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Emergency Power Supply

JET Model PS-835


Part Number 501-1228-( )

Component Maintenance Manual

This manual contains maintenance instructions for the PS-835


Emergency Power Supply. This information is supplemented and
kept current by changes or revisions, service letters and service
bulletins.

24-30-02
L-3 Communications Avionics Systems
5353 52nd Street, S.E. TP-329 (Revision B, Change 5)
Grand Rapids, MI 49512-9704, USA March 13, 2009
www.as.l-3com.com
Foreword

This manual provides information intended for use by persons who, in accordance with current regulatory
requirements, are qualified to install or repair this equipment. Installation requirements may vary,
depending on the particularities of each aircraft, and this manual is intended as a guideline for that
purpose. If further information is required, please contact:

L-3 Communications Avionics Systems


Attn: Field Service Engineering
5353 52nd Street, S.E.
Grand Rapids, MI USA 49512-9704
Telephone: (800) 453-0288 or (616) 949-6600
Fax: (616) 977-6898
www.as.l-3com.com

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

L-3 Communications Avionics Systems


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

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

Copyright 2005 thru 2009


L-3 Communications Avionics Systems
(Formally Goodrich Avionics Systems, Inc)

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

24-30-02
TP-329 Forward - Page A
Revision B, Change 5 March 13, 2009
Record Of Revisions

Assigned To: Location:


Rev. Insertion By Rev. Insertion By Rev. Insertion By
No. Date No. Date No. Date

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

24-30-02
TP-329 Record of Revisions - Page i
Revision B, Change 1 March 31, 2005
L-3 Avionics Systems
Component Maintenance Manual
Model PS-835( ) // 501-1228-( )

This page intentionally left blank.

24-30-02
TP-329 Record of Revisions - Page ii
Revision B, Change 1 March 31, 2005
L-3 Avionics Systems
Component Maintenance Manual
Model PS-835( ) // 501-1228-( )

List of Effective Pages

Dates of original and changed pages are:

Original ........................................................................................................................................Circa 1984


Reissue .......................................................................................................................... September 01/1995
Revision 1 .......................................................................................................................March 31/1996
Revision A .........................................................................................................................March 30/2002
Change 1 .....................................................................................................................February 28/2003
Revision B .....................................................................................................................February 28/2004
Change 1 ........................................................................................................................March 31, 2005
Change 2 ......................................................................................................................February 3, 2006
Change 3 .......................................................................................................................August 29, 2007
Change 4 ......................................................................................................................January 24, 2008
Change 5 ........................................................................................................................March 13, 2009

Revision and Changes

Revisions are used to correct major volumes of text or sections of a manual. Manuals at new
revision incorporate all previous changes as well as any new changes or updates. Destroy old
revisions when new revision is received.

Changes are used to correct minor volumes of text or sections of a manual. A vertical line in the
outer margins of the page indicates the portion of the text affected by the change. Changes to
illustrations (other than diagrams and schematics) are identified with a miniature pointing hand.
Shading is used to highlight the area of diagrams and schematics containing a change.

INSERT LATEST CHANGED PAGES DESTROY SUPERSEDED PAGES.

Those responsible for maintaining this publication should ensure that all previous changes have been
received and incorporated.

Use the Publication Index located on the Avionics Systems, web site [www.as.l-3com.com] to verify
revision and changes to manuals.

24-30-02
TP-329 List of Effective Pages - Page iii
Revision B, Change 5 March 13, 2009
L-3 Avionics Systems
Component Maintenance Manual
Model PS-835( ) // 501-1228-( )

Revision Highlights
Revision B, Change 1
Add note to page 102 explaining the use of J1-10 during the Constant-Voltage Charging Method.
Correct pin location on page 104, made corrections to Figure 103, added and corrected information
for Capacity Testing starting on page 111, inserted new Figure 104, Corrected Figure 105, corrected
test steps on page 117.
Revision B, Change 2
Added SB501-1228-15 to Figure 1 (pg.4). Updated Figure 7 (pg.11). Updated information in Testing
and Fault Isolation with that of SL-80P (pg.102, 103, 104, 105, 106). In Repair section incorporated
replacement instructions (taken from SL-84B) for battery cells and packs (pg.601). Also consolidated
repair section removing pages 605 and 606. In Assembly section added battery cell and pack
replacement information (pg.702). Added replacement statement to figure-item 2-5 in IPL (pg1013).

Revision B, Change 3
Added "Note" to various test procedures to ensure test switch was returned to normal. Updated
general information to match changes made to installation manual. Updated special tools and
equipment information. Added Scotch Grip 847 to consumable list (replaces Vulcabond). Added
standoff insulators to assembly instructions. Corrected various typo's and error's to figure callouts.
Revision B, Change 4
Changed Test and Fault Isolation section to more closely match procedures in other documentation.
Revision B, Change 5
Incorporated new model PS-835G (501-1228-07) to the following pages:
Pg 1: Update General information para. Pg 5: Add G model to Figure 2.
Pg 7: Add G model to Figure 4. Pg 11: Add G model to Figure 7.
Pg 19/20: Update caption of Figure 10. Pg 105: Add G model to step 6) & 8). Pg 107: Add G
model to Figure 101. Pg 113 thru 114: Add G model. Pg 805 -806: Add G model to Figure 802
and data in paragraph for installation kit. Pg 811/812: Add G model to Figure 807. Add G model
to Figure 901.
Pg 1009 thru 1010, Pg 1013: Add G model to parts list.

Made corrections to the following:


Pg A: Updated export compliance statement.
Pg 103: Correction to paragraph 4.B.
Pg 104: Reformatted paragraph 6 to match other publications.
Pg 107: Removed Ohmmeter (item 3) and manufacturer/model Genrad Model 1864 from Figure 101.
Corrected para. B. 4).
Pg 108: Corrected Para. "C. 1)" by replacing call-out of Ohmmeter (Figure 101, Item 3) with
DVM (Figure 101, Item 2). Corrected paragraph C. (note).
Pg 111: Corrected Para. "e. (2)" by replacing call-out of Ohmmeter (Figure 101, Item 3) with
DVM (Figure 101, Item 2).
Pg 601: Removed Ohmmeter (item 3) and manufacturer/model Genrad Model 1864 from Figure 602.
Pg 901: Removed Ohmmeter (item 3) and manufacturer/model Genrad Model 1864 from Figure 901.
Pg 1002 thru 1003: Incorporate new part numbers added to IPL lists.
Pg 1009 thru 1010: Corrected Item 70 by adding missing A1 CCA part numbers.
Pg 1011/1012: Added part numbers for assembly items not included in early revisions of the manual.
Pg 1013: Corrected effectivity codes in item 5.
Pg 1015: Added part numbers for assembly items (260, 265, 270, & 275) not included in early
revisions of the manual.

24-30-02
TP-329 List of Effective Pages - Page iv
Revision B, Change 5 March 13, 2009
L-3 Avionics Systems
Component Maintenance Manual
Model PS-835( ) // 501-1228-( )

Section Page Date Section Page Date


Title Page March 13, 2009 Description and 17/18 February 28/2004
Operation (cont.) 19/20 March 13, 2009
Foreword A March 13, 2009
21/22 February 28/2004
23/24 February 28/2004
Record of i-ii March 31/2005
25/26 February 28/2004
Revisions

Testing and Fault 101 January 24, 2008


List of Effective iii-vi March 13, 2009
Isolation
Pages
102 January 24, 2008
Table of Contents vii August 29, 2007 103 March 13, 2009
viii January 24, 2008 104 March 13, 2009
ix-x August 29, 2007 105 March 13, 2009
106 January 24, 2008
Introduction xi August 29, 2007
107 March 13, 2009

Service Directives xii August 29, 2007 108 March 13, 2009
List 109 January 24, 2008
110 January 24, 2008
List of Figures xiii January 24, 2008
111 March 13, 2009
112 January 24, 2008
List of Symbols xiv August 29, 2007
and Abbreviations 113 March 13, 2009
114 March 13, 2009
Description and 1 March 13, 2009 115 March 13, 2009
Operation 2 February 28/2004 116 January 24, 2008
3 February 28/2004 117 January 24, 2008
4 February 3, 2006 118 January 24, 2008
5 March 13, 2009 119 January 24, 2008
6 February 28/2004 120 January 24, 2008
7 March 13, 2009
8 February 28/2004 Disassembly 301 February 28/2004

9 August 29, 2007 302 February 28/2004

10 February 28/2004 303 February 28/2004

11 March 13, 2009 304 February 28/2004

12 August 29, 2007


Cleaning 401 February 28/2004
13 February 28/2004
402 February 28/2004
14 February 28/2004
15/16 February 28/2004

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TP-329 List of Effective Pages - Page v
Revision B, Change 5 March 13, 2009
L-3 Avionics Systems
Component Maintenance Manual
Model PS-835( ) // 501-1228-( )

Section Page Date Section Page Date


Check 501 August 29, 2007 Illustrated Parts 1001 February 28/2004
List
502 August 29, 2007
1002 March 13, 2009
1003 March 13, 2009
Repair 601 August 29, 2007
1004 February 28/2004
602 March 13, 2009
1005 February 28/2004
603 February 3, 2006
1006 February 28/2004
604 February 3, 2006
1007/ 1008 February 28/2004
605 Removed
1009 March 13, 2009
606 Removed
1010 March 13, 2009
1011/ 1012 March 13, 2009
Assembly 701 August 29, 2007
1013 March 13, 2009
702 August 29, 2007
1014 February 28/2004
703 February 3, 2006
1015 March 13, 2009
704 August 29, 2007
1016 February 28/2004
705 August 29, 2007
1017 February 28/2004
706 February 28/2004
1018 February 28/2004
1019 February 28/2004
Fits and 801 February 28/2004
Clearances 1020 February 28/2004
802 February 28/2004
803 February 28/2004
804 February 28/2004
805 March 13, 2009
806 March 13, 2009
807 February 28/2004
808 February 28/2004
809/ 810 February 28/2004
811/ 812 March 13, 2009

Special Tools, 901 March 13, 2009


Fixtures and
Equipment
902 August 29, 2007

24-30-02
TP-329 List of Effective Pages - Page vi
Revision B, Change 5 March 13, 2009
L-3 Avionics Systems
Component Maintenance Manual
Model PS-835( ) // 501-1228-( )

Table of Contents

Section Page

Record of Revisions ............................................................................................................. i


List of Effective Pages ......................................................................................................... ii
Table of Contents ................................................................................................................. v
Introduction.......................................................................................................................... ix
Service Directives List ......................................................................................................... x
List of Figures ...................................................................................................................... xi
List of Symbols and Abbreviations...................................................................................... xii

Description and Operation


1. General ................................................................................................................................. 1
2. Purpose of Equipment .......................................................................................................... 1
3. Physical Description............................................................................................................. 1
4. Functional Description ......................................................................................................... 1
5. Continued Airworthiness ..................................................................................................... 2
6. MOD Status.......................................................................................................................... 3
7. Environmental Test Qualifications ...................................................................................... 5
8. Specifications ....................................................................................................................... 7
9. Affiliated Equipment............................................................................................................ 7
10. Charge and Discharge Performance..................................................................................... 8
A. General Battery and Cell Information................................................................... 8
B. Battery/Cell Outgassing ....................................................................................... 8
C. Storage Time and Temperature............................................................................. 9
D. Cell Current Discharge Time ................................................................................ 10
E. Cell Voltage Discharge Time................................................................................ 11
11. Operation.............................................................................................................................. 12
12. Theory of Operation............................................................................................................. 12
A. Power Input .............................................................................................................. 12
B. Heating Resistor ........................................................................................................... 13
C. Heater Control .............................................................................................................. 13
D. Over-Temperature Protection....................................................................................... 13
E. Battery Voltage Level Detection.................................................................................. 13
F. Test .............................................................................................................. 14

24-30-02
TP-329 Table of Contents - Page vii
Revision B, Change 3 August 29, 2007
L-3 Avionics Systems
Component Maintenance Manual
Model PS-835( ) // 501-1228-( )

Table of Contents (continued)


Section Page

Testing and Fault Isolation


1 General .............................................................................................................................................. 101
2 Battery Testing ................................................................................................................................ 102
3 Charging Procedures ......................................................................................................................... 102
4 Preflight Checks (Recommended) .................................................................................................... 103
5 Periodic Checks (Required 3 to 6 Months) ....................................................................................... 104
6 Capacity Testing (Required Annually) ............................................................................................. 104
7 Cell Isolation Test ............................................................................................................................. 106
8 Performance Test .............................................................................................................................. 107
9 Battery Monitor CCA Test Procedures ............................................................................................. 116

Disassembly
1. General .............................................................................................................................................. 301
2. Disassembly Procedures .................................................................................................................... 301
3. Repair ................................................................................................................................................. 303

Cleaning
1 General .............................................................................................................................................. 401
2 External Cleaning .............................................................................................................................. 401
3 Internal Cleaning ............................................................................................................................... 401

Check
1 General .............................................................................................................................................. 501
2 On-Aircraft Checks ........................................................................................................................... 501
3 Checks After Repair and During Re-Assembly ................................................................................. 501
4 Inspection After Repair and During Re-Assembly............................................................................. 502
5 Storage ............................................................................................................................................... 502

Repair
1 General ............................................................................................................................................... 601
2 Battery Cell and Pack Replacement ................................................................................................... 601
3 Circuit Card Assembly Repair............................................................................................................ 601
4 Consumable Materials ........................................................................................................................ 601
5 Special Tools ...................................................................................................................................... 602
6 Moisture and Fungus Proofing ........................................................................................................... 603
7 Performance Test................................................................................................................................ 603

24-30-02
TP-329 Table of Contents - Page viii
Revision B, Change 4 January 24, 2008
L-3 Avionics Systems
Component Maintenance Manual
Model PS-835( ) // 501-1228-( )

Assembly
1 General ....................................................................................................................................... 701
2 Assembly Tools, Fixtures, and Consumables..................................................................................... 701
3 Assembly Procedures ......................................................................................................................... 702
4 Performance Test................................................................................................................................ 705
5 PS-835 Storage ................................................................................................................................... 705

Fits and Clearances


1 General ............................................................................................................................................... 801
2 Emergency Power Supply Location ................................................................................................... 801
3 Pre-Installation Inspection and Preparation ....................................................................................... 801
4 Post Installation Check ....................................................................................................................... 801
5 Affiliated Equipment .......................................................................................................................... 803
6 Installation Kits .................................................................................................................................. 805
7 Interconnect Diagrams ....................................................................................................................... 805

Special Tools, Fixtures, Test Equipment and Consumables


1 General ............................................................................................................................................... 901
2 Load Resistor...................................................................................................................................... 901
3 Connector Alignment Gage................................................................................................................ 901

Illustrated Parts List


1 General ............................................................................................................................................. 1001
2 Numerical Index ............................................................................................................................... 1001
3 Part Reference Designator Index...................................................................................................... 1004
4 Detailed Parts List ....................................................................................................................... 1005

Service Bulletin Information

24-30-02
TP-329 Table of Contents - Page ix
Revision B, Change 3 August 29, 2007
L-3 Avionics Systems
Component Maintenance Manual
Model PS-835( ) // 501-1228-( )

This page intentionally blank.

