pins 16 and 21
2
+28 VDC
Pin 5 and 6
7
Aircraft Ground
Pin 12 to Pin 14
9
Output (Load)
Pin 17 to Pin 23
10
Output (Load)
11
Output (Load)
18
Pin 7
Aircraft-Specific Jumper and Operation Truth Table Figure 4 (Sheet 14 of 15)
Copyright 2004 by: Radiant Power Corp., a HEICO Company
25-60-03
Page 23 Aug 2009
RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER RPS1-B EMB 135BJ / 145 FAMILY AIRCRAFT INTERCONNECT CHART BPS Connector Pin (J1-)
Aircraft Connector Pin for Emergency Packs
Jumper Wires
1
28 VDC Return
Pin 1 to Pins 12 and 17
2
Pin C (+28 VDC Essential Buss)
Pin 2 to Pin 4
3
Pin A
Pin 5 to Pin 6
7
Aircraft Ground
Pin 13 to Pin 21
9
Output (Load)
Pin 18 to Pin 22
10
Output (Load)
Pin 19 to Pin 23
11
Output (Load)
24
Pin B
OPERATION TRUTH TABLE Pin J1-2 Voltage (Input Power)
Pin J1-3 Status
Pin J1-24 Status
Lights Status
Attendant Switch Position
+28 VDC
0 VDC
0 VDC
OFF
OFF
0 VDC
0 VDC
0 VDC
OFF
AIRCRAFT OFF LATCHED
0 VDC
0 VDC
+28 VDC
OFF
ARMED
0 VDC
0 VDC
0 VDC
ON
ARMED
0 VDC
+28 VDC
+28 VDC
ON
ON
Aircraft-Specific Jumper and Operation Truth Table Figure 4 (Sheet 15 of 15)
Copyright 2004 by: Radiant Power Corp., a HEICO Company
25-60-03
Page 24 Aug 2009
RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER RPS1-B
TESTING AND FAULT ISOLATION 1.
General A.
This section contains bench test and fault isolation procedures (starting this page), recommended battery maintenance procedures (page 114) and optional on-aircraft fault testing (page 121).
B.
Perform the tests in the order given before disassembly to identify damaged parts. Perform the tests after assembly to select the Select In Test (SIT) components and to verify performance.
C.
The recommended test equipment and materials are given in Table 101. NOTE: Equivalent items can be used.
D.
All tests must be performed at standard laboratory conditions, defined as follows: Ambient Temperature: 70o 5o F Relative Humidity: 35% to 65% Atmospheric Pressure: 25 to 32 in Hg
E.
All test equipment must be calibrated to NIST (National Institute of Standards and Technology) standards.
F.
Unless otherwise specified, the primary power applied to the test unit is 28 ±0.5 VDC. Test Equipment and Materials Table 101 Nomenclature
Connector, Electrical Diode, Light Emitting Lamp, Incandescent (7 Required) Megohmmeter, 100 megohms, 500 VDC, ±2% Full Scale Multimeter (Ohmmeter, Ammeter or Voltmeter can be used), 0 to 10 Amps DC (±2% Full Scale), 0 to 100 VDC (3-1/2 digits) 200 to 300 kilohms Power Supply, 0 to 8 VDC (E1) 0 to 32 VDC (E2) Switch, Momentary Contact, SPST (S1) Switch, Toggle SPST (S4 through S7) Switch, Toggle SPST (on, off, on) Switch, Toggle DPDT (S11) RPS1-B Battery Housing Analyzer Kit
Part or Specification Number
Source (CAGE)*
BACC45FN16-24S or 48-16R16-24S Mfg P/N SSILXH9GD-150 No. 82 Model 1644-9701
The Boeing Co. (81205) Amphenol Corp. (77820) Chicago Miniature Lamp Inc. (71744) General Electric Co. (0EE74) Quadtech Inc. (0PK96)
Model 77
Model 6631 E3641A --------550-13057-00
John Fluke Mfg. Co., Inc. (89536)
Agilent (89536)
Commercially Available Commercially Available Commercially Available Commercially Available Radiant Power Corp. (1MXA1)
*Refer to Table 1001 in the IPL for the address.
Copyright 2004 by: Radiant Power Corp., a HEICO Company
25-60-03
Page 101 Aug 2009
RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER RPS1-B 2.
Test Procedures A.
Insulation Resistance Test WARNING: THIS TEST APPLIES HIGH VOLTAGE WHICH CAN CAUSE DEATH OR SEVERE SHOCK. SET POWER SWITCHES TO OFF BEFORE CONNECTING AND DISCONNECTING EQUIPMENT USE CAUTION DURING TEST. CAUTION: THE BATTERY HOLDER ASSEMBLY MUST BE REMOVED FROM THE UUT BEFORE THIS TEST. THIS TEST CAN DAMAGE THE BATTERY CELLS. (1) Remove the battery holder assembly (5, IPL Figure 1), as follows: (a)
Turn the 1/4-turn fastener (25) counterclockwise approximately 90° to the stop. The fasteners should retract from the force of the retraction springs (30).
CAUTION:
(b)
DO NOT LIFT THE BATTERY HOLDER ASSEMBLY BEFORE SLIDING IT AWAY FROM THE ELECTRONICS ASSEMBLY. DOING SO CAN DAMAGE THE PIN CONTACTS ON PCB ASSEMBLY A2.
Carefully slide the battery holder assembly (5) out away from the electronics assembly (120 or 120A) to disconnect pin contacts J3-1 and J3-2 on regulator PCB assembly A2 from pin sockets J2-1 and J2-2 (60 and 65). Remove the battery holder assembly.
(2) Connect a megohmmeter (Table 101) between connector J1, pin 1, and the chassis assembly (130). (3) Apply 500 ±10 VDC. Hold the voltage for 30 seconds or until the resistance reading stabilizes, and measure the insulation resistance. (4) The insulation resistance must be 100 meg-ohms minimum. (5) Repeat the test between all connector J1 pins, except for pin J1-7, and the chassis. (6) Decrease the voltage to zero. B.
Control Logic Test CAUTION: THE BATTERY HOLDER ASSEMBLY MUST BE REMOVED FROM THE UUT BEFORE THIS TEST. THIS TEST CAN DAMAGE THE BATTERY CELLS. (1) Remove the battery holder assembly (5, IPL Figure 1), as follows: (a)
Turn the 1/4-turn fastener (25) counterclockwise approximately 90°0 to the stop. The fasteners should retract from the force of the retraction springs (30).
Copyright 2004 by: Radiant Power Corp., a HEICO Company
25-60-03
Page 102 Aug 2009
RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER RPS1-B CAUTION:
(b)
DO NOT LIFT THE BATTERY HOLDER ASSEMBLY BEFORE SLIDING IT AWAY FROM THE ELECTRONICS ASSEMBLY DOING SO CAN DAMAGE THE PIN CONTACTS ON PCB ASSEMBLY A2.
Carefully slide the battery holder assembly (5) out away from the electronics assembly (120 or 120A) to disconnect pin contacts J3-1 and J3-2 on regulator PCB assembly A2 from pin sockets J2-1 and J2-2 (60 and 65). Remove the battery holder assembly.
(2) Install the Unit Under Test (UUT) in the test setup (Figure 101). Connect power supply E1 to pin sockets J2-1 (+) and J2-2 (-) (60 and 65, IPL Figure 1). All switches must be open. NOTE: Connector J1, Pin 8 is connected through an LED (Table 101) to show the presence of VCC (reference) for all tests. Any time the LED is not energized is a test failure. CAUTION: DO NOT APPLY MORE THAN 12.0 VDC AT PIN SOCKETS J2-1 AND J22. HIGH VOLTAGE CAN DAMAGE THE UUT (3) Turn on power supply E1. Set the voltage to 8.0 VDC. NOTE: A momentary drop in the DC power supply voltage when the lamp load is initially applied can cause the UUT to go into low battery cutoff. Preloading the power supply will prevent the cutoff. The amount of preload will vary depending on the DC power supply used. (4) Close switch S1. (5) Cycle switches S2 through S7 and S11 to perform tests 1 through 14 in Table 102. Adjust power supplies E1 and E2 as specified. Measure the output voltage at test points A(+) and C(-) (Figure 101). •
The output voltage must be as specified in Table 102.
(6) Decrease the voltage to zero. C.
TEST Switch Test (1) Install the UUT in the test setup (Figure 101). Connect power supply E1 at pin sockets J2-1(+) and J2-2(-) (60 and 65, IPL Figure 1). NOTE: The battery holder assembly must be removed from the UUT (2) Turn on power supply E2 and set it to 28 ±1 VDC. Close switch S1. (3) Open switches S2, S3, S4, S5 and S7. Close switch S6 (ground). Switch S11 to the “A” position. (4) Push TEST switch SW1 on the side of the UUT.
Copyright 2004 by: Radiant Power Corp., a HEICO Company
25-60-03
Page 103 Aug 2009
RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER RPS1-B •
The test lamps must turn on.
(5) Release TEST switch SW1. •
The test lamps must turn off.
(6) Remove power from E1 and E2. D.
Low Battery Cut-Off Test (1) Install the UUT in the test setup (Figure 101). Connect power supply E1 at pin sockets J2-1 (+) and J2-2 (-) (60 and 65, IPL Figure 1). (2) Open S1 through S7 switches. •
All test lamps must be off.
(3) Turn on power supply E2 and set it to 28 ±1 VDC. Close switch S1. (4) Turn on power supply E1 and set it to 7.5 ±0.1 VDC. •
All test lamps must turn on.
(5) Slowly decrease the voltage at power supply E1 until the test lamps turn off. Measure the voltage. •
The voltage must be greater than 4.8 VDC.
(6) Decrease the voltage to zero. E.
Charging Test (1) Install the UUT in the test setup (Figure 101). (2) Disconnect power supply E1 at pin sockets J2-1(+) and J2-2(-) (60 and 65, IPL Figure 1). (3) Install the battery holder assembly (5), as follows: NOTE: The batteries must be fully charged. (a)
Insert the battery holder assembly (5) into the chassis assembly (130).
(b)
Press the battery holder assembly (5) against the chassis and carefully slide it inward to insert pin contacts J3-1 and J3-2 on regulator PCB assembly A2 into pin sockets J2-1 and J2-2 (60 and 65).
CAUTION: DO NOT TURN THE 1/4-TURN FASTENERS PAST THE DETENT (c)
Turn the 1/4-turn fastener (25) clockwise approximately 90°, to the stop. An audible click will be heard when the stop is reached. The fasteners should compress the retraction springs (30).
Copyright 2004 by: Radiant Power Corp., a HEICO Company
25-60-03
Page 104 Aug 2009
RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER RPS1-B (4) Close switch S6. (5) Turn on power supply E2 and set it to 22 VDC. Close switch S1. (6) Measure the current at test point I1 (Figure 101). (7) The charging current must be between 300 and 375 milliamperes. (8) Set power supply E2 to 32 VDC. Measure the current at test point I1. (9) The charging current must be between 300 and 375 milliamperes. (10) Decrease the voltage to zero. F.
Battery Discharge Test (1) Install the UUT in the test setup (Figure 101). (2) Disconnect power supply E1 at pin sockets J2-1 (+) and J2-2 (-) (60 and 65, IPL Figure 1). (3) Install the battery holder assembly (5), as follows: NOTE: The batteries must be fully charged. (a)
Insert the battery holder assembly (5) into the chassis assembly (130).
(b)
Press the battery holder assembly (5) against the chassis and carefully slide it inward-to insert pin contacts J3-1 and J3-2 on regulator PCB assembly A2 into pin sockets J2-1 and J2-2 (60 and 65).
CAUTION: (c)
DO NOT TURN THE 1/4-TURN FASTENERS PAST THE DETENT
Turn the 1/4-turn fastener (25) clockwise approximately 90° to the stop. An audible click will be heard when the stop is reached. The fasteners should compress the retraction springs (30).
(4) Close switch S6. (5) Turn on power supply E2 and set it to 28 ±1 VDC. Close switch S1. (6) Open switches S1 and S6. Measure the output voltage across test points A(+) and C(-). (a)
• All test lamps must turn on and stay on for 15 minutes minimum.
(b)
• The output voltage must be between 5.7 and 6.7 VDC for 15 minutes.
(c)
• After 15 minutes, the lamps must stay on until the low battery cut-off voltage (which must exceed 4.8 VDC).
Copyright 2004 by: Radiant Power Corp., a HEICO Company
25-60-03
Page 105 Aug 2009
RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER RPS1-B (7) Decrease the voltage to zero. (8) If there was insufficient battery capacity or a low open circuit voltage, the battery assembly should be cycled as follows and then retested. If the test fails again, all six batteries should be replaced in accordance with disassembly and assembly instructions. (a)
Close switches S2, S3 and S6
(b)
Turn on power supply E2 and set it to 22 VDC. Close switch S1. Measure the current at test point I1.
(c)
• The charging current must be between 300 and 375 milliamperes.
(d)
Charge the UUT at 350 milliamperes for 16 to 24 hours.
(e)
Open switch S1.
(f)
Discharge the battery assembly into a 7 Ampere load until it reaches the cutoff voltage.
(g)
Repeat this cycle.
(9) Disconnect and remove the UUT (10) Refer to ASSEMBLY for final assembly instructions.
Copyright 2004 by: Radiant Power Corp., a HEICO Company
25-60-03
Page 106 Aug 2009
RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER RPS1-B Control Logic Test Requirements Table 102 Power Supply E2 Voltage S1 (J1-2)
Load Lamp
Output Voltage Across Load
S2 (J1-3)
S3 (J1-4)
S4 (J1-12)
S5 (J1-17)
S6 (J1-18)
S7 (J1-24)
S11
0 or 28vdc
Open
Open
Open
Open
Open
Open
A
ON
5.7 to 6.7vdc
2
0 or 28vdc
Open
Open
Open
Open
GND
Open
A
OFF
0vdc
3
0 or 28vdc
GND
Open
Open
Open
GND
Open
A
ON
5.7 to 6.7vdc
4
28vdc
Open
GND
Open
Open
GND
Open
A
OFF
0vdc
5
28vdc
GND
GND
Open
Open
GND
Open
A
OFF
0vdc
6
0vdc
GND
GND
Open
Open
GND
Open
A
ON
5.7 to 6.7vdc
7
0 or 28vdc
Open
Open
Open
Open
GND
28vdc
A
ON
5.7 to 6.7vdc
8
28vdc
Open
Open
GND
Open
GND
Open
A
ON
5.7 to 6.7vdc
9
28vdc
Open
Open
GND
GND
GND
Open
A
OFF
0vdc
1 0 1 1 * 1 2 1 3 1 4
0vdc
Open
Open
GND
GND
GND
Open
A
ON
5.7 to 6.7vdc
28vdc
GND
28vdc
GND
GND
GND
Open
B
OFF
0vdc
0vdc
GND
GND
GND
GND
GND
Open
B
OFF
0vdc
0vdc
28vdc
GND
GND
GND
GND
28vdc
B
OFF
0vdc
0vdc
28vdc
GND
GND
GND
GND
Open
B
ON
5.7 to 6.7vdc
T e s t 1
Switch Positions
NOTE: * Step #12 must be preformed after step #11. NOTE: * Switch #11 A: Jumpers Pins (J1-13 to J1-14) and (J1-15to J1-16) B: Jumpers Pins (J1-13 to J1-15)
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RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER RPS1-B
Bench Test Set Up Figure 101 NOTES: 1. REPLACE BATTERY HOLDER ASSEMBLY WITH POWER SUPPLY E1 (AND THE EXTERNAL PRELOAD, IF USED) FOR THE CHARGING AND BATTERY DISCHARGE TESTS. 2. A MOMENTARY DROP IN DC POWER SUPPLY VOLTAGE WHEN THE LAMP LOAD IS INITIALLY APPLIED CAN CAUSE THE UUT TO GO INTO LOW BATTERY CUTOFF PRELOADING THE DC POWER SUPPLY MAY BE REQUIRED TO PREVENT THIS.
