Transcript
TM 11-6625-3069-13-2
POWER SUPPLY TESTER P/N: 11047-001 FOR AIRBORNE POWER SUPPLY (APS) P/N: 99022-001A NSN: 6130-01-496-5020 March 15, 2007
Tester Manufactured by EG&G POWER SYSTEMS 1 AEROVISTA PARK SAN LUIS OBISPO, CA 93401 Airborne Power Supply Manufactured by Blackhawk Management Corporation 1324 Wyckoff Road Wall Township, NJ 07753-6800
DISTRIBUTION STATEMENT A. Approved for public release; distribution is unlimited. *This manual supersedes TM 11-6625-3069-13-2, dated 05 September 1984, including all changes.
HEADQUARTERS, DEPARTMENT OF THE ARMY
15 MARCH 2007
TABLE OF CONTENTS Section
Page
1.0
General ........................................................................................................................................1
1.1
Description ..................................................................................................................................1
1.2
Specifications ..............................................................................................................................1
2.0
Panel Layout and Controls ..........................................................................................................6
2.1
Front Panel ..................................................................................................................................6
2.2
Rear Panel ...................................................................................................................................6
3.0
Operation ...................................................................................................................................11
3.1
Installation .................................................................................................................................11
3.2
General Description...................................................................................................................11
3.2.1
Description of Rated Load Test.................................................................................................11
3.2.2
Description of Ripple Measurement..........................................................................................12
4.0
Theory of Operation ..................................................................................................................13
4.1
System .......................................................................................................................................13
4.2
Control Board ............................................................................................................................13
4.3
Fault Buffer ...............................................................................................................................24
4.4
Recommended Spare Parts ........................................................................................................25
5.0
Troubleshooting and Fault Isolation..........................................................................................26
5.1
Overcurrect Operation ...............................................................................................................26
5.2
Overvoltage Operation ..............................................................................................................26
5.3
Remote Operation......................................................................................................................26
Appendix A – Final Acceptance Test .........................................................................................................A-1
i
FIGURE LIST Figure Number
Title
Page
1
Cable Assembly, Block Diagram, P/N 11404-001 ...............................................................2
2
Installation Control Drawing, Test Set PS 99022, P/N .........................................................7 P/N 11426-001
3
Detailed Nomenclature, Power Supply Tester, P/N 11428-001............................................9
4
Block Diagram, P/N 11400-001..........................................................................................12
5
Top Assembly Schematic, Wiring Diagram (two sheets), ............................................ 17-19 P/N 11402-001
6
Schematic Control Board, P/N 11401-001..........................................................................21
7
Fault Buffer Schematic Diagram ........................................................................................24
TABLE LIST Table Number
Title
Page
1
Cable Assembly – Parts List, PL11404-001 .........................................................................3
2
Cable Assembly – Wire List, WL11404-001........................................................................4
A-1
Rated Load Test Procedure .............................................................................................. A-2
ii
1.0
GENERAL
1.1
DESCRIPTION Airborne Power Supply Test Set, P/N 11047-001, is a bench top or rack mount instrument intended to be used for field maintenance of Airborne Power Supply, PIN 99022-001. The tester contains fixed loads for each for the ten buses of the power supply and has the capability of dynamically loading any of the ten buses one at a time. The tester also has the capability of providing an overvoltage or overcurrent to a selected bus. Bus current and voltage are monitored by front panel digital voltage and current meters.
1.2
SPECIFICATIONS Input Power:
28 Volts DC, 50 Amps maximum (Tester consumes 250 milliamps maximum). Three phase 120/208 volt, 400 hertz, 50 amps maximum (Tester uses 100 volt amperes maximum).
Output Power:
Power is supplied to the power supply from the input power sources via a special Cable Assembly (Figure 1, Tables 1 and 2, Cable Assembly, P/N 11401-001).
Operating Temperature Range: 0 to 50 degrees centigrade. Warm-up Time: One minute (for readings with specified accuracy). Loading Accuracy: Plus or minus 5%. Voltage and Current Meter Reading Accuracy: Plus or minus 2%. Mechanical:
Weight:
45 pounds maximum
Dimensions:
Capable of being mounted in a standard 19-inch rack (refer to Figure 2, Installation Control Drawing)
1
2 Figure 1. Cable Assembly Block Diagram, P/N 11401-001
Table 1. Cable Assembly – Parts List PL11404-001 Item No.
Qty.
Meas.
Manufacturer’s Part or Identifying No. WL11404-001
Nomenclature or Description
1
Ref
Wire List (Reference)
2
15
EA MS3367-4
Cable Ties, 4 in.
3
15
EA MS3367-5
Cable Ties, 5 in.
