Battery Power Supply

RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER BPS7

TRANSMITTAL LETTER TO:

HOLDERS OF COMPONENT MAINTENANCE MANUAL 25-65-02, REVISION 14

REVISION NO. 15, DATED JANUARY 2012 HIGHLIGHTS The pages that have been added or revised are outlined below together with the highlights of the revision. Chapter/Section and Page No.

Description of Change

Title Page: T-1

REFLECT Revision 15

Record of Revisions: RR-1

ADDED Revision 15

List of Effective Pages: LEP-1 & LEP-2

UPDATED the effective date for all applicable pages and corrected description & operation page numbers

Introduction Page Intro-2: Section 4 Testing and Fault Isolation Page 102: Table 101: Oscilliscope Page 109: Section 8.A Page 120: Section 6.B Disassembly Page 301: Section 1.A.NOTE Page 303: Section 4.CAUTION

Page 304: Section 4.A.(3).(f). CAUTION Page 304: Section 4.A.(3).(g).NOTE Check Page 502: Table 501: Corrective Action, First two rows

Repair Page 601: Section 1.A.CAUTION

Copyright 2004 by: Radiant Power Corp., a HEICO Company

CORRECTED typo

CHANGED from 64504A-E0I/910 ADDED DL1540 alternate CHANGED from “…the card. PCB assemblies repaired at facilities other than Radiant are not guaranteed by Radiant.” CORRECTED typo

CHANGED from “…the cards. PCB assemblies repaired at facilities other than Radiant are not guaranteed by Radiant.” CHANGED from “UNITS UNDER WARRANTY SHOULD BE RETURNED TO RADIANT POWER CORP. FOR REPAIR. REMOVAL OF THE TOP COVER WILL VOID THE WARRANTY. DO NOT…” CHANGED from “PCB ASSEMBLIES REPAIRED AT FACILITIES OTHER THAN RADIANT ARE NOT GUARANTEED BY RADIANT.” CHANGED from “…the cards. PCB assemblies repaired at facilities other than Radiant are not guaranteed by Radiant.”

CHANGED from “…repair; other than replacement of SIT components, PCB assemblies repaired at facilities other than Radiant are not guaranteed by Radiant.”

CHANGED from “UNITS UNDER WARRANTY SHOULD BE RETURNED TO RADIANT POWER CORP. FOR REPAIR. REMOVAL OF THE COVER ASSEMBLY WILL VOID THE WARRANTY. THE PCB…DAMAGE. PCB ASSEMBLIES REPAIRED AT FACILITIES OTHER THAN RADIANT POWER CORP. ARE NOT GUARANTEED BY RADIANT.

25-65-02

Highlights-1 Jan 2012

RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER BPS7 Chapter/Section and Page No.

Description of Change

Page 601: Section 1.B.

DELETED “If the BPS is under warranty, return it to Radiant Power Corp. for repair. Removal of the cover assembly in the warranty period will void the warranty.”

Page 605: Table 602

CORRECTED wire colors

Assembly (including storage) Page 703: Table 702 Pages 710-711: Section 4.D.NOTE

CORRECTED wire colors CHANGED from “…the cards. PCB assemblies repaired at facilities other than Radiant are not guaranteed by Radiant.”

Special Tools, Fixtures and Equipment Page 901: Oscilloscope Page 902

ADDED DL1540 alternate CORRECTED heading from “(Sheet 1 of 2)”

Illustrated Parts List Page 1003: Table 1001 Page 1012 Page 1016 Page 1031: Item 2020

Copyright 2004 by: Radiant Power Corp., a HEICO Company

REMOVED CAGE 49956 ADDED CAGE 60336 REMOVED TTL REQ for 2020 REMOVED item 595 DELETED

25-65-02

Highlights-2 Jan 2012

RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER BPS7

RADIANT POWER CORP. 7135 16th STREET EAST, STE. 101 SARASOTA, FL

34243

(FORMERLY DERLAN INC.)

Component Maintenance Manual With Illustrated Parts List

Battery Power Supply Part Number: BPS7-2 (BOEING SCD S283T014-2 Part Number: BPS7-3 (BOEING SCD S283T014-3

THIS MANUAL CONTAINS PROPRIETARY INFORMATION OF RADIANT POWER CORP., AND IS TENDERED SUBJECT TO THE CONDITION THAT NO COPY OR OTHER REPRODUTION BE MADE IN WHOLE OR IN PART, AND THAT NO OTHER USE BE MADE OF SUCH INFORMATION WITHOUT EXPRESS WRITTEN PERMISSION OF RADIANT POWER CORP.

Copyright 2004 by: Radiant Power Corp., a HEICO Company

REVISION 15

25-65-02

Page T-1 Jan 2012

RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER BPS7

THIS PAGE INTENTIONALLY LEFT BLANK

Copyright 2004 by: Radiant Power Corp., a HEICO Company

25-65-02

T-2 Aug 2009

RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER BPS7

RECORD OF REVISIONS REVISION NUMBER A B C D E F G H I J 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

REVISION DATE Apr 20/83 Jan 12/84 Oct 1/84 Nov 30/84 Oct 1/85 Feb 1/88 Jul 19/88 Jan 10/90 Sep 15/90 Feb 1/94 Jan 15/97 Oct 15/97 Nov 15/98 Feb 1/00 May 15/00 May 2004 May 2004 Nov 2004 March 2006 Jul 2006 Aug 2007 Jul 2008 Aug 2009 Sep 2010 Jan 2012

DATE FILED

Copyright 2004 by: Radiant Power Corp., a HEICO Company

BY

REVISION NUMBER

REVISION DATE

25-65-02

DATE FILED

BY

Page RR-1 Jan 2012

RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER BPS7

THIS PAGE INTENTIONALLY LEFT BLANK

Copyright 2004 by: Radiant Power Corp., a HEICO Company

25-65-02

Page RR-2 Aug 2009

RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER BPS7

RECORD OF TEMPORARY REVISIONS REVISION NUMBER

REVISION DATE

DATE FILED

BY

Copyright 2004 by: Radiant Power Corp., a HEICO Company

REVISION NUMBER

REVISION DATE

DATE FILED

25-65-02

BY

Page TR-1 Aug 2009

RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER BPS7

THIS PAGE INTENTIONALLY LEFT BLANK

Copyright 2004 by: Radiant Power Corp., a HEICO Company

25-65-02

Page TR-2 Aug 2009

RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER BPS7

SERVICE BULLETIN LIST SERVICE BULLETIN 25-BPS7-2-1

ISSUE DATE Jan 15/97

DATE FILED

Copyright 2004 by: Radiant Power Corp., a HEICO Company

BY

SERVICE BULLETIN

ISSUE DATE

25-65-02

DATE FILED

BY

Page SB-1 Aug 2009

RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER BPS7

THIS PAGE INTENTIONALLY LEFT BLANK

Copyright 2004 by: Radiant Power Corp., a HEICO Company

25-65-02

Page SB-2 Aug 2009

RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER BPS7

LIST OF EFFECTIVE PAGES Subject

Page

Title Page

T-1 T-2

Jan 2012 BLANK

Record of Revisions

RR-1 RR-2

Jan 2012 BLANK

Record of Temporary Revisions

TR-1 TR-2

Aug 2009 BLANK

Service Bulletin List

SB-1 SB-2

Aug 2009 BLANK

List of Effective Pages

LEP-1 LEP-2

Jan 2012 Jan 2012

Table of Contents

TC-1 TC-2

Sep 2010 BLANK

Introduction

Intro-1 Intro-2 Intro-3 Intro-4

Sep 2010 Jan 2012 Aug 2009 BLANK

1 2 3 4 5 6 7 8 9 10 11 12

Aug 2009 Aug 2009 Aug 2009 Aug 2009 Aug 2009 Aug 2009 Aug 2009 Aug 2009 Aug 2009 Aug 2009 Sep 2010 BLANK

101 102 103 104 105 106 107 108 109 110 111 112 113 114 115

Sep 2010 Jan 2012 Aug 2009 Aug 2009 Aug 2009 Aug 2009 Aug 2009 Aug 2009 Jan 2012 Aug 2009 Aug 2009 Aug 2009 Aug 2009 Aug 2009 Aug 2009

Description and Operation

Testing and Fault Isolation

Date

Copyright 2004 by: Radiant Power Corp., a HEICO Company

Page

Subject

Date

116 117 118 119 120 121 122 123 124

Aug 2009 Sep 2010 Sep 2010 Aug 2009 Jan 2012 Aug 2009 Aug 2009 Aug 2009 Aug 2009

Disassembly

301 302 303 304 305 306 307 308

Jan 2012 Aug 2009 Jan 2012 Jan 2012 Aug 2009 Aug 2009 Aug 2009 Aug 2009

Cleaning

401 402

Sep 2010 Aug 2009

Check

501 502 503 504

Aug 2009 Jan 2012 Aug 2009 BLANK

Repair

601 602 603 604 605 606 607 608

Jan 2012 Aug 2009 Aug 2009 Aug 2009 Jan 2012 Aug 2009 Aug 2009 BLANK

Assembly (including Storage)

701 702 703 704 705 706 707 708 709 710 711 712 713 714

Aug 2009 Aug 2009 Jan 2012 Aug 2009 Sep 2010 Aug 2009 Aug 2009 Aug 2009 Aug 2009 Jan 2012 Jan 2012 Aug 2009 Aug 2009 Aug 2009

25-65-02

Page LEP-1 Jan 2012

RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER BPS7 Subject

Page

Date

715 716

Aug 2009 BLANK

Special Tools, Fixtures, and Equipment

901 902

Jan 2012 Jan 2012

Illustrated Parts List

1001 1002 1003 1004 1005 1006 1007 1008 1009 1010 1011 1012 1013 1014 1015 1016 1017 1018 1019 1020 1021 1022 1023 1024 1025 1026 1027 1028 1029 1030 1031 1032

Aug 2009 Sep 2010 Jan 2012 Aug 2009 Aug 2009 Aug 2009 Aug 2009 Aug 2009 Sep 2010 Sep 2010 Sep 2010 Jan 2012 Aug 2009 BLANK Aug 2009 Jan 2012 Sep 2010 Aug 2009 Aug 2009 Sep 2010 Aug 2009 Aug 2009 Aug 2009 Sep 2010 Sep 2010 Sep 2010 Sep 2010 Sep 2010 Sep 2010 Sep 2010 Jan 2012 BLANK

Copyright 2004 by: Radiant Power Corp., a HEICO Company

Subject

Page

25-65-02

Date

Page LEP-2 Jan 2012

RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER BPS7

TABLE OF CONTENTS Subject

Page

Description and Operation Testing and Fault Isolation Automatic Test Requirements Disassembly Cleaning Check Repair Assembly (Including Storage) Fits and Clearances Special Tools, Fixtures, and Equipment Illustrated Parts List

1 101 Not Applicable 301 401 501 601 701 Not Applicable 901 1001

LIST OF FIGURES Figure 1 2 3 101 103 104 105 106 107 109 601 701 IPL 1

Page Battery Power Supply Aircraft Interface Diagram Circuit Schematic Bench Test Setup Battery Charging Battery Discharge Hook-up Battery Housing Analyzer Memory Effect Date Code Locations Fuse Locations and Bending Clinch Nut Installation Battery Connection Diagram Battery Power Supply

4 5 7 105 120 121 122 117 118 110 605 705 1015

LIST OF TABLES Table 1 101 102 103 301 401 501 601 602 701 702 703 901 1001

Page Technical Properties Test Equipment and Materials Control Logic Test Requirements Fault Isolation Procedures Disassembly Materials Cleaning Materials Check Procedures Repair Tools and Materials Connector J1 Wire List Assembly Tools and Materials Assembly Wire List Storage Materials Special Tools, Fixtures, and Equipment Manufacturer Names and Addresses EQUIPMENT DESIGNATOR INDEX NUMERICAL INDEX PARTS LIST

Copyright 2004 by: Radiant Power Corp., a HEICO Company

10 102 104 111 302 401 501 602 605 702 703 715 901 1002 1006 1009 1020

25-65-02

Page TC-1 Sep 2010

RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER BPS7

THIS PAGE INTENTIONALLY LEFT BLANK

Copyright 2004 by: Radiant Power Corp., a HEICO Company

25-65-02

Page TC-2 Aug 2009

RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER BPS7

INTRODUCTION 1.

Scope This Component Maintenance Manual (CMM) contains maintenance instructions and lists replacement parts to assist qualified repair personnel in off-aircraft maintenance of Battery Power Supply (BPS), part number BPS7-2 and BPS7-3. Radiant Power Corp. of Sarasota, FL makes the BPS.

2.

Product Support Services Repair and overhaul services, replacement parts, technical documentation, and other product support services are available from Radiant Power Corp. Please contact our Sales Department at: Radiant Power Corp. 7135 16th Street East, Suite 101 Sarasota, FL. 34243 USA

3.

Telephone: FAX:

1-941-739-3200 1-941-739-3201

Usage Guide A.

Refer to the Table of Contents to find the necessary maintenance procedures or other data. This CMM is written to ATA 100, Revision 30 and AECMA Simplified English. (1) Description and Operation describes the purpose, primary components, and technical properties of the BPS. (2) Testing and Fault Isolation contains bench test and fault isolation procedures. (3) Disassembly contains procedures to disassemble the BPS for repair or part replacement. (4) Cleaning contains procedures to clean the BPS (5) Check contains procedures to check parts for damage. (6) Repair contains procedures to refinish and rework parts to serviceable condition. (7) Assembly contains procedures to reassemble and store the BPS. (8) Illustrated Parts List contains the information necessary to order replacement parts. An equipment designator index, a numerical index, and exploded-view drawings are provided to help find and identify the parts. The introduction to the IPL gives more data.

B.

The recommended tools and materials are given in each section. Equivalent items can be used.

C.

WARNINGS, CAUTIONS and NOTES

Copyright 2004 by: Radiant Power Corp., a HEICO Company

25-65-02

Page Intro-1 Sep 2010

RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER BPS7 (1) WARNINGS are provided before potentially dangerous procedures, materials, methods, and processes which must be followed precisely to avoid injury. (2) CAUTIONS are provided before procedures, materials, methods, and processes which must be followed precisely to avoid equipment damage. (3) NOTES are provided after applicable procedure steps when necessary to highlight or clarify information. 4.

General Safety Precautions The following general safety precautions must be observed during all phases of operation, service, and repair of the BPS.

ELECTROSTATIC DISCHARGE

GROUNDING

EXPLOSIVE ENVIRONMENT LIVE CIRCUITS

DO NOT SERVICE OR ADJUST ALONE

DO NOT SUBSTITUTE PARTS

SHOCK

.