Copyright 2004 by: Radiant Power Corp., a HEICO Company
CAUTION: POWER SUPPLY E1 VOLTAGE MUST NOT EXCEED 12.0 VDC. HIGH VOLTAGE CAN DAMAGE THE UUT. VOLTAGE MEASUREMENT POINTS ARE AS FOLLOWS: 28 VDC POWER SUPPLY D(+) AT J1-2 C(-) AT J1-1 BATTERY VOLTAGE B(+) AT J2-1 B(-) AT J2-2 OUTPUT VOLTAGE A(+) AT J1-9 C(-) AT J1-1
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RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER RPS1-B 3.
Fault Isolation Procedures A.
Fault isolation procedures for the tests given in this section are provided in Table 102. The procedures isolate faults to the board level only. With exception of the SIT components identified in the IPL, Radiant Power Corp. recommends that the PCB assemblies be returned to Radiant Power Corp. for repair by technicians familiar with the layout and function of the card. PCB assemblies repaired at facilities other than Radiant Power Corp. are not guaranteed by Radiant Power Corp.
B.
Any test procedure step that does not pass is considered a failure. After fault isolation and replacement of the damaged component, repeat the entire test procedure to verify that the problem has been corrected.
C.
The most likely failure mode in the unit is one or all of the output line fuses being blown. These are F1, F2, and F3, (40 or 40A) which are 5 amp “Pico” fuses listed in the parts list as figure 3 item # 40. The fuses are located between the battery pack and the electronics “brick”. Remove the battery pack according to the normal procedure to access the fuses. The three fuses are located as shown below, and on the PCB assembly drawing on Page 1018.
FUSES listed from top to bottom: F1, F2, and F3. Each fuse is inserted into a socket and can be removed and inserted with needle nose pliers.
WARNING: If the unit has a blown fuse, then the most likely cause is a wiring, or electrical short on the aircraft. The aircraft wiring must be investigated to determine the cause of the failure. The maximum load for each output line is 2.5 amps. Do not reinstall the RPS1-B on the aircraft until the cause of the fuse failure is determined. Fuse Location Figure 102
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RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER RPS1-B Bend replacement fuses as shown below:
Fuse Bending Figure 103 4.
Schematic Diagrams Schematic diagrams of the BPS battery pack electronic circuits are provided in DESCRIPTION AND OPERATION.
5.
SIT Resistor Replacement This Test Plan details the procedure to select the proper value for R21 on the A2 board of the RPS1-B. A.
Instrumentation All measurements shall be made with instruments and methods whose accuracy have been verified to the satisfaction of the buyer. All instruments and test equipment shall conform to laboratory standards whose calibration is traceable to the prime standards at the National Institute of Standards and Technology.
B.
Test Equipment Requirement The following test equipment or equivalent shall be used in accomplishing the test specified herein:
Quantity
Equipment
Three
Multi-meter, Digital Power Supply Power Supply
one one one one
Charging cable Test Fixture
Model or P/N Model 77 6631 E3641A RT-801 RT 909
Copyright 2004 by: Radiant Power Corp., a HEICO Company
Mfg.
Range
Accuracy
John Fluke Mfg. Co., Inc. Agilent. Agilent
*
2%
0 to 8 VDC 0 to 32 VDC *
* *
*
*
Radiant Power Corp Radiant Power Corp
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*
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RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER RPS1-B C.
Procedure (1) Set the 0-12 volt power supply to 8.0 volts. (2) Start with an 806-Ohm resistor for R21. (3) Install the unit in the test set. (4) OPEN switches 1-7 lights should come on. (5) Verify the output voltage is between 6.5 to 6.7 volts. (6) If the output voltage is out of range adjust R21 to get the correct output voltage.
NOTE: To increase the output voltage increase R21 (732 to 900 ohms) Fault Isolation Procedures Table 103 (Sheet 1 of 3) Trouble
Probable Cause
Corrective Action
INSULATION RESISTANCE TEST The insulation resistance is not as specified.
Cut or cracked wire insulation; open or short circuit or solder connection; solder flux path to ground.
Check the wire circuits, solder connections, and pin and socket contacts for damage; verify wire routing per ASSEMBLY, Table 702 and DESCRIPTION AND OPERATION, Figure 3; refer to REPAIR to replace damaged pin contacts in connector J1.
Excessive moisture inside the cover assembly (110, IPL Figure 1).
Dry the UUT thoroughly with compressed shop air; examine the unit carefully for corrosion or other moisture damage.
The UUT did not turn off (no output voltage) in test 2 in Table 102.
Damaged component in test switch circuit on logic PCB assembly A1 (15 or 15A, IPL Figure 2).
Replace logic PCB assembly A1 (15 or 15A).
The UUT did not turn on (output voltage) in tests 1, 3, 6, 7, 8 and 10 in Table 102.
One or more Fuses blown, possibly F1, F2 or F3.
Check if F1, F2, F3 (40 or 40A) is blown with a continuity meter.
Damaged transistor Q2 (35) or damaged component in regulator circuit on PCB assembly A2 (10).
Replace the damaged component.
CONTROL LOGIC TEST
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RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER RPS1-B Fault Isolation Procedures Table 103 (Sheet 2 of 3) Trouble
Probable Cause
Corrective Action
CONTROL LOGIC TEST (continued)
Damaged component in logic output or low voltage disconnect circuits on logic PCB assembly A1 (15 or 15A).
Replace logic PCB assembly A1 (15 or 15A).
The UUT did not turn off (no output voltage) in tests 4, 5 and 9 in Table 102.
Damaged component in 28 VDC sensing circuit on logic PCB assembly A1 (15 or 15A).
Replace logic PCB assembly A1 (15 or 15A).
One or more Fuses blown, possibly F1, F2 or F3.
Check if F1, F2, F3 (40 or 40A)is blown with a continuity meter.
If one or more lamps did not turn on, blown fuse F1, F2 or F3 (100, IPL Figure 3).
If there is no output voltage at pin 9, replace fuse F1 (40 or 40A); if there is no voltage at pin 10, replace fuse F2 (40 or 40A); if there is no voltage at pin 11, replace fuse F3 (40 or 40A).
Damaged TEST switch SW1 (100, IPL Figure 2) or solder lug (105).
Replace the damaged component.
Damaged component in test switch circuit on logic PCB assembly A1 (IS or 15A).
Replace logic PCB assembly A1 (15 or 15A).
One or more Fuses blown, possibly F1, F2 or F3.
Check if F1, F2, F3 (40 or 40A) is blown with a continuity meter.
Damaged component in control logic circuit on logic PCB assembly A1 (15 or 15A, IPL Figure 2).
Replace logic PCB assembly A1 (15 or 15A)
Damaged component in low voltage disconnect circuit on logic PCB assembly A1 (15 or 15A).
Replace logic PCB assembly A1 (15 or 15A).
TEST SWITCH TEST The test lamps do not turn on and off as specified.
LOW BATTERY CUTOFF TEST All test lamps do not turn on as specified (para. 2.D, Step (4)).
The low battery cutoff voltage is lower than specified (para. 2.D, Step (5)).
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RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER RPS1-B Fault Isolation Procedures Table 103 (Sheet 3 of 3) Trouble
Probable Cause
Corrective Action
CHARGING TEST The charging current is not as specified (para. 2.E, Steps (6) and (7)).
Damaged resistor R1 or R2 (65, IPL Figure 2), transistor Q1 (30), or component in charging circuit on regulator PCB assembly A2 (10).
Replace the damaged component.
Damaged or improperly installed battery holder assembly (5, IPL Figure 1).
Reinstall the battery holder assembly (5) and make sure connector pins J2-1 and J2-2 are inserted fully into the sockets; if the test fails again, disassemble and repair the battery holder assembly.
One or more Fuses blown, possibly F1, F2 or F3.
Check if F1, F2, F3 (40 or 40A) is blown with a continuity meter.
If the output voltage is greater than 6.5 VDC, the resistance of SIT resistor R21 (35, IPL Figure 3) is too high.
Decrease the resistance of SIT resistor R21 within the range 732 to 900 and retest; solder the resistor leads in place after final selection.
If the output voltage is less than 6.1 VDC, the resistance of SIT resistor R21 (35) is too low.
Increase the resistance of SIT resistor R21 within the range 732 to 900 and retest; solder the resistor leads in place after final selection.
Damaged transistor Q2 (35, IPL Figure 2).
Replace transistor Q2 (35).
Damaged component in regulator circuit on regulator PCB assembly A2 (10).
Replace regulator PCB assembly A2 (10).
BATTERY DISCHARGE TEST The output voltage is not as specified (para. 2.F, Step (6)).
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RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER RPS1-B
BATTERY MAINTENANCE AND STORAGE 1.
2.
General A.
Testing schedule and procedure should be in accordance with the operator’s procedures approved by a certification authority. If an operator wishes guidance on changing the intervals from the operator’s previously established intervals, the operator may contact Radiant Power or the aircraft manufacturer for specific recommendations.
B.
This section also includes sample methods for battery charging and storage when batteries are to be returned to immediately-dispatched aircraft. Because the Emergency Passenger Egress Lighting Systems are must-work systems for aircraft dispatch, the operators should assure that the batteries installed on the aircraft have enough charge to power the emergency lights. The sample procedures provide the guidance for operators’ procedures.
Storage Requirements for Battery Packs Battery Packs may be stored without damage in a charged or discharged condition over the temperature range of –30°C to +70°C (-22°F to +158°F). Long term storage (over 3 months) should be at temperatures less than +35°C (+95°F).
3.
New Stock Maintenance Exemption New stock purchased from Radiant or Radiant’s authorized distributors has a seven year nomaintenance-required shelf life for the electronics and 38 month no-maintenance-required shelf life for the battery pack and batteries. If the components remain in the purchaser’s stock beyond the shelf life, simple inspection, testing, or conditioning may be required. Testing and conditioning may be done at the discretion of the purchaser in accordance with their procedures based on their previous experience with parts in long-term storage. Date Code Locations:
Date Code: Month/Year
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RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER RPS1-B 4.
Battery Pack Removal Recommendation Removal and Bench testing Removal and bench-testing of 2013-1A Battery Packs is suggested at 18-month intervals for most operators of large commercial transport aircraft or similar aircraft applications. Recommended test/reconditioning procedures are detailed in Testing and Fault Isolation section/paragraph 2.F. The battery capacity test is normally done with a fully charged battery pack.
5.
On-Aircraft Testing/Maintenance A.
RPS1-B systems should be tested periodically on-aircraft to remove built-up “memory effect”. For operators seeking new procedures or using new type aircraft, the following sample procedure explains what a procedure may include. The operator may also contact Radiant Power or the aircraft manufacturer for specific recommendations. Sample On-Aircraft Testing/Maintenance procedure (1) Three times per year, the lighting system is tested for a period of 10 minutes minimum, 15 minutes maximum. (2) At the end of the illumination period, the aircraft electrical system is powered for at least 3.5 hours before the next gate departure to recharge the batteries. Acceptance criteria for 1: Observation (that is, no numerical data required; only need mechanic signoff that lighting system was turned on for 10-15 minutes) Acceptance criteria for 2: Observation or aircraft schedule (that is, no numerical data required; only need signoff that ground power was applied to aircraft or the aircraft was powered for 3.5 hours before gate departure)
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RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER RPS1-B B.
Commentaries (1) Acceptance Criteria
Acceptance Criteria commentary: The intention of the acceptance criteria is to minimize the burden put on the operators. All that is supposed to happen is that the mechanic turns on lights for 10-15 minutes and the batteries get recharged for 3-1/2 hours. The emergency lighting system load is 7 Amperes and it must run for 10 minutes by FAR requirement. This corresponds to 7 A x 1/6 hour = 1.16 A-hr. The charging rate on the RPS1-B is 0.35A so it takes 1.16/0.35 = 3.3 hours to replenish the battery with the minimum amount of energy required. Normal aircraft operations will completely “top-off” the batteries. Neither the 10-15 minute time, nor the 3-1/2 hour time is critical. There is a reasonable expectation that if the times are slightly shorter or longer than required the system would maintain its flightreadiness. For example, the batteries will still have more reserve energy after the 10-15 minute discharge because the batteries have a relatively high capacity relative to the FAR requirements. Thus, if the recharge time is only 3 hours, the battery capacity will meet the FAR requirements with the combination of the recharge energy and reserve energy. If the aircraft schedule is such that it is powered for at least 3-1/2 hours before departure, the batteries will be recharged. For example, if the mechanics schedule the 10-minute test at the beginning of another maintenance activity, and then recharge the batteries (by having ground power applied to the aircraft) while continuing the maintenance activity, the batteries will have the required energy. There is no need to record the time intervals, just simply note that the aircraft was powered for at least the minimum interval. In another example, if the 10-minute test is done as soon as the passengers deplane from the last flight of the day, and the operator knows that the aircraft will be powered for another 2 hours during normal cabin cleaning and at-gate maintenance tasks, plus the aircraft will be powered up for 1-1/2 hours in the morning before the first departure, the “schedule” criteria is met. No data needs to be recorded other than that the battery was recharged in accordance with a schedule that would provide the recharge time.
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RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER RPS1-B (2) Memory Effect Engineering commentary – “Memory Effect”: Nickel Cadmium batteries exhibit a characteristic called “battery memory”. Battery memory makes good cells appear to have less capacity than they should. Continuously charging a battery or partially discharging a battery causes battery memory. Battery memory is worse at high ambient temperatures. Battery memory is removed by periodically discharging the batteries. The discharge process removes the battery memory down to the level of discharge. Deep-cycling batteries (which can only be done on the bench because the battery undervoltage protection circuit in the RPS1-B needs to be defeated) completely removes all memory-effect residue and reconditions the battery to its maximum capacity. > 10 min.
>15 min.
> 30 min. 2-3 min.
New Battery (over 30 minutes run time)
"Memory Effect" (2-3 minutes of run time)
After On-Board Maintenance (at least 10 minutes of run time)
After Bench Testing/ Deep-cycling (maximum run time, based on battery lifetime, no memoryaffected areas)
Prime Power (battery capacity not affected by memory) Usable Power (mixed normal and memory-affected areas of battery)
Power not available (memory-effect has made battery voltage too low)
"W orn-out" area of battery (due to battery life time)
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RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER RPS1-B 6.
Charging Batteries for Return-to-Service If a stored Battery Pack is to be installed on an aircraft that is returning to service, the Battery Pack must be charged before the aircraft is deemed ready for passenger service. That is, a fully discharged battery pack will not meet the requirements of US FAA FAR 25.812 paragraph (i), which requires that the Battery Pack must provide 10 minutes’ worth of energy. Charging of the Battery Pack may be accomplished in different ways. Some samples are listed below: A.
Charge on-aircraft for at least 6 hours. Six hours is the time in which completely discharged batteries will absorb the minimum amount of energy required to meet the 10 minutes FAR requirement. Charging is accomplished by aircraft ground power, aircraft idling, or aircraft ferrying. Battery packs in this condition are not fully charged, but do contain enough energy to meet the requirements; the batteries will be fully charged during normal aircraft operations of the first flight day.
B.
Charge on bench for 16 hours at nominal current (330-370 mA) within the 31 days previous to the installation on the aircraft and maintain the stored batteries at an average room temperature. Average room temperature simply means a controlled environment; no monitoring of temperature is required because failure of environmental controls will be obvious to personnel working in the area.
C.
Charge on bench for 16 hours at nominal current (330-370 mA) within the 123 days previous to the installation on the aircraft and maintain the stored batteries at an average refrigerator temperature. Average refrigerator temperature simply means the normal controlled environment of a home or industrial refrigerator (0°C to +5°C / 32°F to 41°F); no monitoring of temperature is required because failure of environmental controls will be obvious to personnel working in the area.
D.
Fast-charge on bench for 20 minutes at high rate current (5 A) before installation on aircraft. This procedure is used when an immediate dispatch of the aircraft is required and no previously charged stored batteries exist. Radiant Power and other manufacturers can provide dedicated equipment to perform this function. This procedure should be done only with dedicated test equipment or specially trained operators because the battery voltage and temperature must be monitored continuously during this fast charge.