4
1
EA MS3106A24-9P
Connector; PA
5
1
EA MS3106A18-20P
Connector; PB
6
2
EA MS3106A28-12S
Connector; PC, P D
7
1
EA MS3106A22-14S
Connector; PE
8
1
EA MS3106A24-12S
Connector; P1
9
1
EA MS27473E12F8S
Connector; P2
10
6
EA MS27473E20F16P
Connector; P4, P5, P6, P10, P11, P12
11
3
EA MS27473E20F16PA
Connector; P16, P17, P18
12
1
EA MS27473E12F98P
Connector; P19
13
1
EA MS3057-10A-W/B
Clamp (PB)
14
1
EA MS3057-12A-W/B
Clamp (PE)
15
4
EA MS3057-16A-W/B
Clamp (P1, PA, PC, PD)
16
10
FT MIL-W-16878D TYPE-D
Wire, 8 Gauge
17
250
FT
Wire, 16 Gauge, WHT, TEFZEL
18
125
FT MIL-W-16878D TYPE-B
Wire, 20 Gauge, WHT
3
Table 2. CABLE ASSEMBLY – WIRE LIST WL11404-001
FROM P4-A P4-B P4-C P4-D P4-E P4-F P4-J P4-K P4-L P4-M P4-R P4-S P5-A P5-B P5-J P5-K P5-L P5-M P6-J P6-R P6-A P6-G P6-L P10-A P10-B P10-C P10-D P10-E P10-F P10-G P10-H P10-J P10-K P11-A P11-B P11-J Pl1-K P12-A P12-J P16-A P16-B P16-C P16-D
TO PC-A PC-B PC-C PC-D PC-E PC-F PC-L PC-M PC-V PC-W PC-J PC-K PC-G PC-H PC-N PC-P PC-X PC-¥ PE-E PE-H PE-A PE-K PE-J PD-A PD-B PD-C PD-D PD-E PD-F PD-6 PD-d PC-R PC-S PD-G PD-H PC-T PC-U PE-B PE-F PD-T PD-U PD-V PD-W
WIRE SIZE (A WG) 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 20 20 20 20 20 16 16 16 16 16 16 16 16 16 16 16 16 16 16 20 20 16 16 16 16
COLOR CODE WHT WHT WHT WHT WHT WHT WHT WHT WHT WHT WHT WHT WHT WHT WHT WHT WHT WHT WHT WHT WHT WHT WHT WHT WHT WHT WHT WHT WHT WHT WHT WHT WHT WHT WHT WHT WHT WHT WHT WHT WHT WHT WHT
4
REMARKS BUS 1P + 5 BUS 1G + 5 BUS 1P + 5 BUS 1G + 5 BUS 1P + 5 BUS 1G + 5 BUS 5P + 15 BUS 5G + 15 BUS 9P - 15 BUS 9G - 15 BUS 8P + 36 BUS 8G + 36 BUS 1P + 5 BUS 1G + 5 BUS 5P + 15 BUS 5G + 15 BUS 9P - 15 BUS 9G - 15 BUS 5 (+15) SENSE BUS 8 (+36) SENSE BUS 1 (+5) SENSE BUS 10 (-5) SENSE BUS 9 (+15) SENSE BUS 2P + 5 BUS 2G + 5 BUS 2P + 5 BUS 2G + 5 BUS 2P + 5 BUS 2G + 5 BUS 10P - 5.2 BUS 10G - 5.2 BUS 6P + 15 BUS 6G + 15 BUS 2P + 5 BUS 2G + 5 BUS 6P + 15 BUS 6G + 15 BUS 2 (+5) SENSE BUS 6 (+15) SENSE BUS 3P + 5 BUS 3G + 5 BUS 3P + 5 BUS 3G + 5
Table 2. CABLE ASSEMBLY – WIRE LIST - Continued WL11404-001
FROM P16-E P16-F P16-G P16-H P16-J P16-K P16-R P16-S P17-A P17-B P17-G P17-H P17-J P17-K P17-R P17-S P18-R P18-C P18-J P19-A P19-G P19-H P19-J P19-K P1-A P1-C P2-A P2-B P2-C P2-D P2-E
TO PD-X PD-Y PD-J PD-K PC-Z PC-a PD-L PD-M PD-Z PD-a PD-N PD-P PC-b PC-d PD-R PD-S PE-D PE-C PE-G PE-R PE-L PE-P PE-N PE-M PA-A PA-B PB-A PB-B PB-C PB-D PB-E
WIRE SIZE (A WG) 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 20 20 20 20 20 20 20 20 8 8 20 20 20 20 20
COLOR CODE WHT WHT WHT WHT WHT WHT WHT WHT WHT WHT WHT WHT WHT WHT WHT WHT WHT WHT WHT WHT WHT WHT WHT WHT WHT WHT WHT WHT WHT WHT WHT
5
REMARKS BUS 3P + 5 BUS 3G + 5 BUS 4P + 5 BUS 4G + 5 BUS 7P + 15 BUS 7G + 15 BUS 4P + 5 BUS 4G + 5 BUS 3P + 5 BUS 3G + 5 BUS 4P + 5 BUS 4G + 5 BUS 7P + 15 BUS 7G + 15 BUS 4P + 5 BUS 4G + 5 BUS 4 (+5) SENSE BUS 3 (+5) SENSE BUS 7 (+15)SENSE FAULT CMN RTN OVER TEMP HIGH TEMP REMOTE SHUTOFF + 28V INPUT 28V RTN 115 VAC 400 Hz øA 115 VAC 400 Hz øA 115 VAC 400 Hz øA NEUTRAL GROUND
2.0
PANEL LAYOUT AND CONTROLS
2.1
FRONT PANEL Front panel controls are defined by Figure 2, Detail Nomenclature, P/N 11428-001.
2.2
REAR PANEL Input power is supplied by means of connectors mounted on the rear panel. Description and location are defined in Figure 3, Installation Control Drawing.
6
A
A AIR OUT
.55 MIN
4.0 1.8
.55 MIN
MS3102A24-12P
1.7
.25 MAX
J1 1.8 18.0 MAX J2 8.75 REF
.125 1.5
AIR IN 4.0
MS3102A18-20P
19.0 7.5
1.0
MS3102A18-20S
2.5
2.5 .8
.8 .5
4.0
8.75+.05 BNC
JB
RIPPLE
JE
5.75 6.8
1.5 JC JD
FAN
2.75
JA
3.5
1.5
1.75
.5
1.5 .20 MAX
.5
.5 1.525
4.69 x 4.69
MS3102A22-14P MS3102A24-9S
Figure 2. Installation Control Drawing Test Set PS 99022, P/N 11426-001 7/(8 blank)
Control
Reference Designator
28 Volts
CB1
50 amp 2 pole circuit breaker that interrupts the 28 volt input power.
400 Hertz
CB2
5 amp 3 pole circuit breaker that interrupts the 120/208 3Pphase 400 Hz input power.
