Sm-5924

Transcript

SM 5924 1000 Technology Drive, Pittsburgh, PA 15219 645 Russell Street, Batesburg, SC 29006 F-42 DC/DC CONVERTER ASTS USA Part No. N16920401 ƒ Installation ƒ Operation ƒ Maintenance © Copyright 2009 Ansaldo STS USA, Inc. SM 5924, Rev. 1 June 2009 Notices Proprietary Notice This document and its contents are the property of Ansaldo STS USA, Inc. (formerly known as Union Switch & Signal Inc., and hereinafter referred to as "ASTS USA"). This document is furnished to you on the following conditions: 1.) That no proprietary or intellectual property right or interest of ASTS USA is given or waived in supplying this document and its contents to you; and, 2.) That this document and its contents are not to be used or treated in any manner inconsistent with the rights of ASTS USA, or to its detriment, and are not to be copied, reproduced, disclosed or transferred to others, or improperly disposed of without the prior written consent of ASTS USA. Important Notice ASTS USA constantly strives to improve our products and keep our customers apprised of changes in technology. Following the recommendations contained in the attached service manual will provide our customers with optimum operational reliability. The data contained herein purports solely to describe the product, and does not create any warranties. Within the scope of the attached manual, it is impossible to take into account every eventuality that may arise with technical equipment in service. Please consult an ASTS USA local sales representative in the event of any irregularities with our product. ASTS USA expressly disclaims liability resulting from any improper handling or use of our equipment, even if these instructions contain no specific indication in this respect. We strongly recommend that only approved ASTS USA spare parts are used as replacements. SM 5924, Rev. 1, June 2009 i Revision History Revision History REV. 0 1 DATE May, 1981 June, 2009 NATURE OF REVISION Initial Issue Revised value of C3 in Figure 4–1 Copyright© 2009, Ansaldo STS USA, Inc. 1000 Technology Drive, Pittsburgh, PA USA 15219-3120 645 Russell Street, Batesburg, SC 29006 www.ansaldo-sts.com All rights reserved. ii SM 5924, Rev. 1, June 2009 Table of Contents Table of Contents 1 2 3 4 5 6 DESCRIPTION...................................................................................................................................1-1 1.1 Electrical....................................................................................................................................1-1 PRINCIPLES OF OPERATION .........................................................................................................2-1 2.1 Input Filter .................................................................................................................................2-1 2.2 Over Voltage Protection............................................................................................................2-1 2.3 Switching Mode Pre-Regulator .................................................................................................2-1 2.4 Power Converter .......................................................................................................................2-1 INSTALLATION .................................................................................................................................3-1 3.1 Mounting ...................................................................................................................................3-1 3.2 Electrical Connections ..............................................................................................................3-1 3.3 Calibration ...............................................................................................................................3-1 MAINTENANCE