Operators may provide alternative or additional charging and testing procedures if desired. These other procedures may be done to provide consistent maintenance or battery-shop procedures between aircraft types, for example. Specific recommendations can be provided from Radiant Power or the aircraft manufacturer. Sample Storage/Charge Options for Batteries Returning to Service on Passenger Aircraft 123 Days maximum
31 Days maximum
Charge on Bench @ 350 mA for 16 hours; store in refrigerator
Charge on Bench @ 350 mA for 16 hours; store at room temperature
Copyright 2004 by: Radiant Power Corp., a HEICO Company
6 hours minimum Charge on Aircraft
20 minutes Fast Charge on Bench @5A
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RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER RPS1-B 7.
Battery Charging Procedure The purpose of this section to provide new users with typical procedures for bench charging. Established users should use their approved procedures. A.
Use a power supply with a minimum voltage of 12 volts and an adjustable current limit. Hook up the power supply, meters, etc, as shown on the drawing below.
CAUTION:
DO NOT HOOK UP THE BATTERY PACK YET!
Battery Discharge Figure 104 B.
Adjust the output voltage to 10 volts for every battery pack that is in series, and turn the current limit all the way down. Now hook up the battery pack. Adjust the current limit on the power supply to 350 milliamps +/- 20 milliamps. Leave the batteries charging for 1520 hours (16 hours nominal). After the 16 hours of charge disconnect the battery from the charger. Measure the battery pack voltage with a meter and ensure that the battery has fully charged to a normal value of 7.5 to 8.8 volts.
Number of battery packs Voltage Current
1
2
3
4
5
10 volts 350 milliamps
20 volts 350 milliamps
30 volts 350 milliamps
40 volts 350 milliamps
50 volts 350 milliamps
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RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER RPS1-B 8.
Battery Discharging Procedure The purpose of this section is to provide new users with typical procedures for bench discharging. Established users should use their approved procedures. A.
Battery Discharge Hookup:
YOU MUST MONITOR THE BATTERY VOLTAGE CONTINUOUSLY! Battery Charge Figure 105 B.
Turn on the discharge switch and allow the battery to discharge until it reaches a voltage of 4.8 – 5.6 volts. Do not allow the voltage to go any lower. This discharge time can take anywhere from a few minutes to 35 minutes, depending on the battery’s state of charge. The voltage normally holds very steady for most of the discharge curve, followed by a steep decrease in voltage at the very end of the discharge. Pay attention!
C.
Once the battery cutoff voltage is reached then turn the switch off, and allow the battery pack to cool for 30 minutes before charging.
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RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER RPS1-B
OPTIONAL ON-AIRCRAFT TESTING FOR RPS1-B NOTE: These tests may be performed on-aircraft in the event of problems reported by flight crew or mechanics. 1.
General In response to requests from operators, Radiant Power Corp. has made an on-aircraft test set available. The Battery Housing Analyzer (BHA) provides quick GO/NO-GO and qualitative testing for the RPS1-B. The purpose of this test set is to allow mechanics to diagnose the problems that flight crew or mechanics might report when operating the Emergency Egress Lighting System or when performing a daily test on it. The BHA is a portable instrument designed to be carried on-board the aircraft by the mechanic. It allows the mechanic to check the RPS1-B charger for proper operation while the RPS1-B remains installed on the aircraft. The BHA also can perform a quick test of the battery pack as well. This test is not a full capacity check of the battery, since that would require a 16-hour recharge of the battery onaircraft after the test. It tests for grossly under-performing batteries, as could cause a test failure during the daily checks of the Emergency Egress Lighting System. Specifically, the BHA provides measurement of the battery charging current, charging opencircuit voltage, battery no-load voltage, and the battery loaded voltage. The BHA kit includes the analyzer, a two-foot battery tester cable and a 6.5-foot charging fixture cable. This cable is long enough that the mechanic can use the analyzer from a convenient location while testing an RPS1-B in an inconvenient location. Instructions for the Analyzer are reproduced below.
Battery Housing Analyzer Figure 106
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RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER RPS1-B 2.
Aircraft Charging Test NOTE: IF THE AIRCRAFT CHARGER BEING TESTED FALLS OUTSIDE OF THE SPECIFIED TOLERANCES, FURTHER MAINTENANCE IS REQUIRED. A.
Remove the battery holder assembly (5, IPL Figure 1), as follows: (1) Turn the 1/4-turn fastener (25) counterclockwise approximately 90° to the stop. The fasteners should retract from the force of the retraction springs (30). CAUTION:
DO NOT LIFT THE BATTERY HOLDER ASSEMBLY BEFORE SLIDING IT AWAY FROM THE ELECTRONICS ASSEMBLY. DOING SO CAN DAMAGE THE PIN CONTACTS ON PCB ASSEMBLY A2.
(2) Carefully slide the battery holder assembly (5) out away from the electronics assembly (120 or 120A) to disconnect pin contacts J3-1 and J3-2 on regulator PCB assembly A2 from pin sockets J2-1 and J2-2 (60 and 65). Remove the battery holder assembly. B.
Ensure analyzer power & load switches are in the off position.
C.
Install the charging fixture cable in place of the removed battery holder assembly (5). Connect the charging fixture cable leads to the BHA input jacks. CAUTION: ENSURE PROPER POLARITY. IF AT ANY TIME THE REVERSE POLARITY LED FLASHES, CORRECT BEFORE PROCEEDING.
D.
Turn on aircraft power to the charger assembly.
E.
Switch power ON/OFF switch to the ON position with the load switch in the OFF position. The voltage must be 13.8 volts to 15.0 volts.
F.
Switch the load ON/OFF switch to the ON position. The voltage must be 6.8 volts to 8.0 volts. Charge current must indicate 300 mA or greater.
G.
Depress the battery condition switch and read the battery voltage on the battery voltage meter. (The LED lights are for quick reference only.) Voltage must be greater than 6.8 volts but less than 8.0 volts. Low < 6.8 volts (Amber) FAILURE Normal > 6.8 volts (Green) PASS High > 8.0 volts (Red) FAILURE
H. 3.
Release battery condition switch.
Battery Pack Test NOTE: IF THE BATTERY PACK BEING TESTED FALLS OUTSIDE OF THE SPECIFIED TOLERANCES FURTHER MAINTENANCE IS REQUIRED. A.
Ensure analyzer power & load switches are in the off position.
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RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER RPS1-B B.
Attach battery tester cable from the BHA input jacks to the battery pack to be tested. CAUTION: ENSURE PROPER POLARITY. IF THE REVERSE POLARITY LED FLASHING, CORRECT BEFORE PROCEEDING.
C.
Switch power ON/OFF switch to the ON position with the load switch in the OFF position.
D.
Depress the battery condition switch and read the battery voltage on the battery voltage meter. (The LED lights are for quick reference only.) Voltage must be greater than 6.8 volts. Low < 6.8 volts (Amber) FAILURE Normal > 6.8 volts (Green) PASS High > 8.0 volts (Red) OK
E.
Release battery condition switch.
F.
Switch load ON/OFF switch to the ON position. The voltage meter must read 6.8 volts or greater, and current meter must read 300 mA or greater.
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RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER RPS1-B
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RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER RPS1-B
DISASSEMBLY 1.
General A.
This section contains disassembly instructions in the same sequence as the IPL. Before disassembly, refer to TESTING AND FAULT ISOLATION or CHECK to identify the damaged components. Disassemble the BPS battery pack only as far as necessary to remove the damaged or worn parts. NOTE: With the exception of the Select In Test (SIT) components identified in the IPL, Radiant Power Corp. recommends the PCB assemblies be returned to Radiant Power Corp. for repair by technicians familiar with the layout and function of the card. PCB assemblies repaired at facilities other than Radiant Power Corp. are not guaranteed by Radiant Power Corp.
B.
This CMM covers maintenance of the RPS1-B configuration only. Contact Radiant Power Corp. for maintenance of the earlier configurations given below: Part Number RPS1 RPS1-A
C.
0001 through 0016 0017 through 0052
Two electrically identical but physically different logic PCB assemblies are used in the RPS1-B configuration depending on the serial number. Both variations are covered in this CMM. Part Number 11-0041-1 11-0041-2
2.
Serial Numbers
Serial Numbers
IPL Figure-item Number
0626 and subsequent 0053 through 0625
2-15 2-15A
D.
Note the methods of insulation (shrink sleeving, etc.) and routing of electrical wire leads for assembly reference. Unsolder the wire leads from the terminals or pads and tag all wires to aid assembly.
E.
Refer to IPL Figure 1 for an exploded-view illustration of the BPS battery pack. Refer to DESCRIPTION AND OPERATION, Figure 2, for assembly views.
Tools and Materials A.
All repair work on PCB must be done at an Electrostatic Discharge (ESD) safe workbench. Refer to paragraph 3, below, for general ESD handling instructions and workbench requirements.
B.
The recommended materials are given in Table 301. NOTE: Equivalent materials can be used.
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RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER RPS1-B 3.
Handling Instructions for Electronic Devices The BPS battery pack contains electronic components that can be damaged by ESD and rough handling. The general handling precautions and instructions given below will help minimize or eliminate possible damage. WARNING: THE BPS BATTERY PACK CONTAINS HIGH VOLTAGE CIRCUITS WHICH CAN CAUSE DEATH OR SEVERE SHOCK. FOLLOW THE SAFETY PRECAUTIONS GIVEN IN THE INTRODUCTION TO THIS CMM TO PREVENT INJURY CAUTION:
THE PCB ASSEMBLIES CONTAIN ESD SENSITIVE DEVICES. HANDLE THE PCB ASSEMBLIES IN ACCORDANCE WITH STATIC CONTROL PROCEDURES TO PREVENT COMPONENT DAMAGE. THE BPS BATTERY PACK CONTAINS SENSITIVE ELECTRONIC COMPONENTS THAT CAN BE DAMAGED BY ROUGH HANDLING AND EXPOSURE TO HIGH HUMIDITY, WATER OR OTHER LIQUIDS, CIGARETTE SMOKE, AND OTHER CONTAMINATION. USE THE BPS BATTERY PACK IN AN ENVIRONMENT SUITABLE FOR ELECTRONIC COMPONENTS AND HANDLE THE UNIT WITH CARE TO PREVENT DAMAGE.
A.
If liquid or grease is spilled on or in the BPS battery pack, immediately remove power and wipe off the liquid or grease. Do not touch the BPS battery pack until power has been removed.
B.
Do not use or store the BPS battery pack in a high humidity environment or in direct sunlight. High humidity can short or corrode electronic components.
C.
All integrated circuits (ICs), surface mounted devices, and many other semiconductors are susceptible to ESD. Careless handling during repair can drastically decrease the component life.
D.
When handling ESD sensitive devices, work at an ESD safe workbench. The workbench should include: (1) A grounded conductive sheet covering the bench work area. (2) A grounded wrist strap in contact with skin. (3) If the chair or the floor is nonconducting, the chair must have a ground strap. (4) ESD safe tools and equipment. Use plastic instead of metal tools where possible to prevent short circuits.
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RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER RPS1-B Disassembly Materials Table 301 Nomenclature Alcohol, Isopropyl Cloth, Lint-Free
Part or Specification Number Federal Specification TT-I-735 Military Specification MIL-C-85043
Stripper, Conformal Coating
Humiseal No. 20
Source Commercially Available Commercially Available Columbia Chase Corp. (99109)
* Refer to Table 1001 in the IPL for the address.
4.
E.
Store the PCB assemblies in protective antistatic shipping bags until ready for use. Do not store the PCB assemblies in conventional plastic snow, Styrofoam, or plastic trays.
F.
Once removed from the bags; PCB assemblies must be handled in accordance with static control procedures. The preferred method is to handle PCB assemblies with clean lint-free cloths or rubber gloves only on the edge of the board. If gloves or cloths are not available, wash your hands to remove oils and handle the boards only on the edges; do not touch the conductive patterns or components.
G.
Do not stack PCB assemblies. Stacking can damage surface mounted components.
H.
The work station must be clean. To prevent contamination of PCB assemblies, there must be no smoking, eating, or drinking in the work area.
Disassembly Instructions NOTE: Refer to REPAIR for instructions to replace the adhesive-backed labels (15, IPL Figure 1), damaged clinch nuts (160 Figures) (32 IPL Figures), all riveted components, and all bonded components. CAUTION:
UNITS UNDER WARRANTY SHOULD BE RETURNED TO RADIANT POWER CORP. FOR REPAIR. REMOVAL OF THE TOP COVER WILL VOID THE WARRANTY.
CAUTION:
THE PCB ASSEMBLIES CONTAIN SENSITIVE ELECTRONIC COMPONENTS THAT CAN BE DAMAGED BY ESD AND ROUGH HANDLING. HANDLE THE PCB ASSEMBLIES WITH CARE TO PREVENT DAMAGE.
CAUTION:
DO NOT OVERHEAT ELECTRONIC COMPONENTS WHEN UNSOLDERING WIRE LEADS. USE A HEAT SINK AND LOW WATTAGE SOLDER GUN TO PREVENT DAMAGE. USE A SOLDER SUCKER AND/OR SOLDER WICK TO REMOVE EXCESS SOLDER.
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RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER RPS1-B A.
Battery Holder Assembly (5, IPL Figure 1) (1) Remove the battery holder assembly (5), as follows: (a)
Turn the 1/4-turn fastener (25) counterclockwise approximately 90° to the stop. The fasteners should extend from the force of the retraction springs (30).
CAUTION:
(b)
DO NOT LIFT THE BATTERY HOLDER ASSEMBLY BEFORE SLIDING IT AWAY FROM THE ELECTRONICS ASSEMBLY DOING SO CAN DAMAGE THE PIN CONTACTS ON REGULATOR PCB ASSEMBLY A2.
Carefully slide the battery holder assembly (5) out away from the electronics assembly (120 or 120A) to disconnect pin contacts J3-1 and J3-2 on regulator PCB assembly A2 from pin sockets J2-1 and J2-2 (60 and 65). Remove the battery holder assembly.
CAUTION: AS SOON AS THE BOTTOM HALF OF THE BATTERY CASE IS REMOVED, INSERT A PIECE OF INSULATING MATERIAL BETWEEN PIN SOCKETS J2-1 AND J2-2 TO, PREVENT SHORTING DURING MAINTENANCE. (2) Disassemble the battery holder assembly (5), as follows: (a)
Refer to REPAIR to replace the adhesive-backed battery holder label (15).
(b)
Remove the nuts (40A), the flat washers (45), and the screws (50). Turn the battery case (20) over and remove the bottom half case. Insert a piece of insulating material (tape, paper, etc.) between pin sockets J2-1 and J2-2 (60 and 65).
(c)
Remove the split ring retainers (35) or the Teflon flat washers (35A), the 1/4turn fasteners (25), and the retraction springs (30).
(d)
Unsolder the wire braid (90) on the end of the batteries (55) opposite pin sockets J2-1 and J2-2 (60 and 65).
CAUTION:
(e)
DISASSEMBLY OF THE BATTERY PACK TO REPLACE INDIVIDUAL BATTERIES IS NOT RECOMMENDED. THIS CAN RESULT IN A MISMATCH OF CELL CAPACITY SUFFICIENT TO CAUSE CELL REVERSAL AND PERMANENT CELL DAMAGE. RADIANT POWER CORP. RECOMMENDS REPLACEMENT OF ALL SIX BATTERIES IF ANY ONE BATTERY IS DAMAGED.
Remove the batteries (55) from the top half of the battery case (20). Unsolder the remaining wire braid (90) only if the batteries are damaged and must be replaced. Replace all six batteries if any one battery is damaged. NOTE: Instructions are given in ASSEMBLY to reconnect the batteries.
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RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER RPS1-B CAUTION: DO NOT REMOVE THE INSULATING MATERIAL FROM BETWEEN PIN SOCKETS J2-1 AND J2-2 UNTIL AFTER THE REAR WIRE BRAID (90) OR THE BATTERIES HAVE BEEN REMOVED. (f)
Remove the insulating material from between pin sockets J2-1 and J2-2 (60 and 65).
(g)
Remove the nuts (70), the washers (80 and 85), and pin sockets J2-1 and J2-2 (60 and 65).
CAUTION: DO NOT USE SOLVENT CLEANERS ON THE BATTERY CASE. SOLVENTS CAUSE DAMAGE TO THE LEXAN MATERIAL. (h)
B.