JA
JA
Output 28 volt power to the power supply being tested.
JB
JB
Output 400 Hz power to the power supply being tested.
JC
JC
Bus 1, 5, 6, 7, 8, and 9 power from the power supply being tested.
JD
JD
Bus 2, 3, 4, and 10 power from the power supply being tested.
JE
JE
Bus sense lines directed to the tester voltmeter - also a sense for return, inhibit, and fault signals from the power supply being tested.
Bus Select Switch
S1
Selects the bus to be tested.
Bus Select Indicators
DS1-10
START Switch
S3
Momentarily depressing this switch initiates testing.
STOP Switch
S2
Stops the test immediately when momentarily depressed.
TIMER CONT Switch
S4
IN TEST
DS14
OVER CURRENT Select Switch
S6
Current Adjust OVER VOLTAGE Select Switch
Function/Description
Verifies position of S1.
M2
M1
Specification Chart
S1
DS1 - 10
CB2
FIELD MAINTENANCE TEST SET PN 11047-001 +15
1
6
2
7
3
8
When in ON position allows adjustable current loading on selected bus.
4
9
R37
Adjust the current loading on the selected bus up to 120% of full load.
5
10
S7
When in ON position allows a voltage to he applied to the selected bus to test the overvoltage protection of the power supply.
+5
+15 +15
+5
Selects a 10 second test or a continuous test time.
-36
+5
-15
+5
OVER VOLTAGE Adjust
CB1
R38
Lights when test is in progress.
OFF
RIPPLE
IN TEST
HIGH TEMP Indicator
DS11
OVER TEMP Indicator
DS12
Lights when power supply overtemp sensor is activated.
FAULT Indicator
DS13
Lights when power supply remote fault signal is activated.
RIPPLE Indicator
J3 & J4
VOLTS Meter
M1
Meter that measures the output voltage of the selected bus via sense lines received from JE.
AMPS Meter
M2
Meter that measures the current in the selected bus.
FAULT
ON START
HIGH TEMP
STOP
OVER TEMP
Turns off the power supply under test when placed in the up position.
JD
TIMER
ON
INHIBIT
JA
Lights when power supply high temp sensor is activated. CONT
OFF OVER VOLTAGE
J3 & J4 2 BNC jacks used to differentially measure AC ripple on the power supply under test.
JC
JE
OFF OVER CURRENT
S5
28 VOLTS DC
JB
Adjust the voltage applied to the selected bus when in overvoltage test mode.
REMOTE INHIBIT Switch
400 HERTZ
-5
S6 & R37
S7 & R38
IN TEST
S3
REMOTE
TEST CONTROLS
S2
S4
S5
DS12
DS11
JA
JE
JB
JD
JC
DS13
Figure 3. Detailed Nomenclature, Power Supply Tester, P/N 11428-001 9/(10 blank)
3.0
OPERATION
3.1
INSTALLATION With both tester circuit breakers placed in the OFF position, connect the incoming power to J1 and J2 located on the rear panel (see Figure 3, Installation Control Drawing, P/N 11426-001). Connect the special interface cable assembly between the tester and the power supply. Power will be supplied to the tester and to the power supply when the tester’s circuit breakers are placed in the ON position. Both the 28 volt and the 400 hertz power must be available for the tester to operate. Connect the Airborne Power Supply (APS) to the Test Set (PN:11047 -001) as follows: W1 Cable: W2 Cable: W3 Cable:
W4 Cable:
PA to JA on Test Set P1 to J1 on APS PB to JB on Test Set P2 to J2 on APS PC to JC on Test Set PD to JD on Test Set P3 to J4 on APS P4 to J5 on APS P5 to J10 on APS P6 to J11 on APS P8 to J17 on APS PE to JE on Test Set P2 to J6 on APS P3 to J12 on APS P4 to J18 on APS P7 to J16 on APS
To connect the digital multimeter (DMM) to the Test Set, a BNC(M) to BNC(M) cable and a BNC dual banana adaptor are required. First connect the BNC dual banana plug adapter into meter, then connect one end of BNC cable to banana plug adaptor and the other end to J3 on Test Set.
3.2
GENERAL DESCRIPTION The tester operates in three basic modes: A. Rated Load Operation B. Overload Operation C. Overvoltage Operation Operation in any of these modes is on one of the ten buses selected by the BUS SELECT switch. The operator selects the bus to be tested and depresses the START switch. Depressing the STOP switch immediately interrupts the test. Refer to Section 5 for a description of the Overcurrent and Overvoltage modes of operation.