AND TROUBLESHOOTING ..................................................................................4-1 4.1 General .....................................................................................................................................4-1 4.2 Converter Regulator Section.....................................................................................................4-1 4.3 CONVERTER OUTPUT SECTION ..........................................................................................4-3 4.4 CBI – Electronic Control Board (N451120-4101) .....................................................................4-3 4.5 C33-OVER VOLTAGE CONTROL BOARD (N451120-4301) ..................................................4-4 4.5.1 Checks ..........................................................................................................................4-4 4.5.2 Optional Surge Protection Modification ........................................................................4-5 4.6 CB2 STARTING CONTROL BOARD (N451120-3002) ............................................................4-5 PARTS LIST ......................................................................................................................................5-1 RAIL TEAM AND TECHNICAL SUPPORT ......................................................................................6-1 SM 5924, Rev. 1, June 2009 iii Table of Contents List of Figures Figure 3–1. Plug Connector Pinning ...................................................................................................3-1 Figure 4–1. F-42 DC/DC Converter Schematic Diagram ....................................................................4-2 Figure 4–2. CB3 Voltage Control Board Surge Protection Modification.................................................4-6 Figure 5–1. F-42 DC/DC Converter Parts Location.............................................................................5-7 List of Tables Table 5–1. N451033-2901 Parts List .................................................................................................5-1 Table 5–2. N451033-2902 Parts List .................................................................................................5-3 Table 5–3. N451033-2903 Parts List .................................................................................................5-3 Table 5–4. N451033-2904 Parts List .................................................................................................5-4 iv SM 5924, Rev. 1, June 2009 DESCRIPTION 1 DESCRIPTION The F-42 DC/DC Converter is a completely transistorized power supply for use in train control systems. The converter basically consists of an electronically controlled pre-regulator and an inverter with rectified and filtered outputs. The unit is designed for use as a DC source of 32V at up to 7.5 amps on locomotive and car equipment for cab signals and/or intermittent inductive train stops. 1.1 • Electrical Operating Temperature -40° F to +160° F • Input Voltage 60 VDC to 80 VDC. However, a drop to 45 VDC when the unit is operating will not damage the unit. The input wires must be twisted pairs. • Output Voltage 32 VDC ±5% at 0 to 7.5 amp load, over the full ambient temperature range. The output shall not be less than 28V if the input voltage drops to 45V during a transient condition. The converter is capable of starting with a lamp load of four 15 watt, 34 volt signal lamps in multiple, and a resistance load as required to bring the total load to 240 watts. • Overload The converter is capable of supplying 11.25 amps for ten minutes without damage over a temperature range of -40° F to 140° F. • Ripple (output) The ac ripple shall not exceed 2.5%. • Overload Protection The 32 VDC output is not fused but is self protected. A short circuit across this winding