24-30-02
TP-329 Table of Contents - Page x
Revision B, Change 3 August 29, 2007
L-3 Avionics Systems
Component Maintenance Manual
Model PS-835( ) // 501-1228-( )

Introduction

This Component Maintenance Manual with Illustrated Parts List has been prepared by the Technical
Publications Department of Avionics Systems. It provides information needed to operate, maintain,
and repair specific avionics equipment. Block diagrams, schematic diagrams, and exploded views
are used and referenced within this manual to present the information. An Illustrated Parts List is
included to provide information for ordering replacement parts.

Common system maintenance procedures are not presented in the interest of clarity. The best-
established shop and line practices should be used where no specific procedures are given. When
direct current polarities are not defined with a given voltage value, the voltage is assumed to be
positive with respect to ground. Abbreviations and symbols used in this manual are defined in the
List of Symbols and Abbreviations. All weights and measurements in the manual are in English
units, unless otherwise stated.

This manual contains all practical information for the Operation, Testing, Disassembly/Assembly,
and Service and Repair of all variations of the PS-835( ) Emergency Power Supply. The manual in
published according to ATA-100 Specification for Manufacturers Technical Data for aviation
product manuals, to include style, format and content.

The manual is partitioned into sections, with tables, illustrations, and cross-references to information
located in other sections.

Section Page Group


Description and Operation 1-98
Testing and Fault Isolation 101-198
Disassembly 301-398
Cleaning 401-498
Check 501-598
Repair 601-698
Assembly 701-798
Fits and Clearances 801-898
Special Tools, Fixtures and Equipment 901-998
Illustrated Parts List 1001-1098
Service Letters and Bulletins

Comments, corrections, deletions, additions, clarifications or other pertinent information should be


directed to the Technical Publications Department, Avionics Systems, 5353 52nd Street S.E., Grand
Rapids, Michigan, USA 49512-9704, phone number [1-800-253-9525 or (616) 949-6600].

Avionics Systems maintains this manual to insure correct and current information by means of
revision notices, Service Letters and Service Bulletins. Follow the instructions provided with
revision notices concerning page replacement and notations to the Record of Changes page (page i).
See www.as.l-3com.com for revision levels on all Avionics Systems Technical Publications.

24-30-02
TP-329 Introduction - Page xi
Revision B, Change 3 August 29, 2007
L-3 Avionics Systems
Component Maintenance Manual
Model PS-835( ) // 501-1228-( )

Service Directives List

Directive Numbers

Service Bulletins
SB501-1228-1( )
SB501-1228-2( )
SB501-1228-3( )
SB501-1228-4( )
SB501-1228-5( )
SB501-1228-6( )
SB501-1228-7 ALERT
SB501-1228-8( )
SB501-1228-9( )
SB501-1228-10( )
SB501-1228-11( )
SB501-1228-12( )
SB501-1228-13( )
SB501-1228-14( )
SB501-1228-15( )

Service Letters
SL-48( )
SL-59()
SL-64( )
SL-80( )
SL-84( )
SL-85( )
SL-105()
SL-109( )

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

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

24-30-02
TP-329 Service Directives - Page xii
Revision B, Change 3 August 29, 2007
L-3 Avionics Systems
Component Maintenance Manual
Model PS-835( ) // 501-1228-( )

List of Figures

Figure Title Page


1 Service Bulletins and Modifications 3
2 Environmental Qualifications 5
3 PS-835 Emergency Power Supply 6
4 Specifications 7
5 Cell Storage Time vs. Temperature 9
6 Typical Discharge Time for Cells 10
7 Discharge Curves 11
8 Schematic for Models E and F 15/16
9 Schematic for Models E and F 17/19
10 Schematic for Models A through D 19/20
11 Schematic for Models A through D 21/22
12 Schematic for Models C and D 23/24
13 Schematic for Models A and B 25/26
101 Test Equipment and Fixtures 107
102 PS-835 Test Setup Schematic 108
103 Connector Pin Continuity Table 109
104 PS-835 Access Panel 112
105 Individual Cell Monitor LED's 116
106 Circuit Cart Assembly Test Setup 117
401 Modified Acid Brush 402
601 Consumable Materials 601
602 Special Tools and Equipment 602
603 Wire List for Models A, B, C, and D 603
604 Wire List for Models E and F 604
701 Tools and Consumables 701
702 Solder Pad Locations 703
801 Affiliated Equipment 804
802 Typical Interconnections for Models A through 806
803 Typical Interconnections for Models E and F 807
804 Interconnections for AC Indicators 808
805 Interconnections for DC Indicators 808
806 Installation Drawing for Models E and F 809/810
807 Installation Drawing for Models A through D 811/812
901 Special Tools and Equipment 901
IPL 1 Emergency Power Supply 1007/1008
IPL 2 Battery Circuit Card Assembly 1011/1012
IPL 3 Battery Monitor CCA 1017

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TP-329 List of Figures - Page xiii
Revision B, Change 4 January 24, 2008
L-3 Avionics Systems
Component Maintenance Manual
Model PS-835( ) // 501-1228-( )

List of Symbols and Abbreviations

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

A Ampere
AC Alternating Current
awg American Wire Gauge
AMP Ampere
AR As Required
CH Chemical Hazard
CCA Circuit Card Assembly
CCW Counterclockwise
CW Clockwise
DC Direct Current
Hz Hertz (frequency)
inch
lbs pounds
in-lbs Inch-Pounds (torque)
Max maximum
MSDS Material Safety Data Sheet
PWB Printed Wiring Board
RPM revolutions per minute
UUT unit under test
Vdc Volts direct current
Vac Volts alternating current
+ (plus) or (minus)
Angular Degree
F Temperature Fahrenheit
C Temperature Celsius
Ohm

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TP-329 Symbols and Abbreviations - Page xiv
Revision B, Change 3 August 29, 2007
L-3 Avionics Systems
Component Maintenance Manual
Model PS-835( ) // 501-1228-( )

Description and Operation

1. General

This manual provides description and theory of operation for Models PS-835 A through G Emergency
Power Supplies, part numbers 501-1228-01 through -06 (respectively). Models C, D, E, F and G are
current and Models A and B are considered obsolete, see Service Bulletins and Modifications table
Figure 1. Models A, C, and E use 2.5Ah cells and Models B, D, F, and G use 5.0Ah cells.
Model Number Part Number
A 501-1228-01
B 501-1228-02
C 501-1228-03
D 501-1228-04
E 501-1228-05
F 501-1228-06
G 501-1228-07

2. Purpose of Equipment
The Model PS-835 Emergency Power Supply is designed as a 24 Vdc (nominal) emergency power
source for prolonging the operation of a connected standby attitude indicator when the aircraft main
power buss has de-energized. The aircraft main power buss provides trickle charging to the PS-835
while the aircraft performs normally.
The output of the PS-835 can be subsequently converted using either Avionics Systems Model SI-
100( ) Static Inverter or the SC-841 Static Converter to provide power for standby indicators of
different power requirements.

The SI-100 provides outputs of 115 Vac or 5 Vac, 400Hz either at single or three phase alternating
current. The SC-841 provides direct current outputs of 2.0 to 6.5 Vdc (user adjustable).

3. Physical Description
The PS-835 Emergency Power Supply is fully enclosed unit, designed to easily mount onto an
existing avionics shelf or the optional mounting rack Avionics Systems Model MTG-101 (part
number 572-1424-01), with models available with lightning surge protection. The face of the unit
provides individual cell monitor LED's, voltage output monitor LED's, battery Heater Operation
Monitor LED's, and a battery test switch.
4. Functional Description
A. Power Input
Aircraft 28 Vdc is connected to the emergency power buss through pin 10 of connector J1. The
input is diode isolated from the internal batteries and circuits to prevent battery discharge in the
event of a short circuit, or battery draw caused by low input from the aircraft main DC buss,
such as at engine start.

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TP-329 Description - Page 1
Revision B, Change 5 March 13, 2009
L-3 Avionics Systems
Component Maintenance Manual
Model PS-835( ) // 501-1228-( )

B. Battery Heating

Battery heating is provided by an etched foil Heating Resistor (HR1) mounted onto the unit
chassis.

With 28 Vdc applied to the unit and the temperature is 19C (66F) the green HEATER ON
LED (Figure 1, Item 3) will come on showing that the heater is operating. The red LED will
come on if the temperature exceeds 55C.

The heating element, also, functions as a test load during the time the power supply is being
tested aboard the aircraft. The HEATER ON LED will come on when the TEST SWITCH
(Figure 1, Item 4) on the front panel is pressed.

C. Over-Temperature Protection

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

D. Battery Voltage Level Detection

There are four OUTPUT VOLTAGE MONITOR LED's on the front panel of the supply (Figure
3, Item 2). These indicate the state-of-charge of the stored power. The LED's go on when the
TEST SWITCH is pressed or when the supply is being charged.

The power supply is considered greater than 50% charged when the 24V LED momentarily
illuminates when the TEST SWITCH is pressed, and fully discharged when the 20V LED is
goes out.

5. Continued Airworthiness (Maintenance)

PS-835 Emergency Power Supplies require periodic checks and scheduled testing. Refer to the
Testing and Fault Isolation section of this manual for the following checks:

Periodic 3-6 Month Check


Annual Capacity Testing

A need for maintenance is indicated when unit fails the tests described above or functional
monitoring as described below.

Functional monitoring is based upon the following:

Observation of self-test failure notification (applicable only when unit has self-test capability).

Visual observation by the user.

This unit has unlimited service life, where service life is defined as that point in time when repair is
no longer economical.

24-30-02
TP-329 Description - Page 2
Revision B February 28/2004
L-3 Avionics Systems
Component Maintenance Manual
Model PS-835( ) // 501-1228-( )

6. MOD Status

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

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

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

Modification Kits and


Model and Part
Service Bulletin MOD # Purpose part required for
Number
Modification
SB501-1228-1( ) A-501-1228-01 1 Wiring modification to
B-501-1228-02 prevent connector J2 arcing
during extreme vibrations.
SB501-1228-2( ) A-501-1228-01 2 Replace Thermal Resistor to MOD Kit 504-1637-01
B-501-1228-02 reduce shorting possibility.
SB501-1228-3( ) B-501-1228-02 3 Add insulation plate to prevent MOD Kit 504-1638-01
shorting possibility between
cell BT12 and chassis.
SB501-1228-4( ) A-501-1228-01 3 Modify wiring to prevent MOD Kit 504-1642-01
B-501-1228-02 4 CCA damage because loss of
grounding isolation between
battery and chassis.
SB501-1228-5( ) A-501-1228-01 4 Additional instructions to (Pervious MOD 3 and 4
B-501-1228-02 5 insure previous MOD's 3 and instructions failed to
4 are properly applied. instruct soldering wire
back onto lug)
SB501-1228-6( ) A-501-1228-01 5 Replace and reposition MOD Kit 504-1648-01
B-501-1228-02 6 resistors A2R1 and A2R7 on
Battery Monitor CCA.
SB501-1228- A-501-1228-01 6 Modify wiring to provide self-
7ALERT B-501-1228-02 7 testing capability for fuse
C-501-1228-03 1 failure.
D-501-1228-04 1
SB501-1228-8( ) A-501-1228-01 N/A Modifies Models A and B into MOD Kit 504-1745-01
B-501-1228-02 Models C and D to meet DO- Re-identifies CCA A2
160A voltage spike test. from 542-1634-01 to
(Factory only) 542-1495-01

Figure 1: Service Bulletins and Modifications

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Modification Kits and


Model and Part
Service Bulletin MOD # Purpose part required for
Number
Modification
SB501-1228-9( ) A-501-1228-01 7 Replace Battery Monitor CCA Replace CCA A2 part
B-501-1228-02 8 to improve Heater Circuit number 542-1495-01
C-501-1228-03 2 performance. with CCA A2 part
D-501-1228-04 2 number 542-1521-01.
SB501-1228-10( ) A-501-1228-01 Modify wiring to circumvent MOD Kit 504-1746-01
B-501-1228-02 fuse for emergency operation. (All previous MOD's to
C-501-1228-03 Re-identifies Models C and D A, B, C, and D must
D-501-1228-04 into Models E and F. first have been
performed)
SB501-1228-11( ) A-501-1228-01 8 Prevent possible shorting MOD Kit 504-1811-01
C-501-1228-03 3 between cells and chassis.
E-501-1228-05 1
SB501-1228-12( ) A-501-1228-01 9 Prevent possible shorting MOD Kit 504-1839-01
B-501-1228-02 9 between cells and chassis.
C-501-1228-03 4
D-501-1228-04 3
E-501-1228-05 2
F-501-1228-06 1
SB501-1228-13( ) A-501-1228-01 10 Modify wiring to prevent
B-501-1228-02 10 improper charging.
C-501-1228-03 5
D-501-1228-04 4
E-501-1228-05 3
F-501-1228-06 2
SB501-1228-14( ) D-501-1228-04 5 Prevent shorting of cell leads
Serial No's by correcting wire routing and
8647 and improved soldering of cell
higher. terminals.
SB501-1228-15() A-501-1228-01 11 To add warning instructions Warning Label (p/n
B-501-1228-02 11 for proper care and 535-1873-01)
C-501-1228-03 6 maintenance of battery pack to
D-501-1228-04 6 prevent voiding warranty.
E-501-1228-05 4
F-501-1228-06 3

Figure 1: Service Bulletins and Modifications (Cont.)

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7. Environmental Test Qualifications

The following tests have been conducted to satisfy DO-160A test conditions.