3.2.1
Description of RATED LOAD TEST For this test the OVERCURRENT and OVERVOLTAGE switches must be in the OFF position. The bus to be tested is selected by the BUS SELECT switch. The selected bus voltage and current are 11
monitored by the front panel meters. Before pressing the START switch the operator should note the current and voltage readings. Internal fixed resistance loads are applied to all buses. Fixed bus loads are as follows: Plus 5 Volts Plus 15 Volts Plus 36 volts Minus 15 Volts Minus 5 Volts
3.5 Amps 1.5 Amps 0.2 Amps 1.5 Amps 2.5 Volts
Load testing is initiated by depressing the START switch and will continue until the STOP switch is depressed or the internal timer times out (approximately 10 seconds). Continuous operation is allowed in rated load testing only. This is accomplished by placing S4 in the CONT position. 3.2.2
Description of RIPPLE MEASUREMENTS: Two methods maybe used for taking this measurement. One method is to connect 2 BNC-BNC cables between the 2 BNC connectors located on the front panel of the test set and a 5 MHz Oscilloscope with a differential measurement mode. This method allows for differentially measuring the AC ripple and noise on the selected power supply bus. The next method is to use a Voltmeter (Meterman 34XR True RMS or Equivalent) by connecting a BNC cable to a banana plug or similar adapter that allows the meter leads to be attached. This method allows the VRMS to be measured for each Bus. All readings must be equal to or less than values listed below: Bus 1-4 50 mVpp or 0.03535 VRMS Bus 5-7 150 mVpp or 0.10605 VRMS Bus 8 360 mVpp or 0.25452 VRMS Bus 9 150 mVpp or 0.10605 VRMS Bus 10 50 mVpp or 0.03535 VRMS
12
4.0
THEORY OF OPERATION
4.1
SYSTEM In the description to follow, reference is made to Figure 4, Power Supply Tester Block Diagram P/N 11400-001, and Figure 5, Top Assembly Schematic, P/N 11402-001. The basic function of the tester is to test the individual power supply cards of the Airborne Power Supply, PIN 99022-001. At the same time the tester provides a small amount of load current on all the busses at all times. This fixed load is 10% for all busses, except the minus five bus (bus 10) which is loaded to 25%. The power to the power supply is accepted by rear panel connectors and is passed through circuit breakers to connectors on the tester's front panel. A special cable assembly connects the tester to the power supply. Ten (10) double pole relays provide isolation and switching to the single active load, an NPN power transistor. The control board is operated from an isolated power supply and provides the base drive to the active load. Double pole relays are used so that the proper polarity can be switched to the power resistor. Current is controlled in the power transistor by a feedback scheme in which the voltage across emitter resistors (R30 and R31 of the schematic) is feedback and compared to a precision reference voltage. The active load comes on at a rate of approximately 100 milliseconds (from 10% to maximum). Precision shunts are used in each bus and are switched to the digital current meter by the BUS SELECTOR switch. The digital voltmeter measures the voltage of the selected bus from sense lines directed to the meter by the BUS SELECTOR switch. These sense lines carry no load current and are connected via the cable assemblies to the connectors of the power supply under test. The power supply can provide continuous rated load testing of a bus; but for Overload test and the Overvoltage test an internal timer interrupts testing after approximately 10 seconds. If desired, the timer mode can also be used for Rated Load testing. The Overvoltage test is accomplished by providing a secondary source of power capable of overriding the fixed loads. To prevent excessive voltages the maximum input is limited depending upon the position of the BUS SELECTOR switch.
4.2
CONTROL BOARD In the description to follow, reference is made to Figure 6, Control Board Schematic, P/N 11404001.
13
The control board accepts signals and power from components of the main assembly and provides the following primary outputs: 1. 2. 3. 4.
Relay drive power (J6 pin 9). Base drive signal for dynamic load transistor (J4 pin 2). Power and control signals to current and voltage meter (J5). Overvoltage power to buses (J6 pin 13)
Bus Selection Circuitry: J1 receives a positive 28 volts on pins 1 through 10 corresponding to the bus selected by the position of BUS SELECTOR switch of the top assembly. Pin 11 of J1 is the 28V return, and is isolated from the logic ground of the Control Board. The 28 volt power is transmitted to one side of relays of the top assembly by J2 of the Control Board. Diodes of U17 and U18 are used to isolate the relays and prevent more than one relay being energized at a time. Consider the selection of BUS 1 (+5 volts). Positive 28 volts is received at pin 1 of J1 and provides 28 Volts minus one diode drop to pin 1 of J2 (supplying power to one side of the control coil of K1 of the top assembly). The other side of the control coil of all relays of the top assembly is fed from pin 9 of J6. Thus when pin 9 of J6 is pulled to the 28 volt return by Q3 the selected relay will be energized. Q3 is energized when the optocoupler U13 is unenergized (i.e., when pin 2 of U2 is high). This is the IN TEST mode and the lamp designated IN TEST on the front panel is also energized by Q3. The setreset binary U1 provides the start or stop test control. When pin 10 of U1 is low, pin 2 of U2 will be high, thus energizing Q3. When power is first turned on to the Tester, pin 10 of U1 comes up in the "1" mode -- Q3 off. The binary can be set to the IN TEST mode by momentarily depressing the START switch on the front panel which is input to the Control Board on pin 1 of J6. The binary is set to the STOP mode by depressing the STOP switch on the front panel which is input on P6 pin 3. The binary is also set to the STOP mode by time out to the timer composed of R23, C6, CR7, R38 and one section of U1. When C6 charges to a level above the logic "1" level of U1, then pin 9 of U1 goes low, setting the binary back to the STOP state (U1 pin 10 high). The binary is also set to this state by the OVERVOLTAGE or OVERCURRENT control switches being placed to the on position. These signals, received on pins 8 and 11 of J6, momentarily force pin 12 of U1 to a logical low state. The binary can also be forced to the STOP mode when Q7 is energized due to an Overcurrent at pin 13 of J6. The last condition in which the binary is forced to the STOP mode is when the BUS SELECTOR switch is moved to another bus position. This is accomplished by Q1 and Q2 and associated circuitry. The dynamic load transistor located external from the Control Board receives its base drive from Q4 though pin 2 of J4. It is driven from an error amplifier that receives a "request" current on pin 12 (U4) and a feedback signal from a current sense resistor (R30 and R31) located on the top assembly. The "request" is determined by the selection of the bus, which in turn energizes one of the optocouplers U8-U12. The energized optocoupler drives a switch (U5) which drives one of five resistors R1-R5. Under the Rated Load test 8.0 Volts appears at pin 5 of J6 and feeds the resistor network through R6.