will stop the magnetic oscillator which can remain shorted indefinitely without damage to the unit. To restart after a short circuit has been removed; the input circuit should be opened and then closed after a delay of a few seconds. The input is fused at 10A. The unit is designed to handle 150% load for ten minutes without damage. SM 5924, Rev. 1, June 2009 1-1 DESCRIPTION • Overvoltage Protection Overvoltage protection is provided by a crowbar circuit comprised of SCR-1 and printed circuit board CB3. The input voltage trip point is controlled by diode Dl which triggers the SCR-1 gate with input voltages between 95V and 105V and will blow fuse Fl. The crowbar circuit is immediately reset by the opened circuit. Replacement of fuse F1 should restore operation of the unit. Similar protection is provided across the pre-regulator output capacitor C3 to protect against a malfunction of the input circuit. The trip point is controlled by diode D4 between 40.8V and 45.2V and prevents excessive voltage being applied to the output circuits. • Transient Voltage The converter input is designed to withstand a surge voltage of 20,000V for 5 micro seconds from line to ground, and a 3000V, 60 Hz dielectric test at 1 milliampere maximum for 1 minute as follows: a. Input terminals shorted to chassis. b. Output terminals shorted to chassis. c. Input terminals shorted to output terminals. A diode is placed across the input circuit to prevent a reverse polarity application and also to suppress inductive transients that occur on the battery line when the battery is disconnected. 1-2 SM 5924, Rev. 1, June 2009 PRINCIPLES OF OPERATION 2 PRINCIPLES OF OPERATION As an aid in understanding the theory of operation, refer to the schematic diagram shown in Figure 4–1. 2.1 Input Filter Power is supplied through a filter consisting of inductors L1, and L2, and capacitors C1 and C2. Reverse polarity and inductive transient protection is provided by diode Dl. This circuitry removes the steep wave front surges. 2.2 Over Voltage Protection SCR-1 and circuit board CB3 monitor the input voltage appearing across capacitor C2 and the pre-regulator voltage across capacitor C3. The circuit is immune to steep wave front surges of short duration, but will respond to a sustained high voltage of many milliseconds duration. 2.3 Switching Mode Pre-Regulator The main components of this circuitry are the transistors Q1 and Q2 diode D2, Reactive Transformer T1, output capacitor C3’ and electronic circuit board CB1. CB1 senses the voltage across C3 and controls the gate (Q1 and Q2) to regulate the output voltage. CB1 also senses the current flowing through resistor R5 and current-limits the output by also controlling the gate. A disconnect is provided through pins 5 and 6 of connector P3 (on CB3) to make the circuit inoperative if circuit board CB3 is not connected to protect against over voltage. The preregulator can be separated from the output converter by disconnecting connector TP7-1 for test purposes. 2.4 Power Converter The power for this circuitry is obtained from the pre-regulated voltage developed across capacitor C3. The switching bridge transistors Q4, Q5, Q6, and Q7 are controlled by magnetic oscillator T2 which operates at approximately 400 Hz. The bridge is connected to the load through an isolating transformer T3. The starting circuit is shown as C°B2 which connects resistors R5 and R6 to -DC to permit starting with a lamp load. The resistors are automatically disconnected from -DC when the voltage across capacitor C3 reaches a pre-determined voltage. Initially capacitor C1 is discharged, therefore, when the voltage across capacitor C3 begins to rise at turn-on, transistor Q1 turns on, then transistor Q2 follows when the emitter of Q1 reaches the Zener voltage of D2. This allows the voltage across C3 to reach about half its final voltage before the converter is permitted to start under full load. Capacitor C1 charges steadily toward the C3 value and turn off occurs when the base of Q1 is driven negatively to approximately the Zener voltage of D2. On time is controlled by the values of C1, R1, and R2 and is purposely made about twice the normal starting time. SM 5924, Rev. 1, June 2009 2-1 PRINCIPLES OF OPERATION 2-2 SM 5924, Rev. 1, June 2009 INSTALLATION 3 INSTALLATION 3.1 Mounting The converter can be mounted either horizontally or vertically on 7-3/8" x 8" centers with four 3/8" bolts. 