Peel or cut the fuse retainer pad (95) off the battery case (20) only if the pad is damaged. Clean the battery case with alcohol and lint-free cloths to remove any adhesive film.
Battery Charger Assembly (100, IPL Figure 1) NOTE: Refer to REPAIR for instructions to replace damaged clinch nuts (160, IPL Figure 1 and 32, IPL Figure 3), the adhesive-backed labels, and the riveted components. CAUTION: DO NOT OVERHEAT ELECTRONIC COMPONENTS WHEN UNSOLDERING WIRE LEADS. USE A HEAT SINK AND LOW WATTAGE SOLDER IRON TO PREVENT DAMAGE. USE A SOLDER SUCKER AND/ OR SOLDER WICK TO REMOVE EXCESS SOLDER. (1) Refer to REPAIR to replace the adhesive-backed chassis nameplate (105). CAUTION: PCB ASSEMBLIES A1 AND A2 CONTAIN SENSITIVE ELECTRONIC COMPONENTS THAT CAN BE DAMAGED BY ESD AND ROUGH HANDLING. HANDLE THE PCB ASSEMBLIES WITH CARE TO PREVENT DAMAGE. (2) Remove the screws (115) and carefully lift the cover assembly (110) off the electronics assembly (120 or 120A). CAUTION: DO NOT LIFT THE ELECTRONICS ASSEMBLY BEFORE SLIDING IT AWAY FROM THE BATTERY HOLDER ASSEMBLY DOING SO CAN DAMAGE THE PIN CONTACTS ON REGULATOR PCB ASSEMBLY A2. (3) Remove the screws (125). Carefully slide the electronics assembly (120 or 120A) out away from the battery holder assembly (5) to disconnect pin contacts J3-1 and J3-2 on regulator PCB assembly A2 from pin sockets J2-1 and J2-2 (60 and 65). CAUTION: DO NOT PULL OR TWIST THE WIRE LEADS WHILE REMOVING COMPONENTS. PULLING OR TWISTING THE WIRE LEADS CAN BREAK SOLDER CONNECTIONS AND DAMAGE WIRE LEADS.
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RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER RPS1-B (4) Disassemble the electronics assembly (120 or 120A), as follows: (a)
Refer to REPAIR to replace the adhesive-backed TEST switch label (5, IPL Figure 2).
(b)
Remove the screws (95) from the front panel (125). Do not move the front panel until specified below.
(c)
Remove the screws (20) and the washers (25) from logic PCB assembly A1 (15 or 15A). Do not move PCB assembly A1 until specified below.
(d)
Remove the screws (20), the washers (25), and the insulator (12) from regulator PCB assembly A2 (10). Do not move PCB assembly A2 until specified below.
(e)
Unfold the electronics assembly as needed for access to the damaged components. Use caution to avoid damage to solder connections on components that do not require replacement. NOTE: The PCB assemblies are conformal coated. The wire leads can be unsoldered through the conformal coating, or the coating can be stripped off with Humiseal stripper (Table 301). Instructions are given in ASSEMBLY to reapply the conformal coating.
(f)
Tag and unsolder the wire leads from TEST switch SW1 (100) to pads 16 and 22 on logic PCB assembly A1 (15 or 15A). Remove the hex nut and the switch from the front panel (125). Reinstall the hex nut on the switch body for reuse.
(g)
Tag and unsolder the wire lead from connector J1 (110) to the solder lug (105). Remove the solder lug.
CAUTION:
(h)
PCB ASSEMBLIES REPAIRED AT FACILITIES OTHER THAN RADIANT POWER CORP. ARE NOT GUARANTEED BY RADIANT POWER CORP.
Tag and unsolder the wire leads from logic PCB assembly A1 (15 or 15A). Remove logic PCB assembly A1. NOTE: With exception of the SIT components identified in the IPL, Radiant Power Corp. recommends that PCB assemblies A1 and A2 be returned to Radiant Power Corp. for repair by technicians familiar with the layout and function of the cards. PCB assemblies repaired at facilities other than Radiant Power Corp. are not guaranteed by Radiant Power Corp.
(i)
Tag and unsolder the wire leads from regulator PCB assembly A2 (10). Remove PCB assembly A2. Remove the screws (10, IPL Figure 3), the washers (15), transistor Q3 (5), the Thermal insulator pad (20), the bracket assembly (30), and the insulator strip (25) from the printed circuit board (130). Discard the mica insulator. Refer to REPAIR to replace damaged clinch nuts (32). Replace PCB assembly A2 if any other components are damaged.
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RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER RPS1-B
C.
(j)
Tag and unsolder the wire leads for transistor Q1 (30) and the solder lug (60). Remove the screws (45), the nuts (40), transistor Q1, the Thermal insulator pad (50), the insulator strip (55), and the solder lug. Discard the mica insulator.
(k)
Tag and unsolder the wire leads for transistor Q2 (35) and the solder lug (60). Remove the screws (45), the nuts (40), transistor Q2, the Thermal insulator pad (50), the insulator strip (55), and the solder lug. Discard the mica insulator.
(l)
Tag and unsolder the wire leads to resistor R1 and/or R2 (65). Remove the screws (80 or 80A), the washers (75), the nuts (70), and the resistor(s).
Chassis Assembly (130, IPL Figure 1) (1) Refer to REPAIR to replace the riveted brackets (140). (2) Refer to REPAIR to replace damaged clinch nuts (160). (3) Replace the chassis assembly (130) if any other components are damaged.
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RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER RPS1-B
CLEANING 1.
Cleaning Materials The recommended cleaning materials are given in Table 401. NOTE: Equivalent items can be used.
2.
Cleaning Instructions WARNING: THE CLEANING SOLVENTS ARE VERY FLAMMABLE AND CAN IRRITATE YOUR EYES AND NOSE. USE THE SOLVENTS ONLY IN WELL VENTILATED AREAS AWAY FROM OPEN FLAMES. FLUSH IRRITATED EYES WITH WATER. CAUTION:
THE PCB ASSEMBLIES CONTAIN SENSITIVE ELECTRONIC COMPONENTS THAT CAN BE DAMAGED BY ESD AND ROUGH HANDLING. HANDLE PCB ASSEMBLIES WITH CARE TO PREVENT DAMAGE. DO NOT GET THE ELECTRONIC AND ELECTRICAL COMPONENTS TOO WET. EXCESS MOISTURE CAN DAMAGE THE COMPONENTS. Cleaning Materials Table 401
Nomenclature Alcohol, Isopropyl
Part or Specification Number Federal Specification TT-I-735
Brush, Stiff-Bristle, Nonmetallic
Federal Specification H-B-1490
Cleaning Solvent, (Recommended)
Formula 409 Calla 301A 815MX
Source Commercially Available
Commercially Available
Clorox Co. (4T284) Baker Chemicals (19457) Brulin and Co. (94058)
Cloth, Lint-Free
Military Specification MIL-C-85043
Commercially Available
Goggles, Safety
---
Commercially Available
Swab, Cotton
---
Commercially Available
Tank Compressed Air, 20 psig (140 kPag)
---
Commercially Available
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RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER RPS1-B A.
Use clean cotton swabs and isopropyl alcohol (Table 401) to clean the circuit boards and the electrical/electronic components. Wipe the components dry with clean, lint-free cloths.
CAUTION:
B.
DO NOT USE CLEANING SOLVENTS ON THE BATTERY HOLDER ASSEMBLY OR THE BATTERY CASE ASSEMBLY. THE SOLVENTS CAN CAUSE CRACKING OF THE LEXAN MATERIAL.
Use clean cotton swabs and isopropyl alcohol (Table 401) to clean the battery holder assembly (5, IPL Figure 1) and the battery case assembly (20). Wipe the components dry with clean, lint-free cloths.
WARNING: WEAR SAFETY GOGGLES OR GLASSES WHEN YOU USE COMPRESSED AIR. POINT THE AIR STREAM AWAY FROM OTHER PEOPLE. C.
Clean all other components in a sonic bath or use lint-free cloths and the solvent (Table 401). Use a nonmetallic, stiff-bristle brush if necessary to scrub the parts. Dry the parts with clean, lint-free cloths or clean shop air at less than 20 psig (140 kPag) pressure.
D.
Store the nonelectronic components in clean plastic bags or on clean, lint-free cloths until they are needed for CHECK and ASSEMBLY. Store the PCB assemblies as specified in DISASSEMBLY.
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RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER RPS1-B
CHECK Component check procedures are given in Table 501. Use bright light and a 5 power or greater magnifier to aid visual examinations. Check Procedures Table 501 (Sheet 1 of 3) Component
Method of Inspection
Check For
Threaded Parts
Visual
Crossed or stripped threads; loose attaching hardware.
Solder Connections
Visual
Loose or broken solder connections; cracked or deteriorated wiring insulation; burns or other signs of open or short circuits.
Corrective Action Replace damaged components.
Refer to REPAIR to repair solder connections.
Electrical Wire Leads
Visual
Cracked or cut insulation; cut wire strands; check all wires for continuity; verify that all wires are properly routed and bundled.
Refer to ASSEMBLY to replace damaged wire leads during final assembly.
Battery Holder Assembly (5, IPL Figure 1)
Visual
Crossed or stripped head on the 1/4-turn fasteners (25); deformation.
Replace the damaged fasteners (25).
Visual
Unreadable label (15); cut or torn edges; loose adhesive bond.
Refer to REPAIR to replace the adhesivebacked labels.
Dimensional
Deformed or permanently set retraction spring (30); the nominal free length is 0.75 inch (1.9 cm); the ends must be square within 2deg.and the spring must roll smoothly on a flat surface.
Replace the damaged spring.
Visual
Cracked or chipped battery case assembly (20).
Replace the battery case assembly (20).
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RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER RPS1-B Check Procedures Table 501 (Sheet 2 of 3) Component
Method of Inspection
Check For
Corrective Action
Battery Holder Assembly (5, IPL Figure 1)(continued)
Visual
Leakage from a cracked or corroded battery (55) cell; cut or detached battery tab.
Replace the batteries (55) or battery holder assembly (5); instructions to connect new batteries are given in ASSEMBLY.
Chassis Nameplate (105)
Visual
Cut wire braid (90).
Replace the wire braid (90).
Visual
Unreadable; cut or torn edges; loose adhesive bond.
Refer to REPAIR to replace the adhesive-backed nameplate.
Visual
Corrosion; chemical film finish scratched or worn to base metal.
Refer to REPAIR to remove corrosion and apply Alodine over the damaged areas.
Visual
Deformation; check mounting holes for cracks.
Replace the cover assembly (110).
Visual
Unreadable silkscreen markings; damaged insulated tape.
Refer to REPAIR to replace the silkscreen markings and tape.
Visual
Deformed front panel (125, IPL Figure 2); check mounting holes for cracks.
Replace the front panel (125).
Visual
Bent or damaged pin contacts in connector J1 (110); sheared or deformed locking tabs; damaged shell or corroded seal.
Refer to REPAIR to replace damaged pin contacts or wire leads, or replace the damaged connector (110).
Visual
Crossed or stripped threads on the switch SW1 (100) housing or in the hex nut; damaged terminals or push button switch mechanism.
Replace switch SW1 (100).
Cover Assembly (110)
Electronics Assembly (120 or 120A)
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RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER RPS1-B Check Procedures Table 501 (Sheet 3 of 3) Component Electronics Assembly (120 or 120A)
Chassis Assembly (130)
Method of Inspection
Check For
Corrective Action
Visual
Cracked or burned resistor R1 or R2 (65).
Replace the damaged resistor (65).
Visual
Loose or damaged board mounted components or damaged circuit traces on logic PCB assembly A1 (15 or 15A); discolored, cracked, or chipped circuit board; warpage or twist greater than 1.5%.
Replace logic PCB assembly A1 (15 or 15A); Radiant Power Corp. recommends that damaged PCB assemblies be returned to Radiant Power Corp. for repair; other than replacement of SIT components, PCB assemblies repaired at facilities other than Radiant Power Corp. are not guaranteed by Radiant Power Corp.
Visual
Loose or damaged board mounted components or damaged circuit traces on regulator PCB assembly A2 (10); discolored, cracked, or chipped circuit board; warpage or twist greater than 1.5%.
Replace regulator PCB assembly A2 (10); Radiant Power Corp. recommends that damaged PCB assemblies be returned to Radiant Power Corp. for repair; other than replacement of SIT components, PCB assemblies repaired at facilities other than Radiant Power Corp. are not guaranteed by Radiant Power Corp.
Visual
Loose or damaged clinch nuts (160) in the bracket assemblies (140); stripped threads in the clinch nuts; bent bracket.
Refer to REPAIR to replace the damaged clinch nuts (160), or replace the damaged bracket assembly (140).
Visual
Loose or crooked standoffs (150 and 155); stripped internal threads.
Replace the chassis assembly (130).
Visual
Deformed chassis (165); cracks around the mounting holes.
Replace the chassis assembly (130).
Visual
Corroded chassis (165); chemical film finish scratched or worn to base metal.
Refer to REPAIR to remove corrosion and apply Alodine over the damaged areas.
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RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER RPS1-B
REPAIR 1.
General A.
Use the appropriate procedures given below to repair damaged parts. Refer to ASSEMBLY to replace damaged wire leads and repair solder connections during final assembly of the BPS battery pack. Paragraph 2 3 4 5 6 7 8
CAUTION:
Repair Action
Tools and Materials Repair Minor Thread Damage Replace Pin Contacts in Connector J1 Replace Clinch Nuts Repair Cover Assembly Repair Chemical Film Finishes Replace Riveted Components
UNITS UNDER WARRANTY SHOULD BE RETURNED TO RADIANT POWER CORP. FOR REPAIR. REMOVAL OF THE TOP COVER WILL VOID THE WARRANTY THE PCB ASSEMBLIES CONTAIN SENSITIVE ELECTRONIC COMPONENTS THAT CAN BE DAMAGED BY ESD AND ROUGH HANDLING. HANDLE THE PCB ASSEMBLIES WITH CARE TO PREVENT DAMAGE. PCB ASSEMBLIES REPAIRED AT FACILITIES OTHER THAN RADIANT POWER CORP. ARE NOT GUARANTEED BY RADIANT POWER CORP.
B.
If the BPS battery pack is under warranty, return it to Radiant Power Corp. for repair. Removal of the top cover in the warranty period will void the warranty.
C.
For field repair, refer to TESTING AND FAULT ISOLATION and/or CHECK to identify the damaged component, and then refer to DISASSEMBLY and ASSEMBLY to replace the components. Refer to the referenced IPL figure, and item number to order replacement components.
D.
Follow industry standard practices to solder components and wire leads.
E.
PCB assemblies A1 and A2 contain fragile electronic components and circuits. The handling precautions and instructions given below will minimize or eliminate possible damage. NOTE: With exception of the Select In Test (SIT) components identified in the IPL, Radiant Power Corp. recommends that the PCB assemblies be returned to Radiant Power Corp. for repair by technicians familiar with the layout and function of the cards. PCB assemblies repaired at facilities other than Radiant Power Corp. are not guaranteed by Radiant Power Corp.
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RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER RPS1-B (1) All integrated circuits (ICs), surface mounted devices, and many other semiconductors are susceptible to ESD (electrostatic discharge). Careless handling during repair can drastically decrease the component life. (2) All work on PCB must be done at an electrostatic discharge (ESD) safe work bench. Refer to REPAIR for general ESD handling instructions and work bench requirements. (3) Store the PCB assemblies in protective antistatic shipping bags until ready for use. Do not store the PCB assemblies in conventional plastic snow, Styrofoam, or plastic trays. Once removed from the bags, PCB assemblies must be handled in accordance with static control procedures. The preferred method is to handle PCB assemblies with clean lint-free cloths or rubber gloves only on the edge of the board. If gloves or cloths are not available, wash your hands to remove oils and handle the boards only on the edges; do not touch the conductive patterns or components. (4) Once removed from the bags, PCB assemblies must be handled in accordance with static Component Maintenance Manual control procedures. The preferred method is to handle PCB assemblies with clean lint-free cloths or rubber gloves only on the edge of the board. If gloves or cloths are not available, wash your hands to remove oils and handle the boards only on the edges; do not touch the conductive patterns or components. (5) Do not stack the PCB assemblies. Stacking can damage surface mounted components. (6) The work station must be clean. To prevent contamination of the PCB assemblies, there must be no smoking, eating, or drinking in the work area. 2.