14
+28V IN 3 PHASE 208V, 400Hz
PA +5V S H U N T
DIGITAL METER (AMPS)
TO BUS 10 SHUNT
+5V S H U N T
+5V S H U N T
+5V S H U N T
+15V S H U N T
+15V S H U N T
+15V S H U N T
+36V S H U N T
-15V S H U N T
-5.2V PB
S H U N T
POWER SUPPLY
PC P1
10% FULL LOAD
PD
P2
PE
P4 P5 P6 P10 P11
TO BUS 10 SHUNT
P12 P16 P17
TO VOLTAGE SENSE LINES
DIGITAL METER (VOLTS)
P18 VOLTAGE SENSE LINES
P19
TO RELAY COILS
SENSE GROUND
+28V ACTIVE LOAD BUS 1
BUS 10
REMOTE FAULT ON
CONTROL BOARD
HIGH TEMP.
OVER TEMP.
ON IN TEST OFF OVER CURRENT
ON OFF OVER VOLTAGE
START
STOP TIMER CONTINUOUS
Figure 4. Block Diagram, Power Supply Tester, P/N 11400-001 15/(16 blank)
S1C-2 R1 50mV 50A
S1D-2
R11 2Ω 25W
4 6
1 2
3 5
34
R32 12Ω .3W
1 2
K1 R12 2Ω
S1C-3 JD
+5V
+5V
+5V
-5.2V
2P
A
2R
B C D
S1C-4
2P
E
S1D-4
2R
F
2P
G
2R
H
4P
J K
4P
L
4R
M
4P 4R
N P
4P
R
4R
S
3P
T
3R
U
3P
V
3R
W
3P
X
3R
Y
3P
Z
3R
a
10P
b
10R
d
+5V
+36V
+15V
+15V -15V
-15V
A
1R
B
1P
C
1R
D
1P
E
1R
F
1P
G
1R
H
8P
J
8R
K
5P
L
5R
M
5P 5R
N P
6P
R
6R
S
6P
T
6R
U
9P
V
9R
W
9P
X
9R
Y
R33 12Ω .3W K2 R13 2Ω A1P6-950314-2
R3 50mV 50A
25W
4 6
1 2
3 5
34
M3100AA45
R34 12Ω .3W
1 2
A1P4 R35 12Ω .3W B
C3
.1
S1C-5
1
Q1 R4 50mV 50A
S1D-5
1 2
E
R14 2Ω 25W
2
4 6 3 5
34 1 2
K4
1
E2
E3
3 5 A B
R21 .1Ω
4
2 R22
4 6 2
R31 .1Ω 50W
R30 .1Ω 50W R15 10Ω 50W
R5 .01Ω
3
1
S1C-6 S1D-6
.1Ω
R23 .1Ω
R24 E2 NEG
.1Ω
K5
S1C-7
R16 10Ω 50W
S1D-7 R6 .01Ω 1
JD 1P
3 5
34 1 2
2P
25W
4 6
1 2
2R
4R
R2 50mV 50A
S1D-3
4 6 3 5
2 A B
1
1
3 5 A B
K8
R19 10Ω 50W R9 .01Ω 1
4 6 3 5
2 A B
Z a
JC-X
7P
b
7R
d
A1P2
K9
R25
R26
R27
R28
.1Ω 50W
.1Ω 50W
.1Ω 50W
.1Ω 50W
R20 2Ω 75W R10 .01Ω 1
1 2 3 4 5 6 7 8 9 10
CB1 30 AMP
B
BB
A
φC
C
B
-
JB A
AA
B
BB
C CB2 5 AMP
S1C-10 S1D-10
7P
φA 120/208 V 400 Hz φB INPUT
+ 28 VOLTS OUTPUT
J2
4 6 2
B
K7 R18 180Ω 10W
R8 .01Ω
A
B -
S1C-9 S1D-9
AA
A
28 VOLTS INPUT
3 5
2 A B
7R
+
JA
B1 A
4 6
R7 .01Ω
S1C-11 S1D-11
J1 R17 10Ω 50W
S1C-8 S1D-8
-
+
K6
A
φA
B
φB
C
φC
CC
120/208 V 400 Hz OUTPUT
NUETRAL
D
D
NUETRAL
GROUND
E
E
GROUND
+28 VOLT +28 VOLT RETURN TO T1-1
TO SHEET 2
TO T1-2
4 6 3 5
2 A B
K10
E1
Figure 5a. Top Assembly Schematic, Wiring Diagram, P/N 11402-001 (Sheet 1 of 2) 17/(18 blank)
T1
A
BUS 1 SENSE 2 3 4 5 6 7 8 9 10 SENSE COMMON PWR SUPPLY INHIBIT HIGH TEMP OVER TEMP PWR SUPPLY FAULT
P3
3
B C D
14
4
1
5
E F G
15
H J
CB2-BB + 28 RTN
K L M N P R
9
w
11 b
E2
DS2
~
12
S5
13
DS3
+
CR1
c
2
1
10
DS14
~
-
R36 1k .5W
+ ci
1 P6-12 3
1
START
2
S3
1
STOP S2
2
4
2 TIMER 54 1 CONT
INHIBIT P7
A2 FAULT BUFFER
1
DS4
3 7 5
DS11
6
DS12
OVER TEMP
DS6
8
DS13
FAULT
DS7
2
2
HIGH TEMP
DS5
8
3
2 W S6
4 5
4 1 2
6
7 8
DS9
9
7
10
DS10
11 w 14 1
1
+5 +5 +5 +5 +15 +15 +15 -36 -15 -5
1
1
c
1 A1 CONTROL BOARD
13
w S7
+28 w
w S1D
b
w
S1C
S1B
w
w
w
SIC
S1A
ON
1 OFF
OVERCURRENT
A 2 w 1 1 MIN R37 w 500 Ω 2 MAX 1 MIN
5
6
DS8
OFF
+ 28
2
7
a
DS1
1
IN TEST
5 6
10
CB2-CC
SHT 1
9
4
7 8
2
P6
3
6
1
K1-2 SHT1
2
R38 500 Ω 2 MAX 2 ON
OVERVOLTAGE
A 1 OFF
Q1-C SEE SHT 1
2 B 1
11
a 11
11
11
To R1-R10 SHT1
11 RIPPLE J3 J4
VOLTS M1
AMPS M2
H L S I C B K 9 8
L S N I C B K 9 8
10 9
P8 1 Q5 2N6385
2
C2 .1
3 1 8 6 7 4 5
13 11 12 2 3
P4 Q1-C Q1-B R30-1 R30-2
1 2 3 4
SEE SHEET 1
P2 1-10
RELAY DRIVE POWER
SEE SHEET 1
Figure 5b. Top Assembly Schematic, Wiring Diagram, P/N 11402-001 (Shet 2 of 2) 19/(20 blank)
+12V
+12V
R8 2K +12V 1/8W 4 U4/A 1% 2 1 3 R9 LM324 10K 11 1/8W 1% GND
14X 1N4153-1 3
CR12
J1
CR13
1
1
CR14 CR15
2
R48 10K
K2
10
R49 10K
R51 10K
R50 10K
R52 10K SAT
2
CR16
U5/A 2 1
3
R41