3.2 Electrical Connections Electrical connections are made to a plug connector mounted on the converter. Connecting cables should be twisted pairs to minimize pick-up between the input and output circuitry. The pinning for the connectors is shown in Figure 3–1. +32VDC, 7.5 AMP OUT D +60 TO +80VDC INPUT A B- OUTPUT B- INPUT B C VIEW OF PLUG CONNECTOR FOR -2901 UNIT B- INPUT 2 +60 TO +80VDC INPUT UG0106.0045.00 B- OUTPUT +32VDC, 7.5 AMP OUT 3 1 4 VIEW OF PLUG CONNECTOR FOR -2904 UNIT Figure 3–1. Plug Connector Pinning 3.3 Calibration The converter should be calibrated at room temperature (+77°F). Calibration rheostat R15 is located on control board CB1. The unit must be opened to gain access to R15. 1. Place an output load of 4 amperes across the output terminals P4-C and P4-D. 2. Apply 70 VDC power to the input leads P4-A and P4-B. 3. Attach voltmeter leads across PA-C and-P4-D and adjust R15 for a 32V output. The unit should be calibrated for proper output after any component or board replacement. SM 5924, Rev. 1, June 2009 3-1 INSTALLATION 3-2 SM 5924, Rev. 1, June 2009 PARTS LIST 4 MAINTENANCE AND TROUBLESHOOTING 4.1 General Maintenance consists of an occasional check of the output voltage. If no output voltage is indicated, check the input circuit for a blown fuse (Fl, 10 amp slow-blow). To calibrate the output voltage, refer to Section 3.3. If improper output voltage or no output voltage is obtainable, troubleshoot the converter by following the steps in the Sections that follow. The schematic is shown in Figure 4–1. F-42 DC/DC Converter Schematic Diagram is shown in Figure 4–1. 4.2 Converter Regulator Section 1. Disconnect terminal TP7-1 located between transistor Q4 emitter and capacitor C3. This separates the pre-regulator from the converter output section. 2. Place a DC voltmeter (0-50V) across the terminals of C3 (tie point TP6-4 and collector of Q5) and a 0-100 VDC variable power supply (approximately 1 amp capacity) across the + and - input terminals of connector P4. 3. Slowly increase the voltage from OV and observe that the output voltage is rising with the input voltage. At approximately 38V input, adjust the control pot R15 of CB1 for a 32V output. NOTE If a 32V output cannot be obtained, the cause may be due to faulty printed circuit boards CB1 or CB3 or components mounted on the chassis. Transistors Q1, Q2, and Q3, should be checked for short circuits. See checkout procedures for printed circuit boards CB1 and CB3 in Sections 4.4 and 4.5. If the requirements in Steps 1 to 3 are met, proceed with Step 4. 4. Readjust the voltage from OV, as indicated in Step 3, and observe that the output voltage does not rise above 32V with the input range from 0V to 45V. The input current should be approximately 0.1 amps at this point. 5. Gradually increase the input voltage to +80V and observe that the output voltage remains at 32V. The input current should be approximately 0.1 amps at this point. The current will vary slightly with component variations. SM 5924, Rev. 1, June 2009 4-1 Figure 4–1. F-42 DC/DC Converter Schematic Diagram 4-2 SM 5924, Rev. 1, June 2009 PARTS LIST 6. Place a scope (dc operation) across the base and emitter of Q1. Observe that not less than 1V and not more than 2V reverse bias is being applied during the off time of Q1. The bias circuit, consisting of diode D3 and leads 1S and 2S of transformer Tl, must be operational before loads can be applied to the converter. The bias voltage should vary between 1V and 2V over the voltage range of 40 to 80 volts. 