Tools and Materials A.
The recommended tools and materials are given in Table 601.
NOTE: Equivalent items can be used.
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RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER RPS1-B Repair Tools and Materials Table 601 Part or Specification Number
Nomenclature Abrasive Cloth, Aluminum Oxide
Source (CAGE)*
Federal Specification P-C-451
Alodine, Brush
Commercially Available
No. 120
Ink, Epoxy (Black)
Henkel Corp. (84063)
Hysol 50-700R
Insertion/Extraction Tool, Pin Contact
Military Specification MS24256R12
Commercially Available
Pin Contact, Electrical Connector
Military Specification MIL-C-26636
Commercially Available
---
Commercially Available
Press Hydraulic or Mechanical Silkscreen Template, Nameplate and ESD Caution
11-0054
Solder, Resin Core, Composition Sn63
Federal Specification QQ-S-571
Commercially Available
Solder Iron, Low Wattage (24 to 40 Waft)
---
Commercially Available
Military Specification MIL-1-1966
Commercially Available
BMS13-48C or MIL-W-22759 (Raychem 55A0111-20, -24)
Commercially Available
Tape, Glass Fiber Insulated
Wire, Electrical, 20 and 24 AWG (select size and color per Table 602)
Radiant Power Corp.
*Refer to Table 1001 in the IPL for the address
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RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER RPS1-B 3.
Handling Instructions for Electronic Devices The BPS battery pack contains electronic components that can be damaged by ESD and rough handling. The general handling precautions and instructions given below will help minimize or eliminate possible damage. WARNING: THE BPS BATTERY PACK CONTAINS HIGH VOLTAGE CIRCUITS WHICH CAN CAUSE DEATH OR SEVERE SHOCK. FOLLOW THE SAFETY PRECAUTIONS GIVEN IN THE INTRODUCTION TO THIS CMM TO PREVENT INJURY. CAUTION:
THE PCB ASSEMBLIES CONTAIN ESD SENSITIVE DEVICES. HANDLE THE PCB ASSEMBLIES IN ACCORDANCE WITH STATIC CONTROL PROCEDURES TO PREVENT COMPONENT DAMAGE.
A.
THE BPS BATTERY PACK CONTAINS SENSITIVE ELECTRONIC COMPONENTS THAT CAN BE DAMAGED BY ROUGH HANDLING AND EXPOSURE TO HIGH HUMIDITY, WATER OR OTHER LIQUIDS, CIGARETTE SMOKE, AND OTHER CONTAMINATION. USE THE BPS BATTERY PACK IN AN ENVIRONMENT SUITABLE FOR ELECTRONIC COMPONENTS AND HANDLE THE UNIT WITH CARE TO PREVENT DAMAGE.
B.
If liquid or grease is spilled on or in the BPS battery pack, immediately remove power and wipe off the liquid or grease. Do not touch the BPS battery pack until power has been removed.
C.
Do not use or store the BPS battery pack in a high humidity environment or in direct sunlight. High humidity can short or corrode electronic components.
D.
All integrated circuits (ICs), surface mounted devices, and many other semiconductors are susceptible to ESD. Careless handling during repair can drastically decrease the component life.
E.
When handling ESD sensitive devices, work at an ESD safe work bench. The work bench should include: (1) A grounded conductive sheet covering the bench work area. (2) A grounded wrist strap in contact with skin. (3) If the chair or the floor is nonconducting, the chair must have a ground strap. (4) ESD safe tools and equipment. Use plastic instead of metal tools where possible to prevent short circuits.
F.
Store the PCB assemblies in protective antistatic shipping bags until ready for use. Do not store the PCB assemblies in conventional plastic snow, Styrofoam, or plastic trays.
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RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER RPS1-B G.
4.
Once removed from the bags, PCB assemblies must be handled in accordance with static control procedures. The preferred method is to handle PCB assemblies with clean lint-free cloths or rubber gloves only on the edge of the board. If gloves or cloths are not available, wash your hands to remove oils and handle the boards only on the edges; do not touch the conductive patterns or components.
Repair Minor Thread Damage, Repair damaged threads with an appropriate die or tap if less than 50 percent of one thread is damaged. Replace non-repairable parts.
5.
Replace Pin Contacts in Connector J1 NOTE: Refer to DESCRIPTION AND OPERATION, Figure 3 for a schematic diagram. A wire list for connector J1 is given in Table 602. A.
6.
Use the insertion/extraction tool to insert the pin contacts into the appropriate connector J1 (110) sockets. Refer to Table 602.
Replace Clinch Nuts Use this procedure to replace damaged clinch nuts (160, IPL Figure 1 and 32, IPL Figure 3). A.
Support the bracket or heatsink on the press (Table 601) so it does not move or bend.
B.
Use a punch and the press to push out the damaged nut. Do not bend or crimp the bracket or heatsink around the mounting hole.
C.
Install a new clinch nut in the mounting hole. Put the shank on the punch side as shown in Figure 601.
CAUTION: D.
DO NOT CRUSH THE NUT OR DAMAGE THE THREADS. THE HOLE IN THE PUNCH OR ANVIL MUST CLEAR THE THREADS.
With the punch and anvil surfaces parallel, apply force until the shank of the clinch nut is flush with the underside of the bracket or heatsink. NOTE: The punch or anvil must apply force to the knurled collar of the nut but must have a cavity that fits over the threads so force is not applied to the barrel. Refer to Figure 601.
E.
Examine the clinch nut and the bracket or heatsink for deformation or other damage. (1) The clinch nuts must be aligned and mounted flush with each other. (2) There must be no deformation or cracks around the bracket or heatsink mounting holes.
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RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER RPS1-B Connector J1 Wire List Table 602 Wire Color Orange Orange Orange Orange Orange Orange Orange Orange Orange Orange Orange Orange Orange Orange Orange Orange Orange Orange Orange Orange Orange Orange Orange Orange
Wire Size (AWG)
Connector J1 Pin J1-1 J1-2 J1-3 J1-4 J1-5 J1-6 J1-7 J1-8 J1-9 J1-10 J1-11 J1-12 J1-13 J1-14 J1-15 J1-16 J1-17 J1-18 J1-19 J1-20 J1-21 J1-22 J1-23 J1-24
20 24 24 24 20 20 24 24 20 20 20 24 24 24 24 24 24 24 24 24 24 24 24 24
From Component A2-16 A2-11 A1-11 A1-2 A2-2 A2-15 Solder Lug A1-17 A2-6 A2-5 A2-4 A1-12 A1-13 A1-10 A1-9 A1-6 A1-1 A1-18 A1-3 A1-7 A1-8 A1-14 A1-4 A1-5
Clinch Nut Installation Figure 601
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RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER RPS1-B 7.
Repair Cover Assembly NOTE: This procedure repairs the nameplate and ESD caution silkscreen markings and the insulating tape on the cover assembly (110, IPL Figure 1). Do this procedure after repair of the chemical film finish. WARNING: PAINT THINNER IS VERY FLAMMABLE AND CAN DAMAGE YOUR EYES AND NOSE. USE THE MATERIALS ONLY IN WELL VENTILATED AREAS AWAY FROM OPEN FLAMES. WEAR RUBBER GLOVES AND GOGGLES TO PROTECT YOUR HANDS AND EYES.
8.
A.
Use paint thinner (Table 601) to remove the damaged ink markings.
B.
Refer to CLEANING to clean the repair area.
C.
Use the template and black ink (Table 601) to reapply silkscreen markings.
D.
Replace the insulated tape (Table 601) as needed on the inner surface of the cover. The tape is used in two places to insulate the cover from the electronics assembly.
Repair Anodized Finishes WARNING: ALODINE IS VERY FLAMMABLE AND CAN DAMAGE YOUR EYES AND NOSE. USE ALODINE ONLY IN WELL VENTILATED AREAS AWAY FROM OPEN FLAMES. WEAR RUBBER GLOVES, AN APRON, AND GOGGLES FOR SAFETY. A.
Repair damaged anodized finishes with No. 120 brush Alodine (Table 601) as specified below. NOTE: This procedure gives general instructions for skilled technicians. Refer to Technical Process Bulletin No. 1161, available from the Henkel Corp. (CAGE 84063), for complete instructions.
B.
The Alodine is light brown to orange in color. It is not available in other colors, so the repaired area may not match the original anodize finish.
C.
Clean the component to remove grease, oil, and corrosion.
D.
Apply undiluted Alodine liberally to the aluminum surface. Apply as many coats as needed. Allow approximately one minute reaction time between the applications. NOTE: The Alodine will dry faster when the Alodine and the part are at room temperature (approximately 65°F to 75°F). One to five minutes is normally required for the coat to dry. The Alodine can be applied with an acid-resistant brush, swab, synthetic sponge, or portable spray equipment..
E.
Remove any excess Alodine with clean water and lint-free cloths.
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RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER RPS1-B F. 9.
Use lint-free cloths or compressed air at less than 20 psig (138 kPag) to dry the part. Pay close attention to the seams, joints, and crevices.
Replace Riveted Components NOTE: Use this procedure to replace cracked or loose rivets or to replace damaged components attached with rivets. CAUTION: DO NOT ENLARGE THE RIVET MOUNTING HOLE. A.
Drill out the damaged rivet with a drill bit smaller than the diameter of the rivet (145, IPL Figure 1) shank. Do not enlarge the mounting hole beyond the minimum needed to remove the rivet. NOTE: The diameter of the rivet shank is given in the NOMENCLATURE column of the IPL. The size of the rivet holes are controlled by standard shop-practice use of oversize replacement rivets. The minimum pitch and edge distances for rivets are determined by the original design and should be closely matched during repair.
B.
Install new rivets (145) as needed to secure the battery mounting brackets (140).
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RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER RPS1-B
ASSEM BLY (INCLUDING STORAGE) 1.
General A.
This section contains reassembly, packaging, and storage instructions. The procedures are arranged in the reverse sequence of DISASSEMBLY and the IPL. Skip procedures and/or procedure steps as applicable if the BPS battery pack is already partially assembled. NOTE: Refer to REPAIR for instructions to replace the 15, IPL Figure 1), damaged clinch nuts (160 IPL Fig. 1 (32 IPL Fig. 3), all riveted components, and all bonded components.
B.
Refer to IPL Figure 1 for an exploded-view illustration of the BPS battery pack. Refer to DESCRIPTION AND OPERATION, Figure 3, for wire routing.
C.
This CMM covers maintenance of the RPS1-B configuration only. Contact Radiant Power Corp. for maintenance of the earlier configurations given below: Part Number RPS1 RPS1-A
D.
11-0041-1 11-0041-2
2.
0001 through 0016 0017 through 0052
Two electrically identical but physically different logic PCB assemblies are used in the RPS1-B configuration depending on the serial number. Both variations are covered in this CMM. Part Number
E.
Serial Numbers
Serial Numbers 0626 and subsequent 0053 through 0625
IPL Figure-item Number 2-15 2-15A
All work must be done at an electronics work bench. Refer to paragraph 2, below, for general handling instructions and work bench requirements. No other special tools or equipment are required.
Tools and Materials A.
The recommended tools and materials are given in Table 701. NOTE: Equivalent items can be used.
B.
All work on PCB must be done at an electrostatic discharge (ESD) safe work bench. Refer to REPAIR for general ESD handling instructions and work bench requirements. No other special tools or equipment are required.
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Page 701 Aug 2009
RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER RPS1-B 3.
Handling Instructions for Electronic Devices PCB assemblies A1 and A2 contain fragile electronic components and circuits. The handling precautions and instructions given below will minimize or eliminate possible damage. A.
All integrated circuits (ICs), surface mounted devices, and many other semiconductors are susceptible to ESD (electrostatic discharge). Careless handling during repair can drastically decrease the component life.
B.
When handling ESD sensitive devices, work at an ESD safe work bench. The bench should include: (1) A grounded conductive sheet covering the bench work area. (2) A grounded wrist strap in contact with skin. (3) If the chair or the floor is nonconducting, the chair must have a ground strap. (4) ESD safe tools and equipment. Use plastic instead of metal tools where possible to prevent short circuits.
C.
Store the PCB assemblies in protective antistatic shipping bags until ready for use. Do not store the PCB assemblies in conventional plastic snow, Styrofoam, or plastic trays.
D.
Once removed from the bags, PCB assemblies must be handled in accordance with static control procedures. The preferred method is to handle PCB assemblies with clean lint-free cloths or rubber gloves only on the edge of the board. If gloves or cloths are not available, wash your hands to remove oils and handle the boards only on the edges; do not touch the conductive patterns or components.
E.
Do not stack PCB assemblies. Stacking can damage surface mounted components.
F.
The work station must be clean. To prevent contamination of PCB assemblies, there must be no smoking, eating, or drinking in the work area.
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RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER RPS1-B 4.
Electrical Wire Replacement NOTE: This procedure provides general instructions to select and solder new wire leads during assembly. Refer to MIL-STD-454, Requirement 5 for soldering instructions. CAUTION:
DO NOT OVERHEAT ELECTRONIC COMPONENTS WHEN SOLDERING WIRE LEADS. USE A HEAT SINK AND LOW WATTAGE SOLDER IRON TO PREVENT DAMAGE. USE A SOLDER SUCKER AND/OR SOLDER WICK TO REMOVE EXCESS SOLDER. PCB ASSEMBLIES A1 AND A2 CONTAIN SENSITIVE ELECTRONIC COMPONENTS THAT CAN BE DAMAGED BY ESD AND ROUGH HANDLING. HANDLE THE PCB ASSEMBLIES WITH CARE TO PREVENT DAMAGE.
A.
Trim new wire leads as needed to the length given in Table 702. Select the wire color and gage to match. NOTE: All wire lengths to be ±1/16 inch (±1.6 mm). Pre-strip all wire ends to 1/8 inch (3.2 mm).
B.
Solder the wire leads to the applicable terminals given in Table 703 with the solder given in Table 701. Duplicate the original wire routing as closely as possible. Refer to REPAIR to replace the connector J1 wire leads and pin contacts. NOTE: Refer to DESCRIPTION AND OPERATION, Figure 3, for wire routing.
5.
Assembly Instructions A.
Chassis Assembly (130, IPL Figure 1) (1) Refer to REPAIR to replace the riveted battery assembly brackets (140). (2) Refer to REPAIR to replace the clinch nuts (160).
B.
Battery Charger Assembly (100, IPL Figure 1) NOTE: This procedure contains information for wire routing. Duplicate the original wire routing, insulation, and soldering methods as closely as possible. A point-topoint wire list is given in Table 703. A schematic diagram showing all connections is given in DESCRIPTION AND OPERATION, Figure 3.
C.
Install resistors R1 and R2 (65, IPL Figure 2), as follows: (1) Solder the wire leads to resistor R1 and/or R2 (65). Refer to paragraph 3, above, and Figure 701. (2) Lightly coat the threads of the screws (80) with thread lock compound (Table 701). Secure the resistors to the bracket assemblies (85 and 90) with the screws, the washers (75), and the nuts (70).
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RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER RPS1-B D.
Install transistor Q2 (35), as follows: (1) Solder the wire leads between transistor Q2 (35) and the solder lug (60) and regulator PCB assembly A2 (10). Refer to paragraph 3, above and Table 703. (2) Secure transistor Q2 (35), Thermal insulator pad, and an insulator strip (55) to the bracket assembly (85) with the screws (45A or 45B) and the nuts (40). Install the solder lug (60) under the upper nut as shown in Figure 701. NOTE: Install a new Thermal insulator pad (50) at each overhaul.
Resistor R1/R2 Wiring Diagrams Figure 701
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RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER RPS1-B E.