Copyright 2004 by: Radiant Power Corp., a HEICO Company

ALL INTEGRATED CIRCUITS (ICS), SURFACES FOLLOW THE PCB HANDLING PROCEDURES GIVEN IN REPAIR TO AVOID ESD DAMAGE. CARELESS HANDLING DURING REPAIR CAN DRASTICALLY DECREASE THE COMPONENT LIFE. CONNECT EQUIPMENT AND PERSONNEL TO ELECTRICAL GROUND TO MINIMIZE SHOCK HAZARDS. WHEN HANDLING PCB ASSEMBLIES, PLACE THEM ON A GROUNDED WORKBENCH. DO NOT OPERATE THE BPS IN THE PRESENCE OF FLAMMABLE GASES OR FUMES. THE BPS CONTAINS HIGH VOLTAGE ELECTRICAL CIRCUITS. DO NOT SERVICE THE UNIT WITH THE POWER ON. TO AVOID INJURY, ALWAYS DISCONNECT POWER AND DISCHARGE THE CIRCUITS BEFORE MAINTENANCE. ONLY QUALIFIED MAINTENANCE PERSONNEL ARE AUTHORIZED TO REPLACE OR ADJUST INTERNAL COMPONENTS OF THE BPS. MAINTENANCE PERSONNEL MUST BE FAMILIAR WITH HIGH VOLTAGE EQUIPMENT SAFETY GUIDELINES. ANOTHER PERSON CAPABLE OF PROVIDING FIRST AID AND RESUSCITATION MUST BE PRESENT. DO NOT ALTER OR ADD TO THE MECHANICAL OR ELECTRICAL DESIGN OR MODIFY EQUIPMENT OF THE BPS. DESIGN CHANGES AND ADDITIONS CAN ALTER SAFETY CHARACTERISTICS AND CREATE A HAZARD. ANY DESIGN ALTERATIONS OR ADDITIONS WILL VOID THE WARRANTY. DO NOT INSTALL SUBSTITUTE PARTS OR DO ANY UNAUTHORIZED MODIFICATIONS TO THE EQUIPMENT. TO PREVENT ELECTRICAL DISCHARGE, DO NOT EXPOSE THE EQUIPMENT TO RAIN OR HIGH HUMIDITY. VISUALLY CHECK FOR PINCHED, OUT OF PLACE, OR FRAYED WIRING DURING MAINTENANCE. COMPONENTS AND/OR WIRING THAT APPEAR TO HAVE OVERHEATED OR ARE OTHERWISE DAMAGED SHOULD BE REPLACED WITH COMPONENTS THAT MEET THE ORIGINAL SPECIFICATIONS. DO A SAFETY CHECK OF THE ENTIRE UNIT BEFORE RETURNING THE EQUIPMENT FOR OPERATION

25-65-02

Page Intro-2 Jan 2012

RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER BPS7 5.

Verification Dates Procedure

6.

Date

Testing/Fault Isolation

Apr 28/82

Disassembly

Apr 28/82

Assembly

Apr 28/82

Revision Service Revised pages will be issued when necessary to correct errors or to add new configurations. The revised part of the page will be identified by a change bar or capital R in the left margin.

7.

Abbreviations and Unit Symbols Abbreviations and unit symbols used in this manual are defined below. All weights and measurements are given first in English standard units followed by the metric equivalent in parentheses. Assy ATA AWG BPS BT C C CAGE Cm CMM D DC EFF ESD F F F Fig. GND Hz IC ID IPL J K kg

Assembly Air Transport Association American Wire Gage Battery Power Supply Battery degree Celsius Capacitor Commercial And Government Entity centimeter Component Maintenance Manual Diode Direct Current Effectivity Electrostatic Discharge Farad Fuse degree Fahrenheit Figure Ground Hertz Integrated Circuit Inner Diameter Illustrated Parts List Jack Kilo kilogram (I kg = 2.205 lb.)

Copyright 2004 by: Radiant Power Corp., a HEICO Company

kPag lb. LRU M MEK mm N·m NHA NIST No. PCB P P/N psig Q R RF SB SCD SIT SPST SW UUT V VDC W

kiloPascal - gage (1 kPag 0. 145 psig) pound Line Replaceable Unit Mega Methyl-Ethyl-Ketone Millimeter Newton-meter (torque) Next Higher Assembly National Institute of Standards and Technology Number Printed Circuit Board Receptacle (Plug) Part Number pounds per square inch - gage Transistor Resistor Reference Service Bulletin Source Control Drawing Select In Test Single Pole, Single Throw Switch Unit Under Test Vendor Voltage, Direct Current Watt

25-65-02

Page Intro-3 Aug 2009

RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER BPS7

THIS PAGE INTENTIONALLY LEFT BLANK

Copyright 2004 by: Radiant Power Corp., a HEICO Company

25-65-02

Page Intro-4 Aug 2009

RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER BPS7

DESCRIPTION AND OPERATION 1.

Purpose A.

2.

The battery Power Supply (BPS) provides direct current (DC) power to operate emergency aircraft lights and the off-wing emergency escape system squib.

Primary Components A.

The primary components of the BPS are shown in Figure 1.

B.

The BPS consists of battery assembly BT1 and an electronics assembly mounted on aluminum chassis. The battery assembly and the electronics assembly are separate, fully contained modules that can be independently removed for repair or replacement.

C.

Battery assembly BT1 consists of six Nickel-Cadmium batteries mounted in a lightweight, durable plastic holder or case. The batteries are wired in series and connected to red and black pin sockets J2-1 and J2-2. The pin sockets connect directly to pin contacts J3-1 and J3-2 on PCB assembly A2 when the battery assembly is installed in the chassis against the electronics assembly. The battery assembly can easily be removed by disengaging two ¼-turn fasteners, then sliding the assembly out of the chassis away from the electronics assembly.

D.

The electronics assembly is made up of Printed Circuit Board (PCB) assemblies A1 and A2, connector J1, resistors R1 and R2 TEST switch SW1, and transistors Q1 and Q2. A cover assembly provides protection from moisture and handling damage. All electronic components including solder connections are conformal coated. The cover can easily be removed for maintenance access. The electronics assembly can also be removed from the chassis by removing the mounting screws, then sliding the assembly out of the chassis away from battery assembly BT1.

E.

All components except battery assembly BT1 are secured by standard attaching hardware. All wire connections are soldered. The chassis, cover assembly and other exposed aluminum components have a chemical film finish for protection from corrosion.

F.

A single 24-pin BACC45FN16-24P electrical connector provides the electrical interface with the aircraft. The connector mates to a BACC45FN16-24S receptacle. The interface circuits are described in Figures 2 and 3 and Table 1.

G.

The BPS is a Line Replaceable Unit (LRU). It mounts against a flat surface with fasteners through the four 0.192/0.203 inch (4.88/5.16 mm) diameter mounting holes in the chassis. It can be removed and replaced on the aircraft in less than 5 minutes without the use of special tools.

Copyright 2004 by: Radiant Power Corp., a HEICO Company

25-65-02

Page 1 Aug 2009

RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER BPS7 3.

Differences Between Configurations Battery power supply BPS7-3 is the current configuration. BPS7-2 is an obsolete configuration that should be upgraded in accordance with Service Bulletin 25-BPS7-2-1 when the units are opened for troubleshooting or repair to improve reliability and extend the service life. The upgrade will:

4.

A.

On serial numbers 376 and lower, add capacitor C15 to PCB assembly A2, or replace the PCB assembly with the current configuration (P/N 2006-2).

B.

On serial numbers 620 and lower, replace the dark-grey molybdenum plated self-locking nut (P/N NAS679C06M or NAS679A06) used to secure the solder lug to transistor Q2 with a silver plated nut (P/N NAS679C06 or MS21043-06).

C.

Replace obsolete battery assembly BT1 (P/N 2013-1) with battery assembly, P/N 20131A. Battery assembly 2013-1 can be used if desired, however, on both the BPS7-2 and BPS7- 3 configurations.

Functional Description (Figures 2 and 3) A.

The BPS supplements the aircraft main battery to operate the emergency aircraft lights and the off-wing emergency escape system squib. It monitors the main battery voltage, charges and maintains battery pack BT1, and discharges power when the main battery voltage drops below a threshold indicative of loss of battery power or electrical malfunction.

B.

When 22 to 32 VDC from the aircraft electrical system is present at connector J1, pin 2, transistor Q1 and charging circuits on PCB assembly A2 provide 300 to 375 mil-amperes constant charging current to the six-cell battery pack.

C.

The logic circuits on PCB assembly A1 monitor the main battery voltage and input signals from the three-position pilot control switch, a remote momentary contact test switch, and TEST switch SW1 mounted on the BPS (Figure 3). With the pilot control switch in the OFF position, the BPS will not discharge. In the ON position, the BPS output voltage will be 6.1 to 6.5 VDC at all times. If there is a fault condition or the switch is in the ARM position, the output voltage will be 6.1 to 6.5 VDC when the main battery voltage drops to 11 VDC for more than 1 second; otherwise, the output voltage will be zero.

D.

Momentarily pressing either test switch will turn on the emergency lights for 50 to 70 seconds. The test switches are provided to confirm circuit continuity, the condition of the emergency aircraft lights, and function of the BPS. It does not assure adequate battery capacity in an emergency.

E.

The logic circuits on PCB assembly A1 include a low battery cutoff circuit and a slow turn on feature. The low battery cutoff circuit senses battery voltage and automatically turns the BPS off when the voltage drops to 5.4 VDC minimum. This avoids deep discharging of the batteries, a condition that can result in cell reversal and permanent battery damage. Once the BPS has been shut-off due to low battery voltage, an under voltage latch prevents reset and operation of the BPS until 28VDC power is again present at connector J1, pin 2 and the pilot's control switch is set to the ON or ARM position.

Copyright 2004 by: Radiant Power Corp., a HEICO Company

25-65-02

Page 2 Aug 2009

RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER BPS7

F.

The slow turn-on feature limits the lamp inrush current to prolong the life of the aircraft emergency lights.

G.

The regulator circuits on PCB assembly A2 maintain the output voltage across the emergency lights to between 6.1 and 6.5 VDC when the load is 7.0 Amperes.

Copyright 2004 by: Radiant Power Corp., a HEICO Company

25-65-02

Page 3 Aug 2009

RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER BPS7

Battery Power Supply Figure 1

Copyright 2004 by: Radiant Power Corp., a HEICO Company

25-65-02

Page 4 Aug 2009

RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER BPS7

Aircraft Interface Diagram Figure 2 (Sheet 1 of 2)

Copyright 2004 by: Radiant Power Corp., a HEICO Company

25-65-02

Page 5 Aug 2009

RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER BPS7

Aircraft Interface Diagram Figure 2 (Sheet 2)

Copyright 2004 by: Radiant Power Corp., a HEICO Company

25-65-02

Page 6 Aug 2009

RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER BPS7

Circuit Schematic Figure 3 (Sheet 1 of 3)

Copyright 2004 by: Radiant Power Corp., a HEICO Company

25-65-02

Page 7 Aug 2009

RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER BPS7

Circuit Schematic Figure 3 (Sheet 2 of 3)

Copyright 2004 by: Radiant Power Corp., a HEICO Company

25-65-02

Page 8 Aug 2009

RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER BPS7

Circuit Schematic Figure 3 (Sheet 3 of 3)

Copyright 2004 by: Radiant Power Corp., a HEICO Company

25-65-02

Page 9 Aug 2009

RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER BPS7

5.

6.

H.

The batteries are high temperature, matched D-size nickel-cadmium cells with higher voltage electrolyte and lower internal resistance than normally available. Each cell is rated 1.25 VDC at 149°F (65°C) and 3.5 ampere-hours (minimum) when discharged at the one hour one-hour or C rate. The cells are connected in series by solder tabs, forming a 7.5 VDC (nominal) battery. The battery pack provides sufficient power to sustain, through the control circuits, a 7 Ampere lamp load at 6.1 to 6.5 VDC for a minimum of 15 minutes or to fire two of the emergency escape system squibs connected in parallel with 30 millisecond, 5 volt square wave pulses. Under worst-case conditions, the BPS has enough battery capacity to meet the requirements of FAR 25.812.

I.

Fuses F1 through F4 (310, IPL Figure 1) limit the output voltage at pins 9 through 16 of connector J1 to 5 Amperes.

Operation A.

To charge the BPS, continuously apply 22-32 VDC voltage (28 VDC nominal) across pins 2(+) and 1(-) of connector J1. A fully discharged battery pack will charge from 0% of full capacity to 100% in less than 16 hours at 77°F (25°C).

B.

Set the pilot control switch to the proper position to discharge the BPS. With the switch in the OFF position, the BPS will not discharge. In the ON position, the BPS output voltage will be 6.1 to 6.5 VDC at all times. If there is a fault condition or the pilot switch is in the ARM position, the output voltage will be 6.1 to 6.5 VDC when the main battery voltage drops to 11 VDC for more than 1 second; otherwise, the output voltage will be zero.

C.

Momentarily press the remote test switch or TEST switch SW1 on the BPS to turn on the emergency lights for 50 to 70 seconds. A successful test will indicate that the BPS is functioning properly and is connected correctly in the circuit, and the emergency lights are functioning properly The test will also show that the BPS is charged sufficiently to turn on the emergency lights, but it will not show adequate battery capacity for the 15 minutes duration required by Boeing specification S283T014.