7. If all tests for the pre-regulator section are acceptable, remove all test equipment and the power supply from the pre-regulator section circuits and proceed to check out the output section in paragraph Section 4.3. 8. If the foregoing requirements are not met, proceed to check out boards CB1 and CB3 (preregulator section) in accordance with Sections 4.4 and 4.5. 4.3 CONVERTER OUTPUT SECTION 1. Disconnect terminal TP7-1 (as indicated in Step 1 of Section 4.2). This separates the preregulator section from the output section. 2. Connect a variable do power supply (approximately1 amp, 50 VDC maximum capacity) across tie point TP7-1 and the DC input terminal or between the emitter of Q4 and the collector of Q5. 3. Place a scope across the + lS and 2S leads of the out-put transformer T3 (the AC input terminals of rectifier BR1). 4. Slowly increase the input voltage from 0V to 10V and observe that the output waveform across +1S and 2S is a symmetrical square wave without spikes. The input current should not exceed 0.2 amp at the 10 VDC input level. 5. If Step 4 is satisfactory, increase the input voltage to 32V. The DC output voltage should be approximately 33.2V and the input current approximately 0.520 amp. 6. If the preceding requirements are not met, proceed to Section 4.6 and check out CB2 accordingly. 7. If both sections of the power supply meet test specifications, connect terminal TP7-1 and recalibrate the unit according to the calibration paragraph (Section 3.3). Anytime a board is replaced, the unit must be re-calibrated. Boards found to be faulty, should be returned to ASTS USA for adjustment and repair. 4.4 CBI – Electronic Control Board (N451120-4101) The function of this control board (Pre-regulator Section) is to sense the pre-regulated voltage and to trigger the input gate as required to hold regulation. Q1 controls the gate (through external SM 5924, Rev. 1, June 2009 4-3 circuitry) and is triggered ON and OFF as the voltage across C3 rises and falls. A current limiting function is also provided to limit starting transients. 1. Inspect all soldered joints. 2. Attach a variable DC power supply to terminals 7 (+) and 4 (-). The maximum voltage required should not exceed 35 Volts, and the current should not exceed 0.1 amp. 3. Place a 0-5 volt DC voltmeter across terminals 3 (+) and 4 (-) 4. Adjust the input voltage slowly to 32V and observe that the input current is less than 0.060 amps Current in excess of 0.060 amps may indicate a shorted component. 5. With the input voltage held at 32 volts, slowly rotate pot R15 until a point is reached which switches the voltmeter ON and OFF. This switching point must fall within the range of R15. 6. Failure to meet this test is an indication that one or more components are faulty or the IC (Integrated Circuit ua 723) is inoperable. 7. Perform the following steps to check out the IC. a. The IC reference voltage, pin 4 (+) to output pin 4 (-) should fall between 6.8 and 7.5 volts. A high impedance DC voltmeter or a scope should be used for this measurement. b. The IC input at the switch point, pin 2 (+) to pin 4 (-), should be approximately the same value as the reference voltage. Use a high impedance voltmeter or scope for this check. c. If Steps (a) and (b) are acceptable, and Dl is of proper value, failure to switch may indicate a shorted output. In this case, the voltage output at pin 6 will remain at approximately 12 volts under all conditions, and a constant voltage will appear across R1. An open output would result in a constant OV output. 