Name of Test Qualified to DO-160A elements:


Low Temperature Section 4.0 Cat. A2F2
Humidity Section 6.0 Cat. B
Vibration Section 8.0 Cat. J
Explosion Section 9.0 Cat. E
Voltage Spikes Section 17 Cat. B for Models A and B
(obsolete)
Section 17 Cat. A for Models C, D, E, F and
G
Temperature Variation Section 5.0 Cat. B
Magnetic Effect Section 15
Audio Frequency Conducted Section 18 Cat. A
Susceptibility
Electromagnetic Compatibility Section 19 Cat. A
Section 20 Cat. A
Section 21 Cat. A

Figure 2: Environmental Qualifications

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Figure 3: PS-835 Emergency Power Supply

1 Individual Cell Monitor LED's


2 Output Voltage Monitor LED's
3 Battery Heater Operation Monitor LED's
4 Test Switch
5 Individual Cell Dip Switches

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8. Specifications

Part Number 501-1228-01, -02, -03, -04, -05, -06, -07


Certification: FAA-PMA (for 501-1228-03, -04, -06, -07)
RTCA Compliance: Environmental: DO-160A
Size: Length: 14.110 max.
Height: 7.774 max.
Width: 2.400 max.
Weight: Model A, C, E - 8 lbs. [3.65Kg]
Model B, D, F, G - 13 lbs.[6.0Kg]
Power Requirements: Input: 28 to 30 Vdc, 15 Amp max.
Output: 24 Vdc nominal, 10 Amp max. steady state
Model A, C, E - 2.5 Amp Hour
Model B, D, F, G - 5.0 Amp Hour
See Figure 6 Current Discharge Times
and Figure 7 Voltage Discharge Curves
Operating Altitude Sea level to 55,000 ft. at 25C
Operating Temperature: -55C to +70C
Storage Temperature: -55C to +85C
Connector Type: Model A, B, C, D, G: DPXB-13-33S-0001 (Avionics Systems P/N
S24140-01)
Model E, F: DPXB-13-33S-0019 (Avionics Systems P/N S24140-02)
Service Life: The EPS has unlimited service life.
Figure 4: Specifications
9. Affiliated Equipment

A. SI-100 Static Inverter

The SI-100 Static Inverter provides for alteration of the PS-835 output for use of equipment that
requires alternating current (AC). See Avionics Systems Installation Instructions TP-346 for
additional information.
The Model SI-100A Static Inverter (Avionics Systems part number 501-1240-01) has 3,
400Hz, 115Vac, 25VA output capability.
The Model SI-100B Static Inverter (Avionics Systems part number 501-1240-02) has 1,
400Hz 115Vac, 75VA output capability, or 1, 400Hz, 5Vac, 5VA output capability.
B. SC-841 Static Converter

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

C. BC-815 Battery Charger

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

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D. MTG-101 Mounting Rack

ATR Mounting Rack MTG-101 (Avionics Systems part number 572-1424-01) for use with PS-
835D when desired.

10. Charge and Discharge Performance

A. General Battery and Cell Information

The cells are constructed with thin pure lead plates. The overall chemistry is typical of the
traditional lead-acid battery. A unique aspect of the sealed lead-acid cell is that the majority of
the oxygen generated within the cell during an overcharge condition is recombined within the
cell. The quality of the lead grids used in construction minimize the evolution of hydrogen
when overcharging occurs.

Each cell has a self-resealing release valve designed to operate in the 50-60 psi range. In
normal use, the battery internal cell pressure never exceeds 20 psi. This means that in normal
conditions the cell can be operated in a perfect vacuum and still have a sufficient safety margin,
so that venting will not occur.

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

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

B. Battery/Cell Out-Gassing

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

CAUTION: CELL/BATTERY CORROSION IS EVIDENCE OF THE LOSS OF SEAL, LIKELY CAUSED BY


OUT GASSING. CELLS MUST BE REPLACED WHEN CORROSION IS APPARENT.

All lead-acid cells and batteries produce gasses during charging. The amount and type of gas
produced depends on state of charge, rate of charge, chemical composition of the electrolyte,
and general condition of the battery. Normally, gasses produced are recombined within the
cells to form oxides and water. Venting occurs when excessive charge rates are placed on the
battery or because of a defective cell (s) which subjects the remaining good cells to excessive
charge rates. Venting may also result from battery abuse or neglect.

If the odor of rotten eggs becomes apparent in the cockpit, pull the aircraft Emergency Power
Supply circuit breaker. The rotten egg odor is evidence that the lead-acid cells vent due to
prolonged high rate overcharging. Although the possibility of toxic levels is extremely remote,
the precaution of pulling the circuit breaker will prevent increased discomfort from the odor.

Venting is an indication that the Power Supply in not controlling the charging process. If
venting occurs the factory recommends that the Power Supply be removed from the
aircraft, tested according to the procedures listed in this manual, and to replace the
defective cell(s).

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C. Storage Time and Temperature

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

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

Low storage temperatures on fully charged cells lessen the rate of self-discharge, thus
increasing shelf life. There is no danger of damage to cells since they will not freeze even at
temperatures of -75 F. On the other hand, high storage temperatures will accelerate self-
discharge of the cells and storage under such conditions is not recommended. Refer to Figure 5.

Figure 5: Cell Storage Time vs. Temperature

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D. Cell Current Discharge Time

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

Figure 6: Typical Discharge Time for Sealed Lead Acid Cells

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E. Cell Voltage Discharge Time

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

Figure 7: PS-835( ) Discharge Curves

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11. Operation
A. Battery Testing
The majority of the components installed in the PS-835 operate only during test functions. The
exceptions are those associated with the battery heating system, and the over 55C warning
system.
NOTE: Test functions should be performed only with the main buss not providing power
to the unit (off or disconnected).
Toggling the remote or pressing the unit TEST SWITCH (Figure 3, Item 4) on the power supply
front panel bypasses the thermostatic heat control system. That, in-turn, applies the battery
voltage to the internal battery heater. While in the TEST mode, the batteries are placed under
an approximate 7.5 load. The voltage level detection system will then analyze the battery
voltage level and will cause the appropriate OUTPUT VOLTAGE MONITOR LED's to go on.
NOTE: Ensure Test Switch is returned to normal position and all LED's are extinguished.
NOTE: If the unit TEST SWITCH or Remote Test Switch is depressed at a battery
ambient temperature of 55C or greater, the unit internal heater will not turn ON
to provide a test load for the unit battery. This is not an ideal condition for
battery state of charge tests and should not be considered valid.

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

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

12. Theory of Operation

All the schematic diagrams are included in this section. Any distinctions between drawing numbers
and assembly part numbers that apply to the description of the Theory of Operation are highlighted.

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

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

Various MOD level units exist in the field and are distinguished in this description by the various
Battery Monitor CCA part numbers that may appear for repair.

* Components on Battery Monitor CCA part numbers 542-1364-( ) and 542-1495 ( ).


**Components on Battery Monitor CCA part numbers 542-1521-( ), 542-2625-( ) and 542-2635-( ).

A. Power Input

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

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

B. Heating Resistor (A1HR1)

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

C. Heater Control

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

D. Over-Temperature Protection

Thermal Resistor A1RT1 is a temperature sensitive device that changes resistance rapidly (to
over 1 Megohm) if the temperature of the surface where it is mounted exceeds +55 C (131 F).
During normal operation or test, the potential applied to the inverting input pin 6 of *A2U1
(**A2U1-13) is such that *A2U1 output pin 7 (**A2U1-14) is high, turning ON transistor
*A2Q6 (**A2Q3).

If the temperature exceeds +55 C, Thermal Resistor A1RT1 will change value reducing the
conduction current and applying a high positive voltage to the inverting inputs of *A2U1-pin 6
(**A2U1-pin 13). This causes *A2U1-pin 7 (**A2U1-pin 14) to go low, OVER 55 C LED
A2DS18 to go on, and turning off transistor *A2Q6 (**A2Q3), thereby preventing heating
resistor operation. The circuit will remain in this state until the temperature of Thermal Resistor
A1RT1 is low enough to again permit conduction.

E. Battery Voltage Level Detection

The outputs of *A2U1-pins 1, 8 and 14 (**pins 1, 7 and 8) and A2U2-pin 8 are normally high
due to the voltage applied to the non-inverting inputs by *A2Q7 (**A2Q1), resistor *A2R18
(**A2R21) and the voltage applied to the inverting inputs from voltage divider network
resistors *A2R19 through A2R22, A2R24 and A2R25 (**A2R5, A2R6, A2R12, A2R17,
A2R22 and A2R23).

The potentiometer *A2R25 (**A2R5) is adjusted so that OUTPUT VOLTAGE MONITOR


LED DS15 will go out when the voltage at J1 connector pin J1-11 is below 24 Vdc. When this
requirement has been met, the remaining OUTPUT VOLTAGE MONITOR LED's will go on or
off when their representative voltage levels are present at J1 connector pin J1-11.

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F. Test

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

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

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

NOTE: INDIVIDUAL CELL MONITOR LED's (DS1 through DS12) function as


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

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J1 Connector

506-2090B

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

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This schematic represents Models E and F after


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

506-1622C
Figure 9: PS-835 Models E and F Schematic Diagram

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J1 Connector
Model PS-835( ) // 501-1228-( )

This schematic represents Models A, B, C, and D after


replacement of A2 CCA 542-1521-01 with 542-2635-01.
See Service Bulletin table Figure 1 and SB501-1228-9( ).
506-2086A

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

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This schematic represents Models A, B, C, and D


after replacement of A2 CCA 542-1495-01 with
542-1521-01. See Service Bulletin table Figure 1
and SB501-1228-9( ).

506-1512G

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

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506-1486E

This schematic represents Models A and B that have been converted to


Model C and D with the re-identification of A2 CCA from 542-1364-
01 to 542-1495-01. See Service Bulletin table Figure 1 and SB501-
1228-8( ). Models C and D that include the A2 CCA's (542-1495-xx)
Figure 12: PS-835 Models C and D Schematic Diagram are obsolete and are no longer supported.

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506-1287L
This schematic includes wiring changes prompted by MOD 1 to both
Model A and B and MOD 6 for Model A and MOD 7 for Model B. See
Service Bulletin table Figure 1. Models A and B that include the A2
Figure 13: PS-835 Models A and B Schematic Diagram
CCA (542-1495-01) are obsolete and are no longer supported.

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Testing and Fault Isolation

1. General

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

NOTE: Read these procedures thoroughly before proceeding with any testing.

These instructions will offer reference to supporting Illustrated Parts List illustrations that will
appear in parenthesis identifying figure and item number (sample 1-50). In addition, electronic
components will include Reference Designator identification in parenthesis indicating the major
assembly and component reference number that is listed or identified on the appropriate schematic
(sample A1R8). Schematic drawings are located in the Description and Operation section.
A. Battery/Cell Out-gassing (Venting)
CAUTION: SOME OF THE TYPES OF GASSES THAT MAY VENT FROM A CELL ARE TOXIC AND
SHOULD NOT BE CONTAINED IN A CLOSED, NON-VENTED AREA.

CAUTION: CELL/BATTERY CORROSION IS EVIDENCE OF THE LOSS OF SEAL, LIKELY CAUSED BY


OUT GASSING. CELLS MUST BE REPLACED WHEN CORROSION IS APPARENT.

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

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

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2. Battery Testing

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

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

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

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

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

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

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

A. Constant-Voltage Charging Method


Locally manufacture a power cable using 16AWG wire and the appropriate mating connector
See Figure 101, Item 7 & 8. Include a Diode (15 ADC (min), 50.0 PIV or greater, See Figure
101, Item 6) to prevent battery discharge in case of loss of power from the power source.

Using the external power supply (Figure 101, Item 1), apply 29.0 0.5 Vdc (10A maximum
current limited) to J1 connector pins 11 (+) and 7 (-) and charge the unit for 16 hours. The
batteries should reach 80% capacity within 1 hour and full charge at 16 hours.
J1 pin 11 +
PS-835 (16AWG conductors)
Power Supply Power Supply
J1 pin 7 (ground)
_

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

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B. Constant-Voltage Float (trickle) Charging Method

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

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

C. BC-815 Battery Charger Method

Install the BC-815 Battery Charger (Avionics Systems part number 501-1321-01) into the PS-
835 Emergency Power Supply and charge for no-less-than 23 hours. Charge time depends upon
the batteries state-of-charge. Charging for 23 hours will essentially guarantee a full charge.

The BC-815 provides a constant charging current of either 0.5 A or 0.25 A, selectable by a
switch on the face of the unit. The AMBER LED illuminates when power is applied by placing
the ON / OFF switch to ON. When the unit being charged is within 90.0% of full charge, the
GREEN LED illuminates indicating that the BC-815 has automatically switched to the trickle
charge mode. The charger/battery combination may be operated in this mode indefinitely
without damage to the BC-815 or to the batteries being charged.

D. BC-815 Battery Float (trickle) Charging Method

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

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

4. Preflight Checks (Recommended)


NOTE: This check will indicate an accurate condition of the unit only upon the intial attempt.
Repeated checks will not reveal accuratly because stored energy is used each time the
TEST SWITCH is depressed.
A. Pre-Flight Check for Aircraft with Remote Test Capability
With no power applied to the PS-835 Emergency Power Supply, press and hold for 5 seconds
the cockpit remote TEST SWITCH in the TEST position. The remote test lamp must, at least,
momentarily illuminate to indicate that the Power Supply is adequately charged. If no
illumination of the remote test lamp is apparent for the period that switch is held, the
Emergency Power Supply is incapable of providing power in an emergency.
B. Pre-Flight Check for Aircraft with NO Remote Test Capability
Access the Emergency Power Supply. Perform the check as listed in paragraph 5, Periodic
Checks.

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5. Periodic Checks (Required 3 to 6 Months)

With no power applied to the PS-835 Emergency Power Supply, press TEST SWITCH (Figure 104,
Item 4) (or remote cockpit test switch) into TEST position for 5 seconds. The PS-835 indicates that it
is adequately charged when the VOLTAGE LEVEL 24Vdc LED (Figure 104, Item 2) (or remote test
indicator), at least, illuminates momentarily, AND the 20Vdc LED (Figure 104, Item 6) remains lit
during the test.
NOTE: Ensure Test Switch is returned to normal position and all LED's are extinguished.
If the VOLTAGE LEVEL 24Vdc LED does not, at least, momentarily illuminate while the 20Vdc
LED is illuminated, the Emergency Power Supply is incapable of providing power in an emergency.
Proceed to Fault Isolation Test, Step 7.