Technical Properties Technical properties of the BPS are given in Table 1. Technical Properties Table 1 (Sheet 1 of 2) Property Description Manufacturer Nomenclature Part Number Radiant Power Corp. Boeing

Copyright 2004 by: Radiant Power Corp., a HEICO Company

Specification Radiant Power Corp. Battery Power Supply (BPS) BPS7-2, BPS7-3 S283T014-2, S283T014-3

25-65-02

Page 10 Aug 2009

RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER BPS7

Technical Properties Table 1 (Sheet 2 of 2) Property Functional Properties Input Power Output Power Voltage Emergency Lights Emergency Escape System Squibs Full Charge Battery Voltage Low Battery Cutoff Voltage Current Output Charging Charging Time

Battery Pack Data Number of Batteries Battery Type Rating Fully-Charged Voltage Insulation Resistance Removal and Replacement Time Electrical Connector Mating Connector Dimensions and Weight Overall Dimensions Height Width Overall Between Mounting Hole Centerlines Length Overall Between Mounting Hole Centerlines Diameter of Mounting Holes (4 Places) Weight Battery Holder Assembly Battery Charger Assembly

Copyright 2004 by: Radiant Power Corp., a HEICO Company

Specification

22.0 to 29.5 VDC (28 VDC nominal) 6.1 to 6.5 VDC for 15 minutes for each of eight emergency lights. 30 millisecond, 5 volt square wave pulses to fire two squibs, connected in parallel. 7.5 VDC nominal 5.4 VDC minimum Limited to 5 Amperes by Fuses F1, F2, F3 and F4 300 to 375 mil-amperes at 22 to 32 VDC input voltage Charge from 0% of full capacity to 100% in less than 16 hours at 77°F (25°C) 6 connected in series Nickel-Cadmium 3.5 ampere-hours 1.25 VDC at 149°F (65°C) 100 meg-ohms minimum at 500 VDC 5 minutes maximum with no special tools BACC45FN1 6-24P BACC45FN1 6-24S

2.0 inches (5.1 cm) maximum 3.5 inches (8.9 cm) maximum 2.700 ±0.01 0 inches (6,858 ±0,025 cm) 10.7 inches (27.2 cm) maximum 10. 100 ±0.01 0 inches (25.654 ±0.025 cm) 0.192/0.203 inch (4.88/5.16 mm) 2.3 lbs (1.05 kg) maximum 0.94 lbs (0.43 kg) maximum

25-65-02

Page 11 Sep 2010

RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER BPS7

THIS PAGE INTENTIONALLY LEFT BLANK

Copyright 2004 by: Radiant Power Corp., a HEICO Company

25-65-02

Page 12 Aug 2009

RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER BPS7

TESTING AND FAULT ISOLATION 1.

General A.

This section contains bench test and fault isolation procedures (starting this page), recommended battery maintenance procedures (page 114) and optional on-aircraft fault testing (page 122).

B.

Perform the tests in the order given before disassembly to identify damaged parts. Perform the tests after assembly to select the Select in Test (SIT) components and to verify performance. Paragraph 2 3 4 5 6 7 8

C.

Procedure INSULATION RESISTANCE TEST CONTROL LOGIC TEST ONE MINUTE TEST SWITCH TEST LOW BATTERY CUT-OFF AND RESET TEST CHARGING TEST SQUIB FIRING AND BATTERY DISCHARGE TEST FAULT ISOLATION PROCEDURES

The recommended test equipment and materials are given in Table 101. NOTE: Equivalent items can be used.

D.

All tests must be performed at standard laboratory conditions, defined as follows: Ambient Temperature: 73º 5º F (22.8º±2.8º C) Relative Humidity: 35% to 65% Maximum Atmospheric Pressure: 25 to 32 in Hg

E.

All test equipment must be calibrated to NIST (National Institute of Standards and Technology) standards.

F.

Unless otherwise specified, the primary power applied to the test unit is 28 ±0.5 VDC.

Copyright 2004 by: Radiant Power Corp., a HEICO Company

25-65-02

Page 101 Sep 2010

RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER BPS7 Test Equipment and Materials Table 101 Nomenclature Connector, Electrical Function Generator, 5V, 0.2 Amp, 30 millisecond Square Wave Lamp, Incandescent (Test Load) (7 Required) Meg-ohmmeter, 100 meg-ohms, 500 VDC, ±2% Full Scale Multi-meter (Ohmmeter, Ammeter or Voltmeter can be used), 0 to 10 Amps DC (±2% Full Scale), 0 to 100 VDC (3-1/2 digits) 200 to 300 kilo-ohms Oscilloscope, Digital Storage, TwoChannel Power Supply, 0 to 12 VDC min/ 25A min (E1) Power Supply, 0 to 32 VDC min/ 2A min (E2) Resistor, 47.5 1 W, 1 % 4.75 5W, 1% 0.47 100W, 10% Switch, Momentary Contact, SPST (S1) Switch, Toggle SPST (S2, S3, S4) (3 Required) Transistor Transistor Wire, Electrical, 16/18 AWG BPS7-3 Battery Housing Analyzer Kit

Part or Specification Number BACC45FN16-24S or 48-16R16-24S

The Boeing Co. (81205) Amphenol Corp. (77820)

Model 1400

Krohn-Hite Corp. (88865)

No. 82

General Electric Co. (0EE74)

Model 1644-9701

Quadtech Inc. (0PK96)

Model 8010A, 8012A, 77 or 85 III

John Fluke Mfg. Co., Inc. (89536)

34401A

Hewlett-Packard Co. (28480)

54504A-E01/910 DL1540 Model DCR40-25B2 Model 1692 Model DCR40-25B2 Model 1601

Hewlett-Packard Co. (28480) Yokogawa (60336) Sorensen BK Precision (0GXY1) Sorensen BK Precision (0GXY1)

Source (CAGE)*

RWR81S47R5FR RWR74S4R75FR RE77GR470

Commercially Available

---

Commercially Available

---

Commercially Available

JANTX2N3055 JANTX2N4399 BMS13-48C or MIL-W-22759 550-13058-00

Commercially Available Commercially Available Commercially Available Radiant Power Corp. (1MXA1)

*Refer to Table 1001 in the IPL for the address.

Copyright 2004 by: Radiant Power Corp., a HEICO Company

25-65-02

Page 102 Jan 2012

RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER BPS7 2.

Insulation Resistance Test WARNING: THIS TEST APPLIES HIGH VOLTAGE WHICH CAN CAUSE DEATH OR SEVERE SHOCK SET POWER SWITCHES TO OFF BEFORE CONNECTING AND DISCONNECTING EQUIPMENT USE CAUTION DURING TEST CAUTION: BATTERY ASSEMBLY BT1 MUST BE REMOVED FROM THE UUT BEFORE THIS TEST THIS TEST CAN DAMAGE THE BATTERY CELLS. A.

Remove battery assembly BT1 (445 or 445A, IPL Figure 1), as follows: (1) Turn the 1/4-turn fasteners (450 or 450A) counterclockwise approximately 90° to the stop. The fastener should retract from the force of the retraction spring (465). CAUTION: DO NOT LIFT BATTERY ASSEMBLY BT1 BEFORE SLIDING IT AWAY FROM THE ELECTRONICS ASSEMBLY. DOING SO CAN DAMAGE THE PIN CONTACTS ON PCB ASSEMBLY A2. (2) Carefully slide battery assembly BT1 (445 or 445A) out away from the electronics assembly (40) to disconnect pin contacts J3-1 and J3-2 on PCB assembly A2 (205) from pin sockets J2-1 and J2-2 (535 and 540). Remove battery assembly BT1.

B.

Connect a meg-ohmmeter (Table 101) between the connector J1, pin 1, and the chassis assembly (400).

C.

Apply 500 ±10 VDC. Hold the voltage for 30 seconds or until the resistance reading stabilizes, and measure the insulation resistance. •

3.

The insulation resistance must be 100 meg-ohms; minimum.

D.

Repeat the test between all connector J1 pins and the chassis except for pin J1-7.

E.

Decrease the voltage to zero.

Control Logic Test CAUTION: BATTERY ASSEMBLY, BT1, MUST BE REMOVED FROM THE UUT BEFORE THIS TEST! THIS TEST CAN DAMAGE THE BATTERY CELLS! A.

Remove battery assembly, BT1 (445 or 445A, IPL Figure 1), as follows: (1) Turn the 1/4-turn fasteners (450 or 450A) counterclockwise approximately 90° to the stop. The fastener should retract from the force of the retraction spring (465). CAUTION: DO NOT LIFT BATTERY ASSEMBLY BT1 BEFORE SLIDING IT AWAY FROM THE ELECTRONICS ASSEMBLY. DOING SO CAN DAMAGE THE PIN CONTACTS ON PCB ASSEMBLY A2. (2) Carefully slide battery assembly BT1 (445 or 445A) out away from the electronics assembly (40) to disconnect pin contacts J3-1 and J3-2 on PCB assembly A2 (205) from pin sockets J2-1 and J2-2 (535 and 540). Remove battery assembly BT1.

Copyright 2004 by: Radiant Power Corp., a HEICO Company

25-65-02

Page 103 Aug 2009

RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER BPS7 B.

Install the Unit Under Test (UUT) in the test setup (Figure 101, shown on next page). Connect power supply E1 at connector J2, pins 1 (+) and 2(-) (535 and 540). Do not connect the squib firing test circuit at connector J1, pin 18.

C.

Turn on power supply E1. Set E1 to 8 VDC.

CAUTION: DO NOT APPLY MORE THAN 12.0 VDC AT CONNECTOR J2, PINS 1(+) AND 2(-). HIGH VOLTAGE CAN DAMAGE THE UUT NOTE: A momentary drop in the DC power supply voltage when the lamp load is initially applied can cause the UUT to go into low battery cutoff. Preloading the power supply will prevent the cutoff. The amount of preload will vary depending on the DC power supply used. D.

Close switch S1.

E.

Perform tests 1 through 8 in Table 102. Adjust power supply E2 as specified. Measure the output voltage at test points A(+) and C(-) (Figure 101). •

F.

The output voltage must be as specified in Table 102.

Decrease the voltage to zero. Control Logic Test Requirements Table 102

Test

Switch S2 Position (J1-3)

Switch S3 Position (J1-4)

Power Supply E2 Voltage (J1-2)

Output Voltage Across Test Points A(+) and C(-) (J1-9 thru J1-15)

1

Closed

Closed

11.0 VDC

No Voltage

2

Closed

Closed

28.0 VDC

No Voltage

3

Open

Closed

11.0 VDC

6.1 to 6.5 VDC

4

Open

Closed

28.0 VDC

6.1 to 6.5 VDC

5

Closed

Open

11.0 VDC

6.1 to 6.5 VDC After 1 Sec. Delay

6

Closed

Open

28.0 VDC

No Voltage

7

Open

Open

11.0 VDC

6.1 to 6.5 VDC After 1 Sec. Delay

8

Open

Open

28.0 VDC

No Voltage

Copyright 2004 by: Radiant Power Corp., a HEICO Company

25-65-02

Page 104 Aug 2009

RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER BPS7

Bench Test Setup Figure 101

Copyright 2004 by: Radiant Power Corp., a HEICO Company

25-65-02

Page 105 Aug 2009

RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER BPS7 4.

One Minute Test Switch Test A.

Install the UUT in the test setup (Figure 101). Connect power supply E1 at connector J2, pins 1(+) and 2(-) (535 and 540, IPL Figure 1). Do not connect the squib firing test circuit at connector J1, pin 18.

B.

Turn on power supply E2 and set it to 28 ± 1 VDC. Close switch S1.

C.

Close switches S2 and S3.

D.

Momentarily push TEST switch SW1 on the side of the UUT •

E.

Open switches S2 and S3.

F.

Momentarily close switch S4. •

G. 5.

The test lamps must turn on and stay on for 60±10 seconds.

The test lamps must turn on and stay on for 60±10 seconds.

Turn off power supply E2.

Low Battery Cut-Off and Reset Test A.

Install the UUT in the test setup (Figure 101). Connect power supply E1 at connector J2, pins 1 (+) and 2 (-) (535 and 540, IPL Figure 1). Do not connect the squib firing test circuit at connector J1, pin 18.

B.

Close switches S2 and S3. Open switch S1. •

All test lamps must be off.

C.

Turn on power supply E2 and set it to 28 ±1VDC. Close switch S1.

D.

Turn on power supply E1 and set it to 8 VDC.

E.

Open switch S2. •

F.

Open switch S1. •

G.

All test lamps must stay on.

Slowly decrease the voltage at power supply E1 until the test lamps turn off. Measure the voltage. •

H.

All test lamps must turn on.

The voltage must be no lower than 5.4 VDC.

Increase the voltage at power supply E1 to 8 VDC. •

The test lamps must stay off.

Copyright 2004 by: Radiant Power Corp., a HEICO Company

25-65-02

Page 106 Aug 2009

RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER BPS7 I.

Close switches S1 and S2, then open switch S2. •

J. 6.

The lamps must turn on only after switch S2 is opened.

Decrease the voltage to zero.

Charging Test A.

Install the UUT in the test setup (Figure 101). Do not connect the squib firing test circuit at connector J1, pin 18.

B.

Disconnect power supply E1 at connector J2, pins 1 (+) and 2(-) (535 and 540, IPL Figure 1).

C.

Install battery assembly BT1 (445 or 445A), as follows: NOTE: Battery assembly BT1 must be fully charged. (1) Insert battery assembly BT1 (445 or 445A) into the chassis assembly (400). (2) Press battery assembly BT1 (445 or 445A) against the chassis and carefully slide it inward to insert pin contacts J3-1 and J3-2 on PCB assembly A2 (205) into pin sockets J2-1 and J2-2 (535 and 540). CAUTION: DO NOT TURN THE 1/4 TURN FASTENERS PAST THE DETENT. (3) Turn the 1/4-turn fasteners (450 or 450A) clockwise approximately 90° to the stop. An audible click will be heard when the stop is reached. The fasteners should compress the retraction springs (465).

D.

Close switches S2 and S3.

E.

Turn on power supply E2 and set it to 22 VDC. Close switch S1.

F.

Measure the current at test point I1. •

G.

Set power supply E2 to 32 VDC. Measure the current at test point I1. •

H. 7.

The charging current must be between 300 and 375 mil-amperes.

The charging current must be between 300 and 375 mil-amperes.

Decrease the voltage to zero.

Squib Firing and Battery Discharge Test A.

Install the UUT in the test setup (Figure 101).

B.

A fully charged battery assembly must be installed. Refer to paragraph 6.C, above, if necessary to install battery assembly BT1.

Copyright 2004 by: Radiant Power Corp., a HEICO Company

25-65-02

Page 107 Aug 2009

RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER BPS7 C.

Connect the squib firing test circuit at connector J1, pin 18. Disconnect the load circuits at connector J1, pins 9 through 15.

D.

Open switch S1. Close switches S2 and S3.

E.

Setup the function generator to output a 5V, 0.2 Amp, 30-millisecond square wave. Measure the output voltage across connector J1, pin 18 and 1. •

The output voltage must be 6.0 VDC minimum.

F.

Turn off the function generator.

G.

Disconnect the squib firing test circuit at connector J1, pin 18. Connect the load circuits at connector J1, pins 9 through 15.

H.

Turn on power supply E2 and set it to 28 ±1 VDC. Close switch S1.

I.

Open switch S3, then open switch S1. •

J.

All test lamps must turn on.

Measure the output voltage across test points A(+) and C(-). •

All test lamps must stay on for 15 minutes minimum.

•

The output voltage must be between 6.1 and 6.5 VDC for 15 minutes.

K.

Decrease the voltage to zero.

L.

If there was insufficient battery capacity or a low open circuit voltage, the battery assembly should be cycled as follows and then retested. If the test fails again, all six batteries should be replaced in accordance with disassembly and assembly instructions. (1) Close switches S2 and S3. (2) Turn on power supply E2 and set it to 22 VDC. Close switch S1. Measure the current at test point I1. •

The charging current must be between 300 and 375 mil-amperes.