8. Current limiting - the components on the control board involved with this function are resistors R7, R8, R9, R10, and R11, and diode D3. When attached to R5 through pins 5 and 6, the in-rush current will be limited to approximately 18amperes upon starting the inverter. A check of component values, location, and inspection of soldered joints will insure proper operation of this circuitry. A memory scope with probes placed across R3 is necessary to determine the exact current limiting point. 9. If the foregoing tests for CB1 are not satisfactory, replace with an operable board. 4.5 C33-OVER VOLTAGE CONTROL BOARD (N451120-4301) 4.5.1 Checks 1. Check the following Zener diode voltages and component values. (Pre-regulated Section) 2. For Dl, use pins 4(+) and 2(-). The Zener voltage at 0.020 amperes should fall between 95V and 105V (across D1 only). 4-4 SM 5924, Rev. 1, June 2009 PARTS LIST 3. For D4, use pins 1(+) and 2(-). The Zener voltage at 0.020 amperes should fall between 40.8V and 45.2V (across D4 only). 4. If board CBC does not meet the specified requirements, replace with a board in operating condition. 4.5.2 Optional Surge Protection Modification F-42 units manufactured prior to 1975 (serial numbers lower than XX75XX) may experience unusual fuse blowing problems when exposed to surge conditions. The optional modification described below can sometimes alleviate or reduce the number of fuses blown in this situation. Refer to Figure 4–2 for orientation with these wiring changes. 1. The lead from P3 to pin 2 (CB3) to TP6-2 should be moved so that it goes directly from P3, pin 2 to SCR1 cathode. This lead should be a black wire and should be twisted together with a green wire that runs from P3, pin 3 (CB3) to SCR1 Gate. 2. The wire that goes from TP6-2 to SCR1 cathode should be moved so that it goes from TP6-2 to Dl anode. 3. Change resistor R2 from 82 ohms to 180 ohms, 1/2 watt. 4. Change resistor R3 from 200 ohms to 430 ohms, 1/2 watt. 4.6 CB2 STARTING CONTROL BOARD (N451120-3002) Check the Zener diode voltage. Operational tests can be performed by observing the ON and OFF operation of Q2 which, during the starting cycle, connects the 130 ohm and 62 ohm starting resistors to DC (output pin 1). If board CB2 does not meet test specifications, replace with a board in operating condition. SM 5924, Rev. 1, June 2009 4-5 * ∞ = Twisted Pair Figure 4–2. CB3 Voltage Control Board Surge Protection Modification 4-6 SM 5924, Rev. 1, June 2009 PARTS LIST 5 PARTS LIST The parts for the F-42 DC/DC converter are listed in Table 5–1, Table 5–2and Table 5–3. The tables are keyed to Figure 5–1. Table 5–1. ITEM NO. 15 20 25 30 35 40 45 55 60 65 70 75 80 85 90 95 100 105 110 115 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 245 250 255 260 270 275 280 285 290 295 300 305 N451033-2901 Parts List DESCRIPTION TRANSFORMER,REACTOR TRANSFORMER, OUTPUT SCR-10-32X3/4 FLH SS WASHER,10 PLATE SST WSHR-SST LOCK NO 10 NUT,10-32 HEX SST TRANSFORMER,DRIVER SCREW,6-32X1-1/4 WSHR-SST PLATE NO 6 WASHER,SST LOCK NO 6 COIL,0.25 OHM BRACKET WSHR-#5 PL FL STEEL BUSHING SCREW-3/8X4-1/2 CAP WASHER, 3/8 SPR.STL. BD F42 STARTER CIR BOARD,ELECTRONIC CI PCB,CROWBAR F42 SCR-SST 6-32X5/16PAN TERM-INSUL 1417-7-12 TERM-10 SHKPKF LCKG STRIP-KULKA MARKER INSULATION TRANSISTOR,PNP,16A,140V,2N6031,TO-3 TRANSISTOR,NPN SI 2N5050 NUT-1/4-28 HEX SCR-SST6X1/2 SLFTPG SOCKET,XSTR TO 3 SCR-4-40X3/4 FLAT SS SOCKET,XSTR TO 66 SCR-SST 4-40X1/2 PAN WSHR-SST LOCK NO 4 NUT-NO4-40 SST HEX SCR,400V,20A(RMS) MIN,STUD MOUNT RECTIFIER,BRIDGE STAND-OFF WSHR-SST LOCK NO 8 NUT-NO8-32 SST HEX RESISTOR,400 OHMS 25 WATT RESISTOR,.045 OHM 50 WATT BLOCK-TERM.,699ST-10 RESISTOR,50 OHMS 25 WATT RESISTOR,150 OHMS 25 WATT SCREW,4-40X1/4 PAN SS DIODE,RECTIFIER,12A,600V,DO-4 CAPACITOR,1000 MFD 150V CAPACITOR,2000 MFD 50 VDC SM 5924, Rev. 1, June 2009 PART NO. N436560 N436561 J5252740112 