Install transistor Q1 (30), as follows: (1) Solder the wire leads between transistor Q1 (30), the solder lug (60), and regulator PCB assembly A2 (10). Refer to paragraph 3, above and Table 703. (2) Solder the wire lead from the transistor Q1 (30) emitter to resistor R2 (65). (3) Secure transistor Q1 (30), Thermal insulator pad, and an insulator strip (55) to the bracket assembly (90) with the screws (45A or 45B) and the nuts (40). Install the solder lug (60) under the upper nut as shown in Figure 701. NOTE: Install a new Thermal insulator pad (55) at each overhaul.
F.
Install transistor Q3 (5, IPL Figure 3) on regulator PCB assembly A2, as follows: (1) Refer to REPAIR to replace the damaged clinch nuts (32). (2) Secure transistor Q3 (5), Thermal insulator pad, the bracket assembly (30), and an insulator strip (25) to the swaged standoffs on regulator PCB assembly A2 with the screws (10) and the washers (15). NOTE: Install a new Thermal insulator pad (20) at each overhaul.
G.
Solder the wire leads between logic PCB assembly A1 (15 or 15A, IPL Figure 2) and regulator PCB assembly A2 (10). Refer to paragraph 3, above and Table 703. NOTE: With exception of the SIT components identified in the IPL, Radiant Power Corp. recommends that PCB assemblies A1 and A2 be returned to Radiant Power Corp. for repair by technicians familiar with the layout and function of the cards. PCB assemblies repaired at facilities other than Radiant Power Corp. are not guaranteed by Radiant Power Corp..
H.
Solder the connector J1 (110) wire leads to the PCB assemblies (10 and 15 or 15A).
I.
Solder the wire leads between TEST switch SW1 (100) and logic PCB assembly A1 (15 or 15A).
J.
Solder the wire lead from connector J1 (110), pin 7, to the solder lug (105).
K.
Visually examine all solder connections, wire leads, and wire routing. Refer to Table 703 and Figure 3 in DESCRIPTION AND OPERATION.
WARNING: THE CONFORMAL COATING CAN IRRITATE YOUR EYES AND NOSE. APPLY THE COATING ONLY IN A WELL VENTILATED AREA. FLUSH IRRITATED EYES WITH WATER. CAUTION:
THE WORK AREA AND BRUSH MUST BE CLEAN TO PREVENT CONTAMINATION.
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RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER RPS1-B L.
Touch-up the conformal coating (Table 701) on the electronics assembly (120 or 120A, IPL Figure 1) as given below. NOTE: This step applies conformal coating to the electronics assembly using a synthetic fiber brush. This is the preferred method for repairs over aerosol sprays or dipping the assembly in a dip tank. (1) Fold open the circuit boards and other components as needed to access the conformal coated surfaces. (2) Use a stiff bristle brush, plastic blade, or an equivalent tool to remove loose particles, ridges of coating material, and other defects in the conformal coating. The coated areas must have no visible blisters, cracking, peeling, pin holes or wrinkles. There must be no bubbles in contact with or bridging conductive surfaces. (3) Flood the area with isopropyl alcohol (Table 701) to wash off particles and soluble contamination. (4) Allow the electronics assembly to air dry for 30 minutes. (5) Examine the electronics assembly under black, ultraviolet light. Identify bare areas, other than solder connections, where the conformal coating has been worn through or scraped off. (6) Pour the necessary amount of Humiseal conformal coating (Table 701) from the sealed container into a temporary container. NOTE: The Humiseal conformal coating must be stored in a sealed container or it will form a skin of solid material after approximately four hours. The skin can be dissipated by pouring a 1/16 to 1/8 inch layer of thinner, Humiseal No. 20, over the material and covering the container with a tightly fitting cover. (7) Apply the conformal coating material with a synthetic (not natural) fiber brush. Coat all solder connections and the nonconductive areas of the PCB assemblies, including both sides of the printed circuit board, all board mounted components and their leads, and all exposed conductors. Do not coat electrical and mechanical mating surfaces, such as connector contact points, screw threads, bearing surfaces, etc. Mask the surfaces and components before application of the coating material, and carefully remove any tape residue and other contamination after the material has been applied. The coating must be 0.001 to 0.003 inch (0.025 to 0.076 mm) thick, when measured on a flat, unobstructed surface. (8) The coated areas must have no visible blisters, cracking, peeling, pin holes or wrinkles. There must be no bubbles in contact with or bridging conductive surfaces. (9) Examine the electronics assembly under black, ultraviolet light. Identify bare areas that require conformal coating. Reapply conformal coating to cover defective or bare areas, as required.
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RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER RPS1-B (10) Allow the conformal coating to cure in accordance with the manufacturer's instructions. M.
Lightly coat the threads of TEST switch SW1 (100, IPL Figure 2) with thread lock compound (Table 701). Install the switch through the solder lug (105) and the front panel (125) with the hex nut provided.
N.
Lightly coat the threads of the screws (20) with thread lock compound. Secure regulator PCB assembly A2 (10) and the insulator (12) to the mounting brackets (85 and 90) with the screws and the washers (25). NOTE: Install the insulating washers (25) on both sides of the printed circuit board. Install new washers at each overhaul.
O.
Lightly coat the threads of the screws (20) with thread lock compound. Secure logic PCB assembly A1 (15 or 15A) to the mounting brackets (85 and 90) with the screws and the washers (25). NOTE: Install the insulating washers (25) on both sides of the printed circuit board. Install new washers at each overhaul.
P.
Install connector J1 (110) in the front panel (125) with the screws (115) and the nuts (1 20A).
Q.
Secure the front panel (125) to the mounting brackets (85 and 90) with the screws (95).
CAUTION:
R.
DO NOT LIFT THE ELECTRONICS ASSEMBLY AFTER MATING THE PIN CONTACTS AND SOCKETS. DOING SO CAN DAMAGE THE PIN CONTACTS ON REGULATOR PCB ASSEMBLY A2.
Install the electronics assembly (120 or 120A, IPL Figure 1), as follows: (1) Lightly coat the bottoms of the transistor Q1, and Q2 and Q3 mounting brackets with thermal compound (Table 701). (2) Insert the electronics assembly (120 or 120A) into the chassis assembly (130). (3) Press the electronics assembly (120 or 120A) against the chassis and carefully slide it inward to insert pin contacts J3-1 and J3-2 on regulator PCB assembly A2 into pin sockets J2-1 and J2-2 (60 and 65) in the battery holder assembly (5). (4) Lightly coat the threads of the screws (125) with thermal compound (Table 701). Install the screws through the chassis assembly (130) and into the electronics assembly (120 or 120A).
S.
Refer to REPAIR to replace the adhesive-backed chassis nameplate (105) or the silkscreen markings, as applicable.
T.
Install the cover assembly (110) with the screws (115).
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RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER RPS1-B 6.
Battery Holder Assembly (5, IPL Figure 1) A.
Bond the fuse retainer pad (95, IPL Figure 1) to the top half of the battery case (20), as follows: CAUTION: DO NOT USE SOLVENT CLEANERS ON THE BATTERY CASE (20). SOLVENTS CAN DAMAGE THE LEXAN MATERIAL. (1) Clean the mounting area on the top half of the battery case (20) with isopropyl alcohol and lint-free cloths (Table 701). (2) Bond the fuse retainer pad (95) to the top half of the battery case (20) with adhesive (Table 701).
CAUTION: DO NOT SOLDER THE WIRE BRAID (90) ON THE END OF THE BATTERY PACK OPPOSITE PIN SOCKETS J2-1 AND J2-2 UNTIL THE SOCKETS ARE CONNECTED AND INSULATED. B.
Solder the batteries (55) in series as shown in Figure 702. Do not connect the wire braid (90) opposite pin sockets J2-1 and J2-2 (60 and 65) until the pin sockets are soldered and insulated (step (6), below). NOTE: Replacement batteries (55) are shipped with integral solder tabs. All six batteries should be replaced if any one battery is damaged or corroded.
Battery Connection Diagram Figure 702
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RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER RPS1-B C.
Cut two 1.375-inch (3.49 8.9 cm) lengths of wire braid (90). Solder one wire braid to the positive tab on the battery pack and one to the negative tab. Refer to Figure 702.
D.
Install two shoulder washers (85) back to back through each pin socket (60 and 65) mounting hole in the top half of the battery case (20). Insert the pin sockets through the shoulder washers and install the flat washers (80) and the nuts (70).
E.
Turn the top half of the battery case (20) upside down and install the batteries (55) with the solder tabs facing up (out away from the case). Loop the positive and negative wire braids (90) up along the outside and over the top of pin sockets J2-1 and J2-2 (60 and 65). NOTE: The wire braid (90) from the positive battery pack terminal connects to red pin socket J2-1 (60). The wire braid from the negative terminal connects to black pin socket J2-2 (65). Refer to Figure 701.
CAUTION: F.
DO NOT TIN THE BRAID MORE THAN 1/4 INCH (6 MM) FROM THE PIN SOCKET TINNING CAN DECREASE THE FLEXIBILITY OF THE BRAID.
Solder the positive and negative wire braids (90) to pin sockets J2-1 and J2-2 (60 and 65). Refer to paragraph 3, above.
CAUTION: INSERT A PIECE OF INSULATING MATERIAL BETWEEN PIN SOCKETS J2-1 AND J2-2 TO PREVENT SHORTING DURING MAINTENANCE. G.
Insert a piece of insulating material (tape, paper, etc.) between pin sockets J2-1 and J2-2 (60 and 65).
H.
Solder the rear wire braid (90) to the applicable battery (55) tabs. Refer to Figure 701.
I. Rotate each group of three batteries (55) inward, tucking the intermediate solder tabs behind the integral insulators in the top half of the battery case (20). Loop the rear wire braid (90) inward between the batteries. J. Install the 1/4-turn fasteners (25) and the retraction springs (30) in the pockets in the top half of the battery case (20). Install the Teflon washers (35A) on the fasteners inside the case. CAUTION:
K.
MAKE SURE THERE IS NO CONTACT BETWEEN PIN SOCKETS J2-1 AND J2-2 OR ANY OTHER OPPOSITELY CHARGED COMPONENT BEFORE THE INSULATING MATERIAL IS REMOVED.
Remove the insulating material from between pin sockets J2-1 and J2-2 (60 and 65).
Copyright 2004 by: Radiant Power Corp., a HEICO Company
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RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER RPS1-B L.
Install the bottom half of the battery case (20), with the insulator inserted between pin sockets J2-1 and J2-2 (60 and 65). The Teflon washers (35A) must be installed between the top and bottom half cases. The 1/4-turn fasteners (25) must extend through the matching holes in the bottom half.
CAUTION:
M.
Install the screws (50) and the nuts (40A) to secure the top and bottom halves of the battery case (20) together. Tighten the nuts snug but not enough to damage the battery case.
CAUTION:
N.
DO NOT OVERTIGHTEN THE SCREWS (50) AND THE NUTS (40A). THE BATTERY CASE IS MADE OF A LIGHTWEIGHT PLASTIC MATERIAL THAT CAN CRACK.
DO NOT LIFT THE BATTERY HOLDER ASSEMBLY AFTER MATING THE PIN CONTACTS AND SOCKETS. DOING SO CAN DAMAGE THE PIN CONTACTS ON PCB ASSEMBLY A2.
Install the battery holder assembly (5), as follows: (1) Insert the battery holder assembly (5) into the chassis assembly (130). (2) If the electronics assembly (120 or 120A) is installed, press the battery holder assembly (5) against the chassis and carefully slide it inward to insert pin contacts J3-1 and J3-2 on regulator PCB assembly A2 into pin sockets J2-1 and J2-2 (60 and 65). (3) If the electronics assembly (120 or 120A) is not installed, press the battery holder assembly (5) against the chassis and carefully slide it inward to a position over the receptacles (135) in the chassis brackets. CAUTION: DO NOT TURN THE 1/4-TURN FASTENERS PAST THE DETENT. (4) Turn the 1/4-turn fasteners (25) clockwise approximately 90° to the stop. An audible click will be heard when the stop is reached. The fasteners should compress the retraction springs (30).
O.
Refer to TESTING AND FAULT ISOLATION to bench test the BPS.
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RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER RPS1-B 7.
Packaging Instructions Protect the BPS battery pack from humidity and shock by packaging the unit when it is not in use or for transport. Repack the BPS battery pack in the original shipping container when possible. CAUTION:
THE PCB ASSEMBLIES CONTAIN ESD SENSITIVE DEVICES. REFER TO REPAIR FOR ESD SAFE HANDLING PROCEDURES. THE BPS BATTERY PACK CONTAINS SENSITIVE ELECTRONIC COMPONENTS THAT CAN BE DAMAGED BY ROUGH HANDLING AND EXPOSURE TO HIGH HUMIDITY, WATER OR OTHER LIQUIDS, CIGARETTE SMOKE, AND OTHER CONTAMINATION. USE THE BPS BATTERY PACK IN AN ENVIRONMENT SUITABLE FOR ELECTRONIC COMPONENTS AND HANDLE THE UNIT WITH CARE TO PREVENT DAMAGE.
A.
Refer to REPAIR for ESD safe handling procedures.
B.
If loose components must be shipped, pack the PCB assemblies in antistatic shipping bags. Pack all other components in clean plastic bags. The materials given below are unacceptable and prohibited from use in any packaging where they could come into direct contact with the PCB assemblies. (1) Untreated styrofoam, polyform or polystyrene sheets, black inserts, and foam filler pieces (for example, foam peanuts). (2) Untreated plastic boxes. (3) Static-generating plastic wrap, bags, or bubble pack. (4) Pink poly foam and bubble wrap that is not certified Amine-free. (5) Untreated connector plastic dust covers.
C.
If the original shipping containers are not available, pack the BPS battery pack, as follows: (1) Write the maintenance data and dates on a tag. Attach the tag to the battery pack. (2) Install a protective cap (Table 7023) on connector J1. (3) Overwrap the battery pack in nylon film or bubble wrap to cushion the unit and prevent damage to the barrier bag. (4) Pack the battery pack in a corrugated paper box. Fill all voids with cellulose wadding or brown Kraft paper. (5) Add a sufficient amount of desiccant and sea the box with packing tape. (6) Write the BPS battery pack nomenclature, part number, and maintenance/test dates on the box.
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RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER RPS1-B 8.
Storage Instructions CAUTION:
THE PCB ASSEMBLIES CONTAIN ESD SENSITIVE DEVICES. REFER TO REPAIR FOR ESD SAFE HANDLING PROCEDURES. THE BPS BATTERY PACK CONTAINS SENSITIVE ELECTRONIC COMPONENTS THAT CAN BE DAMAGED BY ROUGH HANDLING AND EXPOSURE TO HIGH HUMIDITY, WATER OR OTHER LIQUIDS, CIGARETTE SMOKE, AND OTHER CONTAMINATION. USE THE BPS BATTERY PACK IN AN ENVIRONMENT SUITABLE FOR ELECTRONIC COMPONENTS AND HANDLE THE UNIT WITH CARE TO PREVENT DAMAGE.
A.
Refer to REPAIR for ESD safe handling procedures.
B.
Refer to ASSEMBLY, paragraph 6 to package the BPS battery pack for storage.
C.
Store the BPS battery pack in an area suitable for electronic equipment. The storage area must have adequate ventilation with low humidity, dust, and protection from direct sunlight and high heat. (1) Store the BPS in a cool, dry area, as follows: (a)
Battery Packs may be stored without damage in a charged or discharged condition over the temperature range of –30°C to +70°C (-22°F to +158°F). Long term storage (over 3 months) should be at temperatures less than +35°C (+95°F).
(b)
The batteries will self-discharge at a rate dependent on time and temperature. At room temperature of 72°F (22°C), the rate is approximately 1.5% every 24 hours. The rate increases as the storage temperature increases, and decreases as the temperature decreases. The batteries should always be recharged for 16 hours at a constant current of 350 milliamperes before use.
(c)
To store the BPS charged and ready for immediate use, fully charge the BPS at 350 milliamperes for 16 to 20 hours and store the unit for no more than 30 days at an ambient temperature of 77°F (25°C). After 30 days, the BPS should be discharged to the cutoff voltage of 5.4 VDC, and then recharged at 350 milliamperes for 16 to 24 hours. Repeat this cycle to maintain charged batteries ready for immediate use.