(3) Charge the UUT at 350 mil-amperes for 16 to 24 hours. (4) Open switch S1. (5) Discharge the battery assembly into a 7-Ampere load until it reaches the cutoff voltage. (6) Recharge the battery for 16 hours. M.

Disconnect and remove the UUT

Copyright 2004 by: Radiant Power Corp., a HEICO Company

25-65-02

Page 108 Aug 2009

RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER BPS7 N. 8.

Refer to ASSEMBLY for final assembly instructions.

Fault Isolation Procedures A.

Fault isolation procedures for the tests given in this section are provided in Table 103. The procedures isolate faults to the board level only. With exception of the SIT components identified in the IPL, Radiant Power Corp. recommends that the PCB assemblies be returned to Radiant Power Corp. for repair by technicians familiar with the layout and function of the card. Radiant Power Corp does not assume responsibility for any repairs and/or maintenance performed and parts and/or sub-assemblies which is not in accordance to procedures described in this manual.

B.

Any test procedure step that does not pass is considered a failure. After fault isolation and replacement of the damaged component, repeat the entire test procedure to verify that the problem has been corrected.

C.

The most likely failure mode in the unit is one or all of the output line fuses being blown. These are F1, F2, F3, and F4, which are 5 amp “Pico” fuses (310, IPL Figure 1). The fuses are located between the battery pack and the electronics “brick”. Remove the battery pack according to the normal procedure to access the fuses. The four fuses are located as shown below.

Copyright 2004 by: Radiant Power Corp., a HEICO Company

25-65-02

Page 109 Jan 2012

RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER BPS7

FUSES listed from top to bottom: F1, F2, F3, F4. Each fuse is inserted into a socket, and can be removed and re-inserted with needle nose pliers.

Warning: If the unit has a blown fuse, then the most likely cause is a wiring, or electrical short on the aircraft. The aircraft wiring must be investigated to determine the cause of the failure. The maximum load for each output line is 2.5 amps. Do not reinstall the BPS7-3 on the aircraft until the cause of the fuse failure is determined. Bend replacement fuses as shown below

Figure 109

Copyright 2004 by: Radiant Power Corp., a HEICO Company

25-65-02

Page 110 Aug 2009

RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER BPS7 Fault Isolation Procedures Table 103 (Sheet 1 of 3) Trouble

Probable Cause

Corrective Action

Cut or cracked wire insulation; open or short circuit or solder connection; solder flux path to ground.

Check the wire circuits, solder connections, and pin and socket contacts for damage; verify wire routing per ASSEMBLY, Table 702 and DESCRIPTION AND OPERATION, Figure 3; refer to REPAIR to replace damaged pin contacts in connector J1. Dry the UUT thoroughly with compressed shop air; examine the unit carefully for corrosion or other moisture damage.

INSULATION RESISTANCE TEST

The insulation resistance is not as specified.

Excessive moisture inside the cover assembly (10A or 10B, IPL Figure 1). CONTROL LOGIC TEST

The UUT did not turn off (no output voltage) in tests 1 and 2 in Table 102. The UUT did not turn on (output voltage) in tests 3, 4, 5 and 7 in Table 102.

The UUT did not turn off (no output voltage) in tests 6 and 8 in Table 102.

Damaged component in test switch circuit on PCB assembly A1 (85). One or more fuses blown, possibly F1, F2, F3, F4.

Replace PCB assembly A1 (85).

Damaged transistor Q2 (350) or damaged component in regulator circuit on PCB assembly A2 (205). Damaged component in logic output or low voltage disconnect circuits on PCB assembly A1 (85). Damaged component in 28 VDC sensing circuit on PCB assembly A1 (85).

Replace the damaged component.

One or more fuses blown, possibly F1, F2, F3, F4.

Check if F1, F2, F3, F4 (310) is blown with a continuity meter. Replace as necessary.

Check if F1, F2, F3, F4 (310) is blown with a continuity meter. Replace as necessary.

Replace PCB assembly A1 (85).

Replace PCB assembly A1 (85).

ONE MINUTE TEST-SWITCH TEST

The test lamps do not turn on or stay on for the time specified (para. 4.D, Step (4).

Copyright 2004 by: Radiant Power Corp., a HEICO Company

25-65-02

Page 111 Aug 2009

RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER BPS7 Fault Isolation Procedure Table 1 (Sheet 2 of 3)

Trouble

Probable Cause

ONE MINUTE TEST-SWITCH TEST

(Cont’d)

The test lamps do not turn on or stay on for the time specified (para. 4.F, Step (6)).

LOW BATTERY CUTOFF AND RESET TEST All test lamps do not turn on and stay on [para. 5.E, Steps (5) and (6)].

The low battery cutoff voltage is lower than specified para. 5.G, Step (7). All test lamps do not turn on as specified [para. 5.L, Steps (8) and (9)].

The low battery cutoff voltage is lower than specified [para. 5.G, Step (7)]. All test lamps do not turn on as specified (para. 5.L, Steps (8) and (9)).

Corrective Action

Damaged TEST switch SW1 (70) or solder lug (75). One or more fuses blown, possibly F1, F2, F3, F4.

Replace the damaged component

Damaged component in test switch circuit on PCB assembly A1 (85).

Replace PCB assembly A1 (85).

One or more fuses blown, possibly F1, F2, F3, F4.

Check if F1, F2, F3, F4 (310) is blown with a continuity meter. Replace as necessary

Damaged component in test switch circuit on PCB assembly A1 (85). Damaged component in control logic circuit on PCB assembly A1 (85).

Replace PCB assembly A1 (85).

One or more fuses blown, possibly F1, F2, F3, F4.

Check if F1, F2, F3, F4 (310) is blown, with a continuity meter. Replace as necessary.

Damaged component in low voltage disconnect circuit on PCB assembly A1 (85). Damaged component in control logic circuit on PCB assembly A1 (85).

Replace PCB assembly A1 (85).

One or more fuses blown, possibly F1, F2, F3, F4.

Check if F1, F2, F3, F4 (310) is blown with a continuity meter. Replace as necessary.

Damaged component in low voltage disconnect circuit on PCB assembly A1 (85).

Replace PCB assembly A1 (85).

Copyright 2004 by: Radiant Power Corp., a HEICO Company

Check if F1, F2, F3, F4 (310) is blown with a continuity meter. Replace as necessary.

Replace PCB assembly A1 (85).

Replace PCB assembly A1 (85).

25-65-02

Page 112 Aug 2009

RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER BPS7 Fault Isolation Procedure Table 1 (Sheet 3 of 3)

Trouble

9.

Probable Cause

Corrective Action

CHARGING TEST

The charging current is not as specified [para. 6.F & G, Steps (6) and (7)].

SQUIB FIRING AND BATTERY DISCHARGE TEST The output voltage is not as specified [para. 7.E, I, J, Step (5)].

The output voltage is not as specified and the test lamps do not stay on for the time specified [para. 2.F, Step (5)].

Damaged or improperly installed battery assembly BT1 (445 or 445A).

Reinstall battery assembly BT1 (445 or 445A) and make sure connector pins J2-1 and J2-2 are inserted fully into the sockets; if the test fails again, disassemble and repair the battery assembly.

One or more fuses blown, possibly F1, F2, F3, F4.

Check if F1, F2, F3, F4 (310) is blown, with a continuity meter. Replace as necessary. Replace transistor Q2 (350).

Damaged transistor Q2 (350). Damaged component in regulator circuit on PCB assembly A2 (205). Battery assembly BT1 (445 or 445A) requires cycling.

Battery assembly BT1 (445 or 445A) has a damaged battery cell or circuit. Damaged transistor Q2 (350). Damaged component in regulator circuit on PCB assembly A2 (205).

Copyright 2004 by: Radiant Power Corp., a HEICO Company

Replace PCB assembly A2 (205).

Refer to paragraph 7L to cycle battery assembly BT1.

Repair or replace battery assembly BT1 (445 or 445A). Replace transistor Q2 (350). Replace PCB assembly A2 (205).

25-65-02

Page 113 Aug 2009

RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER BPS7 BATTERY MAINTENANCE 1.

2.

General A.

Testing schedule and procedure should be in accordance with the operator’s procedures approved by a certification authority. If an operator wishes guidance on changing the intervals from the operator’s previously established intervals, the operator may contact Radiant Power or the aircraft manufacturer for specific recommendations.

B.

This section also includes sample methods for battery charging and storage when batteries are to be returned to immediately-dispatched aircraft. Because the Emergency Passenger Egress Lighting Systems are must-work systems for aircraft dispatch, the operators should assure that the batteries installed on the aircraft have enough charge to power the emergency lights. The sample procedures provide the guidance for operators’ procedures.

New Stock Maintenance Exemption A.

New stock purchased from Radiant or Radiant’s authorized distributors has a seven year no-maintenance-required shelf life for the electronics and 38 month no-maintenancerequired shelf life for the battery pack and batteries. If the components remain in the purchaser’s stock beyond the shelf life, simple inspections, testing, or conditioning may be required. Testing and conditioning may be done at the discretion of the purchaser in accordance with their procedures based on their previous experience with parts in long-term storage.

3.

Battery Pack Removal Recommendations Removal and Bench Testing Removal and bench-testing of 2013-1A Battery Packs is suggested at 18-month intervals for most operators of large commercial transport aircraft or similar aircraft applications. The battery capacity test is normally done with a fully charged battery pack.

4.

On-Aircraft Testing/Maintenance A.

BPS7-3 systems should be tested periodically on-aircraft to remove built-up “memory effect”. For operators seeking new procedures or using new type aircraft, the following sample procedure explains what a procedure may include. The operator may also contact Radiant Power or the aircraft manufacturer for specific recommendations.

Copyright 2004 by: Radiant Power Corp., a HEICO Company

25-65-02

Page 114 Aug 2009

RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER BPS7 B.

Sample On-Aircraft Testing/Maintenance Procedure (1) Three times per year, the lighting system is tested for a period of 10 minutes minimum, 15 minutes maximum. (2) At the end of the illumination period, the aircraft electrical system is powered for at least 3.5 hours before the next gate departure to recharge the batteries. Acceptance criteria of 1: Observation (that is, no numerical data required; only need mechanic signoff that lighting system was turned on for 10-15 minutes). Acceptance criteria of 2: Observation or aircraft schedule (that is, no numerical data required; only need signoff that ground power was applied to aircraft or the aircraft was powered for 3.5 hours before gate departure).

C.

Commentaries (1) Acceptance Criteria (2) Memory Effect

Copyright 2004 by: Radiant Power Corp., a HEICO Company

25-65-02

Page 115 Aug 2009

RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER BPS7

Acceptance Criteria commentary: The intention of the acceptance criteria is to minimize the burden put on the operators. All that is supposed to happen is that the mechanic turns on lights for 10-15 minutes and the batteries get recharged for 3-1/2 hours. The emergency lighting system load is 7 Amperes and it must run for 10 minutes by FAR requirement. This corresponds to 7 A x 1/6 hour = 1.16 A-hr. The charging rate on the BPS73 is 0.35A so it takes 1.16/0.35 = 3.3 hours to replenish the battery with the minimum amount of energy required. Normal aircraft operations will completely “top-off” the batteries. Neither the 10-15 minute time, nor the 3-1/2 hour time is critical. There is a reasonable expectation that if the times are slightly shorter or longer than required the system would maintain its flight-readiness. For example, the batteries will still have more reserve energy after the 10-15 minute discharge because the batteries have a relatively high capacity relative to the FAR requirements. Thus, if the recharge time is only 3 hours, the battery capacity will meet the FAR requirements with the combination of the recharge energy and reserve energy. If the aircraft schedule is such that it is powered for at least 3-1/2 hours before departure, the batteries will be recharged. For example, if the mechanics schedule the 10-minute test at the beginning of another maintenance activity, and then recharge the batteries (by having ground power applied to the aircraft) while continuing the maintenance activity, the batteries will have the required energy. There is no need to record the time intervals, just simply note that the aircraft was powered for at least the minimum interval. In another example, if the 10-minute test is done as soon as the passengers deplane from the last flight of the day, and the operator knows that the aircraft will be powered for another 2 hours during normal cabin cleaning and atgate maintenance tasks, plus the aircraft will be powered up for 1-1.2 hours in the morning before the first departure, the “schedule” criteria is met. No data needs to be recorded other than that the battery was recharged in accordance with a schedule that would provide the recharge time.

Copyright 2004 by: Radiant Power Corp., a HEICO Company

25-65-02

Page 116 Aug 2009

RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER BPS7

Engineering commentary – “Memory Effect”:

Nickel Cadmium batteries exhibit a characteristic called “battery memory”. Battery memory makes good cells appear to have less capacity than they should. Continuously charging a battery or partially discharging a battery causes battery memory. Battery memory is worse at high ambient temperatures. Battery memory is removed by periodically discharging the batteries. The discharge process removes the battery memory down to the level of discharge. Deep-cycling batteries (which can only be done on the bench because the battery undervoltage protection circuit in the BPS7 needs to be defeated) completely removes all memory-effect residue and reconditions the battery to its maximum capacity.

> 10 min.

>15 min.

> 30 min. 2-3 min.

New Battery (over 30 minutes run time)

"Memory Effect" (2-3 minutes of run time)

After On-Board Maintenance (at least 10 minutes of run time)

After Bench Testing/ Deep-cycling (maximum run time, based on battery lifetime, no memoryaffected areas)

Prime Power (battery capacity not affected by memory) Usable Power (mixed normal and memory-affected areas of battery)

Power not available (memory-effect has made battery voltage too low)

"W orn-out" area of battery (due to battery life time)

Memory Effect Figure 106

Copyright 2004 by: Radiant Power Corp., a HEICO Company

25-65-02

Page 117 Sep 2010

RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER BPS7

Date Code Locations Figure 107

Copyright 2004 by: Radiant Power Corp., a HEICO Company

25-65-02

Page 118 Sep 2010

RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER BPS7 5.

Charging Batteries for Return-to-Service If a stored Battery Pack is to be installed on an aircraft that is returning to service, the Battery Pack must be charged before the aircraft is deemed ready for passenger service. That is, a fully discharged battery pack will not meet the requirements of US FAA FAR 25.812 paragraph (i), which requires that the Battery Pack must provide 2q0 minutes worth of energy. Charging of the Battery Pack may be accomplished in different ways. Some samples are listed below: A.