4
10K R42
CR18 CR19
4
U5/B
U8
10K R43 CR20
5
5
CR21
6
10K
7 8
10K
9
R47
10
10K
CR24
9
CR25
10
CR11 14 3
11
U10 8
C16 .1
R46
CR23
8
U9
C17 .1
10K R45
6
CR22
7
C18 .1
10K R44
U12
C14 .1
K1 +12V R53
GND1
R24 10K
8
11 R35 2K
+12V R23 10K
CR26
C5 .1
U2/E
R17 10K
R18 10K
1
GND
C2 10 20V +12V R19 10K
2
4
U2/A
3
C3 .1 GND
CR31
U2/B
1N4153-1 +
GND
GND
CR5
10 20V
CR7 C6 10 20V GND
PART OF J6
Q3
R38 10K
C11 .1 CR6
U1/A
Q9 2N3019
R22 15K
R21 3.3K
1 2
9 10
3 R15 1K 1/8W 1%
C29 .1 GND
1 2 3
C26 10 20V
C24 .1 GND
470
2
CR1 +
+
C19 470 30V
1 GND
R16 1K
.301 3W
C20 10 20V
R36 9.09K 1/8W 1% R37 1K 1/8W 1% 16 9 K2 15
K1
2 8 1
+12V
5 10
4
PART OF J6
9
1 11 13 12 7 8 6
12 1N4153-1 13
C30 .1
C31 .1
CR10 Q6
C27 .1
R32
C10 .01
3
U14
J8
.1 7W 1% R31 500 5W 1%
7812
GND
1
+12V
R40 1M
Q8
CR30
R34 24.9K
+ -
J4
CR9
GND
R20 1.5K
R33 8.2K U13
U4/C
+12V
CR2
.1
R14
CR8
C21 220 30V
4 C12
C28 220 1N5550 75V
4
+
CR35 CR36
GND
+5V
U15
5
CR37
K1 15
R27 15
2 78MO5
CR4
R13 1K
14 U4/D
17.4K 1/8W 1% 8
3
C22 220 30V
CR34
9 16
R26 220
U16 +
J5 +5V
6
200K LM324
+
78M05
CR32 CR33
C13
-
13
R25 10K
U1/C
U2/C
12
1K
10% 1N5550 CR3
7 Q4
.1 R12
U5/F 13
1.5 K
U1/B
+12V R39 1M
LM324
CR29
3
GND
U6/A
U2/F
.1
J3
U6/D 9
1.5 K C4
1 C1 .1
CR28 1.5 K 2
+12V
5
R11
U6/B 4 3
CR27
8
7
C7 .1
GND
R5
U6/C 6 5
GND
6
C8 .1
U6/E 10 11
Q1
Q2
R10 12V 1K
GND R7 4.02K 1/8W 1%
SAT
US/D 9
12
+12V PART OF J6
SAT
5.49K 1/8W 1% + C9 10 20V R54 10 GND U6/F 12 13
U11
C15 .1
R1
R6 22.24K 100K 1/8W R2 1/8W 4 3 1% 1% 9.76K SAT 1/8W US/C R3 6 5 1% 9.76K 1/8W SAT 27.4K 1% 1/8W US/E R4 1% 11 10
CR17
3
SAT
PART OF J6
2N2907A
GND 14
GND C23 .1 GND
R29 10K
Q7
2N2222A
C25 .1
R30 10K
10 GND 9
GND1
Figure 6. Schematic, Control Board P/N 11401-001 21/(22 blank)
The voltage divider is made up of R6 and one of the resistors R1 through R5. When in the Overcurrent test mode the voltage at pin 5 of J4 is variable up to 10.0 Volts. When Bus 8 is selected (plus 36 volts), K1 is energized, transferring the feedback current sample from pin 3 of J4 to the pin 8 of U4 via the relay contacts of K1. This is done because the current sample voltage requires amplifying before feeding into the comparator. The relay provides a secondary function of changing the decimal point on the voltmeter (pins 6, 7, and 8 of J5). Resistors R36 and R37, through pins 1, 9, and 10 of J5 are used to divide the 36 Volt sense voltage by 10. Overvoltage Tests: Q5, Q8, Q9 and Q10 and associated components is a variable gain voltage amplifier. Gain is controlled by the resistance in the emitter of Q9. Pin 14 of J6 is connected to a potentiometer located on the front panel. The voltage on the base of Q9 provides a limit on the maximum voltage allowed on the output and is selected by the resistor network composed of R20, R21, and R22 along with U6 and R25. When not in the Overvoltage mode the voltage at the base of Q9 is held low by U2 pin 10. The voltage amplifier receives an unregulated voltage on pin 12 of J6 t hat changes level as a function of the BUS SELECTION switch. Regulators and Meter Controls: U15 and U16 are five Volt regulators providing power for the voltage and current meters. U14 is a precision voltage regulator that provides logic power. Its output is also used to provide a reference for the voltage and current requests. K2 is energized only when buses 1 through 4 are selected. Its relay contacts provide the decimal point selection for the current meter.