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RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER RPS1-B Assembly Tools and Materials Table 701 Nomenclature
Part or Specification Number RTV 102
Adhesive Alcohol, Isopropyl
Solder, Resin Core, Composition Sn63
Commercially Available
---
Commercially Available
Military Specification MIL-1-46058, Class C, Type UR (Humiseal 1A20)
Commercially Available
---
Commercially Available
120-2
Thermal Compound
Military Specification MIL-S-22437(Loctite Grade H)
The Wakefield Corp. (92218) Loctite Corp. (05972)
---
Commercially Available
BMS13-48C or MIL-W-22759 (Raychem 55A0111-20, -24)
Commercially Available
Ultraviolet Light, Black Wire, Electrical, 20 and 24 AWG (select size and color per Table 702)
Columbia Chase Corp. (99109)
Federal Specification QQ-S-571
Solder Iron, Low Wattage (24 to 40 Waft)
Thread Lock Compound
General Electric Supply Co. (9G944)
Federal Specification TT-I-735
Brush, Synthetic Fiber Conformal Coating, Brush Application
Source
*Refer to Table 1001 in the IPL for the address. Storage Materials Table 702 Description
Part Number or Specification Number
Source (CAGE)*
Bag, Polyethylene
Military Specification MIL-B-117
Commercially Available
Box, Corrugated Paper
Federal Specification PPP-B-636
Commercially Available
---
Cover, Protective Tape, Packing
Protective Closures Inc. (99017)
Federal Specification JAN-P-127
Commercially Available
---
Commercially Available
Tag, Identification
*Refer to Table 1001 in the IPL for the address.
Copyright 2004 by: Radiant Power Corp., a HEICO Company
25-60-03
Page 713 Aug 2009
RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER RPS1-B Assembly Wire List Table 703 Wire Color Orange Orange Orange Orange Orange Orange Orange Orange Orange Orange Orange Orange Orange Orange Orange Orange Orange Orange Orange Orange Orange Orange Orange Orange Orange Orange Orange Orange Orange Orange Orange Orange Orange Orange Orange Orange Orange Orange Orange Orange Orange Orange Orange
Wire Size (AWG) 24 24 24 24 24 24 24 24 24 24 24 24 24 24 24 24 24 24 24 24 24 24 20 20 20 20 20 20 24 20 20 20 24 24 20 24 20 20 24 20 24 24 20
Copyright 2004 by: Radiant Power Corp., a HEICO Company
From Component A1-1 A1-2 A1-3 A1-4 A1-5 A1-6 A1-7 A1-8 A1-9 A1-10 A1-11 A1-12 A1-13 A1-14 A1-15 A1-16 A1-17 A1-18 A1-19 A1-20 A1-21 A1-22 A2-1 A2-2 A2-3 A2-4 A2-5 A2-6 A2-7 A2-8 A2-9 A2-10 A2-11 A2-12 A2-13 A2-14 A2-15 A2-16 A2-17 A2-18 A2-19 A2-20 Resistor R2
To Component J1-17 J1-4 J1-19 J1-23 J1-24 J1-16 J1-20 J1-21 J1-15 J1-14 J1-3 J1-12 J1-13 J1-22 A2-17 TEST Switch S1 J1-8 J1-18 A2-20 A2-14 A2-12 TEST Switch S1 Q2-E (Emitter) J1-5 Q2-C (Collector) J1-11 J1-10 J1-9 Q1-B (Base) Resistor R1 Q1-C (Collector) Resistor R1 J1-2 A1-21 Resistor R2 A1-20 J1-6 J1-1 A1-15 Q2-C (Collector) Q2-B (Base) A1-19 Q1-E (Emitter)
25-60-03
Page 714 Aug 2009
RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER RPS1-B
SPECIAL TOOLS, FIXTURES AND EQUIPMENT The recommended special tools, fixtures, and test equipment are given in Table 901. NOTE: Equivalent items can be used. Special Tools, Fixtures, and Equipment Table 901 (Sheet 1 of 2) Nomenclature
Part Number
Source (CAGE)*
Use
Bright Light
---
Commercially Available
To assist in the inspection of parts.
Brush, Synthetic Fiber
---
Commercially Available
To apply Humiseal conformal coating.
Connector, Electrical
BACC45FN1 6-24S or 48-16R1624S
The Boeing Co. (81205) Amphenol Corp. (77820)
Mating connector to connect test equipment to BPS for bench tests.
Diode, Light Emitting
83SF5LR
Chicago Miniature Lamp Inc. (71744)
To indicate VCC power during bench tests.
Commercially Available
To replace damaged pin contacts in connector J1.
General Electric Co. (0EE74)
Load to simulate emergency lights for bench tests.
Insertion/Extraction Tool, Pin Contact
MS24256R12
Lamp, Incandescent (Test Load) (7 Required)
No.82
Megohmmeter, 100 megohms, 500 VDC, ±2% Full Scale
Model 16449701
Quadtech Inc. (0PK96)
To measure the insulation resistance of the BPS circuits.
Multimeter (Ohmmeter, Ammeter or Voltmeter can be used), 0 to 10 Amps DC (±2% Full Scale), 0 to 100 VDC (3-1/2 digits); 200 to 300 kilohms
Model 8010A or 8012A
John Fluke Mfg. Co., Inc. (89536)
To measure voltage, current, and resistance for bench tests.
Power Supply, 0 to 8 VDC
Model 6631B
Agilent. (28480)
DC power source E1 for bench tests.
Power Supply, 0 to 32 VDC (E2)
Model E3641A
Agilent. (28480)
DC power source E2 for bench tests.
*Refer to Table 1001 in the IPL for the address.
Copyright 2004 by: Radiant Power Corp., a HEICO Company
25-60-03
Page 901 Aug 2009
RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER RPS1-B Special Tools, Fixtures, and Equipment Table 901 (Sheet 2 of 2) Nomenclature Press, Hydraulic or Mechanical RPS1-B Battery Housing Analyzer Kit
Part Number ---
550-13057-00
Source (CAGE)*
Use
Commercially Available
To press new clinch nuts in the brackets and heatsink..
Radiant Power Corp. (1MXA1)
To perform on-aircraft testing of RPS1-B battery and charger.
Switch, Momentary Contact, SPST (S1)
---
Commercially Available
Switch for bench test setup.
Switch, Toggle SPST (S4 through S7) (4 Required)
---
Commercially Available
Switch for bench test setup.
Switch, Toggle SPST on, off, on (S2 &, S3)
---
Commercially Available
Switch for bench test setup.
Switch, Toggle DPDT (S11)
---
Commercially Available
Switch for bench test setup.
Solder Iron, Low Wattage (24 to 40 Waft)
---
Commercially Available
To solder wire connections to the circuit board pads and other electronic/electrical components.
Tank or Shop Compressed Air, 20 psi (140 Pkg)
---
Commercially Available
To clean and dry BPS components.
Thread Chaser
---
Commercially Available
To repair damaged threads.
*Refer to Table 1001 in the IPL for the address.
Copyright 2004 by: Radiant Power Corp., a HEICO Company
25-60-03
Page 902 Aug 2009
RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER RPS1-B
ILLUSTRATED PARTS LIST 1.
Introduction A.
Purpose This IPL illustrates and lists authorized replacement parts.
B.
Guide to Use of the IPL (1) If the part number is not known: (a)
Find the part in the exploded-view illustrations.
(b)
Refer to the parts list and find the item number in the FIG. ITEM column.
(2) If the part number is known:
2.
(a)
Refer to the parts list, numerical index, or equipment designator index and find the part in the PART NUMBER column.
(b)
Refer to the exploded-view illustration to identify the attaching hardware and related assembly parts.
Manufacturer Names and Addresses The CAGE codes for the companies that make the parts, the materials, the special tools, and the test equipment referenced in this CMM are given in Table 1001. The codes are taken from Cataloging Handbook H4/H8. No code is given in the parts list when the part is made by Radiant Power Corp. or to a Radiant Power Corp. Source Control Drawing (SCD).
3.
Equipment Designator Index The Equipment Designator Index is an aid to find electronic and electrical components in the Detail Parts List by equipment designator. The equipment designator, the figure number, and the item number are given for each entry. The equipment designators are sorted one character at a time, from left to right. The correct sequence is (1) dash, (2) letters A through Z, and (3) numerals 0 through 9.
4.
Numerical Index The Numerical Index is an aid to find the parts in the Detail Parts List by part number. The figure number, the item number, and the total quantity are given for each entry. The part numbers are sorted one character at a time, from left to right. The correct sequence is (1) dash, (2) letters A through Z, and (3) numerals 0 through 9.
Copyright 2004 by: Radiant Power Corp., a HEICO Company
25-60-03
Page 1001 Aug 2009
RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER RPS1-B Manufacturer Names and Addresses Table 1001 (Sheet 1 of 2) CAGE
Name and Address
28480
Agilent Technologies 3000 Minuteman Rd. Andover, MA 01810-1032
00779
Amp Inc. 2800 Fulling Mill Road (P.O. Box 3608) Harrisburg, PA 17105
0EE74
General Electric Co. GE Lighting Div. 4400 ox Ad. (P.O. Box 4705) Glen Allen, VA 23060
1MXA1
Radiant Power Corp. Inc. 11001 US Hwy 41 N. Palmetto, FL 34221
0PK96
Quadtech Inc. 45 Main St. Bolton, MA 01740-1107
05276
ITT Pomona Electronics Div. 1500 E. 9th St. (P.O. Box 2767) Pomona, CA 91766-3835
05972
Loctite Corp. 705 N. Mountain Rd. (P.O. Box 11915) Newington, CT 06111-1411
12405
Dexter Corp. (formerly Hysol) Dexter Electronic Materials Div. 15051 E. Don Julian Rd. Industry, CA 91746
16428
Cooper Industries Inc. Belden Division, Richmond Plant 350 NW N St. Richmond, IN 47374
18565
Chromerics Inc. 77 Dragon Court Woburn, MA 01888
19457
Baker Performance Chemicals Inc. Calla Chemical Operations 11808 S. Bloomfield Sante Fe Springs, CA 90670
39425
McNab Inc. 20 W. MacQueston Parkway Mount Vernon, NY 10550-1841
Copyright 2004 by: Radiant Power Corp., a HEICO Company
CAGE
Name and Address
4T284
Clorox Co. Food Service Products Div. 1221 Broadway Oakland, CA 94612-1637
46384
Penn Engineering and Mfg. Corp. Old Easton Road (P.O. Box 1000) Danboro, PA 18916
49956
Raytheon Co. 141 Spring St. Lexington, MA 02173-7801
53894
Aham-Tor Inc. (ATI) 27901 Front St. Temecula, CA 92390-0739
56964
USECO 444 S. Tustin NO K6 (P.O. Box 6407) Orange, CA 92667-7723
71744
Chicago Miniature Lamp Inc. Chevy Chase Business Park 1080 Johnson Dr. Buffalo Grove, IL 60089
75345
Kirkhill Rubber Co. 300 E. Cypress St. Brea, CA 92621-4007
75915
Littelfuse Tracor Inc. 800 E. Northwest Highway Des Plaines, IL 60016-3049
77820
Amphenol Corp. Bendix Connector Operations 40-6- Delaware St. Sidney, NY 19838-1395
79963
Zierick Mfg. Co. Radio Circle Mount Cisco, NY 10549
81073
Grayhill Inc. 561 Hillgrove Ave. (P.O. Box 10373) La Grange, IL 60525-5914
81205
The Boeing Company 7755 E. Marginal Way (P.O. Box 3707) Seattle, WA 98124
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Page 1002 Aug 2009
RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER RPS1-B Manufacturer Names and Addresses Table 1001 (Sheet 2 of 2) CAGE
5.
Name and Address
84063
Henkel Corp. Horsham Business Center 300 Welsh Road, Building 2, Suite I Horsham, PA 19044
86928
Seastrom Mfg. Co. Inc. 701 Sonora Ave. Glendale, CA 91201-2431
89536
John Fluke Mfg. Co., Inc. 6920 Seaway Boulevard (P.O. Box 9090) Everett, WA 98206-9090
89954
General Electric Co. Aircraft Control Systems Dept. 600 Main St. Johnson City, NY 13790
9G944
General Electric Supply Co. 200 W. River Ave. Pittsburgh, PA 15212-5725
CAGE
Name and Address
92218
The Wakefield Corp. 29 Foundry St. Wakef ield, MA 01880-3206
94222
Southco Inc. 210 N. Brinton Lake Rd. Concordville, PA 19331
94058
Brulin and Co. Inc. 2920 Dr. Andrew J. Brown Dr. (P.O. Box 270) Indianapolis, IN 46206
99017
Protective Closures Co. Inc. Caplugs Division 2150 Elmwood Avenue Buffalo, NY 14207-1910
99109
Columbia Chase Corp. Humiseal Div. 26-60 Brooklyn/Queens Expressway P.O. Box 445 Woodside, NY 11377-0445
Explanation of Detail Parts List Entries The Detail Parts List is arranged in general sequence of disassembly. The parts are illustrated in an exploded-view illustration and listed in the related parts list. A.
FIG. ITEM Column (1) The first number at the top of each FIG. ITEM column is the figure number of the exploded view illustration. The number given opposite each part number is the item number given to the part in the illustration. (2) A dash (-) is put before the item number when it is not illustrated. (3) Alpha-variants A through Z (except I and O) are given to item numbers when necessary to identify added parts, alternative parts, and service bulletin modified parts.
B.
PART NUMBER Column This column contains the part number for each part, as modified to satisfy ATA 200/2000. The modifications can include: (1) Removal of blank spaces and special characters, with the possible exception of dashes. Dashes are permitted only between numeric characters. (2) Use of a shorter part number compatible with ATA 200/2000 if the part number is longer than 15 characters. The full part number is given in the NOMENCLATURE column.
Copyright 2004 by: Radiant Power Corp., a HEICO Company
25-60-03
Page 1003 Aug 2009
RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER RPS1-B C.
NOMENCLATURE Column (1) This column contains the name of each part. The column can also contain the CAGE code of the company that made the part (if it is not made by Radiant Power Corp.), the full part number (if it is longer than 15 digits or modified to ATA 200/2000), any service bulletins that apply to the part, and any obsolete part numbers. (2) The indenture system used in the NOMENCLATURE column shows how each part is related to the others, as follows: 123 End Item or Major Assembly .Detail Parts for End Item or Major Assembly .Subassemblies ATTACHING PARTS .Attaching Parts for Subassemblies *** . . Detail Parts for Subassemblies ATTACHING PARTS . . Attaching Parts for Detail Parts *** (3) Assemblies, subassemblies and detail parts subject to modification, deletion, addition or replacement by an issued service bulletin are annotated to indicate both pre- and post-service bulletin configurations. The term (PRE SB XXXX) in the NOMENCLATURE column designates the original configuration, and the term (POST SB XXXX) identifies assemblies and parts after the modification has been completed. (4) The terms defined below are used when applicable to show the interchangeability of parts.
D.
Term Superseded By
Abbreviation SUPSD BY
Supersedes
SUPSDS
Replaced By
REPLCD BY
Replaces
REPLCS
Definition The part is replaced by and is not interchangeable with the item number designated in the notation. The part replaces and is not interchangeable with the item number designated in the notation. The part is replaced by and is interchangeable with the item number designated in the notation. The part replaces and is interchangeable with the item number designated in the notation.
EFF CODE Column This column contains effectivity codes (A, B, etc.) to show the alternative models or configurations of the end item to which the parts apply. This column is left blank when the parts apply to all models or configurations in the parts list.
E.
UNITS PER ASSY Column The quantity given in this column shows the number of units necessary for one NHA or, when you refer to attaching parts, the quantity to attach one such item. The abbreviation RF (reference) is given to end items and subassemblies.