Charge on-aircraft for at least 6 hours. Six hours is the time in which completely discharged batteries will absorb the minimum amount of energy required to meet the 10 minutes FAR requirement. Charging is accomplished by aircraft ground power, aircraft idling, or aircraft ferrying. Battery packs in this condition are not fully charged, but do contain enough energy to meet the requirements; the batteries will be fully charged during normal aircraft operations of the first flight day.

B.

Charge on bench for 16 hours at nominal current (330-370 mA) within the 31 days previous to the installation on the aircraft and maintain the stored batteries at an average room temperature. Average room temperature simply means a controlled environment; no monitoring of temperature is required because failure of environmental controls will be obvious to personnel working in the area.

C.

Charge on bench for 16 hours at nominal current (330-370 mA) within the 123 days previous to the installation on the aircraft and maintain the stored batteries at an average refrigerator temperature. Average refrigerator temperature simply means the normal controlled environment of a home or industrial refrigerator (0°C to +5°C/32°F to 41°F); no monitoring of temperature is required because failure of environmental controls will be obvious to personnel working in the area.

D.

Fast-charge on bench for 20 minutes at high rate current (5 A) before installation on aircraft. This procedure is used when an immediate dispatch of the aircraft is required and no previously charged stored batteries exist. Radiant Power and other manufacturers can provide dedicated equipment to perform this function. This procedure should be done only with dedicated test equipment or specially trained operators because the battery voltage and temperature must be monitored continuously during the fast charge.

Operators may provide alternative or additional charging and testing procedures if desired. These other procedures may be done to provide consistent maintenance or battery-shop procedures between aircraft types, for example. Specific recommendations can be provided from Radiant Power or the aircraft manufacturer.

Copyright 2004 by: Radiant Power Corp., a HEICO Company

25-65-02

Page 119 Aug 2009

RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER BPS7 Sample Storage/Change Options for Batteries Returning to Service on Passenger Aircraft 123 Days maximum

31 Days maximum

Charge on Bench @ 350 mA for 16 hours; store in refrigerator

Charge on Bench @ 350 mA for 16 hours; store at room temperature

6.

6 hours minimum Charge on Aircraft

20 minutes Fast Charge on Bench @5A

Battery Charging Procedure The purpose of this section to provide new users with typical procedures for bench charging. Established users should use their approved procedures. A.

Use a power supply with a minimum voltage of 12 volts and an adjustable current limit. Hook up the power supply, meters, etc., as shown on the drawing below. DO NOT HOOK UP THE BATTERY PACK YET!

Battery Charging Figure 103 B.

Adjust the output voltage to 10 volts for every battery pack that is in series, and turn the current limit all the way down. Now hook up the battery pack. Adjust the current limit on the power supply to 350 milliamps +/-20 milliamps. Leave the batteries charging for 1520 hours (16 hours nominal). After the 16 hours of charge disconnect the battery from the charger. Measure the battery pack voltage with a meter and ensure that the battery has fully charged to a normal value of 7.5 to 8.8 volts.

Copyright 2004 by: Radiant Power Corp., a HEICO Company

25-65-02

Page 120 Jan 2012

RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER BPS7 Number of battery packs Voltage Current

7.

1

2

3

4

5

10 volts 350 milliamps

20 volts 350 milliamps

30 volts 350 milliamps

40 volts 350 milliamps

50 volts 350 milliamps

Battery Discharging Procedure The purpose of this section is to provide new users with typical procedures for bench discharging. Established users should use their approved procedures. A.

Battery Discharge Hookup:

YOU MUST MONITOR THE BATTERY VOLTAGE CONTINUOUSLY! Battery Discharge Hook-up Figure 104 B.

Turn on the discharge switch and allow the battery to discharge until it reaches a voltage of 4.8-5.6 volts. Do not allow the voltage to go any lower. This discharge time can take anywhere from a few minutes to 35 minutes, depending on the battery’s state of charge. The voltage normally holds very steady for most of the discharge curve, followed by a steep decrease in voltage at the very end of the discharge. Pay attention!

C.

Once the battery cutoff voltage is reached then turn the switch off, and allow the battery pack to cool for 30 minutes before charging.

Copyright 2004 by: Radiant Power Corp., a HEICO Company

25-65-02

Page 121 Aug 2009

RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER BPS7

OPTIONAL ON-AIRCRAFT TESTING FOR BPS7-3 NOTE: These tests may be performed on-aircraft in the event of problems reported by flight crew or mechanics. 1.

General In response to requests from operators, Radiant Power Corp. has made an on-aircraft test set available. The Battery Housing Analyzer (BHA) provides quick GO/NO-GO and qualitative testing for the BPS7-3. The purpose of this test set is to allow mechanics to diagnose the problems that flight crew or mechanics might report when operating the Emergency Egress Lighting System or when performing a daily test on it. The BHA is a portable instrument designed to be carried on-board the aircraft by the mechanic. It allows the mechanic to check the BPS7-3 charger for proper operation while the BPS7-3 remains installed on the aircraft. The BHA also can perform a quick test of the battery pack as well. This test is not a full capacity check of the battery, since that would require a 16-hour recharge of the battery onaircraft after the test. It tests for grossly under-performing batteries, as could cause a test failure during the daily checks of the Emergency Egress Lighting System. Specifically, the BHA provides measurement of the battery charging current, charging opencircuit voltage, battery no-load voltage, and the battery loaded voltage. The BHA kit includes the analyzer, a two-foot battery tester cable and a 6.5-foot charging fixture cable. This cable is long enough that the mechanic can use the analyzer from a convenient location while testing a BPS7-3 in an inconvenient location. Instructions for the Analyzer are reproduced below.

Battery Housing Analyzer Figure 105

Copyright 2004 by: Radiant Power Corp., a HEICO Company

25-65-02

Page 122 Aug 2009

RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER BPS7 2.

Aircraft Charging Test NOTE: IF THE AIRCRAFT CHARGER BEING TESTED FALLS OUTSIDE OF THE SPECIFIED TOLERANCES, FURTHER MAINTENANCE IS REQUIRED. A.

Remove the battery assembly, BT1 (445 or 445A, IPL Figure 1), as follows: (1) Turn the 1/4-turn fastener (450 or 450A) counterclockwise approximately 90° to the stop. The fasteners should retract from the force of the retraction springs (465). CAUTION:

DO NOT LIFT THE BATTERY ASSEMBLY BT1 BEFORE SLIDING IT AWAY FROM THE ELECTRONICS ASSEMBLY. DOING SO CAN DAMAGE THE PIN CONTACTS ON PCB ASSEMBLY A2.

(2) Carefully slide the battery assembly BT1 (445 or 445A) out away from the electronics assembly (40) to disconnect pin contacts J3-1 and J3-2 on regulator PCB assembly A2 (205) from pin sockets J2-1 and J2-2 (535 and 540). Remove the battery assembly BT1. B.

Ensure analyzer power & load switches are in the off position.

C.

Install the charging fixture cable in place of the removed battery assembly BT1 (445 or 445A). Connect the charging fixture cable leads to the BHA input jacks. CAUTION: ENSURE PROPER POLARITY. IF AT ANY TIME THE REVERSE POLARITY LED FLASHES, CORRECT BEFORE PROCEEDING.

D.

Turn on aircraft power to the charger assembly.

E.

Switch power ON/OFF switch to the ON position with the load switch in the OFF position. The voltage must be 13.8 volts to 15.0 volts.

F.

Switch the load ON/OFF switch to the ON position. The voltage must be 6.8 volts to 8.0 volts. Charge current must indicate 300 mA or greater.

G.

Depress the battery condition switch and read the battery voltage on the battery voltage meter. (The LED lights are for quick reference only.) Voltage must be greater than 6.8 volts but less than 8.0 volts. Low < 6.8 volts (Amber) FAILURE Normal > 6.8 volts (Green) PASS High > 8.0 volts (Red) FAILURE

H. 3.

Release battery condition switch.

Battery Pack Test NOTE: IF THE BATTERY PACK BEING TESTED FALLS OUTSIDE OF THE SPECIFIED TOLERANCES FURTHER MAINTENANCE IS REQUIRED. A.

Ensure analyzer power & load switches are in the off position.

Copyright 2004 by: Radiant Power Corp., a HEICO Company

25-65-02

Page 123 Aug 2009

RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER BPS7 B.

Attach battery tester cable from the BHA input jacks to the battery pack to be tested. CAUTION: ENSURE PROPER POLARITY. IF THE REVERSE POLARITY LED FLASHING, CORRECT BEFORE PROCEEDING.

C.

Switch power ON/OFF switch to the ON position with the load switch in the OFF position.

D.

Depress the battery condition switch and read the battery voltage on the battery voltage meter. (The LED lights are for quick reference only.) Voltage must be greater than 6.8 volts. Low < 6.8 volts (Amber) FAILURE Normal > 6.8 volts (Green) PASS High > 8.0 volts (Red) OK

E.

Release battery condition switch.

F.

Switch load ON/OFF switch to the ON position. The voltage meter must read 6.8 volts or greater, and current meter must read 300 mA or greater.

Copyright 2004 by: Radiant Power Corp., a HEICO Company

25-65-02

Page 124 Aug 2009

RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER BPS7

DISASSEMBLY 1.

General A.

This section contains disassembly instructions in the same sequence as the IPL. Before disassembly, refer to TESTING AND FAULT ISOLATION or CHECK to identify the damaged components. Disassemble the BPS only as far as necessary to remove the damaged or worn parts. NOTE: With exception of the Select In Test (SIT) components identified in the IPL, Radiant Power Corp. recommends that PCB assembly A1 and A2 be returned to Radiant Power Corp. for repair by technicians familiar with the layout and function of the cards. Radiant Power Corp does not assume responsibility for any repairs and/or maintenance performed and parts and/or sub-assemblies which is not in accordance to procedures described in this manual.

B.

Radiant Power Corp. recommends replacement of the following components each time the BPS is disassembled. IPL Figure 1 Component Washer, Nonmetallic (Insulating) Insulator, Mica

C.

Item Number 93, 213 230, 360

Radiant Power Corp. recommends modification of early BPS configurations. When the electronics assembly (40, IPL Figure 1) is opened for troubleshooting or repair, as follows: On serial numbers 620 and lower, replace the dark-grey molybdenum plated self-locking nut (P/N NAS679C06M or NAS679A06) used to secure the solder lug (370) to transistor Q2 (350) with a silver plated nut (P/N NAS679C06, item 345 or MS21043-06, item 373).

D.

Replace obsolete battery assembly BT1 (P/N 2013-1) with battery assembly, P/N 20131A. Battery assembly 2013-1 can be used if desired, however, on both the BPS7-2 and BPS7-3 battery power supplies.

E.

Note the routing of electrical wire leads for assembly reference. Unsolder the wire leads from the terminals or pads and tag all wires to aid assembly.

F.

Refer to IPL Figure 1 for an exploded-view illustration of the BPS. Refer to DESCRIPTION AND OPERATION, Figure 2, for assembly views.

G.

The recommended disassembly materials are given in Table 301.

Copyright 2004 by: Radiant Power Corp., a HEICO Company

25-65-02

Page 301 Jan 2012

RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER BPS7 Disassembly Materials Table 301 Nomenclature Alcohol, Isopropyl Cloth, Lint-Free Stripper, Conformal Coating

Part or Specification Number Federal Specification TT-I-735 Military Specification MIL-C-85043 Humiseal No. 20

Source Commercially Available Commercially Available Columbia Chase Corp. (99109)

* Refer to Table 1001 in the IPL for the address. 2.

Special Tools and Equipment All repair work must be done at an Electrostatic Discharge (ESD) safe workbench. Refer to paragraph 3, below, for general ESD handling instructions and workbench requirements. No other special tools or equipment are required.

3.

Handling Instructions for Electronic Devices The BPS contains electronic components that can be damaged by ESD and rough handling. The general handling precautions and instructions given below will help minimize or eliminate possible damage. WARNING: THE BPS CONTAINS HIGH VOLTAGE CIRCUITS, WHICH CAN CAUSE DEATH OR SEVERE SHOCK. FOLLOW THE SAFETY PRECAUTIONS GIVEN IN THE INTRODUCTION TO THIS CMM TO PREVENT INJURY. CAUTION: CAUTION: THE PCB ASSEMBLIES CONTAIN ESD SENSITIVE DEVICES. HANDLE THE PCB ASSEMBLIES IN ACCORDANCE WITH STATIC CONTROL PROCEDURES TO PREVENT COMPONENT DAMAGE. THE BPS CONTAINS SENSITIVE ELECTRONIC COMPONENTS THAT CAN BE DAMAGED BY ROUGH HANDLING AND EXPOSURE TO HIGH HUMIDITY, WATER OR OTHER LIQUIDS, CIGARETTE SMOKE, AND OTHER CONTAMINATION. USE THE BPS IN AN ENVIRONMENT SUITABLE FOR ELECTRONIC COMPONENTS AND HANDLE THE UNIT WITH CARE TO PREVENT DAMAGE. A.

If liquid or grease is spilled on or in the BPS, immediately remove power and wipe off the liquid or grease. Do not touch the BPS until power has been removed.

B.

Do not use or store the BPS in a high humidity environment or in direct sunlight. High humidity can short or corrode electronic components

C.

All integrated circuits (ICs), surface mounted devices, and many other semiconductors are susceptible to ESD. Careless handling during repair can drastically decrease the component life.

D.

When handling ESD sensitive devices, work at an ESD safe workbench. The workbench should include:

Copyright 2004 by: Radiant Power Corp., a HEICO Company

25-65-02

Page 302 Aug 2009

RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER BPS7

(1) A grounded conductive sheet covering the bench work area. (2) A grounded wrist strap in contact with skin. (3) If the chair or the floor is nonconductive, the chair must have a ground strap. (4) ESD safe tools and equipment. Use plastic instead of metal tools where possible to prevent short circuits.

4.

E.

Store the PCB assemblies in protective antistatic shipping bags until ready for use. Do not store the PCB assemblies in conventional plastic snow, Styrofoam, or plastic trays.

F.

Once removed from the bags, PCB assemblies must be handled in accordance with static control procedures. The preferred method is to handle PCB assemblies with clean lint-free cloths or rubber gloves only on the edge of the board. If gloves or cloths are not available, wash your hands to remove oils and handle the boards only on the edges; do not touch the conductive patterns or components.

G.

Do not stack PCB assemblies. Stacking can damage surface mounted components.

H.

The workstation must be clean. To prevent contamination of PCB assemblies, there must be no smoking, eating, or drinking in the work area.