23
4.3
FAULT BUFFER In the description to follow, reference is made to Figure 7, Fault Buffer Schematic Diagram.
Figure 7. Fault Buffer Schematic Diagram The fault buffer circuit senses the OVER TEMP and FAULT signals of the Airborne Power Supply and drives the corresponding lamps on the front panel of the Power Supply Tester. With no signal or a high signal on pin 5 of J7, R1 will bias Q1 to a saturated state, thus biasing Q2 to a cutoff state, this not allowing current to flow through the front panel OVER TEMP lamp, DS11 of the top assembly. When a low signal is applied to pin 5 of J7, Q1 will be biased to a cutoff state, thus allowing R2 to bias Q2 to the saturated state and thus illuminating DS11 on the front panel. The operation of the FAULT lamp, DS13 of the top assembly, is identical to that of the OVER TEMP lamp, except that R4, R5, Q3, and Q4 are used in place of R1, R2, Q1 and Q2. The fault buffer circuit gets its power from the power transformer, T1 of the top assembly. The AC voltage is rectified by CR1 - CR4, thus creating an unregulated 28V power bus. The 28V bus also supplies power to the HIGH TEMP, OVER TEMP, and FAULT lamps, DS11-DS13 of the top assembly.
24
4.4
RECOMMENDED SPARE PARTS The following is a list of parts recommended for quick repair of the tester. Description Control Board Fault Buffer Relay Relay Fan Lamp Lamp Voltmeter Voltmeter Transistor Transistor
Part Number D6690-101 D6700-101 PRD7GYO24 18732C200 MD2482 900-104X-082CL 900-104X-082RT PM-349-20volt PM-349-20mvolt MJ100AA45 JAN2N6385
25
Manufacturer EG&G Power Systems EG&G Power Systems Potter & Brumfield Midtex Rotron Littlefuse Littlefuse Non-Linear Systems Non-Linear Systems Motorola
5.0
TROUBLESHOOTING AND FAULT ISOLATION
5.1
OVERCURRENT OPERATION Place the OVERCURRENT control switch to the ON position. If any test is in process, the test will terminate. Turn the adjustment control fully counterclockwise, select desired Bus using S1, and then depress the START switch. Current loading of the selected bus is now under the operator’s control by means of the adjust control potentiometer. By turning the potentiometer clockwise, loading up to 120% of rated load can be obtained and the proper operation of the current limit function of the power supply under test can be verified. Testing is terminated by depressing the STOP switch or after the timer times out. It should be noted that during this test the Voltage should decrease and the Current will increase. NOTE In Overcurrent and Overvoltage mode, the position of S4 is ignored and the test will stop automatically after time out. An internal solid state load applies the rated load to the selected bus at a controlled rate (approximately 100 milliseconds from minimum to rated). While in testing mode, the IN TEST lamp will be on. The operator should consult the specification chart located on the front panel and verify that the proper output voltage and current do exist while the IN TEST lamp is on.
5.2
OVERVOLTAGE OPERATION Place the OVERVOLTAGE control switch in the ON position, verify that the OVERCURRENT control switch is in the OFF position, and turn the adjustment control to the full counterclockwise position. Next select the desired Bus using S1, and then depress the START switch and slowly turn the adjustment potentiometer clockwise. The bus voltage should increase until the power supply FAULT lamp comes on. Note that the Fault light may come on for the +15 Volt Buses and the -15 Volt Buses.
5.3
REMOTE FUNCTIONS The power supply under test can be turned on or off by the 28V DC circuit breaker which provides a grounding signal back to the power supply. The lamps designated FAULT, HIGH TEMP, and OVER TEMP are activated by signals derived from J19 of the power supply under test.
26
APPENDIX A FINAL ACCEPTANCE TEST
A-1(A-2 blank)
Table A-1. Rated Load Test Procedure (Reference Figure 3) Controls And Switches
Switch Settings
Notes and Comments
Test Set Indicators
Indicators Current Reading
DS1 DS2 DS3 DS4 DS5 DS6 DS7 DS8 DS9 DS10 DS11 DS12 DS13 DS14 M1* M2*
OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF 0 0
DS1 M1* M2*
ON 5 3.5
DS1 M1* M2*
ON 4.75 to 5.25 35 AMPS 35.35 millivolts
DS2 M1* M2*
ON 5 3.5
DS2 M1* M2*
ON 4.75 to 5.25 35 AMPS 35.35 millivolts
Fault Indications
VERIFY BOTH SETS OF LED on the UUT are illuminated, if not, refer to Tech Manual for troubleshoot procedures (TM11-6130442-13-3 Airborne Power Supply)
STEP 1 Initial settings
CB1 CB2 S1 S2 S3 S4 S5 S6 S7 R37 R38
ON ON OFF N/A N/A TIME ON (DOWN) OFF OFF FULLY CC FULLY CC
J3
CONNECT DMM TO J3 PLACE IN AC MODE Allow Unit to run for a minimum of 1 Minute prior to proceeding.