6. Capacity Testing (Required Annually)

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

A. Capacity Test

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

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

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

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

B. Preferred Discharge Test Method (Load Resistor)

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

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

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

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

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

5) Monitor and plot voltage values at 10-minute intervals.

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

a. All INDIVIDUAL CELL MONITOR LEDs (Figure 104, Item 1) must remain on.

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

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

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

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

10) If the plot reveals a discharge curve that meets or exceeds the MINIMUM ACCEPTABLE
DISCHARGE CURVE, the unit is considered satisfactory.

11) If unit discharge plot is satisfactory and no other failures were revealed, perform either of
the Charging Procedures listed in Step 2 within 2 hours of completion of the discharge test.
Return the unit into service or storage as required.

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

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

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

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

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

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

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


6) Start timing the discharge period with the stopwatch now.

7) Monitor and plot voltage values at 10-minute intervals.

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

a. All INDIVIDUAL CELL MONITOR LEDs (Figure 104, Item 1) must remain on.

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

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

10) Compare the voltage vs. time plot created during this test to that of curve identified as
typical for the Internal Load Test Method on the chart in Figure 7.

11) If the plot reveals a discharge curve that exceeds the MINIMUM ACCEPTABLE
DISCHARGE CURVE, the unit is considered satisfactory.

12) Remove Jumper Wire, Voltmeter leads and reinstall cover

13) If the unit discharge plot is satisfactory and no other failures were revealed, perform either
of the Charging Procedures listed in Step 2 within 2 hours of the completion of the
discharge test. Return the unit into service or storage as required.

7. Cell Isolation Test

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

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

A. Press and hold TEST SWITCH (Figure 104, Item 4). If no OUTPUT VOLTAGE MONITOR
LED's come on:
NOTE: Ensure Test Switch is returned to normal position and all LED's are extinguished.
1) Position all INDIVIDUAL CELL DIP SWITCHES to the ON position.

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

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

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

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8. Performance Test
This test is required before a unit can re-enter service after a repair action has been performed on the
unit.
A. Recommended Test Equipment
Figure 101 provides a list of recommended test equipment needed to accomplish the test and
charging requirements for the Model PS-835 Emergency Power Supply. See Special Tools,
Fixture, and Equipment section, Figure 901 for detailed listing.
NOTE: Equivalent equipment may be used for all listed items.

Item Description Manufacturer - Model / Part No.


1 DC Power Supply Hewlett Packard Model 6291
0-30 Vdc 20 amp capacity
2 Digital Voltmeter (DVM) Fluke Model 8050A
3 Delete Delete
4 Load Resistor WireMasters, Inc.
7 1% 150 watt (minimum), Ceramic 136 Alpha Drive,
wire wrap Franklin, TN 37064. Cage Code: 0FVD7
Tel: 800-635-5342
(Part Number WM910053 300 watt version)
5 Stopwatch Meyland Corp. Model 202A
6 Isolation Diode WireMasters, Inc.
15 Amp, 50 Volt PIV (Part Number WM1N3208)
7 Mating Connector for PS-835 A to D, & G P/N: DPXB-13-33S-0001
8 Mating Connector for PS-835 E and F P/N: DPXB-13-33S-0019
9 BC-815 Battery Charger (used in place of Avionics Systems Part No. 501-1321-01
DC power supply)

Figure 101: Test Equipment and Fixtures

B. Test Setup and Conditions


1) Establish a Test Setup stations based on schematics Figure 102 and Figure 106 using the
test equipment listed in Test Equipment and Fixtures Figure 101.
2) All tests must be performed at laboratory ambient temperature (room temperature),
humidity, and atmospheric pressure.

3) All power source settings and load values must be within 2% of the values cited in the
instructions. Time measurements must be within +10% of the specified limits.
4) The Battery Monitor CCA (A2) MUST be correctly calibrated before unit Charging
Procedures and Performance Test Procedures can be performed. See step 8.-C.-C.3)
Battery Monitor CCA Calibration Procedure.
5) Unit must have completed the full charge process within 24 hours before running tests.
6) Open (OFF) all Test Setup switches before energizing the External Power Supply.
7) Position Test Setup switch S5 to INPUT.

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Figure 102: PS-835 Test Setup Schematic

C. Performance Tests Procedures


Before returning a PS-835 Emergency Power Supply to operation the following performance
test must be performed to insure operation of the unit according to original specifications.
NOTE: The Battery Monitor CCA (A2) MUST be correctly calibrated before performing
these procedures. See step 8.-C.-3) Battery Monitor CCA Calibration Procedure.
1) Continuity Test
Remove unit Cover (1-5) and disconnect any external power source from unit.
CAUTION: DO NOT MEASURE J1 CONNECTOR PIN 11 TO PIN 7 OR PIN 12 (GROUND) ON ALL
MODELS AND PIN 9 TO PIN 7 OR PIN 12 (GROUND) ON MODELS E & F.

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

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Connector Pins
From (+) To ( - ) Correct Results
All Models
J1-1 J1-7 Open
J1-1 J2-2 Short
J1-2 J1-7 33K min.
J1-3 J1-7 Open
J1-3 J2-7 Short
J1-4 J1-7 Open
J1-4 J2-15 Short
J1-5 J2-8 Short
J1-5 J1-7 Open
J1-6 J1-7 1M min.
J1-8 J1-7 Open
J1-10 J1-7 20K min.
J1-11 J1-7 CAUTION: DO NOT MEASURE
J1-11 J2-9 Short
J1-12 J1-7 Short
J1-12 J2-5 Short
J1-12 J2-13 Short
J1-12 Chassis Short
J2-8 J2-3 Short
J3-2 J3-5 40-100 (see step 5. d.(3))
J3-24 J3-25 7.40.5

Model A and B
J1-9 J1-7 Open
J1-9 or J1-13 J1-4 or J1-9 or J1-11 Short

Model C & D
J1-1 J1-5 Open
J1-1 J1-11 Open
J1-1 J2-1 Open
J1-3 J1-5 Open
J1-5 J1-13 Open
J1-9 J1-7 Open
J1-12 J1-13 Open

Model E & F
J1-9 J1-7 or J1-12 CAUTION: DO NOT MEASURE
J1-11 J1-9 Short (through F1 fuse)
J1-13 J2-4 or J2-11 Short
Figure 103: Connector Pin Continuity Table

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2) Voltage Test

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

3) Battery Monitor CCA Calibration Procedure

NOTE: The Battery Monitor CCA MUST be correctly calibrated to insure


successful Battery Charging and Capacity Testing Procedures.

NOTE: If calibration cannot be successfully achieved, remove the Battery Monitor


CCA and perform the Battery Monitor CCA Test Procedures, Step 8.

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

b. Check Thermo Resistor (A1RT1) (2-215) to ensure that it is adequately grounded to


the unit chassis. Repair if necessary before proceeding with calibration.

c. Battery Heater Adjustment (Perform only if Battery Monitor CCA not previously
calibrated)

(1) Set External Power Supply to 28 to 30Vdc, open Test Setup switch S4 to prevent
application of load to J1 connector pin J1-11, close Test Setup switch S3 to apply
power to J1 connector pin J1-10.

(2) Find Temperature Control resistor (A2R8) located on the Battery Monitor CCA
(A2) and adjust resistor to so to discover the resistor setting that turns ON the
HEATER ON LED at the current room temperature.

(3) From that point, rotate the resistor adjustment 2 complete turns clockwise to
establish the approximate 20C Heater setting.

WARNING: ADHESIVE (F-900 TORQUE SEAL) HAS BEEN IDENTIFIED AS HAVING A


DEGREE OF HAZARD IN HEALTH, FLAMMABILITY, AND REACTIVITY.
CONSULT THE APPLICABLE MATERIAL SAFETY DATA SHEET PRIOR TO
USE OR ASSOCIATION WITH THIS PRODUCT.

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

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d. Front Panel Battery and Cell Monitor

(1) Position all INDIVIDUAL CELL DIP SWITCHES (Figure 3, item 5) to ON and
confirm that each INDIVIDUAL CELL MONITOR LED goes ON.

(2) Change the External Power Supply setting to 18-19 Vdc, press and hold TEST
SWITCH (Figure 3, Item 4) and observe to confirm that the INDIVIDUAL
CELL MONITOR LED's remain ON. Release the TEST SWITCH.

(3) Change the External Power Supply setting to 28Vdc and confirm that the all
BATTERY VOLTAGE MONITOR LED's remain ON.

(4) Re-position all INDIVIDUAL CELL DIP SWITCHES to OFF.

e. Battery Temperature Protection

(1) Open (OFF) Test Setup switch S3 to eliminate power to the unit.

(2) Use the DVM (Figure 101, Item 2) to measure the resistance value of the
Thermo Resistor (A1RT1), applying the Ohmmeter probes between J3 connector
pins 2 and 5. Resistance must be 40-100.

(3) Replace the Thermo Resistor (A1RT1) if resistance is not between 40-100.

f. Heater and Control Performance

(1) Change External Power Supply to 30 Vdc and close (ON) Test Setup switches S2
and S3.

(2) Observe BATTERY HEATER OPERATION MONITOR LED's (Figure 1, Item


3). Within 30 minutes, the OVER 55C LED must go ON and the HEATER ON
LED must go OFF.

(3) Open (OFF) Test Setup switch S3 to remove external power supply to unit.

(4) Re-install the unit Cover.

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4) Capacity Testing

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

Test Method Preference


External Load Constant Voltage Preferred
Internal Load Constant Voltage Alternate
Automatic Discharge Constant Current Alternate

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

Figure 104: PS-835 Access Panel

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a. External Load Method

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

NOTE: If the INDIVIDUAL CELL MONITOR LED DS12 (DS1 for


models E and F) is the only LED not illuminated, proceed to test
paragraph 7 [Cell Isolation Test].

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

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

NOTE: During the test All INDIVIDUAL CELL MONITOR LEDs


(Figure 104, Item 1) must remain on. Any LED that does go OFF
will represent a defective individual cell, which must be replaced.

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


For Models A, C and E record the output voltage at 20 minutes.

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

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

CAUTION: RECHARGE THE PS-835 WITHIN 2 HOURS AFTER DISCHARGING TO


REDUCE THE POSSIBILITY OF DAMAGE TO BATTERY CELLS.

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

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

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b. Internal Load Method

The internal load method uses the batteries heater blanket to discharge the batteries.
Before conducting this test remove the power supply cover and place a small fan near
the unit (to dissipate heat).

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

NOTE: If the INDIVIDUAL CELL MONITOR LED DS12 (DS1 for


models E and F) is the only LED not illuminated, proceed to test
paragraph 7 [Cell Isolation Test].

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

(3) Connect a jumper to J1 connector pins 11 (24/28Vdc out) and 2 (remote test
switch), and start timing the discharge period with the stopwatch (Figure 101,
Item 4).

NOTE: During the test All INDIVIDUAL CELL MONITOR LEDs


(Figure 104, Item 1) must remain on. Any LED that does go OFF
will represent a defective individual cell, which must be replaced.

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


For Models A, C and E record the output voltage at 20 minutes.

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

CAUTION: RECHARGE THE PS-835 WITHIN 2 HOURS AFTER DISCHARGING TO


REDUCE THE POSSIBILITY OF DAMAGE TO BATTERY CELLS.

(5) Remove the jumper from J1 connector pins 11 and 2 and the DVM from J1
connector pin 11 and 7.

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

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c. Automatic Discharge Method

The Automatic Discharge Method can only be used when a automatic constant-current
battery analyzer is used.

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

NOTE: If the INDIVIDUAL CELL MONITOR LED DS12 (DS1 for


models E and F) is the only LED not illuminated, proceed to test
paragraph 7 [Cell Isolation Test].
(2) Connect unit under test to test equipment and apply power.

Models B, D, F and G will sustain a constant-current discharge of 3.3 Amps


for 48 minutes to not less then 20.0 Vdc.
Models A, C and E will sustain a constant-current discharge of 1.5 Amps for
48 minutes to not less then 20.0 Vdc
(3) A unit that fails to meet the minimum acceptable voltage will require service. A
unit that meets the minimum acceptable voltage proceeds to the Recharging
Procedures Paragraph.
CAUTION: RECHARGE THE PS-835 WITHIN 2 HOURS AFTER DISCHARGING TO
REDUCE THE POSSIBILITY OF DAMAGE TO BATTERY CELLS.

(4) Remove the unit from test equipment.


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

d. Cell Isolation Test

NOTE: No power should be applied to PS-835 Emergency Power Supply


during test.

(1) Press and hold TEST SWITCH (Figure 104, Item 4). If no OUTPUT VOLTAGE
MONITOR LED's come on:
NOTE: Ensure Test Switch is returned to normal position and all LED's
are extinguished.
a) Position all INDIVIDUAL CELL DIP SWITCHES (Figure 104, Item 4) to
the ON position.
b) Press and hold TEST SWITCH (Figure 104, Item 4) and observe the
INDIVIDUAL CELL MONITOR LED's (Figure 104, Item 1).

If all INDIVIDUAL CELL MONITOR LEDs come on except DS12,


the unit is damaged and requires repair.

If all INDIVIDUAL CELL MONITOR LEDs are on, there exist a low-
battery voltage condition. Perform the Charging Procedures of Step 2.

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9. Battery Monitor CCA Test Procedures

This test procedure includes the calibration process to establish the correct voltage values that
illuminate the monitor LED's. The correct calibration of this Battery Monitor CCA is essential for
the successful completion of the unit Charging Procedures and Performance Test.

Construct the CCA Test Setup station according to the wiring schematic in Figure 105.

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

A. INDIVIDUAL CELL MONITOR LED Test

1) Position all INDIVIDUAL CELL DIP SWITCHES to ON.

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

Figure 105: Individual Cell Monitor LED's

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Figure 106: Circuit Card Assembly Test Setup

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B. Battery Monitor CCA Performance Test (542-1521-xx, 542-2625-xx, 542-2635-xx)

NOTE: Obsolete Battery Monitor CCA's 542-1495-xx and 542-1364-xx have no


Performance Tests available. See Service Bulletin and Modification table,
Figure 1.