Disassembly Instructions NOTE: Refer to REPAIR for instructions to replace damaged clinch nuts (226 and 415, IPL Figure 1), adhesive-backed labels, and the riveted components. CAUTION: DO NOT OVERHEAT ELECTRONIC COMPONENTS WHEN UNSOLDERING WIRE LEADS. USE A HEAT SINK AND LOW WATTAGE SOLDER IRON TO PREVENT DAMAGE. USE A SOLDER SUCKER AND/OR SOLDER WICK TO REMOVE EXCESS SOLDER. PCB ASSEMBLIES A1 AND A2 CONTAIN SENSITIVE ELECTRONIC COMPONENTS THAT CAN BE DAMAGED BY ESD AND ROUGH HANDLING. HANDLE THE PCB ASSEMBLIES WITH CARE TO PREVENT DAMAGE A.

Disassemble the battery charger assembly (5), as follows: (1) Remove the screws (15) and carefully lift the cover assembly (10A or 10B) off the electronics assembly (40). CAUTION: DO NOT LIFT THE ELECTRONICS ASSEMBLY BEFORE SLIDING IT AWAY FROM BATTERY ASSEMBLY BT1. DOING SO CAN DAMAGE THE PIN CONTACTS ON PCB ASSEMBLY A2. (2) Remove the screws (35A). Carefully slide the electronics assembly (40) out away from battery assembly BT1 (445 or 445A) to disconnect pin contacts J3-1 and J3-2 on PCB assembly A2 (205) from pin sockets J2-1 and J2-2.

Copyright 2004 by: Radiant Power Corp., a HEICO Company

25-65-02

Page 303 Jan 2012

RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER BPS7 CAUTION: DO NOT PULL OR TWIST THE WIRE LEADS WHILE REMOVING COMPONENTS. PULLING OR TWISTING THE WIRE LEADS CAN BREAK SOLDER CONNECTIONS AND DAMAGE WIRE LEADS. (3) Disassemble the electronics assembly (40), as follows: (a)

Remove the screws (50) from the front panel (45). Do not move the front panel until specified below.

(b)

Remove the screws (90) and the washers (93) from PCB assembly A1 (85). Do not move PCB assembly A1 until specified below.

(c)

Remove the screws (210) and the washers (213) from PCB assembly A2 (205). Do not move PCB assembly A2 until specified below.

(d)

Unfold the electronics assembly (40) as needed for access to the damaged components. Use caution to avoid damage to solder connections on components that do not require replacement. NOTE: The PCB assemblies are conformal coated. The wire leads can be unsoldered through the conformal coating, or the coating can be stripped off with Humiseal stripper (Table 301). Instructions are given in ASSEMBLY to reapply the conformal coating.

(e)

Tag and unsolder the wire leads from TEST switch SW1 (70) to pads 1 and 3 on PCB assembly A1 (85). Remove the hex nut and the switch from the front panel (45). Reinstall the hex nut on the switch body for reuse.

(f)

Tag and unsolder the wire lead from connector J1 (55A) to the solder lug (75). Remove the solder lug.

CAUTION: RADIANT POWER CORP DOES NOT ASSUME RESPONSIBILITY FOR ANY REPAIRS AND/OR MAINTENANCE PERFORMED AND PARTS AND/OR SUB-ASSEMBLIES WHICH IS NOT IN ACCORDANCE TO PROCEDURES DESCRIBED IN THIS MANUAL. (g)

Tag and unsolder the wire leads from PCB assembly A1 (85). Remove PCB assembly A1.

NOTE: With exception of the SIT components identified in the IPL, Radiant Power Corp. recommends that PCB assemblies A1 and A2 be returned to Radiant Power Corp. for repair by technicians familiar with the layout and function of the cards. Radiant Power Corp does not assume responsibility for any repairs and/or maintenance performed and parts and/or sub-assemblies which is not in accordance to procedures described in this manual.

Copyright 2004 by: Radiant Power Corp., a HEICO Company

25-65-02

Page 304 Jan 2012

RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER BPS7

B.

(h)

Tag and unsolder the wire leads from PCB assembly A2 (205). Remove PCB assembly A2.

(i)

Remove the screws (220), the washers (225), transistor Q3 (245), the mica insulator (230), the bracket assembly (215), and the insulator strip (235) from the printed circuit board. Discard the mica insulator. Refer to REPAIR to replace damaged clinch nuts (226). Replace PCB assembly A2 if any other components are damaged.

(j)

Tag and unsolder the wire leads for transistor Q1 (355) and the solder lug (370). Remove the screws (340), the nuts (345), transistor Q1, the mica insulator (360), the insulator strip (365), and the solder lug. Discard the mica insulator.

(k)

Tag and unsolder the wire leads for transistor Q2 (350) and the solder lug (370). Remove the screws (340), the nuts (345), transistor Q2, the mica insulator (360), the insulator strip (365), and the solder lug. Discard the mica insulator.

(l)

Tag and unsolder the wire leads to resistor R1 and/or R2 (375). Remove the screws (380), the washers (383), the nuts (385), and the resistor(s).

Remove and disassemble battery assembly BT1 (445), as follows: NOTE: Battery assembly BT1 (445) is obsolete and should be replaced by item 445A. Battery assembly BT1 (445A) incorporates design improvements to increase the life of the unit. Battery assembly BT1 (445) can be used if desired, however, on both the BPS7-2 and BPS7-3 battery power supplies. (1) Turn the 1/4-turn fasteners (450) counterclockwise approximately 90° to the stop. The fastener should retract from the force of the retraction spring (465). CAUTION: DO NOT LIFT BATTERY ASSEMBLY BT1 BEFORE SLIDING IT AWAY FROM THE ELECTRONICS ASSEMBLY. DOING SO CAN DAMAGE THE PIN CONTACTS ON PCB ASSEMBLY A2. (2) Carefully slide battery assembly BT1 (445) out away from the electronics assembly (40) to disconnect pin contacts J3-1 and J3-2 on PCB, assembly A2 (205) from pin sockets J2-1 and J2-2 (535 and 540). Remove battery assembly BT1. (3) Remove the split ring retainers (460), the 1/4-turn fasteners (450), the washers (455), and the retraction springs (465). (4) Remove the nut (500), the washers (475), the screw (470), and the rear support block (480). (5) Remove the nuts (500), the square washers (495), the screws (485 and 490) and the front, middle, and rear bands (510, 515 and 520). (6) Remove the front support block (480) and the middle support block (505).

Copyright 2004 by: Radiant Power Corp., a HEICO Company

25-65-02

Page 305 Aug 2009

RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER BPS7 CAUTION: AS SOON AS THE TOP BATTERY HOLDER IS REMOVED, INSERT A PIECE OF INSULATING MATERIAL BETWEEN PIN SOCKETS J2-1 AND J2-2 (535 AND 540) TO PREVENT SHORTING DURING MAINTENANCE. (7) Remove the top battery holder (565). Insert a piece of insulating material (tape, paper, etc.) between pin sockets J2-1 and J2-2 (535 and 540). (8) Unsolder the wire braid (572) on the end of the batteries (575) opposite pin sockets J2-1 and J2-2 (535 and 540). CAUTION: DISASSEMBLY OF THE BATTERY PACK TO REPLACE INDIVIDUAL CELLS IS NOT RECOMMENDED. THIS CAN RESULT IN A MISMATCH OF CELL CAPACITY SUFFICIENT TO CAUSE CELL REVERSAL AND PERMANENT CELL DAMAGE. RADIANT RECOMMENDS REPLACEMENT OF ALL SIX BATTERIES IF ANY ONE BATTERY IS DAMAGED. (9) Remove the batteries (575) from the bottom battery holder (570). Remove the glass tape (573) and the remaining wire braid (572) only if the batteries are damaged and must be replaced. Replace all six batteries if any one cell is damaged. NOTE: Instructions are given in ASSEMBLY to reconnect the batteries. CAUTION: DO NOT REMOVE THE INSULATOR MATERIAL FROM BETWEEN PIN SOCKETS J2-1 AND J2-2 UNTIL AFTER THE REAR WIRE BRAID (572) OR THE BATTERIES HAVE BEEN REMOVED. (10) Remove the insulator material from between pin sockets J2-1 and J2-2 (535 and 540). (11) Remove the washers (545), the nuts (550), and pin sockets J2-1 and J2-2 (535 and 540). Remove and discard the grommets (530), the shrink tubing (571), and the connectors (555) only if the components are damaged. CAUTION: DO NOT USE SOLVENT CLEANERS ON THE BATTERY HOLDER ASSEMBLY (560). SOLVENTS CAUSE CRACKING OF THE LEXAN MATERIAL. (12) Peel or cut the fuse retainer pad (525) off the bottom battery holder (570) only if the pad is damaged. Clean the bottom battery holder with alcohol and lint-free cloths (Table 301). (13) Refer to REPAIR to replace the adhesive-backed labels (580, 585 and 590). C.

Remove and disassemble battery assembly BT1 (445A), as follows: NOTE: Battery assembly BT1 (445A) is used on all BPS7-3 battery power supplies, and is the preferred spare for replacement of battery assembly (445) originally shipped on BPS7-2 battery power supplies. Battery assembly BT1 (445A) incorporates design improvements to increase the life of the unit.

Copyright 2004 by: Radiant Power Corp., a HEICO Company

25-65-02

Page 306 Aug 2009

RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER BPS7 (1) Turn the 1/4-turn fasteners (450A) counterclockwise approximately 90° to the stop. The fasteners should extend from the force of the retraction springs (465). CAUTION: DO NOT LIFT BATTERY ASSEMBLY BT1 BEFORE SLIDING IT AWAY FROM THE ELECTRONICS ASSEMBLY. DOING SO CAN DAMAGE THE PIN CONTACTS ON PCB ASSEMBLY A2. (2) Carefully slide battery assembly BT1 (445A) out away from the electronics assembly (40) to disconnect pin contacts J3-1 and J3-2 on PCB assembly A2 (205) from pin sockets J2-1 and J2-2 (535 and 540). Remove battery assembly BT1. CAUTION: AS SOON AS THE BOTTOM HALF CASE IS REMOVED, INSERT A PIECE OF INSULATING MATERIAL BETWEEN PIN SOCKETS J2-1 AND J2-2 (535 AND 540) TO PREVENT SHORTING DURING MAINTENANCE. (3) Remove the nuts (500A), the flat washers (495A), and the screws (490A). Turn the battery case over and remove the bottom half case (570A). Insert a piece of insulating material (tape, paper, etc.) between pin sockets J2-1 and J2-2 (535 and 540). (4) Remove the Teflon flat washers (460A), the 1/4-turn fasteners (450A), and the retraction springs (465). (5) Unsolder the wire braid (572) on the end of the batteries (575) opposite pin sockets J2-1 and J2-2 (535 and 540). CAUTION: DISASSEMBLY OF THE BATTERY PACK TO REPLACE INDIVIDUAL BATTERIES IS NOT RECOMMENDED. THIS CAN RESULT IN A MISMATCH OF CELL CAPACITY SUFFICIENT TO CAUSE CELL REVERSAL AND PERMANENT CELL DAMAGE. RADIANT RECOMMENDS REPLACEMENT OF ALL SIX BATTERIES IF ANY ONE BATTERY IS DAMAGED. (6) Remove the batteries (575) from the top half case (565A). Remove the remaining wire braid (572) only if the batteries are damaged and must be replaced. Replace all six batteries if any one battery is damaged. NOTE: Instructions are given in ASSEMBLY to reconnect the batteries. CAUTION: DO NOT REMOVE THE INSULATING MATERIAL FROM BETWEEN PIN SOCKETS J2-1 AND J2-2 UNTIL AFTER THE REAR WIRE BRAID (572) OR THE BATTERIES HAVE BEEN REMOVED. (7) Remove the insulating material from between pin sockets J2-1 and J2-2 (535 and 540). (8) Remove the washers (530A and 545A), the nuts (550), and pin sockets J2-1 and J22 (535 and 540).

Copyright 2004 by: Radiant Power Corp., a HEICO Company

25-65-02

Page 307 Aug 2009

RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER BPS7 CAUTION: DO NOT USE SOLVENT CLEANERS ON THE TOP HALF CASE (565A). SOLVENTS CAUSE DAMAGE TO THE LEXAN MATERIAL. (9) Peel or cut the fuse retainer pad (525) off the top half case (565A) only if the pad is damaged. Clean the top half case with alcohol and lint-free cloths to remove any adhesive film. (10) Refer to REPAIR to replace the labels (580A). D.

Disassemble the chassis assembly (400), as follows: (1) Refer to REPAIR to replace damaged clinch nuts (415). (2) Refer to REPAIR to replace the riveted brackets (425). (3) Remove and discard the damper pads (433) if the early configuration battery assembly BT1 (445) will be replaced with improved battery assembly BT1 (445A). If removal is necessary, cut or peel the pad off the chassis. Remove any adhesive film with isopropyl alcohol and lint-free cloths (Table 301). (4) Refer to REPAIR to replace the adhesive-backed chassis nameplate (440). (5) Replace the chassis assembly (400) if any other components are damaged

Copyright 2004 by: Radiant Power Corp., a HEICO Company

25-65-02

Page 308 Aug 2009

RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER BPS7

CLEANING 1.

Cleaning Materials The recommended cleaning materials are given in Table 401. NOTE: Equivalent items can be used.

2.

Cleaning Instructions WARNING: THE CLEANING SOLVENTS ARE VERY FLAMMABLE AND CAN IRRITATE YOUR EYES AND NOSE. USE THE SOLVENTS ONLY IN WELL-VENTILATED AREAS AWAY FROM OPEN FLAMES. FLUSH IRRITATED EYES WITH WATER. CAUTION: PCB ASSEMBLIES A1 AND A2 CONTAIN SENSITIVE ELECTRONIC COMPONENTS THAT CAN BE DAMAGED BY ESD AND ROUGH HANDLING. HANDLE THE PCB ASSEMBLIES WITH CARE TO PREVENT DAMAGE. DO NOT GET THE ELECTRONIC AND ELECTRICAL COMPONENTS TOO WET. EXCESS MOISTURE CAN DAMAGE THE COMPONENTS. A.

Use clean cotton swabs and isopropyl alcohol (Table 401) to clean the circuit boards and electrical/electronic components. Wipe the components dry with clean, lint-free cloths. Cleaning Materials Table 401

Nomenclature Alcohol, Isopropyl Brush, Stiff-Bristle, Nonmetallic Cleaning Solvent, (Recommended) Cloth, Lint-Free Goggles, Safety Swab, Cotton Tank Compressed Air, 20 psig (140 kPag)

Part or Specification Number Federal Specification TT-I-735 Federal Specification H-B-1490 Freon TF Formula 409 Calla 301A 815MX Military Specification MIL-C-85043 -------

Copyright 2004 by: Radiant Power Corp., a HEICO Company

Source Commercially Available Commercially Available E.I. Dupont Clorox Co. (4T284) Andpak Inc. (68491) Brulin and Co. (94058) Commercially Available Commercially Available Commercially Available Commercially Available

25-65-02

Page 401 Sep 2010

RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER BPS7 CAUTION: CAUTION: DO NOT USE CLEANING SOLVENTS ON THE BATTERY HOLDER ASSEMBLY OR THE BATTERY CASE ASSEMBLY. THE SOLVENTS CAN CAUSE CRACKING OF THE LEXAN MATERIAL. B.