J4751200110 J4751210109 J4802110105 N4510390403 J525099 J4751200108 J4751210107 N435088 M4511204801 J475175 M4510342001 J5073490172 J4751380113 N4511203002 N4511204101 N4511204301 J5072980105 J731227 J730070 J725808 M4511712401 J7313980032 J7313980031 J480225 J5073010108 J725477 J5252760112 J725476 J5072970108 J4751210105 J4802110102 J7261500047 J7261500029 M4511205701 J4751210108 J4802110104 J7355190098 J7355190100 J776638 J7355190099 J7355190102 J5072970104 J723958 J706732 J702078 5-1 ITEM NO. 310 315 320 325 330 335 340 345 350 355 360 365 370 375 380 385 390 395 400 405 410 415 420 425 430 435 440 445 450 455 465 475 480 481 485 490 495 500 505 510 515 520 530 535 540 545 550 555 560 565 570 590 610 615 620 630 635 645 5-2 DESCRIPTION CAPACITOR,4000 MFD BRKT CAPAC MOUNT BRKT CAPAC MOUNT SCREW,10-32X1/2 FL HD CAPACITOR,0.47 MFD HOLDER,FUSE HPF HPC FUSE,10A., 250V SCR-SST 8-32X1/2 PAN CONNECTOR,MS3102E GASKET,3102A 24 CONN SCR-SST 6-32X1/2 PAN TRANSISTOR,2N1558 GER PNP INSERT,10/32 HELICOIL RESISTOR,1.8 OHM 3-1/4 WATT CONNECTOR,MS3106E 24 22S DIODE,200V,1A,1N4003,AXIAL RESISTOR,15 OHMS 1 WATT RESISTOR,24 OHMS 2 WATT CAP-CAPACITOR CAP-CAPACITOR TERM-RING TONGUE CONN-PLUG 6 TERM CONNECTOR,PLUG 9 TERMINAL TERMINAL,FEMALE 1189 TL SCREW,6-32X3/4 FIL HD SS RECPT-FASTON PIDG RESISTOR,1.5K OHM 25 WATT MYLAR-POLYEST FLM SH SCR-6-32X7/16 PAN HD COMPONENT,SILICONE RUBBER WASHER,3/8" STEEL PL W-12 SPEC M-258-30 W 16 PVC RED M258-30 W 16 PVC BLK M258-30 NAME PLATE SCR-2X1/4IN PARKER GASKET,CORD SCREW,10-32X9/16 FIL HD TAB-QUICK CONNECT COMPOUND-BONDING RECEPTACLE,TIN PL BRASS DIODE-RECT, 12A, 200V, 1N3891R RING RADIATOR RADIATOR SCR-8-32X7/8 PAN HD BAG-FOOD NON-VENTED SCR-8-32X7/16 FLH SS RBR EXTD CHAN X-396 WIRE-#14 AWG,ETFE,WHITE W 18 PVC WHT M258-30 CLIP-ADHSVE BK-3/8 D TERM.,PRE INSUL DIA.G TERM,RING,1/4" STUD,22-16AWG,300V NUT,10-32 HEX STEEL TUBING TAG-SLEEVE,1/4"-0.50",WHITE CABLE TIE, SELF LOCKING PART NO. J701059 J705089 J705090 J052091 J706152 J071890 J710137 J5072950108 J709214 J470057 J5072980108 J731301 J792630 J7355190097 J709218 J723555 J722631 J723417 J709201 J709202 J731458 J709174 J706768 J731355 J522161 J726219 J7355190101 A772090 J5072980107 J041620 J4751320114 A0450170009 A0455250006 A0455250007 M4511084201 J052648 A470066 J522151 J792667 J041637 J723923 J7261500110 M4511204501 N4510332902 N4510332903 J5072950114 J055609 J5253010107 A075114 A0458580009 A0455070007 J703336 J730046 J730041 J048172 A774201 J7928222027 J703310 SM 5924, Rev. 1, June 2009 PARTS LIST ITEM NO. 800 805 815 DESCRIPTION TAPE 2 IN SCOTCH 22 TAPE 3/4WX66 SCO BD PRTCTR-THREAD 1-1/2" Table 5–2. ITEM NO. 5 50 80 120 125 130 135 140 145 510 555 725 730 ITEM NO. 2010 2050 2150 2155 2160 2265 2510 2525 2640 2645 2650 SM 5924, Rev. 1, June 2009 N451033-2902 Parts List DESCRIPTION RADIATOR COLLAR INSULATING INSERT,RIVNUT #6 32 HEAT SINK HEAT SINK HEAT SINK HEAT SINK HEAT SINK HEAT SINK COMPOUND-BONDING SCR-8-32X7/16 FLH SS ENCAPSULANT-EPOXY ES0397 COMPOUND-MOLD RELEASE,#225 Table 5–3. PART NO. A773128 J773078 J703231 PAT NO. M4511204601 M436619 J792260 N4511204403 M4511204901 M4511204902 M4511204903 M4511204407 M4511204406 J041637 J5253010107 A0420010001 A041576 N451033-2903 Parts List DESCRIPTION RADIATOR COLLAR INSULATING HEAT SINK HEAT SINK HEAT SINK STAND-OFF COMPOUND-BONDING SCR-8-32X1 FLH SS MOUNTING PLATE ENCAPSULANT-EPOXY ES0397 COMPOUND-MOLD RELEASE,#225 PART NO. M4511204701 M436619 M4511204405 M4511204408 M4511204404 M4511205702 J041637 J5253010116 M4511204412 A0420010001 A041576 5-3 Table 5–4. ITEM NO. 15 20 25 30 35 40 45 55 60 65 70 75 80 85 90 95 100 105 110 115 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 245 250 255 260 270 275 280 285 290 295 300 305 310 315 320 325 330 335 340 365 370 375 385 390 395 400 5-4 N451033-2904 Parts List DESCRIPTION TRANSFORMER,R CTOR TRANSFORMER, OUTPUT SCR-10-32X3/4 