Copyright 2004 by: Radiant Power Corp., a HEICO Company
25-60-03
Page 1004 Aug 2009
RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER RPS1-B EQUIPMENT DESIGNATOR INDEX PART NUMBER
DESIGNATOR
FIGURE
ITEM
A1 A1 A2 A2 BT1
11-0042-1 11-0042-2 11-0045 11-0045 2013-1A
2 2 2 3 1
15 -15A 10 -1 5
F1 F1 F2 F2 F3 F3 J1 J1 J2-1 J2-2 Q1 Q2 Q3
251005 276005 251005 276005 251005 276005 BACC45FN16-24P 48-10R16-24P 3542-2 3542-0 JANTX2N3716 JANTX2N4399 JANTX2N3741
3 3 3 3 3 3 2 2 1 1 2 2 3
40 -40 40 -40 40 -40 110 -110A 60 65 30 35 5
R1 R2 R21 R21 R21 R21 R21 R21 SW1
RER60F14R0R RER60F14R0R RNC55H7320FR RNC55H7500FR RNC55H7680FR RNC55H7870FR RNC55H8060FR RNC55H8250FR 39-1
2 2 3 3 3 3 3 3 2
65 65 -35A -35B -35C 35 -35D -35E 100
Copyright 2004 by: Radiant Power Corp., a HEICO Company
25-60-03
Page 1005 Aug 2009
RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER RPS1-B NUMERICAL INDEX (Sheet 1 of 2) FIGURE
ITEM
TTL REQ
BACC45FN16-24PN BACN10JC04 BACN10JC06 BACN10JC06C BACR15BA4AD4 BBI-03G BBI-066G BSM1-60A DM101 FE0-440 FE0-440 JANTX2N3716
2 2 1 2 1 2 3 1 2 1 3 2
110 120A 40A 45A 145 55 25 -95 50 160 32 30
1 4 3 4 4 2 1 1 2 12 2 1
JANTX2N3741 JANTX2N4399 MS21043-06 MS21043-06 MS24693-1 MS24693-C1 MS35649-224 MS35649-224 MS51957-12 MS51957-12 MS51957-13 MS51957-13 MS51957-27 MS51957-28 MS51957-29 MS51957-3 MS51957-34 NAS549FL4 NAS620C2
3 2 2 2 1 1 2 1 1 2 2 2 3 2 2 2 1 2 2
5 35 -45B 40A -125 125A 70 80A 115 95 20 115 10 45C -45 -80 50 25 75
1 1 4 4 6 6 4 4 4 4 8 4 2 4 4 2 4 16 4
NAS620C6 NAS620C6 NAS620C8 NAS679A04 NAS679C06 NAS679C06 RER60F14R0R RNC55H7320FR RNC55H7500FR RNC55H7680FR RNC55H7870FR RNC55H8060FR RNC55H8250FR RPS1B S0S440-4 S0S440-6
1 3 1 2 1 2 2 3 3 3 3 3 3 1 1 1
45 15 80 -120 -40 -40 65 -35A -35B -35C 35 -35D -35E -1 150 155
6 4 2 4 3 4 2 1 1 1 1 1 1 RF 4 4
PART NUMBER
AIRLINE STOCK NO.
Copyright 2004 by: Radiant Power Corp., a HEICO Company
25-60-03
Page 1006 Aug 2009
RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER RPS1-B NUMERICAL INDEX (Sheet 2 of 2) FIGURE
ITEM
TTL REQ
S0S440-4 S0S440-6 TA2402A
1 1 3
150 155 20
4 4 1
081-001-006 11-0042-1 11-0042-2 11-0045 11-0048 11-0048-1 11-0049 11-0050-1 11-0050-1 11-0050-2 11-0050-2 11-0051 11-0052 11-0061 2007-1 2007-2 2007-3
1 2 2 2 1 1 1 1 2 1 2 1 1 2 1 2 2
70 15 -15A 10 130 165 100 120 -1 -120A -1A 105 110 12 140 85 90
4 1 1 1 1 1 1 1 RF 1 RF 1 1 1 2 1 1
2008 2009 2013-1A 2017 2020 2022 2025 2042 20442339 276005 3542-0 3542-2 39-1 48-10R16-24P
2 3 1 1 1 1 2 1 1 1 3 1 1 2 2
125 30 5 55 10 30 5 20 15 95A 40 65 60 100 -110A
1 1 1 6 1 2 1 1 1 1 3 1 1 1 1
1 1 2 2 1 1 1 1
85 35A 60 105 25 -35 135 90
4 2 2 1 2 2 2 2
PART NUMBER
AIRLINE STOCK NO.
5607-88 5612-26-31 805-144 805-169 82-19-1040-16 82-32-101-20 82-35-307-55 8654
Copyright 2004 by: Radiant Power Corp., a HEICO Company
25-60-03
Page 1007 Aug 2009
RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER RPS1-B
Battery Power Supply IPL Figure 1 (Sheet 1 of 3)
Copyright 2004 by: Radiant Power Corp., a HEICO Company
25-60-03
Page 1008 Aug 2009
RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER RPS1-B
Battery Power Supply IPL Figure 1 (Sheet 2 of 3)
Copyright 2004 by: Radiant Power Corp., a HEICO Company
25-60-03
Page 1009 Aug 2009
RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER RPS1-B
Battery Power Supply IPL Figure 1 (Sheet 3 of 3)
Copyright 2004 by: Radiant Power Corp., a HEICO Company
25-60-03
Page 1010 Aug 2009
RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER RPS1-B PARTS LIST FIGURE ITEM 1
PART NUMBER
-1
RPS1B
5 10 15
2013-1A 2020 2044
20 25 30 -35
2042 82-19-1040-16 2022 82-32-101-20
35A
5612-26-31
-40
NAS679C06
40A
BACN10JC06
45 50 55 60 65
NAS620C6 MS51957-34 2017 3542-2 3542-0
70 -75 80 85 90
081-001-006 146-001-002 NAS620C8 5607-88 8654
-95
BSM1-60A
95A
2339
100 105 110
11-0049 11-0051 11-0052
115
MS51957-12
AIRLINE STOCK NO.
NOMENCLATURE 1234567 BATTERY POWER SUPPLY . HOLDER ASSY, BATTERY (BT1) . . TAG, INSTRUCTION . . LABEL, BATTERY HOLDER (ADHESIVE-BACKED) . . CASE, BATTERY . . FASTENER, 1/4-TURN (V94222) . . SPRING, RETRACTION . . RETAINER, SPLIT RING (V94222) (PRE SB-004) . . WASHER, FLAT, TEFLON (V86928) (POST SB-004) . . NUT, SELF-LOCKING HEX (SUPSD BY ITEM 40A) . . NUT, SELF-LOCKING HEX (V81205) (SUPSDS ITEM 40) . . WASHER, FLAT . . SCREW, MACHINE-PAN HEAD . . BATTERY, NI-CD, 1.2V . . SOCKET, PIN (RED) (V05276) (J2-1) . . SOCKET, PIN (BLACK) (V05276) (J2-2) . . NUT, 8-32 HEX (V05276) . . DELETED . . WASHER, FLAT . . WASHER, SHOULDER (V86928) . . BRAID, TINNED COPPER WIRE, 1.375 +/- 0.125 INCH LG (V16428) . . PAD, FUSE RETAINER, TYPE 1, GRADE B (V75345) . . PAD, FUSE RETAINER, TYPE 1, GRADE B (V75345) (SUPSDS ITEM 95) . CHARGER ASSY, BATTERY . . NAMEPLATE, CHASSIS . . COVER ASSY ATTACHING PARTS . . SCREW, MACHINE-PAN HEAD ***
EFF CODE
UNITS PER ASSY RF 1 1 1 1 2 2 2 2 3 3 6 3 6 1 1 4 2 4 2 1 1 1 1 1
4
- ITEM NOT ILLUSTRATED
Copyright 2004 by: Radiant Power Corp., a HEICO Company
25-60-03
Page 1011 Aug 2009
RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER RPS1-B PARTS LIST FIGURE ITEM 1
PART NUMBER
120
11-0050-1
-120A
11-0050-2
-125
MS24693-1
125A
MS24693-C1
130 135 140
AIRLINE STOCK NO.
11-0048 82-35-307-55 2007-1
145 BACR15BA4AD4 150 S0S440-4 155 S0S440-6 160 FE0-440 165 11-0048-1
NOMENCLATURE 1234567 . . ELECTRONICS ASSY (S/N 0626 AND SUBSEQUENT) (SUPSDS ITEM 120A) (RF IPL FIG. 2 FOR DETAILS) . . ELECTRONICS ASSY (S/N 0053 THROUGH 0625) (SUPSD BY ITEM 120) (RF IPL FIG. 2 FOR DETAILS) ATTACHING PARTS . . SCREW, FLAT-COUNTERSUNK HEAD . SCREW, FLAT-COUNTERSUNK HEAD (ALT TO ITEM 125) *** . . CHASSIS ASSY . . . RECEPTACLE (V94222) . . . BRACKET, BATTERY MOUNTING ATTACHING PARTS . . . RIVET, 1/8 FLAT HEAD X 1/4 LG (V81205) *** . . . STANDOFF, SELF-CLINCHING, 1/8 INCH (V46384) . . . STANDOFF, SELF-CLINCHING, 3/16 INCH (V46384) . . . NUT, CLINCH, 4-40 SELFLOCKING (V46384) . . . CHASSIS
EFF CODE
UNITS PER ASSY 1
1
6 6
1 2 2
4
4 4 12 1
- ITEM NOT ILLUSTRATED
Copyright 2004 by: Radiant Power Corp., a HEICO Company
25-60-03
Page 1012 Aug 2009
RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER RPS1-B
THIS PAGE INTENTIONALLY LEFT BLANK
Copyright 2004 by: Radiant Power Corp., a HEICO Company
25-60-03
Page 1013 Aug 2009
RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER RPS1-B
Electronics Assembly IPL Figure 2
Copyright 2004 by: Radiant Power Corp., a HEICO Company
25-60-03
Page 1014 Aug 2009
RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER RPS1-B PARTS LIST FIGURE ITEM 2
PART NUMBER
-1
11-0050-1
-1A
11-0050-2
5
2025
10
11-0045
12
11-0061
15
11-0042-1
-15A
11-0042-2
20 25
MS51957-13 NAS549FL4
30 35
JANTX2N3716 JANTX2N4399
40 40A
NAS679C06 MS21043-60
-45
MS51957-29
-45A
BACN10JC06C
-45B
MS21043-06
45C
MS51957
50 55 60
DBX-101 BBI-03G 805-144
AIRLINE STOCK NO.
NOMENCLATURE 1234567 ELECTRONICS ASSY (P/N 11-0050) (S/N 0626 AND SUBSEQUENT) (SUPSDS ITEM 1 A) (RF IPL FIG. 1 FOR NHA) ELECTRONICS ASSY (S/N 0053 THROUGH 0625) (SUPSD BY ITEM 1) (RF IPL FIG. 1 FOR NHA) . LABEL, TEST SWITCH (ADHESIVE-BACKED) . PCB ASSY, REGULATOR (A2) (RF IPL FIG. 3 FOR DETAILS) . INSULATOR, NOMEX (POST SB RPS1-B-33-01) . PCB ASSY, LOGIC (A1).(P/N 11-0042) (SIN 0626 AND SUBSEQUENT) (SUPSDS ITEM 15A) . PCB ASSY, LOGIC (A1) (S/N 0053 THROUGH 0625) (SUPSD BY ITEM 15) ATTACHING PARTS . SCREW, MACHINE-PAN HEAD . WASHER, NONMETALLIC INSULATING *** . TRANSISTOR (Q1) . TRANSISTOR (Q2)
A
UNITS PER ASSY RF
B
RF
EFF CODE
1 1 1 A
1
B
1
8 16
1 1
ATTACHING PARTS . NUT, HEX SELF-LOCKINGNUT, HEX SELF-LOCKING . (SUPSDS ITEM 40) SCREW, MACHINE-PAN HEAD (SUPSD BY ITEM 45A OR 45B) . SCREW, MACHINE-PAN HEAD (V81205) (SUPSDS ITEM 45) . SCREW, MACHINE-PAN HEAD (ALT TO ITEM 45A) . SCREW, MACHINE-PAN HEAD (ALT TO ITEM 45A) *** . THERMAL INSULATOR PAD, . STRIP, INSULATOR (V39425) . LUG, SOLDER (V79963)
4 4 4 4 4 4
2 2 2
-ITEM NOT ILLUSTRATED
Copyright 2004 by: Radiant Power Corp., a HEICO Company
25-60-03
Page 1015 Aug 2009
RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER RPS1-B PARTS LIST FIGURE ITEM 2
PART NUMBER
65
RER60F14R0R
70 75 -80 80A
MS35649-224 NAS620C2 MS51957-3 MS35649-224
85
2007-2
90
2007-3
95
MS51957-12
100
39-1
105 110 -110A
805-169 BACC45FN1624PN 48-10R1624P
115 -120
MS51957-13 NAS679A04
120A
BACN10JC04
125
2008
AIRLINE STOCK NO.
NOMENCLATURE 1234567 . RESISTOR (R1, R2)
EFF CODE
UNITS PER ASSY 2
ATTACHING PARTS . NUT, PLAIN HEX . WASHER, FLAT . SCREW, FLAT-COUNTERSUNK HEAD . SCREW, FLAT-COUNTERSUNK HEAD (ALT TO ITEM 80) ***
2 2 2 2
1
. BRACKET ASSY, Q2 TRANSISTOR MOUNTING . BRACKET ASSY, Q1 TRANSISTOR MOUNTING
1
ATTACHING PARTS . SCREW, MACHINE-PAN HEAD ***
4
1
. SWITCH, PUSHBUTTON (V81073) (SW1) . LUG, SOLDER, NO. 8 (V79963) . CONNECTOR, 24 PIN (V81205) (J1) . CONNECTOR, 24 PIN (V77820) (J1)(ALT TO ITEM 110)
1 1 1
ATTACHING PARTS . SCREW, MACHINE-PAN HEAD . NUT, HEX SELF-LOCKING (SUPSD BY ITEM 120A) . NUT, HEX SELF-LOCKING (V81205) (SUPSDS ITEM 120) ***
4 4 4
. PANEL, FRONT
1
-ITEM NOT ILLUSTRATED
Copyright 2004 by: Radiant Power Corp., a HEICO Company
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Copyright 2004 by: Radiant Power Corp., a HEICO Company
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RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER RPS1-B
Regulator PCB Assembly A2 IPL Figure 3
Copyright 2004 by: Radiant Power Corp., a HEICO Company
25-60-03
Page 1018 Aug 2009
RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER RPS1-B PARTS LIST FIGURE ITEM 3
PART NUMBER
AIRLINE STOCK NO.
NOMENCLATURE
EFF CODE
UNITS PER ASSY RF
-1
11-0045
1234567 PCB ASSY, REGULATOR (A2) (RF IPL FIG. 2 FOR NHA)
5
JANTX2N3741
. TRANSISTOR (Q3)
1
10 15
MS51957-27 NAS620C6
ATTACHING PARTS . SCREW, MACHINE-PAN HEAD . WASHER, FLAT ***
2 2
20
DBX-66
. THERMAL PAD INSULATOR
1
25 30
BBI-066G 2009
1 1
32
FE0-440
35
RNC55H7870FR
-35A
RNC55H7320FR
-35B
RNC55H7500FR
-35C
RNC55H7680FR
-35D
RNC55H8060FR
-35E
RNC55H8250FR
. STRIP, INSULATOR (V39425) . BRACKET ASSY, TRANSISTOR MOUNTING . . NUT, CLINCH, 4-40 SELF-LOCKING (V46384) . RESISTOR, (R21) (SELECT IN TEST) . RESISTOR, (R21) (SELECT IN TEST) (ALT TO ITEM 35) . RESISTOR, (R21) (SELECT IN TEST) (ALT TO ITEM 35) . RESISTOR, (R21) (SELECT IN TEST) (ALT TO ITEM35) . RESISTOR, (R21) (SELECT IN TEST) (ALT TO ITEM 55) . RESISTOR, (R21) (SELECT IN TEST) (ALT TO ITEM 55) . FUSE, SUBMINIATURE, (V75915) (F1, F2, F3) . FUSE, SUBMINIATURE, (V75915) (F1, F2, F3) (SUPSDS ITEM 40)
-40
251005
40A
276005
2 1 1
1
1
1
1
3 3
-ITEM NOT ILLUSTRATED
Copyright 2004 by: Radiant Power Corp., a HEICO Company
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RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER RPS1-B
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