Use clean cotton swabs and isopropyl alcohol (Table 401) to clean the battery holder assembly (560, IPL Figure 1) or the battery case assembly (560A). Wipe the components dry with clean, lint-free cloths.

WARNING: WEAR SAFETY GOGGLES OR GLASSES WHEN YOU USE COMPRESSED AIR. POINT THE AIR STREAM AWAY FROM OTHER PEOPLE. C.

Clean all other components in a sonic bath or use lint-free cloths and the solvent (Table 401). Use a nonmetallic, stiff-bristle brush if necessary to scrub the parts. Dry the parts with clean, lint-free cloths or clean shop air at less than 20 psig (140 kPag) pressure.

D.

Store the non-electronic components in clean plastic bags or on clean, lint-free cloths until they are needed for CHECK and ASSEMBLY. Store the PCB assemblies as specified in DISASSEMBLY.

Copyright 2004 by: Radiant Power Corp., a HEICO Company

25-65-02

Page 402 Aug 2009

RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER BPS7

CHECK Component check procedures are given in Table 501. Use bright light and a 5-power or greater magnifier to aid visual examinations. Check Procedures Table 501 (Sheet 1 of 3)

Threaded Parts

Method of Inspection Visual

Solder Connections

Visual

Electrical Wire Leads

Visual

Cover Assembly (10B, IPL Figure 1)

Visual

Component

Visual Visual Visual

Electronics Assembly (40)

Visual

Visual

Visual

Check For

Crossed or stripped threads; loose attaching hardware. Loose or broken solder connections; cracked or deteriorated wire insulation; burns or other signs of open or short circuits. Cracked or cut insulation; cut wire strands; check all wires for continuity; verify that all wires are properly routed and bundled. Corrosion; chemical film finish scratched or worn to base metal. Deformation; check mounting holes for cracks. Unreadable schematic or ESD cautions. Unreadable FAA-PMA label (32); cut edges or loose bond to cover. Deformed front panel (45); check mounting holes for cracks. Bent or damaged pin contacts in connector J1 (55A); sheared or deformed locking tabs; damaged shell or corroded seal. Crossed or stripped threads on the switch SW1 (70) housing or in the hex nut; damaged terminals or pushbutton switch mechanism.

Copyright 2004 by: Radiant Power Corp., a HEICO Company

Corrective Action

Replace damaged components. Refer to ASSEMBLY to repair solder connections during final assembly

Refer to ASSEMBLY to replace damaged wire leads during final assembly

Refer to REPAIR to remove corrosion and apply Alodine over the damaged areas. Replace the cover assembly (10B). Refer to REPAIR to reapply silkscreen markings. Refer to REPAIR to replace the adhesive-backed label. Replace the front panel (45).

Refer to REPAIR to replace damaged pin contacts or wire leads, or replace the damaged connector (55A).

Replace switch SW1 (70).

25-65-02

Page 501 Aug 2009

RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER BPS7 Check Procedures Table 501 (Sheet 2 of 3) Electronics Assembly (40) (cont’d)

Chassis Assembly (400)

Visual

Loose or damaged board mounted components or damaged circuit traces on PCB assembly A1 (85); discolored, cracked, or chipped circuit board; PCB warp or twist greater than 1.5%.

Visual

Loose or damaged board mounted components or damaged circuit traces on PCB assembly A2 (205); discolored, cracked, or chipped circuit board; PCB warp or twist greater than 1.5%.

Visual

Loose or damaged clinch nuts (226) in the bracket assembly (215); crossed or stripped threads in the clinch nuts; bent bracket. Cracked or burned resistor R1 or R2 (375). Loose or crooked standoffs (405 and 410); crossed or stripped internal threads. Loose or damaged clinch nuts (415); crossed or stripped threads in the clinch nuts. Deformed battery mounting brackets (425); loose or cracked rivets.

Visual Visual

Visual

Visual

Visual

Visual

Deformed chassis (435); cracks around mounting holes. Corroded chassis (435); chemical film finish scratched or worn to base metal.

Copyright 2004 by: Radiant Power Corp., a HEICO Company

Replace PCB assembly A1 (85); Radiant recommends that damaged PCB assemblies be returned to Radiant for repair; Radiant Power Corp does not assume responsibility for any repairs and/or maintenance performed and parts and/or sub-assemblies which is not in accordance to procedures described in this manual. Replace PCB assembly A2 (205); Radiant recommends that damaged PCB assemblies be returned to Radiant for repair; Radiant Power Corp does not assume responsibility for any repairs and/or maintenance performed and parts and/or sub-assemblies which is not in accordance to procedures described in this manual. Refer to REPAIR to replace the damaged clinch nuts (226), or replace the bracket assembly (215). Replace the damaged resistor (375). Replace the chassis assembly (400). Refer to REPAIR to replace the damaged clinch nuts (415), or replace the chassis assembly (400). Refer to REPAIR to replace the brackets (425) or the rivets (430), or replace the chassis assembly (400). Replace the chassis assembly (400). Refer to REPAIR to remove corrosion and apply Alodine over the damaged areas.

25-65-02

Page 502 Jan 2012

RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER BPS7 Check Procedures Table 501 (Sheet 3 of 3) Nameplate (440)

Visual

Battery Assembly BT1 (445 or 445A)

Visual

Dimensional

Visual

Wire Braid (572) Labels (580, 580A, 585, 590 and 593)

Cut or torn edges; loose adhesive bond to the chassis assembly (400). Crossed or stripped head on the 1/4-turn fasteners (450 or 450A); deformation. Deformed or permanently set retraction spring (465); the nominal free length Is 0.75 inch (1.9 cm); the ends must be square and the spring must roll smoothly on a flat surface. Cracked or chipped battery case assembly (560A).

Visual

Leakage from a cracked or corroded battery (575) cell; cut or detached battery tab.

Visual Visual

Cut wires. Unreadable; cut or torn edges; loose adhesive bond.

Copyright 2004 by: Radiant Power Corp., a HEICO Company

Refer to REPAIR to replace the adhesive-backed nameplate (440). Replace the damaged fasteners (450 or 450A).

Replace the damaged spring.

Replace the top half case (565A) or the bottom half case (570A). Replace the batteries (575) or battery assembly BT1 (445A); instructions to connect new batteries are given in ASSEMBLY Replace the wire braid (572). Refer to REPAIR to replace the adhesive-backed labels.

25-65-02

Page 503 Aug 2009

RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER BPS7

THIS PAGE INTENTIONALLY LEFT BLANK

Copyright 2004 by: Radiant Power Corp., a HEICO Company

25-65-02

Page 504 Aug 2009

RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER BPS7

REPAIR 1.

General A.

Use the appropriate procedures given below to repair damaged parts. Refer to ASSEMBLY to replace damaged wire leads and repair solder connections during final assembly of the Battery Power Supply (BPS). Paragraph 2 3 4 5 6 7 8 9

Repair Action TOOL AND MATERIALS HANDLING INSTRUCTIONS FOR ELECTRONIC DEVICES REPAIR MINOR THREAD DAMAGE REPLACE PIN CONTACTS IN CONNECTOR J1 REPLACE CLINCH NUTS REAPPLY SILKSCREEN MARKINGS REPAIR ANODIZED FINISHES REPLACE RIVETED COMPONENTS

CAUTION: THE PCB ASSEMBLIES CONTAIN SENSITIVE ELECTRONIC COMPONENTS THAT CAN BE DAMAGED BY ESD AND ROUGH HANDLING. HANDLE THE PCB ASSEMBLIES WITH CARE TO PREVENT DAMAGE. RADIANT POWER CORP DOES NOT ASSUME RESPONSIBILITY FOR ANY REPAIRS AND/OR MAINTENANCE PERFORMED AND PARTS AND/OR SUBASSEMBLIES WHICH IS NOT IN ACCORDANCE TO PROCEDURES DESCRIBED IN THIS MANUAL.

2.

B.

Deleted

C.

For field repair, refer to TESTING AND FAULT ISOLATION and/or CHECK to identify the damaged component, then refer to DISASSEMBLY and ASSEMBLY to replace the components. Refer to the referenced IPL figure and item number to order replacement components.

D.

Follow industry standard practices to solder components and wire leads.

Tools and Materials A.

The recommended tools and materials are given in Table 601. NOTE: Equivalent items can be used.

B.

All work must be done at an electrostatic discharge (ESD) safe workbench. Refer to REPAIR for general ESD handling instructions and workbench requirements. No other special tools or equipment are required.

Copyright 2004 by: Radiant Power Corp., a HEICO Company

25-65-02

Page 601 Jan 2012

RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER BPS7 Repair Tools and Materials Table 601 Nomenclature

Abrasive Cloth, Aluminum Oxide Alodine, Brush Ink, Epoxy (Black) Insertion/Extraction Tool, Pin Contact Pin Contact, Electrical Connector Press, Hydraulic or Mechanical Silkscreen Template, Nameplate, Schematic, and ESD Caution (Used on 2010-2 Cover) Solder, Resin Core, Composition Sn63 Solder Iron, Low Wattage (24 to 40 Waft) Tubing, Shrink Wire, Electrical, 20 and 24 AWG (select size and color per Table 602)

Part or Specification Number

Federal Specification P-C-451 No. 120 Hysol 50-700R Military Specification MS24256R12 Military Specification MIL-C-26636

Source (CAGE)*

Commercially Available Henkel Corp. (84063) Dexter Corp. (12405) Commercially Available Commercially Available Commercially Available

---

Radiant Power Corp. 2043 Federal Specification QQ-S-571

Commercially Available

---

Commercially Available

HS-105, Class H BMS13-48C or MIL-W-22759 (Raychem 55A0111-20, -24)

Markel Electric Products Co. (83750) Commercially Available

*Refer to Table 1001 in the IPL for the address

Copyright 2004 by: Radiant Power Corp., a HEICO Company

25-65-02

Page 602 Aug 2009

RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER BPS7 3.

Handling Instructions for Electronic Devices The BPS contains electronic components that can be damaged by ESD and rough handling. The general handling precautions and instructions given below will help minimize or eliminate possible damage. WARNING: THE BPS CONTAINS HIGH VOLTAGE CIRCUITS WHICH CAN CAUSE DEATH OR SEVERE SHOCK. FOLLOW THE SAFETY PRECAUTIONS GIVEN IN THE INTRODUCTION TO THIS CMM TO PREVENT INJURY. CAUTION: THE PCB ASSEMBLIES CONTAIN ESD SENSITIVE DEVICES. HANDLE THE PCB ASSEMBLIES IN ACCORDANCE WITH STATIC CONTROL PROCEDURES TO PREVENT COMPONENT DAMAGE. THE BPS CONTAINS SENSITIVE ELECTRONIC COMPONENTS THAT CAN BE DAMAGED BY ROUGH HANDLING AND EXPOSURE TO HIGH HUMIDITY, WATER OR OTHER LIQUIDS, CIGARETTE SMOKE, AND OTHER CONT AMINATION. USE THE BPS IN AN ENVIRONMENT SUITABLE FOR ELECTRONIC COMPONENTS AND HANDLE THE UNIT WITH CARE TO PREVENT DAMAGE. A.

If liquid or grease is spilled on or in the BPS, immediately remove power and wipe off the liquid or grease. Do not touch the BPS until power has been removed.

B.

Do not use or store the BPS in a high humidity environment or in direct sunlight. High humidity can short or corrode electronic components.

C.

All integrated circuits (ICs), surface mounted devices, and many other semiconductors are susceptible to ESD. Careless handling during repair can drastically decrease the component life.

D.

When handling ESD sensitive devices, work at an ESD safe work bench. The work bench should include: (1) A grounded conductive sheet covering the bench work area. (2) A grounded wrist strap in contact with skin (3) If the chair or the floor is nonconducting, the chair must have a ground strap. (4) ESD safe tools and equipment. Use plastic instead of metal tools where possible to prevent short circuits.

E.

Store the PCB assemblies in protective antistatic shipping bags until ready for use. Do not store the PCB assemblies in conventional plastic snow, Styrofoam, or plastic trays.

F.

Once removed from the bags, PCB assemblies must be handled in accordance with static control procedures. The preferred method is to handle PCB assemblies with clean lint-free cloths or rubber gloves only on the edge of the board. If gloves or cloths are not available, wash your hands to remove oils and handle the boards only on the edges; do not touch the conductive patterns or components.

Copyright 2004 by: Radiant Power Corp., a HEICO Company

25-65-02

Page 603 Aug 2009

RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER BPS7

4.

G.

Do not stack PCB assemblies. Stacking can damage surface mounted components.

H.

The work station must be clean. To prevent contamination of PCB assemblies, there must be no smoking, eating, or drinking in the work area.

Repair Minor Thread Damage Repair damaged threads with an appropriate die or tap if less than 50 percent of one thread is damaged. Replace non-repairable parts.

5.

Replace Pin Contacts in Connector J1 NOTE: Refer to DESCRIPTION AND OPERATION, Figure 3 for a schematic diagram. A wire list for connector J1 is given in Table 602.

6.

A.

Use the insertion/extraction tool (Table 601) to remove damaged pin contacts and/or wire leads from connector J1 (55A, IPL Figure 1).

B.

Cut and trim replacement wire leads (Table 601) to the same length as the damaged wire leads. Select the wire color and gage to match.

C.

Use a suitable crimping tool to crimp new pin contacts (Table 601) to the wire leads.

D.

Use the insertion/extraction tool to insert the pin contacts into the appropriate connector J1 (55A) sockets. Fill unused sockets with dummy pin contacts (Table 601).

Replace Clinch Nuts Use this procedure to replace damaged clinch nuts (226 and 415, IPL Figure 1). A.

Support the bracket on the press (Table 601) so it does not move or bend.

B.

Use a punch and the press to push out the damaged nut. Do not bend or crimp the bracket or heatsink around the mounting hole.

C.

Install a new clinch nut in the mounting hole. Put the shank on the punch side as shown in Figure 601.

CAUTION: DO NOT CRUSH THE NUT OR DAMAGE THE THREADS. THE HOLE IN THE PUNCH OR ANVIL MUST CLEAR THE THREADS. D.