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

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

3) Energize and set the External Power Supply to 28 Vdc.

4) Turn switch S1 to position 1.

5) Measure and record voltage at J3 connector pin J3-8 (TP 1). Voltage must be 12.6 7% Vdc.
6) Adjust resistor A2R13 CW so that Test Setup LED CR1 just goes OFF.

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

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

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

8) Increase External Power Supply (measured at TP 2) to 28 Vdc. INDIVIDUAL CELL


MONITOR LED's DS13 through DS16 and Test Setup LED CR3 must go ON.

9) Gradually decrease External Power Supply to 19.8 Vdc, observe and record voltage values
that each LED, DS13 through DS16 and Test Setup LED CR3, go OFF. LED's must go
OFF at:

LED Voltage
DS13 27 0.27 Vdc
DS14 25 0.25 Vdc
DS15 24 0.10 Vdc
CR3 (TP 2) 24 0.10 Vdc
DS16 20 0.20 Vdc

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

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

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

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

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

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

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

12) Open (OFF) Test Setup switch SW3, close (ON) SW6, and adjust External Power Supply
to 28 Vdc as measured at J3 connector pin J3-19 (TP 3).

13) Adjust resistor A2R8 CCW until HEATER ON INDICATOR LED DS17 goes ON, then
close (ON) the Test Setup switch SW3 which must result in cell HEATER ON
INDICATOR LED DS17 to go OFF.

14) Close (ON) switch SW2 and apply Digital Voltmeter lead to pin 24 (TP 4). With switch
SW3 still closed (ON) the voltage reading at pin 24 (TP 4) must be 28 Vdc. Open (OFF)
switch SW3 and voltage reading must be less than 2.5 Vdc.

15) Apply, again, the Digital Voltmeter lead to J3 connector pin J3-19 (TP 3). Open (OFF) Test
Setup switch SW3, close (ON) SW6, and adjust External Power Supply to 26 Vdc.

16) Adjust resistor A2R8 CCW and confirm that HEATER ON INDICATOR LED DS17
remains OFF.

17) Close (ON) switch SW2 and apply Digital Voltmeter lead to pin 24 (TP 4). Close (ON)
switch SW3, voltage reading at J3 connector pin J3-24 (TP 4) must be 26 Vdc. Open
(OFF) switch SW3 and voltage reading must continue to be 26 Vdc.

18) Return External Power Supply to 28 Vdc and open (OFF) Test Setup switch SW3. Open
(OFF) Test Setup switch SW4, observe and confirm the OVER 55 LED DS18 goes ON
and Test Setup LED CR2 goes OFF.

19) Apply the Digital Voltmeter lead to J3 connector pin J3-19 (TP 3) and adjust External
Power Supply to 28 Vdc. Close (ON) Test Setup switches SW2, SW3, and SW4. Place
Test Setup switch SW1 to position 2. Apply Digital Voltmeter lead to pin 24 (TP 4). Open
(OFF) Test Setup switch SW4. The Digital Voltmeter must read 28 Vdc.

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

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

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

C. Post Test Procedures

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

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Disassembly

1. General

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

Disassembly procedures are listed in descending order to allow for successive accessibility to sub-
assemblies and components. These procedures are intended to cover most aspects of disassembly.
De-soldering of components and wires, and the replacement of items such as switches, fasteners, and
other simple operations are not covered explicitly. Technicians working on avionics equipment of
this type should have adequate knowledge of avionics shop practices before attempting any repairs.

Whenever a disassembly procedure involves disconnecting wires from components and/or connector
J1, it is best to tag, mark, or identify the wires that are cut, de-soldered, or otherwise removed. If
wires are cut, do so in a manner that provides an adequate wire for re-connections.

Disassemble the PS-835 Emergency Power Supply only to the level necessary to repair the unit as
revealed in the procedures of the Fault Isolation and Test section.

Any disassembly of the PS-835 for repair or cleaning will require functional testing after re-
assembly and before installation. See the Testing and Fault Isolation section for functional test
procedures and wiring diagrams.

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

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

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

2. Disassembly Procedures

A. Cover Removal

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

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

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B. Front Panel Removal


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

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

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

C. Battery Monitor Circuit Card Assembly (A2) (CCA) Removal

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

D. Cell Removal

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

CAUTION: CELL/BATTERY CORROSION IS EVIDENCE OF THE LOSS OF SEAL, LIKELY CAUSED BY


OUT GASSING. CELLS MUST BE REPLACED WHEN CORROSION IS APPARENT.

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

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

3) Repeat for the next vertical 4-cell group.

4) Pull out the last vertical 4-cell group.

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

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

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

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

E. Heater Element (HR1) Removal

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

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

3) Remove excess adhesive from chassis.

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F. Battery CCA (A1) Disassembly

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

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

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

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

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

3. Repair

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

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Cleaning

1. General

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

2. External Cleaning

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

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

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

3. Internal Cleaning

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

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

With exception to the circuit card assemblies (CCAs), the internal surfaces of the assembly may be
cleaned following the processes for external cleaning above. CCAs can be cleansed using Isopropyl
Alcohol and a modified acid brush. Allow CCA to dry before use.

Remove dust and dirt with a low-pressure jet of clean, dry air. If necessary, use the brush depicted in
Figure 401 to loosen hardened dirt and embedded dust balls.

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Figure 401: Modified Acid Brush

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Check

1. General

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

2. On Aircraft Checks

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

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

C. View Output Voltage Monitor LED's (cockpit remote test lamp for aircraft so equipped).

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

D. Release the TEST SWITCH and reset the aircraft circuit breaker.

NOTE: Ensure Test Switch is returned to normal position and all LED's are extinguished.
3. Checks After Repair and During Re-assembly

A. Perform disassembly according to the Disassembly section.

While in progress of disassembly, check:

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

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

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

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

5) Inspect all soldered connections, even those not unsoldered during disassembly, for broken
or pitted solder, cold joints, and solder quality.
Deficiencies found during inspection should be corrected when repairing a defective unit, or
performed as a preventive maintenance measure to preclude future problems. Repair defects in
accordance with the Repair section of this manual.

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4. Inspection After Repair and During Assembly

A. Perform re-assembly according to Reassembly section.

While in progress of unit re-assembly check:

1) Sufficient service loop exists between interconnected subassemblies.

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

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

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

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

6) Connector J1 is properly covered for storage or handling.

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

5. PS-835 Storage

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

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

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Repair

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

2. Battery Cell and Pack Replacement


NOTE: Refer to SL-84( ) for instructions concerning the replacement of nickel cadmium
(NiCad) battery cells and packs; and lead-acid cells.
When replacing cells within a pack the cells must be the same part number and vendor as the cells
being replaced. Avionics Systems recommends that when any pack has more than 4 defective cells,
all 12 cells should be replaced.
3. Circuit Card Assembly (CCA) Repair
Avionics Systems exercises stringent circuit board manufacturing processes and soldering
requirements. To provide for best circuit board repair results, match these requirements in the CCA
repair process. Avionics Systems uses industry standards IPC-A-610B and ANSI/J-STD-001 (for
class 2 applications) for soldering practices and workmanship standards.
4. Consumable Materials
This table lists the tools, fixtures, and consumable materials necessary to correctly assembly the PS-
835 Emergency Power Supply. Those products listed that are considered chemical hazards are
marked with a CH symbol. Material Safety Data Sheets should be on hand to determine the best
means to safely handle these products.

Part Number Description and Vendor Information Intended Use


ACETONE CH Dow Corning Pre-solder cleaning
SOLDER WICK, PLATO-WICK or equivalent De-solder
R or RMA FLUX CH Pre-solder preparation
SN63WRMA SOLDER-025"DIA. Wire connections and component
installations
#340 HEATSINK COMPOUND CH - Dow Corning Battery Monitor CCA transistors Q2 and Q3
MS3368-3-9C CELL TIE-DOWN STRAPS Cells secured to Battery CCA (A1)
MS3367-4-9 TIE-DOWN STRAP Wire Bundles
1425 (clear) ADHESIVE EPOXY TWO-PART FLEXIBLE CH Securing Transistor Q1 to Battery Monitor
Devcon CCA
732 RTV ADHESIVE SILICONE RUBBER CH - Stabond Corp Secure Cells and Insulator Plates
VULCABOND V36 ADHESIVE RUBBER BASE CH - Stabond Corp Secure Insulator Plates
SCOTCHGRIP-847 ADHESIVE RUBBER BASE CH - 3M Co. Preferred Alternate for Vulcabond V36
F-900 Torque Seal- SEALING LOCKING AND RETAINING COMPOUND Secure Adjustable Resistor Screw
Green CH
1A34 or 1B31 HUMISEAL CH Sealing CCAs against environmental
conditions

Figure 601: Consumable Materials

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Part Number Description and Vendor Information Intended Use

50-0210 SLEEVING 26 AWG NATURAL Insulation of bare leads and wires


M23053/5-103-0 INSULATION SLEEVING Insulation of bare leads and wires
M23053/5-105-0 INSULATION SLEEVING ELECTRICAL HEAT SHRINK Insulation of bare leads and wires
M16878/4BFB2 WIRE RED 22 AWG W11 Internal and interconnecting wiring
M16878/4BGB3 WIRE ORN 20 AWG W9 Internal and interconnecting wiring
M16878/4BGB4 WIRE YEL 20 AWG W1 Internal and interconnecting wiring
M16878/4BGB5 WIRE GRN 20 AWG W2 Internal and interconnecting wiring
M16878/4BGB6 WIRE BLU 20 AWG W12 Internal and interconnecting wiring
M16878/4BGB7 WIRE VIO 20 AWG W3 Internal and interconnecting wiring
M16878/4BGB8 WIRE GRAY 20 AWG W13 Internal and interconnecting wiring
M16878/4BGB9 WIRE WHT 20 AWG W4 Internal and interconnecting wiring
M16878/4BHB1 WIRE BRN 18 AWG W50 Internal and interconnecting wiring
M16878/4BHB0 WIRE BLK 18 AWG W17 W21 W19 W23 W24 W25 W28 Internal and interconnecting wiring
W29 W33 W34 W38 W39 W44 W48 W49 W5 W7 W15
M16878/4BHB2 WIRE RED 18 AWG W10 W14 W18 W20 W22 W26 W27 Internal and interconnecting wiring
W30 W32 W35 W37 W40 W41 W45 W46 W47
QQW343H20S1T WIRE 20 AWG TIN COAT W43 Internal and interconnecting wiring

(see Wiring List Figures 603 and 604)

Figure 601: Consumable Materials (cont.)

5. Special Tools

NOTE: Equivalent equipment may be used for all listed items.

Item Description Characteristic Required


1 DC Power Supply 0-40 Vdc 20amp capacity
Hewlett Packard Model 6291*
2 Digital Voltmeter (DVM) Fluke Model 8050A*
3 Delete Delete
4 Load Resistor 7 1% 150 watt or greater *
(WireMasters, Inc. 136 Alpha Drive, Franklin, TN 37064.
Cage Code: 0FVD7)*
5 Stopwatch Meyland Corp. Model 202A*
6 Isolation Diode WireMasters, Inc.
15 Amp, 50 Volt PIV (Part Number WM1N3208)
7 Adjustable Tension Installation Tool Thomas & Bretts Co.*
Cat. No. WT-199

Figure602: Special Tools and Equipment

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6. Moisture and Fungus Proofing

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

A. Prepare coating HUMISEAL 1A34 or HUMISEAL 1B31 in accordance with manufacturer's


instructions on product. Prepare only enough coating to accomplish the task.

The original CCAs are coated at the factory with Paraxylene C. This coating may be repaired
by applying HUMISEAL 1A34 to the areas of the CCA where repair was accomplished.
HUMISEAL 1A34 may be used on all CCAs, but is expressly used for military qualified units.
HUMISEAL 1B31 is the preferred alternate coating if 1A34 is unavailable for CCAs not
qualified for military use. It is unnecessary and inadvisable to re-coat the entire CCA.

7. Performance Test

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

Wire Number From To Wire Number From To

W1 A1E1 J1 pin 1 W23 BT12 neg AF1-2


W2 A1E2 J1 pin 2 W11 CR1 ANODE A1E12
W3 A1E3 J1 pin 4 W10 CR1 ANODE J1 pin 10
W4 A1E4 J1 pin 6 W15 E18 J1 pin 11
W5 A1E7 J1 pin 7 W42 E18 A1-22
W43 A1E7 A1E9 W1 J1 pin 1 A1E1
W6 A1E7 XF1-1 W2 J1 pin 2 A1E2
W16 A1E8 A1-24 W12 J1 pin 3 A1E14
W43 A1E9 A1E7 W3 J1 pin 4 A1E3
W7 A1E9 J1 pin 12 W13 J1 pin 5 A1E15
W44 A1E9 A1E19 W4 J1 pin 6 A1E4
W8 A1E10 J1 pin 9 W5 J1 pin 7 A1E7
W9 A1E11 J1 pin 13 W8 J1 pin 9 A1E10
W11 A1E12 CR1 ANODE W10 J1 pin 10 CR1 ANODE
A12 A1E14 J1 pin 3 W15 J1 pin 11 E18
W13 A1E15 J1 pin 5 W7 J1 pin 12 A1E9
W44 A1E19 A1E9 W9 J1 pin 13 A1E11
W42 A1-22 E18 W6 XF1-1 A1E7
W16 A1-24 A1E8 W23 XF1-2 B12 neg
W14 BT1 pos A1-22

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

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Wire Number From To Wire Number From To

W1 A1E1 J1 pin 1 W11 CR1 ANODE A1E12


W2 A1E2 J1 pin 2 W10 CR1 ANODE J1 pin 10
W3 A1E3 J1 pin 4 W15 E18 J1 pin 11
W4 A1E4 J1 pin 6 W50 E18 XF1-1
W5 A1E7 J1 pin 7 W1 J1 pin 1 A1E1
W43 A1E7 A1E9 W2 J1 pin 2 A1E2
W49 A1E7 A1 pin 24 W12 J1 pin 3 A1E14
W43 A1E9 A1E7 W3 J1 pin 4 A1E3
W7 A1E9 J1 pin 12 W13 J1 pin 5 A1E15
W44 A1E9 A1E19 W4 J1 pin 6 A1E4
W9 A1E11 J1 pin 13 W5 J1 pin 7 A1E7
W11 A1E12 CR1 ANODE W46 J1 pin 9 XF1-2
W12 A1E14 J1 pin 3 W10 J1 pin 10 CR1 ANODE
W13 A1E15 J1 pin 5 W15 J1 pin 11 E18
W44 A1E19 A1E9 W7 J1 pin 12 A1E9
W45 A1-22 XF1-1 W9 J1 pin 13 A1E11
W48 A1-24 BT12 neg W50 XF1-1 E18
W49 A1-24 A1E7 W45 XF1-1 A1-22
W47 BT1 pos XF1-2 W47 XF1-2 BT1 pos
W48 BT12 neg A1-24 W46 XF1-2 J1 pin 9

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

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Assembly
1. General

Assembly procedures are listed in ascension order, starting at the lowest level of assembly. These
procedures are intended to cover most aspects of assembly. Soldering of components and wires, and
the replacement of items such as switches, fasteners, and other simple operations are not covered
explicitly. Technicians working on avionics equipment of this type should have adequate knowledge
of avionics shop practices before attempting any repairs.
CAUTION: READ AND UNDERSTAND ALL THE INFORMATION IN THIS SECTION BEFORE ATTEMPTING
ASSEMBLY OF THIS UNIT.