STEP 2
S1
1 (+5)
S3
PUSH ONCE While IN TEST IS LIT While IN TEST IS LIT READ DMM TO VERIFY RIPPLE IS EQUAL TO OR BELOW
DMM
STEP 3
S1
2 (+5)
S3
PUSH ONCE
DMM
Note that DS1 is on showing BUS 1 Selected
Note that DS2 is on showing BUS 2 Selected
While IN TEST IS LIT While IN TEST IS LIT READ DMM TO VERIFY RIPPLE IS EQUAL TO OR BELOW
Fault Light DS13 Lights Voltage out of Range Current out of Range Above allowed range
Fault Light DS13 Lights Voltage out of Range Current out of Range Above allowed range
A-3/(A-4 blank)
Table A-1. Rated Load Test Procedure (Reference Figure 3) - Continued
STEP 4
Controls And Switches
Switch Settings
S1
3 (+5)
S3
PUSH ONCE
Note that DS3 is on showing BUS 3 Selected
While IN TEST IS LIT While IN TEST IS LIT READ DMM TO VERIFY RIPPLE IS EQUAL TO OR BELOW
DMM
STEP 5
S1
4 (+5)
S3
PUSH ONCE
Note that DS4 is on showing BUS 4 Selected
While IN TEST IS LIT While IN TEST IS LIT READ DMM TO VERIFY RIPPLE IS EQUAL TO OR BELOW
DMM
STEP 6
S1
5 (+15)
S3
PUSH ONCE
DMM
Notes and Comments
Note that DS5 is on showing BUS 5 Selected
While IN TEST IS LIT While IN TEST IS LIT READ DMM TO VERIFY RIPPLE IS EQUAL TO OR BELOW
Test Set Indicators
Indicators Current Reading
DS3 M1* M2*
ON 5 3.5
DS3 M1* M2*
ON 4.75 to 5.25 35 AMPS 35.35 millivolts
DS4 M1* M2*
ON 5 3.5
DS4 M1* M2*
ON 4.75 to 5.25 35 AMPS 35.35 millivolts
DS5 M1* M2*
ON 15 1.5
DS5 M1* M2*
ON 14.25 to 15.75 15 AMPS 106.05 millivolts
Fault Indications
Fault Light DS13 Lights Voltage out of Range Current out of Range Above allowed range
Fault Light DS13 Lights Voltage out of Range Current out of Range Above allowed range
Fault Light DS13 Lights Voltage out of Range Current out of Range Above allowed range
A-5/(A-6 blank)
Table A-1. Rated Load Test Procedure (Reference Figure 3) - Continued
STEP 7
Controls And Switches
Switch Settings
S1
6 (+15)
S3
PUSH ONCE
Note that DS6 is on showing BUS 6 Selected
While IN TEST IS LIT While IN TEST IS LIT READ DMM TO VERIFY RIPPLE IS EQUAL TO OR BELOW
DMM
STEP 8
S1
7 (+15)
S3
PUSH ONCE
Note that DS7 is on showing BUS 7 Selected
While IN TEST IS LIT While IN TEST IS LIT READ DMM TO VERIFY RIPPLE IS EQUAL TO OR BELOW
DMM
STEP 9
S1
8 (-36)
S3
PUSH ONCE
DMM
Notes and Comments
Note that DS8 is on showing BUS 8 Selected
While IN TEST IS LIT While IN TEST IS LIT READ DMM TO VERIFY RIPPLE IS EQUAL TO OR BELOW
Test Set Indicators
Indicators Current Reading
DS6 M1* M2*
ON 15 1.5
DS6 M1* M2*
ON 14.25 to 15.75 15 AMPS 106.05 millivolts
DS7 M1* M2*
ON 15 1.5
DS7 M1* M2*
ON 14.25 to 15.75 15 AMPS 106.05 millivolts
DS8 M1* M2*
ON 36 0.2
DS8 M1* M2*
ON 34.56 to 37.8 2 AMPS 254.52 millivolts
Fault Indications
Fault Light DS13 Lights Voltage out of Range Current out of Range Above allowed range
Fault Light DS13 Lights Voltage out of Range Current out of Range Above allowed range
Fault Light DS13 Lights Voltage out of Range Current out of Range Above allowed range
A-7/(A-8 blank)
Table A-1. Rated Load Test Procedure (Reference Figure 3) - Continued
STEP 10
Controls And Switches
Switch Settings
S1
9 (-15)
S3
PUSH ONCE
STEP 11
DMM S1
10 (-5)
S3
PUSH ONCE
Notes and Comments
Note that DS9 is on showing BUS 9 Selected
While IN TEST IS LIT While IN TEST IS LIT READ DMM TO VERIFY RIPPLE IS EQUAL TO OR BELOW Note that DS10 is on showing BUS 10 Selected
While IN TEST IS LIT While IN TEST IS LIT
STEP 12 END TEST
DMM CB1 CB2 S1 S2 S3 S4 S5 S6 S7 R37 R38
Test Set Indicators
Indicators Current Reading
DS9 M1* M2*
ON -15 1.5
DS9 M1* M2* DS10 M1* M2*
ON -14.25 to -15.75 15 AMPS 106.05 millivolts ON -5.2 2.5
DS10 M1* M2*
ON -4.75 to -5.25 10 AMPS
DS1 DS2 DS3 DS4 DS5 DS6 DS7 DS8 DS9 DS10 DS11 DS12 DS13 DS14 M1* M2*
35.35 millivolts OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF 0 0
READ DMM TO VERIFY RIPPLE IS EQUAL TO OR BELOW ON ON OFF N/A N/A TIME ON (DOWN) OFF OFF FULLY CC FULLY CC
Fault Indications
Fault Light DS13 Lights Voltage out of Range Current out of Range Above allowed range
Fault Light DS13 Lights Voltage out of Range Current out of Range Above allowed range
*Meters have a +/- 2% Measurement Accuracy
A-9/(A-10 blank)
By Order of the Secretary of the Army:
GEORGE W. CASEY, JR. General, United States Army Chief of Staff
Official: JOYCE E. MORROW Administrative Assistant to the Secretary of the Army 0726901
Distribution: To be distributed in accordance with the initial distribution number (IDN) 361822, requirements for TM 11-6625-3069-13-2.
PIN: 040583-000
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