FLH SS WASHER,10 PLATE SST WSHR-SST LOCK NO 10 NUT-10-32 HEX SST TRANSFORMER DRIVER SCR 6-32X1-1/4 IN WSHR-SST PLATE NO 6 WASHER,SST LOCK NO 6 COIL, 0.25 OHM BRACKET WSHR-#5 PL FL STEEL BUSHING SCREW-3/8X4-1/2 CAP WASHER, 3/8 SPR.STL. BD F42 STARTER CIR BOARD,ELECTRONIC CI PCB,CROWBAR F42 SCR-SST 6-32X5/16PAN TERM-INSUL 1417-7-12 TERM-10 SHKPKF LCKG STRIP-KULKA MARKER INSULATION TRANS, PNP, 2N6031, 140V, 16A XSTR-NPN-SI-2N5050 NUT-1/4-28 HEX SCR-SST6X1/2 SLFT SKT-XSTR TO 3 SCR-4-40X3/4 FLAT SS SKT-XSTR TO 66 SCR-SST 4-40X1/2 PAN WSHR-SST LOCK NO 4 NUT-NO4-40 SST HEX THYRIS-SCR MCR39186A BRIDGE-RECTIFIER STAND-OFF WSHR-SST LOCK NO 8 NUT-NO8-32 SST HEX RES-400 OHMS, 25 W RES-.045 OHMS, 50 W BLOCK-TERM.,699ST-10 RES-50 OHMS, 25 W RES-150 OHMS, 25 W SCREW,4-40X1/4 PAN SS DIODE-15 A, 200 PRV CAPACITOR,1000 MFD 150V CAPACITOR,2000 MFD 50 VDC CAPAC 4000 MFD BRKT CAPAC MOUNT BRKT CAPAC MOUNT SCREW,10-32X1/2 FL HD CAPACITOR,0.47 MFD HLDR-FUSE HPF, HPC FUSE-10A., 250V XSTR-2N1558, GER PNP INSERT 10-32HELICOIL RES-1.8 OHMS, 3-1/4W DIODE-1N4003 200V RESISTOR,15 OHMS 1 WATT RES-24 OHMS 2 WATT CAP-CAPACITOR PART NO. N436560 N436561 J5252740112 J4751200110 J4751210109 J4802110105 N4510390403 J525099 J4751200108 J4751210107 N435088 M4511204801 J475175 M4510342001 J5073490172 J4751380113 N4511203002 N4511204101 N4511204301 J5072980105 J731227 J730070 J725808 M4511712401 J7313980032 J7313980031 J480225 J5073010108 J725477 J5252760112 J725476 J5072970108 J4751210105 J4802110102 J7261500047 J7261500029 M4511205701 J4751210108 J4802110104 J7355190098 J7355190100 J776638 J7355190099 J7355190102 J5072970104 J723958 J706732 J702078 J701059 J705089 J705090 J052091 J706152 J071890 J710137 J731301 J792630 J7355190097 J723555 J722631 J723417 J709201 SM 5924, Rev. 1, June 2009 PARTS LIST ITEM NO. 405 410 415 420 425 430 435 440 445 450 455 465 475 480 481 490 495 500 505 510 515 520 535 540 545 550 555 560 565 570 575 580 585 590 600 605 610 615 620 630 635 645 800 805 SM 5924, Rev. 1, June 2009 DESCRIPTION CAP-CAPACITOR TERM-RING TONGUE CONN-PLUG 6 TERM CONN-PLUG 9 TERM TERM F 1189-TL SCR-6-32X3/4 FILH SS RECPT-FASTON PIDG RES-1.5K OHMS, 25 W. MYLAR-POLYEST FLM SH SCR-6-32X7/16 PAN HD COMPONENT,SILICONE RUBBER WSHR-3/8" STL PL W-12 SPEC M-258-30 W 16 PVC RED M258-30 W 16 PVC BLK M258-30 SCR-2X1/4IN PARKER GASKET,CORD SCREW,10-32X9/16 FIL HD TAB-QUICK CONNECT COMPOUND-BONDING RECEPTACLE,TIN PL BRASS DIODE-RECT, 12A, 200V, 1N3891R RADIATOR RADIATOR SCR-8-32X7/8 PAN HD BAG-FOOD NON-VENTED SCR-8-32X7/16 FLH SS RBR EXTD CHAN X-396 WIRE-#14 AWG,ETFE,WHITE W 18 PVC WHT M258-30 CONN-ARPF-2010 CONN-APD-620421 PLATE,NAME CLIP-ADHSVE BK-3/8 D RING SCR-SST 8-32X1/2 PAN TERM.,PRE INSUL DIA.G TERM-PRE-INSUL DIAGR NUT-10-32 HEX STL TUBING SLEEVE-WIRE MARKER CABLE TIE, SELF LOCKING TAPE 2 IN SCOTCH 22 TAPE 3/4WX66 SCO BD PART NO. J709202 J731458 J709174 J706768 J731355 J522161 J726219 J7355190101 A772090 J5072980107 J041620 J4751320114 A0450170009 A0455250006 A0455250007 J052648 A470066 J522151 J792667 J041637 J723923 J7261500110 N4510332902 N4510332903 J5072950114 J0556092 J5253010107 A075114 A0458580009 A0455070007 J7091460078 J7091460079 M4514961901 J703336 M4511204502 J5072950108 J730046 J730041 J048172 A774201 J7928220001 J703310 A773128 J773078 5-5 5-6 SM 5924, Rev. 1, June 2009 PARTS LIST Figure 5–1. F-42 DC/DC Converter Parts Location SM 5924, Rev. 1, June 2009 5-7/5-8 RAIL Team and Technical Support 6 RAIL TEAM AND TECHNICAL SUPPORT The Rapid Action Information Link Team (RAIL Team) is a group of experienced product and application engineers ready to assist you to resolve any technical issues concerning this product. Contact the RAIL Team in the United States at 1-800-652-7276 or by e-mail at [email protected]. SM 5924, Rev. 1, June 2009 6-1 RAIL Team and Technical Support End of Manual 6-2 SM 5924, Rev. 1, June 2009