NOTE: Detailed assembly procedures for the Battery Pack(s) are listed in the Repair section.
Testing procedures are found in the Testing and Fault Isolation section of this manual.
Disassembly section procedures included encouragement to tag and/or mark wires at disconnection.
If no wire marking was performed at disassembly, take time to identify wires and appropriate
connection points before starting re-assembly process. See Description and Operation section for
Schematic Diagrams.
WARNING: SEVERE (3RD DEGREE) BURNS AND MELTED METAL PARTS CAN RESULT THROUGH
IMPROPER HANDLING OF THE LRU AND SUBASSEMBLIES. THE BATTERIES CONTAINED
WITHIN THE PS-835 ARE CAPABLE OF PRODUCING AND SUSTAINING LARGE CURRENTS (OVER
50 AMPS) FOR SEVERAL MINUTES. REMOVE ALL JEWELRY WHEN WORKING ON THIS
EQUIPMENT.

NOTE: Place the PS-835 assemblies and components on a stable, flat surface with appropriate
lighting. Take special note that storage batteries contained in the PS-835 are charged
and capable of inflicting burns and shocks. Do not proceed with assembly without
reading this entire section.
2. Assembly Tools, Fixtures and Consumables
This table lists the tools, fixtures, and consumable materials necessary to correctly assembly the PS-
835 Emergency Power Supply. Those products listed that are considered chemical hazards are
marked with a CH symbol. Material Safety Data Sheets should be on hand to determine the best
means to safely handle these products.

Item # Tools and Consumable Materials Part Number Source


Consumables:
1. Acetone CH Allied Fibris & Plst
2. Solder Wick PLATO-WICK or equivalent
3. Flux CH R or RMA
4. Solder-025"dia. SN63WRMA
5. HEATSINK COMPOUND CH #340 Dow Corning
6. TIE DOWN STRAP MS3367-4-9
7. ADHESIVE EPOXY TWO-PART FLEXIBLE CH 514-1247-01

Figure 701: Tools and Consumables

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Item # Tools and Consumable Materials Part Number Source

8. CELL TIE DOWN STRAPS P/N 566-1115-01


MS3368-3-9C
9. ADHESIVE SILICONE RUBBER CH 732 RTV Stabond Corp
10. ADHESIVE RUBBER BASE- CH VULCABOND V36 Stabond Corp
SCOTCHGRIP-847 ADHESIVE RUBBER BASE Preferred Alternate for
CH - 3M Co. Vulcabond V36
11. SEALING LOCKING AND RETAINING F-900 Torque Seal- Green Organic Products Co.
COMPOUND CH
12. INSULATING COMPOUND CH 1A34 or 1B31 HUMISEAL
Miscellaneous Hand/Shop Tools:
13. Screwdrivers (Phillips and Standard), Wire Cutters, Needle Nose Pliers, Applicator Brush, Cotton Swab, Toothpick,
Kim wipe, Nut Driver (various sizes), Bench Vise, Solder Iron and associated tools.
See Consumable Materials (Figure 601) and Wiring Lists (Figures 603 and 604) for wire information.

Figure 701: Tools and Consumables (Cont.)


3. Assembly Procedures
A. Heater Element (HR1) Assembly
WARNING: ADHESIVE (VULCABOND V-36) HAS BEEN IDENTIFIED AS HAVING A DEGREE OF HAZARD
IN HEALTH, FLAMMABILITY, AND REACTIVITY. CONSULT THE APPLICABLE MATERIAL
SAFETY DATA SHEET PRIOR TO USE OR ASSOCIATION WITH THIS PRODUCT.

WARNING: ADHESIVE (SCOTCHGRIP-847) HAS BEEN IDENTIFIED AS HAVING A DEGREE OF HAZARD


IN HEALTH, AND FLAMMABILITY. CONSULT THE APPLICABLE MSDS PRIOR TO USE OR
ASSOCIATION WITH THIS PRODUCT.

1) Apply Vulcabond (Scotchgrip 847) adhesive (Figure 701 Item 10) uniformly to Battery
CCA Chassis.
2) Place Heater Element (HR1) (2-45) onto Battery CCA Chassis.
3) Solder Heater Element (HR1) wires onto Battery CCA solder pads #18 and #19 (see Figure
702).
B. Cell Installation (All cells replaced assumed)
NOTE: Refer to SL-84( ) for instructions concerning the replacement of nickel cadmium
(NiCad) battery cells and packs; and lead-acid cells.
CAUTION: WHEN REPLACING CELLS WITHIN A PACK THE CELLS MUST BE THE SAME PART NUMBER
AND VENDOR AS THE CELLS BEING REPLACED. AVIONICS SYSTEMS RECOMMENDS THAT
WHEN ANY PACK HAS MORE THAN 4 DEFECTIVE CELLS, ALL 12 CELLS SHOULD BE
REPLACED.

1) Prepare cells by:


a. For models C and D, de-solder and remove the pre-installed black (negative) wire
from one of the cells. This cell now becomes BT12. See IPL Figure 1 Note A for cell
BT12 location.
b. For models E and F, de-solder and remove the pre-installed red (positive) wire from
one of the cells. This cell now becomes BT1. See IPL Figure 1 Note A for cell BT1.

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

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

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

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

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

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

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

Tie-Down Strap holes are


numbered to correspond to cell
ref. designator numbers.
Example: BT12

Cell solder pads are


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

Heater Element (HR1) solder


pad location
Figure 702: Solder Pad Locations

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WARNING: ADHESIVE (VULCABOND V-36) HAS BEEN IDENTIFIED AS HAVING A DEGREE OF


HAZARD IN HEALTH, FLAMMABILITY, AND REACTIVITY. CONSULT THE APPLICABLE
MATERIAL SAFETY DATA SHEET PRIOR TO USE OR ASSOCIATION WITH THIS
PRODUCT.

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

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

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

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

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

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

C. Battery Monitor CCA (A2) Installation

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

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


2) Align pins of Battery Monitor CCA Connector (P3) to the mounting holes of Battery CCA
Connector (J3) (2-230) and insert CCA into the connector.
3) When replacing LED Diodes (3-195) place 1 or 2, as needed, Insulator Standoff's (3-240)
between CCA and LED.
D. Front Panel Installation
1) Insert Screws (1-50 and 1-40) into the appropriate mounting holes in the Front Panel (1-30).
CAUTION: USE SPECIAL CARE WHEN PLACING WASHER (1-45) ASSOCIATED WITH FRONT
PANEL ASSEMBLY. RE-ASSEMBLY WITHOUT THE WASHER IN PLACE WILL CAUSE
SHORTING THAT WILL DESTROY THE UNIT AND INJURE BYSTANDERS.

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

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E. Cover Installation

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

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

4. Performance Test

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

5. PS-835 Storage

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

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

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Fits and Clearances

1. General
The installation information provided is for typical install situations, not including information for
specific aircraft. Additional information may be obtained from the original aircraft manufacturer.
2. Emergency Power Supply Location

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

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

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

1) The Emergency Power Supply should be accessible for inspection, maintenance, or


removal.

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

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

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

3. Pre-Installation Inspection And Preparation


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

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

C. Units installed after a maintenance action must be tested in accordance with the Performance
Test procedures listed in Testing and Fault Isolation section before installation.

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

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5. Affiliated Equipment

A. SI-100 Static Inverter

The SI-100 Static Inverter provides for alteration of the PS-835 output for use of equipment that
requires alternating current (AC).

The Model SI-100A Static Inverter (Avionics Systems part number 501-1240-01) has 3,
400Hz, 115Vac, 25VA output capability.

The Model SI-100B Static Inverter (Avionics Systems part number 501-1240-02) has 1,
400Hz 115Vac, 75VA output capability, or 1, 400Hz, 5Vac, 5VA output capability.

B. SC-841 Static Converter

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

C. BC-815 Battery Charger

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

D. ATR Mounting Rack

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

E. Transformer (used with SI-100 Static Inverter)

For aircraft applications that require 26Vac output. (Avionics Systems part number 556-2006-
01)

F. Connector Plug for AC and DC powered Indicators

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

G. Mating Connectors

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

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Item 1

Item 2

Item 3

Figure 801: Affiliated Equipment

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6. Installation Kits

Kit Part PS-835 Including Inverter or Connecting to Indicator units:


Number Model Converter
504-1019-01 A-D, G SI-100( ) AI-804 or AI-904 AC powered
504-1019-02 A-D, G SI-100( ) or SC-841 AI-804 or AI-904 DC powered
504-1019-05 E-F SI-100( ) or SC-841 AI-804 or AI-904 AC powered
504-1019-06 E-F SI-100( ) or SC-841 AI-804 or AI-904 DC powered
504-1035-01 A-D, G - - GH-3000 and GH-3100 ESIS

7. Interconnect Diagrams

A. Fuse and Circuit Breakers

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

B. Retrofits

The older PS-823 Emergency Power Supply can be replaced by the PS-835. The PS-823, when
providing 115 Vac output, can be replaced with the PS-835/SI-100 combination to provide
115Vac output, also.

In cases where the previous PS-823 provided 26 Vdc output, add the Transformer (Figure 801,
Item 2 Avionics Systems part number 556-2006-01) to the PS-835/SI-100 combination. See
Figure 801, Item 3 for suggested Transformer location. Tap either phase A or C output leg
when using a SI-100A, 3 -phase Static Inverter.

Test-switch circuitry of the previous PS-823 setup must be altered as indicated below.

PS-823 (/T) Test PS-835 () Test


Comparison Switch Switch
2 EXT 28 Vdc
28 Vdc
2

Test Test
Lamp Lamp
6 6

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

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(* or Microsemi P/N UES702)

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

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*If an existing installation is being converted from a PS-823 to a PS-835


and a Transformer is required, remove wire from power supply mating
connector pin 4 and connect to transformer yellow lead.

Figure 804: Interconnections to AC Powered Indicators

Figure 805: Interconnections to DC Powered Indicators

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Connector Keying for PS-835 models E and F


See Service Bulleting SB501-1228-10( )

507-1182M

Figure 806: PS-835 Models E and F Installation Drawing


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Connector Keying for PS-835 models A, B, C, D, and G


See Service Bulleting SB501-1228-10( )

507-1182P

Figure 807: PS-835 Models A, B, C, D and G Installation Drawing


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Special Tools, Fixtures, and Equipment

1. General

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

Item Description Vendor


1 DC Power Supply Hewlett Packard Model 6291 0-30 Vdc 20amp capacity
2 Digital Voltmeter (DVM) Fluke Model 8050A
3 Delete Delete
7 1% 150 watt or greater *
4 Load Resistor (WireMasters, Inc. 136 Alpha Drive, Franklin, TN 37064.
Cage Code: 0FVD7)*
5 Stopwatch Meyland Corp. Model 202A*
Isolation Diode WireMasters, Inc.
6
15 Amp, 50 Volt PIV (Part Number WM1N3208)
7 Mating Connector for PS-835 A to D, &G P/N: DPXB-13-33S-0001
8 Mating Connector for PS-835 E and F P/N: DPXB-13-33S-0019
BC-815 Battery Charger (used in place of Avionics Systems Part No. 501-1321-01
9
DC power supply)
JF-204A
10 Connector Alignment Gage**
570-4195-01*

Figure 901: Special Tools and Equipment

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

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3. Connector Alignment Gage**


The Connector Alignment Gage, listed above, was added as the result of Service Bulletin SB501-
1228-1A. The service issue concerned the position of J2 Connector for correct and successful pin
contact to the connector of the Static Inverter SI-100, when used in conjunction with the PS-835
Emergency Power Supply.
The J2 Connector, see Figure 801 and 802, position is irrelevant for aircraft applications that do not
include the use of the SI-100. Connector position can also be achieved using a ruler with decimal
inch graduations.

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Illustrated Parts Listing

1. General

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

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

The Illustrated Parts Listing includes three subsections:

Numerical Index
Part Reference Designator Index
Detailed Parts List

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

2. Numerical Index

A. Part Number Column

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

B. IPL Figure and Item Number Column

Lists the Detailed Parts List figure and item number assigned for all parts listed.

C. Total Required Column

Reflects the total quantity for each item number listed.

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Fig/ Fig/ Fig/


Part Number Qty. Part Number Qty. Part Number Qty.
Item Item Item
1N4751A 3-150 1 542-1361-01 thru 1-70 553-1047-01 3-60 1
-8
1N829A 3-125 1 553-1047-01 3-60 1
542-1361-09 1-70 1
501-1228 1-1 553-1060-01 3-135 1
542-1361-09 2-1
501-1228-01 1-1 REF 553-1069-01 3-45 1
542-1361-10 1-70 1
501-1228-02 1-1 REF 554-1108-02 3-35 1
542-1361-10 2-1
501-1228-03 1-1 REF 554-1108-02 3-35 1
542-1361-11 1-70 1
501-1228-04 1-1 REF 554-1108-02 3-35 1
542-1361-11 2-1
501-1228-05 1-1 REF 554-1108-03 3-30 1
542-1361-12 1-70 1
501-1228-06 1-1 REF 554-1108-03 3-30 1
542-1361-12 2-1
501-1228-07 1-1 REF 554-1119-01 2-95 1
542-1364-01 1-75 1
517-1252-01 1-5 1 554-1171-01 3-195 1
542-1495-01 1-75 1
517-1253-01 2-260 1 554-1171-01 3-195 1
542-1495-02 1-75 1
518-1371-01 1-30 1 554-1171-01 3-195 1
542-1521-01 1-75 1
520-1091-02 2-125 1 554-1171-01 3-195 1
542-1521-01 3-1
520-1092-01 2-270 1 554-1171-01 3-195 1
542-2625-01 1-75 1
520-1121-01 2-15 1 554-1171-01 3-195 1
542-2625-01 3-1
520-1132-01 2-265 1 554-1171-01 3-195 1
542-2635-01 1-75 1
528-1036-01 3-200 1 554-1171-01 3-195 1
542-2635-01 3-1
535-1257-01 1-80 1 554-1171-01 3-195 1
549-1011-06 1-55 1
535-1375-01 1-80 1 554-1171-01 3-195 1
549-1121-01 2-110 1
535-1404-01 1-95 1 554-1171-01 3-195 1
549-1159-01 2-215 1
535-1818-01 1-95 1 554-1171-01 3-195 1
549-1170-01 2-5 12
535-1818-03 1-95 1 554-1171-01 3-195 1
549-1170-05 2-5 12
535-1859-01 1-91 1 560-1303-02 2-60 1
549-1170-06 2-5 12
535-1873-01 1-96 1 561-1018-01 3-15 1
551-1022-11 3-160 1
535-1926-01 1-85A 1 563-1033-02 2-230 1
551-1022-13 3-165 1
535-2198-01 1-90 1 563-1033-03 3-20 1
551-1022-13 3-165 1
535-2201-01 1-85 1 563-1039-02 2-235 1
551-1211-04 3-105 1
535-2221-01 1-95 1 563-1725-01 1-100 1
551-1211-04 3-105 1
535-2222-01 1-95 1 568-1566-06 3-205 2
551-1211-06 3-25 1
535-2251-01 1-95 1 568-1578-04 2-170
551-1217-14 3-75 1
536-2402-01 2-145 1 568-1578-05 2-175
551-1217-34 3-65 1
536-2594-01 3-5 1 568-1578-06 2-180
551-1300-05 3-10 12
542-1361-01 thru 2-1 568-1578-07 2-185
-08 551-1301-01 2-45 1
568-1578-09 2-170 1

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Fig/ Fig/ Fig/


Part Number Qty. Part Number Qty. Part Number Qty.
Item Item Item
568-1578-10 2-175 1 MS24693C3 2-20 2 RN55C1001F 3-115 1
568-1578-11 2-180 1 MS24693C3 2-275 6 RN55C1001F 3-185 1
568-1578-12 2-185 1 MS24693C4 2-85 1 RN55C1002F 3-170 1
569-1137-07 3-210 2 MS24693C5 3-225 2 RN55C1002F 3-170 1
569-1149-20 2-10 4 MS353338-135 2-135 2 RN55C1004F 3-95 1
569-1149-26 2-10 4 MS35338-135 1-20 2 RN55C1050F 3-140 1
569-1152-01 2-105 1 MS35338-135 2-250 2 RN55C1822F 3-145 1
569-1157-01 2-225 46 MS35338-135 2-35 1 RN55C2001F 3-180
569-1901-01 1-35 1 MS35338-135 2-70 4 RN55C3162F 3-155 1
577-1019-01 3-100 1 MS35338-139 2-115 1 RN55C4122F 3-85 1
577-1019-01 3-100 1 MS35649-244 1-25 2 RN55C4532F 3-175 1
577-1048-01 2-210 1 MS35649-244 2-140 2 RN55C4990F 3-190 1
580-1513-02 3-215 2 MS35649-244 2-40 1 RN55C5623F 3-120 1
580-1513-09 3-220 1 MS35649-244 2-75 2 RN55C8250F 3-130 1
JAN1N5618 3-55 1 MS35650-304 1-65 2 RN55C9092F 3-50 1
JANTX1N4148-1 3-40 1 MS35650-3255 2-120 1 S21001-33 2-90 1
JANTX1N4148-1 3-40 1 MS51957-14 1-50 4 S21029-06 2-220 1
JANTX1N4148-1 3-40 1 MS51957-14 2-160 1 S22033-04 2-205 1
JANTX1N4148-1 3-40 1 MS51957-14 2-240 2 S23044-13 3-230 24
JANTX1N4148-1 3-40 1 MS51957-14 2-55 3 S23044-24 3-240 18
JANTX1N4148-1 3-40 1 MS51957-15 1-10 2 S24134-01 2-50 1
JANTX1N4148-1 3-40 1 MS51957-15 2-150 2 S24134-02 2-50 1
JANTX1N4148-1 3-40 1 MS51957-16 2-25 1 S26100-04 2-190 1
JANTX1N4148-1 3-40 1 MS51957-19 1-40 1 S32063-06 2-200
M39003/01-2362 3-110 1 NAS671C4 2-255 1 S32068-01 2-80 1
MS15795-803 2-165 3 NAS671C4 2-65 1 S36002-005 1-45 1
MS15795-803 2-30 1 RLR05C2700GS 3-80 1 S36002-007 2-155 2
MS15795-804 1-15 4 RLR07C2001GS 3-90 1 S43003-07 3-235 2
MS15795-804 2-245 2 RLR07C5601GS 3-70 1 S43003-20 2-100 1
MS24693C271 1-60 2 RN55C1001F 3-115 1 SE12XC07S 2-195 3
MS24693C3 2-130 2 RN55C1001F 3-115 1 SE16XC01S 2-200 14

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3. Part Reference Designator Index

A. Part Reference Designator

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

B. IPL Figure Column

This column lists Detailed Parts List IPL Figure number.

C. Item Number

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

Ref. Fig/ Ref. Fig/ Ref. Fig/


Designator Item Designator Item Designator Item
A1 1-70 A1J2 2-235 A2CR8 3-40
A1 1-70 A1J3 2-230 A2CR9 3-40
A1 1-70 A1RT1 2-215 A2D18 3-195
A1 2-1 A1S1 2-205 A2DS1 3-195
A1 2-1 A1U1 2-210 A2DS10 3-195
A1 2-1 A1XF1 2-60 A2DS11 3-195
A1 2-1 A2 1-75 A2DS12 3-195
A1 2-1 A2 1-75 A2DS13 3-30
A1BT1 thru A2 1-75 A2DS14 3-35
2-5
A1BT12
A2 1-75 A2DS15 3-35
A1BT1 thru
2-5 A2 1-75 A2DS16 3-35
A1BT12
A2 1-75 A2DS17 3-30
A1BT1 thru
2-5
A1BT12 A2 3-1 A2DS2 3-195
A1CR1 2-95 A2 3-1 A2DS3 3-195
A1E1 2-200 A2 3-1 A2DS4 3-195
A1E1 2-200 A2C1 3-110 A2DS5 3-195
A1E18 2-110 A2CR1 3-40 A2DS6 3-195
A1E19 2-80 A2CR10 3-40 A2DS7 3-195
A1E7 2-195 A2CR2 3-40 A2DS8 3-195
A1F1 2-90 A2CR3 3-40 A2DS9 3-195
A1F2 2-220 A2CR4 3-40 A2P3 3-20
A1HR1 2-45 A2CR5 3-40 A2Q1 3-135
A1J1 2-50 A2CR6 3-55 A2Q2 3-60
A1J1 2-50 A2CR7 3-40 A2Q3 3-60

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Ref. Fig/ Ref. Fig/ Ref. Fig/


Designator Item Designator Item Designator Item
A2Q4 3-45 A2R2 3-130 A2RT1 3-10
A2R1 3-115 A2R20 3-80 A2S1 3-15
A2R10 3-120 A2R21 3-170 A2U1 3-100
A2R11 3-85 A2R22 3-180 A2U2 3-100
A2R12 3-115 A2R23 3-170 A2U3 3-105
A2R12 3-185 A2R24 3-115 A2U4 3-105
A2R13 3-165 A2R3 3-70 A2U5 3-25
A2R14 3-145 A2R4 3-50 A2VR1 3-125
A2R15 3-95 A2R5 3-165 A2VR2 3-150
A2R16 3-90 A2R6 3-175
A2R17 3-190 A2R7 3-65
A2R18 3-140 A2R8 3-160
A2R19 3-75 A2R9 3-155

4. Detailed Parts List

The Detailed Parts List consists of illustrations and columnar parts listing of component parts for this
equipment. All assemblies, subassemblies, and parts that can be disassembled, repaired or replaced,
and reassembled are included. The Detailed Parts List only lists and illustrates those parts attached
by means other than welding or riveting, or other generally accepted means of permanent
attachment.

Each illustration is assigned a figure number commencing with IPL Figure 1 and progressing
sequentially from there. Alpha variants A thru Z will be assigned to figure numbers when necessary
to add additional figures to show modification or configuration changes, or differences between
units.

A. Figure Number Column

This column reflects the assigned Figure number of an illustration.

B. Item Number Column

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

C. Part Number Column

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

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

D. Nomenclature Column

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

E. Units Per Assembly Column

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

F. Effectivity Code Column

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

G. How To Use The Detailed Parts List

For the following examples, refer to the appropriate lists and indexes within this manual.

1) Finding the Part Number when only the physical location of the part is known:

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

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

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

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

2) Finding the Part Number when only the Part Reference Designator is known:

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

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

3) Finding an Illustration for a known Part Number:

a. Locate the known part number in the Numerical Index. Note the figure and item
number.
b. Turn to the Detailed Parts List and locate the figure and index number for a
description of the part.
c. Turn to the illustration and locate the physical position of that part on the assembly.

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Component Maintenance Manual
Model PS-835( ) // 501-1228-( )
96 15 4 ea

95

10 2 ea

85

80

20 2 ea

25 2 ea

100

75 (A2)

45 CAUTION!
See Assembly section

30

5
35

A Replace Cells in the order for which they are numbered.


Note:
50 3 ea
Arrange Cells to align terminals vertically with positive (+) terminal on bottom.
Invert the position of the Tie-Down Straps for the top row of Cells.
Apply RTV into the shaded areas. Note location of cells BT1 and BT12 for sake of
Disassembly and Assembly wiring instructions.

BT10 BT11 BT12

70 (A1)

BT8 BT7
40 BT9

BT4 BT5 BT6

60 2 ea

91 65 2 ea BT3 BT2 BT1


90

IPL Figure 1: PS-835 Emergency Power Supply

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Parts Listing Page 1001
Revision B February 28/2004
L-3 Avionics Systems
Component Maintenance Manual
Model PS-835( ) // 501-1228-( )

Fig- Nomenclature Units/ Eff.


Part Number
Item 123456 Assy Code
1-1 501-1228 Emergency Power Supply
501-1228-07 Model PS-835G (5 Ah Cell units) G
REF
(Model G is similar to model D, except where indicated)
501-1228-06 Model PS-835F (5 Ah Cell units) REF F
501-1228-05 Model PS-835E (2.5 Ah Cell units) REF E
501-1228-04 Model PS-835D (5 Ah Cell units) REF D
501-1228-03 Model PS-835C (2.5 Ah Cell units) REF C
501-1228-02 Model PS-835B (5 Ah Cell units) Obsolete REF B
501-1228-01 Model PS-835A (2.5 Ah Cell units) Obsolete REF A
5 517-1252-01 COVER ASSEMBLY 1
ATTACHING PARTS
10 MS51957-15 SCREW, MACHINE PAN HEAD 2
15 MS15795-804 WASHER, FLAT-METAL ROUND #4 4
20 MS35338-135 WASHER, LOCK SPRING 2
25 MS35649-244 PLAIN-HEX NUT 2
***
30 518-1371-01 FRONT PLATE 1
35 569-1901-01 PLATE, OVERLAY 1
ATTACHING PARTS
40 MS51957-19 SCREW, MACHINE PAN HEAD 1
45 S36002-005 WASHER, FLAT NON-METALLIC 1
50 MS51957-14 SCREW, MACHINE PAN HEAD 4
***
55 549-1011-06 HANDLE 1
ATTACHING PARTS
60 MS24693C271 SCREW, MACHINE FLAT CSK HEAD 2
65 MS35650-304 NUT 2
***
70 542-1361-12 BATTERY CCA (A1) (5 Ah Cell units) 1 F
See IPL Figure 2
542-1361-11 BATTERY CCA (A1) (2.5 Ah Cell units) 1 E
See IPL Figure 2
542-1361-10 BATTERY CCA (A1) (5.0 Ah cells) B, D, G
See IPL Figure 2
542-1361-09 BATTERY CCA (A1) (2.5 Ah cells) A, C
See IPL Figure 2
542-1361-01 BATTERY CCA (A1) *Obsolete A, B
thru -8

*See Service Bulletins and Modifications table Figure 1.

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TP-329 Illustrated Parts Listing - Page 1009
Revision B, Change 5 March 13, 2009
L-3 Avionics Systems
Component Maintenance Manual
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Fig- Nomenclature Units/ Eff.


Part Number
Item 123456 Assy Code
1-75 542-2635-01 BATTERY MONITOR CCA (A2) See IPL Figure 3 1 A, B, C,
D, E, F,
G
542-2625-01 BATTERY MONITOR CCA (A2) *Obsolete 1 E,F
A, B,
542-1521-01 BATTERY MONITOR CCA (A2) *Obsolete 1
C, D
542-1495-01 BATTERY MONITOR CCA (A2) *Obsolete 1 C, D
542-1495-02 BATTERY MONITOR CCA (A2) *Obsolete 1 C, D
542-1364-01 BATTERY MONITOR CCA (A2) *Obsolete 1 A, B
*See Service Bulletins and Modifications table Figure 1.

80 535-1375-01 PLATE CAUTION 1 E, F, G


A, B,
535-1257-01 PLATE CAUTION Obsolete 1
C, D
85 535-2201-01 PLATE, IDENTIFICATION (Mark with unit model, 1
part, and serial numbers. Also, unit weight and
appropriate MOD level)
85A 535-1926-01 PLATE, IDENTIFICATION (Marked with unit model, 1 G
part no., input power, RCI P/N and appropriate MOD
level. Also mark the serial no.)
90 535-2198-01 PLATE, IDENTIFICATION SECONDARY (Mark 1
with unit part number and serial number) Mount label
on Front Plate just below Handle.
91 535-1859-01 PLATE, DESIGNATION 1
95 535-1818-01 FAA-PMA ID PLATE 1 D
535-1818-02 FAA-PMA ID PLATE 1
535-1818-03 FAA-PMA ID PLATE 1 G
535-2222-01 FAA-PMA ID PLATE 1 F
535-1404-01 FAA-PMA ID PLATE Obsolete D
535-2251-01 FAA-PMA ID PLATE, Obsolete 1 B, C
535-2221-01 FAA-PMA ID PLATE, Obsolete 1 D
96 535-1873-01 WARNING LABEL See Service Bulletin SB501-1228-15 1
100 563-1725-01 DUST CAP, ELECTRICAL CONNECTOR 1

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

155 2 ea 20
150 2 ea 2 ea

160 215 (RT1)


165 3 ea
A Note: Rear Vertical Chassis Member

15
30

240 2 ea 35
210 (U1)
195 3 ea 40

225 46 ea
235
50 (J1)

145

230
(J3) 250 275 2 PL
2 ea

245 255 2 ea 265 25


2 ea

205
(S1) 200 14 ea 55 2 ea 120
220 (F2)
a
275 2 PL
110 (E18)
115

270
105

125

180 140 2 ea

Reverse side view. 135 2 ea

90 (F1) 100
185
65
70

275 2 PL 75
95 (CR1)
170 95

130 2 ea
60 (XF1)
5 12 ea
260
(BT1 thru BT12)
45 (HR1)
190 6 12 ea 80 (E19)

3 ea
10
175
IPL Figure 2: Battery Circuit Card Assembly (A1)

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Illustrated - Page- 1011/1012
Parts Listing Page 1001
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L-3 Avionics Systems
Component Maintenance Manual
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Fig- Nomenclature Units/


Part Number Eff. Code
Item 123456 Assy
2-1 542-1361-12 BATTERY CCA (A1) (5.0 Ah cells) F
See IPL Figure 1 for next higher assembly.
542-1361-11 BATTERY CCA (A1) (2.5 Ah cells) E
See IPL Figure 1 for next higher assembly.
542-1361-10 BATTERY CCA (A1) (5.0 Ah cells) * B, D, G
542-1361-09 BATTERY CCA (A1) (2.5 Ah cells) * A, C
542-1361-01
BATTERY CCA (A1) *Obsolete
thru -08
*See Service Bulletins and Modifications table Figure 1.

5 549-1170-05 CELL, STORAGE LEAD-ACID 2.0V 2.5 Ah A, C, E


(BT1 thru BT12) [See Repair section for replacement 12
instructions]
549-1170-06 CELL, STORAGE LEAD ACID 2.0V 2.5 Ah A, C, E
(BT1 thru BT12) (alternate for 549-1170-05) 12
[See Repair section for replacement instructions]
CELL, STORAGE, LEAD ACID 5.0 Ah B, D, F, G
549-1170-01 (BT1 thru BT12) [See Repair section for replacement 12
instructions]
ATTACHING PARTS
6 TIE-DOWN STRAP
12
(See Tools and Consumables Table Figure 701, Item 8)
***

10 569-1149-26 INSULATOR PLATE 4 A, C, E


569-1149-20 INSULATOR PLATE 4 B, D, F, G

15 520-1121-01 SUPPORT, INVERTER ASSEMBLY 1


ATTACHING PARTS
20 MS24693C3 SCREW, MACHINE FLAT CSK HEAD 2
25 MS51957-16 SCREW 1
30 MS15795-803 WASHER, FLAT #4 1
35 MS35338-135 WASHER, LOCK SPRING 1
40 MS35649-244 NUT, PLAIN-HEX 1
***
45 551-1301-01 HEATING ELEMENT (HR1) 1
50 S24134-02 CONNECTOR (J1) 1 E, F
A, B, C,
S24134-01 CONNECTOR (J1) 1
D, G
ATTACHING PARTS
55 MS51957-14 SCREW, MACHINE PAN HEAD 3
***

24-30-02
TP-329 Illustrated Parts Listing - Page 1013
Revision B, Change 5 March 13, 2009
L-3 Avionics Systems
Component Maintenance Manual
Model PS-835( ) // 501-1228-( )

Fig- Nomenclature Units/


Part Number Eff. Code
Item 123456 Assy
2-60 560-1303-02 FUSE BLOCK (XF1) 1
ATTACHING PARTS
65 NAS671C4 NUT, PLAIN HEXAGON 1
70 MS35338-135 WASHER, LOCK SPRING 4
75 MS35649-244 NUT PLAIN-HEX 2
80 S32068-01 TERMINAL LUG (E19) 1
85 MS24693C4 SCREW, MACHINE FLAT CSK HEAD 1
***

90 S21001-33 FUSE, SIZE 3 SLOW (F1) 1


95 554-1119-01 DIODE, 100V 90A STUD (CR1) 1
ATTACHING PARTS
100 S43003-20 INSULATOR, SEMICONDUCTOR MOUNTING 1
105 569-1152-01 WASHER, SHOULDERED NON-METALLIC 1
110 549-1121-01 TERMINAL LUG (E18) 1
115 MS35338-139 WASHER, LOCK SPRING 1
MS35650-
120 NUT, HEX 1
3255
125 520-1091-02 ANGLE ASSEMBLY 1
130 MS24693C3 SCREW, MACHINE FLAT CSK HEAD 2
MS353338-
135 WASHER, LOCK SPRING 2
135
140 MS35649-244 NUT 2
***

145 536-2402-01 PRINTED WIRING BOARD 1


ATTACHING PARTS
150 MS51957-15 SCREW, MACHINE PAN HEAD 2
155 S36002-007 WASHER, FLAT NON-METALLIC 2
160 MS51957-14 SCREW, MACHINE PAN HEAD 1
165 MS15795-803 WASHER, FLAT #4 3
***

24-30-02
TP-329 Illustrated Parts Listing - Page 1014
Revision B February 28/2004
L-3 Avionics Systems
Component Maintenance Manual
Model PS-835( ) // 501-1228-( )

Fig- Nomenclature Units/


Part Number Eff. Code
Item 123456 Assy
2-170 568-1578-09 SPACER, GAP (self stick version) 1
568-1578-04 SPACER, GAP (replace with 568-1578-09 when
necessary)
175 568-1578-10 SPACER, GAP (self stick version) 1
568-1578-05 SPACER, GAP (replace with 568-1578-10 when
necessary)
*
180 568-1578-11 SPACER, GAP (self stick version) 1
568-1578-06 SPACER, GAP (replace with 568-1578-11 when
necessary)
185 568-1578-12 SPACER, GAP (self stick version) 1
568-1578-07 SPACER, GAP (replace with 568-1578-12 when
necessary)
*Part of MOD Kit 504-1839-01
Per Service Bulletin SB501-1228-12( )

190 S26100-04 PLATE, MODIFICATION 1


TERMINAL, TURRET UN-INSULATED
195 SE12XC07S 3
(E7, E8, and E9)
200 SE16XC01S TERMINAL, STUD (E1 thru E6 and E10 thru E17) 14
S32063-06 TERMINAL, STUD (Obsolete use SE16XC01S) N/A
205 S22033-04 SWITCH, TOGGLE MINIATURE (S1) 1
210 577-1048-01 LINEAR TRANSDUCER (U1) 1
215 549-1159-01 RESISTOR, THERMAL (RT1) 1
220 S21029-06 FUSE (F2)
1
(See Service Bulletin SB501-1228-13)
225 569-1157-01 INSULATOR WASHER SHOULDERED 46
230 563-1033-02 CONNECTOR, ELECTRICAL (J3) 1
235 563-1039-02 CONNECTOR, ELECTRICAL RIGHT-ANGLE (J2) 1
ATTACHING PARTS
240 MS51957-14 SCREW 2
245 MS15795-804 WASHER, FLAT-METAL ROUND #4 2
250 MS35338-135 WASHER, LOCK 2
255 NAS671C4 NUT, PLAIN HEXAGON 1
***
260 517-1253-01 FRAME, Base Assembly 1
ATTACHING PARTS
265 520-1132-01 SUPPORT, Plate 1
270 520-1092-01 SUPPORT, Angle 1
275 MS24693C3 SCREW, MACHINE FLAT CSK HEAD 6
***

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Revision B, Change 5 March 13, 2009
L-3 Avionics Systems
Component Maintenance Manual
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This page intentionally left blank.

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TP-329 Illustrated Parts Listing - Page 1016
Revision B February 28/2004
L-3 Avionics Systems
Component Maintenance Manual
Model PS-835( ) // 501-1228-( )

5
220
195 13 ea
10
190
15
185

20 180
170
2 ea

175
25 100
165
30 2 ea
35
3 ea 160
155
40
9 ea

105
45

185 190
50 180
135 140 145 150
115
120
115 105
115
125 110 100
120
130 2 ea 542-1521-01

542-1521-01

30 95
90
195 85 80

75

55

65 70
60
2 ea
200
225
2 ea
205 2 ea
2 ea
215

210

IPL Figure 3: Battery Monitor CCA 542-2635-01, 542-2625-01, and 542-1521-01


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

Fig- Nomenclature Units/ Eff.


Part Number
Item 123456 Assy Code
BATTERY MONITOR CCA (A2)
3-1 542-2635-01
(See IPL Figure 1 for next higher assembly.)
542-2625-01 BATTERY MONITOR CCA (A2) *Obsolete E, F
542-1521-01 A, B, C,
BATTERY MONITOR CCA (A2) *Obsolete
E, F
542-1495-01 BATTERY MONITOR CCA (A2) *Obsolete 1 C, D
542-1495-02 BATTERY MONITOR CCA (A2) *Obsolete 1 C, D
542-1364-01 BATTERY MONITOR CCA (A2) *Obsolete 1 A, B
*See Service Bulletins and Modifications table Figure 1.

5 536-2594-01 PRINTED WIRING BOARD 1


10 551-1300-05 THERMAL RESISTOR (RT1) 12
15 561-1018-01 SWITCH, ROCKER DIP (S1) 1
20 563-1033-03 CONNECTOR, ELECTRICAL (P3) 1
25 551-1211-06 RESISTOR NETWORK 42.2K 1W 2% SIP8 (U5) 1
30 554-1108-03 DIODE, LED GREEN 90MA T1-3/4 (DS13 and 2
DS17)
35 554-1108-02 DIODE, LED YELLOW 60MA T1-3/4 (DS14 ,DS15, 3
DS16)
40 JANTX1N4148-1 DIODE, FAST 75V 150MA DO-35 (CR1-CR5, CR7- 9
CR10)
45 553-1069-01 TRANSISTOR (Q4) 1
50 RN55C9092F RESISTOR, 90.9K .1W 1% (R4) 1
55 JAN1N5618 DIODE, FAST 600V 1A DO-204AP (CR6) 1
60 553-1047-01 TRANSISTOR (Q2,Q3) 2
65 551-1217-34 RESISTOR, WIRE WOUND 50 2.2W 1% (R7) 1
70 RLR07C5601GS RESISTOR, 5.60K .25W 2% (R3) 1
75 551-1217-14 RESISTOR, WIRE WOUND 2.00K 2.2W 1% (R19) 1
80 RLR05C2700GS RESISTOR, 270 OHM .125W 2% (R20) 1
85 RN55C4122F RESISTOR, 41.2K .1W 1% (R11) 1
90 RLR07C2001GS RESISTOR, 2.0K .25W 2% (R16) 1
95 RN55C1004F RESISTOR, 1 MEG .1W 1% (R15) 1
100 577-1019-01 QUAD OP AMP (U1,U2) 2
105 551-1211-04 RESISTOR, NETWORK (U3,U4) 2
110 M39003/01-2362 CAPACITOR (C1) 1
115 RN55C1001F RESISTOR, 1.00K .1W 1% (R1,R12,R24) 3
120 RN55C5623F RESISTOR, 562K .1W 1% (R10) 1

24-30-02
TP-329 Illustrated Parts Listing - Page 1018
Revision B February 28/2004
L-3 Avionics Systems
Component Maintenance Manual
Model PS-835( ) // 501-1228-( )

Fig- Nomenclature Units/ Eff.


Part Number
Item 123456 Assy Code
3-125 1N829A DIODE, 6.2V 250MW 5% DO-34 (VR1) 1
130 RN55C8250F RESISTOR, 825 OHM .1W 1% (R2) 1
135 553-1060-01 TRANSISTOR, N-CHANNEL FET (Q1) 1
140 RN55C1050F RESISTOR, 105 OHM .1W 1% (R18) 1
145 RN55C1822F RESISTOR, 18.2K .1W 1% (R14) 1
150 1N4751A DIODE, 30V 1W 5% DO-204 (VR2) 1
155 RN55C3162F RESISTOR, 31.6K .1W 1% (R9) 1
160 551-1022-11 RESISTOR, VARIABLE (R8) 1
165 551-1022-13 RESISTOR, VARIABLE (R13,R5) 2
170 RN55C1002F RESISTOR, 10.0K .1W 1% (R21,R23) 2
175 RN55C4532F RESISTOR, 45.3K .1W 1% (R6) 1
180 RN55C2001F RESISTOR, 2.00K .1W 1% (R22)
185 RN55C1001F RESISTOR, 1.00K .1W 1% (R12) 1
190 RN55C4990F RESISTOR, 499 OHM .1W 1% (R17) 1
195 554-1171-01 DIODE, LED RED 5V 7MA T1-3/4 (DS1-D12,D18) 13

200 528-1036-01 HEATSINK AND NUT ASSY 1


ATTACHING PARTS
205 568-1566-06 SPACER 2
210 569-1137-07 WASHER SHOULDERED NON-METALLIC 2
215 580-1513-02 STANDOFF P.C. BD. 2
220 580-1513-09 STANDOFF P.C. BD. 1
225 MS24693C5 SCREW MACHINE FLAT COUNTERSUNK HEAD 2
***

230 S23044-13 INSULATOR STANDOFF 24


235 S43003-07 INSULATOR SEMICONDUCTOR MOUNTING 2
240 S23044-24 INSULATOR STANDOFF 18

24-30-02
TP-329 Illustrated Parts Listing - Page 1019
Revision B February 28/2004
L-3 Avionics Systems
Component Maintenance Manual
Model PS-835( ) // 501-1228-( )

This page intentionally blank.

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Revision B February 28/2004