With the punch and anvil surfaces parallel, apply force until the shank of the clinch nut is flush with the underside of the bracket or heatsink. NOTE: The punch or anvil must apply force to the knurled collar of the nut but must have a cavity that fits over the threads so force is not applied to the barrel. Refer to Figure 601.

Copyright 2004 by: Radiant Power Corp., a HEICO Company

25-65-02

Page 604 Aug 2009

RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER BPS7 Connector J1 Wire List Table 602 Wire Code A C D B A A E B D or K D or K D or K D or K D or K D or K D or K D or K D B

F

Wire Color Black Red Orange Brown Black Black Black Red Green Green Gray Gray Purple Purple Red Red

Wire Size (AWG) 20 20 24 24 20 20 24 24 20 20 20 20 20 20 20 20

Connector J1 Pin J1-1 J1-2 J1-3 J1-4 J1-5 J1-6 J1-7 J1-8 J1-9 J1-10 J1-11 J1-12 J1-13 J1-14 J1-15 J1-16 J1-17 White 20 J1-18 J1-19 Yellow 20 J1-20 J1-21 J1-22 J1-23 Yellow 20 J1-24 *Wires are either color coded or letter coded.

From Component A2-18+ A2-21 A1-7+ A1-9+ A2-19 A2-18 Solder Lug A1-4 A2-9 A2-10 A2-11 A2-12 A2-13 A2-14 A2-15 A2-16 Dummy Pin A2-20 Dummy Pin A2-6 Dummy Pin Dummy Pin Dummy Pin A2-17

Clinch Nut Installation Figure 601

Copyright 2004 by: Radiant Power Corp., a HEICO Company

25-65-02

Page 605 Jan 2012

RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER BPS7 7.

Reapply Silkscreen Markings NOTE: This procedure repairs the schematic, nameplate, and ESD caution silkscreen markings on cover assembly, P/N 2010-2 (10B, IPL Figure 1). Adhesive-backed nameplates (25 and 30) are used on cover assembly, P/N 2010-1 (10A). Do this procedure after repair of the chemical film finish. WARNING: PAINT THINNER IS VERY FLAMMABLE AND CAN DAMAGE YOUR EYES AND NOSE. USE THE MATERIALS ONLY IN WELL VENTILATED AREAS AWAY FROM OPEN FLAMES. WEAR RUBBER GLOVES AND GOGGLES TO PROTECT YOUR HANDS AND EYES.

8.

A.

Use paint thinner (Table 601) to remove the damaged ink markings.

B.

Refer to CLEANING to clean the repair area.

C.

Use the template and black ink (Table 601) to reapply silkscreen markings.

Repair Anodized Finishes WARNING: ALODINE IS VERY FLAMMABLE AND CAN DAMAGE YOUR EYES AND NOSE. USE ALODINE ONLY IN WELL VENTILATED AREAS AWAY FROM OPEN FLAMES. WEAR RUBBER GLOVES, AN APRON, AND GOGGLES FOR SAFETY. A.

Repair damaged anodized finishes with No.120 brush Alodine (Table 601) as specified below. NOTE: This procedure gives general instructions for skilled technicians. Refer to Technical Process Bulletin No.1161, available from the Henkel Corp. (CAGE 84063), for complete instructions. The Alodine is light brown to orange in color. It is not available in other colors, so the repaired area may not match the original anodize finish.

B.

Clean the component to remove grease, oil, and corrosion.

C.

Apply undiluted Alodine liberally to the aluminum surface. Apply as many coats as needed. Allow approximately one minute reaction time between the applications. NOTE: The Alodine will dry faster when the Alodine and the part are at room temperature (approximately 65°F to 75°F). One to five minutes is normally required for the coat to dry. The Alodine can be applied with an acid-resistant brush, swab, synthetic sponge, or portable spray equipment.

D.

Remove any excess Alodine with clean water and lint-free cloths.

E.

Use lint-free cloths or compressed air at less than 20 psig (138 kPag) to dry the part. Pay close attention to the seams, joints, and crevices.

Copyright 2004 by: Radiant Power Corp., a HEICO Company

25-65-02

Page 606 Aug 2009

RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER BPS7 9.

Replace Riveted Components NOTE: Use this procedure to replace cracked or loose rivets or to replace damaged components attached with rivets. CAUTION: DO NOT ENLARGE THE RIVET MOUNTING HOLE. A.

Drill out the damaged rivet with a drill bit smaller than the diameter of the rivet (430, IPL Figure 1) shank. Do not enlarge the mounting hole beyond the minimum needed to remove the rivet. NOTE: The diameter of the rivet shank is given in the NOMENCLATURE column of the IPL. The size of the rivet holes are controlled by standard shop-practice use of oversize replacement rivets. The minimum pitch and edge distances for rivets are determined by the original design and should be closely matched during repair.

B.

Install new rivets (430) as needed to secure the battery mounting brackets (425).

Copyright 2004 by: Radiant Power Corp., a HEICO Company

25-65-02

Page 607 Aug 2009

RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER BPS7

THIS PAGE INTENTIONALLY LEFT BLANK

Copyright 2004 by: Radiant Power Corp., a HEICO Company

25-65-02

Page 608 Aug 2009

RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER BPS7

ASSEMBLY (INCLUDING STORAGE) 1.

General A.

This section contains reassembly, packaging, and storage instructions. The procedures are arranged in the reverse sequence of DISASSEMBLY and the IPL. Skip procedures and/or procedure steps as applicable if the BPS is already partially assembled. NOTE: Refer to REPAIR for instructions to replace the damaged clinch nuts (226 and 415, IPL Figure 1), all riveted components, and all bonded components.

B.

Radiant Power Corp. recommends replacement of the following components each time the BPS is disassembled. IPL Figure 1 Component Washer, Nonmetallic (Insulating) Insulator, Mica

C.

Item Number 93, 213 230, 360

Radiant Power Corp. recommends modification of early BPS configurations when the electronics assembly (40) is opened for troubleshooting or repair, as follows: On serial numbers 620 and lower, replace the dark-grey molybdenum plated self-locking nut (P/N NAS679C06M or NAS679A06) used to secure the solder lug (370) to transistor Q2 (350) with a silver plated nut (P/N NAS679C06, item 345 or MS21043-06, item 373).

2.

D.

Replace obsolete battery assembly BT1 (P/N 2013-1) with battery assembly, P/N 20131A. Battery assembly 2013-1 can be used if desired, however, on both the BPS7-2 and BPS7-3 battery power supplies.

E.

Refer to IPL Figure 1 for an exploded-view illustration of the BPS Refer to DESCRIPTION AND OPERATION, Figure 3, for wire routing.

Tools and Materials A.

The recommended tools and materials are given in Table 701. NOTE: Equivalent items can be used.

B.

All work must be done at an electrostatic discharge (ESD) safe work bench. Refer to REPAIR for general ESD handling instructions and work bench requirements. No other special tools or equipment are required.

Copyright 2004 by: Radiant Power Corp., a HEICO Company

25-65-02

Page 701 Aug 2009

RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER BPS7 Assembly Tools and Materials Table 701 Part or Specification Number

Nomenclature Adhesive

Source General Electric Supply Co. (9G944)

RTV 102

Alcohol, Isopropyl

Federal Specification TT-I-735

Commercially Available

---

Commercially Available

Military Specification MIL-I-46058, Class C, Type UR (Humiseal 1A20)

Columbia Chase Corp. (99109)

Federal Specification QQ-S-571

Commercially Available

---

Commercially Available

Brush, Synthetic Fiber Conformal Coating, Brush Application Solder, Resin Core, Composition Sn63 Solder Iron, Low Wattage (24 to 40 Waft) Thermal Compound

120-2

Thread Lock Compound Tubing, Shrink

The Wakefield Corp. (92218)

Military Specification MIL-S-22473(Loctite Grade H) HS-105, Class H

Ultraviolet Light, Black Wire, Electrical, 20 and 24 AWG (select size and color per Table 702)

Loctite Corp. (05972) Markel Electric Products Co. (83750)

---

Commercially Available

BMS1 3-48C or MIL-W-22759 (Raychem 55A0111-20, -24)

Commercially Available

*Refer to Table 1001 in the IPL for the address

Copyright 2004 by: Radiant Power Corp., a HEICO Company

25-65-02

Page 702 Aug 2009

RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER BPS7 3.

Electrical Wire Replacement NOTE: This procedure provides general instructions to select and solder new wire leads during assembly. Refer to MIL-STD-454, Requirement 5 for general soldering instructions. Assembly Wire List Table 702

Wire Code*

Wire Color

Wire Size (AWG)

Connector J1 Pin

From Component

D C E H D C F G B K B A C D B A A

Yellow Blue Green Gray Orange Blue Blue Purple Yellow White Yellow Black Red Orange Brown Black Black

24 20 24 24 20 20 20 24 20 20 20 20 20 24 24 20 20

A1-6 A2-1 A2-2 A2-3 A2-5 A2-7 A2-7 A2-8 A2-17 A2-20 A2-22 J1-1 J1-2 J1-3 J1-4 J1-5 J1-6

E

Black

24

J1-7

B D or K D or K D or K D or K D or K D or K D or K D or K

Red Green Green Gray Gray Purple Purple Red Red

24 20 20 20 20 20 20 20 20

K

White

20

B

Yellow

20

F G A F B

Yellow Purple Brown Blue White

20 20 20 24 24

J1-8 J1-9 J1-10 J1-11 J1-12 J1-13 J1-14 J1-15 J1-16 J1-17 J1-18 J1-19 J1-20 J1-21 J1-22 J1-23 J1-24 Q1-E (Emitter) R2 SW1 SW1

A2-22 Q2-B (Base) A1-2 A1-8 Q1-B (Base) R1 Q1-C A1-5 Q2-C (Collector) Q2-E (Emitter) R1 A2-18+ A2-21 A1-7+ A1-9+ A2-19 A2-18 Switch SW1 Solder Lug (75) A1-4 A2-9 A2-10 A2-11 A2-12 A2-13 A2-14 A2-15 A2-16 Dummy Pin A2-20 Dummy Pin A2-6 Dummy Pin Dummy Pin Dummy Pin A2-17 R2 A2-4 A1-1 A1-3

A.

Trim new wire leads (Table 701) as needed to the length given in Table 702. Select the wire color and wire gage (AWG) to match.

Copyright 2004 by: Radiant Power Corp., a HEICO Company

25-65-02

Page 703 Jan 2012

RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER BPS7 NOTE: All wire lengths to be ±1/16 inch (±1.6 mm). Pre-strip all wire ends to 1/8 inch (3.2 mm). B.

Solder the wire leads to the applicable terminals given in Table 702 with the solder given in Table 701. Duplicate the original wire routing as closely as possible. Refer to REPAIR to replace the connector J1 wire leads and pin contacts. NOTE: Routing instructions are given in the assembly procedures.

4.

Assembly Instructions NOTE: This procedure contains information for wire routing. Duplicate the original wire routing, insulation, and soldering methods as closely as possible. CAUTION: DO NOT OVERHEAT ELECTRONIC COMPONENTS WHEN SOLDERING WIRE LEADS. USE A HEAT SINK AND LOW WATTAGE SOLDER IRON TO PREVENT DAMAGE. USE A SOLDER SUCKER AND/OR SOLDER WICK TO REMOVE EXCESS SOLDER. PCB ASSEMBLIES A1 AND A2 CONTAIN SENSITIVE ELECTRONIC COMPONENTS THAT CAN BE DAMAGED BY ESD AND ROUGH HANDLING. HANDLE THE PCB ASSEMBLIES WITH CARE TO PREVENT DAMAGE. A.

Assemble the chassis assembly (400), as follows: (1) (Refer to REPAIR to replace the adhesive-backed chassis nameplate (440). (2) Install new damper pads (433) if applicable, as follows: NOTE: The damper pads are not used with the new configuration battery assembly BT1 (445A). (a)

Clean the mounting area with isopropyl alcohol and lint-free cloths (Table 701).

(b)

(Bond the damper pads (433) to the chassis (435) with adhesive (Table 701).

(3) Refer to REPAIR to replace the riveted battery mounting brackets (425). (4) Refer to REPAIR to replace the clinch nuts (415). B.

Assemble and install battery assembly BT1 (445A, IPL Figure 1), as follows: NOTE: Battery assembly BT1 (445A) is used on all BPS7-3 battery power supplies, and is the preferred spare for replacement of battery assembly (445) originally shipped on BPS7-2 battery power supplies. Battery assembly BT1 (445A) incorporates design improvements to increase the life of the unit (1) Refer to REPAIR to replace the labels (580A).

Copyright 2004 by: Radiant Power Corp., a HEICO Company

25-65-02

Page 704 Aug 2009

RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER BPS7 CAUTION: DO NOT SOLDER THE WIRE BRAID (572) ON THE END OF THE BATTERY PACK OPPOSITE PIN SOCKETS J2-1 AND J2-2 UNTIL THE SOCKETS ARE CONNECTED AND INSULATED. (2) Solder the batteries (575) in series as shown in Figure 701. Do not connect the wire braid (572) opposite pin sockets J2-1 and J2-2 (535 and 540) until the pin sockets are soldered and insulated (step (6), below). Use tape (574) to insulate tabs from the cells as shown in Figure 701. Each end is wrapped differently. Install 1.0” (ref) of heatshrink (HS-105) over the four tabs between the cells. NOTE: Replacement batteries (575) are shipped with integral solder tabs. All six batteries should be replaced in any one battery is damaged or corroded. (3) Cut two 2-inch (5.1 cm) lengths of wire braid (572). Solder one wire braid to the positive tab on the battery pack and one to the negative tab. Refer to Figure 701.

NOTE: THE ITEM NUMBERS IN PARENTHESES REFER TO IPL FIGURE 1. Battery Connection Diagrams Figure 701

Copyright 2004 by: Radiant Power Corp., a HEICO Company

25-65-02

Page 705 Sep 2010

RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER BPS7 (4) Install two shoulder washers (530A) back to back through each pin socket (535 and 540) mounting hole in the top half case (565A). Insert the pin sockets through the shoulder washers and install the flat washers (545A) and the nuts (550). (5) Turn the top half case (565A) upside down and install the batteries (575) with the solder tabs facing up (out away from the case). Loop the positive and negative wire braids (572) up along the outside and over the top of pin sockets J2-1 and J2-2 (535 and 540). NOTE: The wire braid (572) from the positive battery pack terminal connects to red pin socket J2-1 (535). The wire braid from the negative terminal connects to black pin socket J2-2 (540). Refer to Figure 701. CAUTION: DO NOT TIN THE BRAID MORE THAN 1/4 INCH (6 MM) FROM THE PIN SOCKET. TINNING CAN DECREASE THE FLEXIBILITY OF THE BRAID. (6) Solder the positive and negative wire braids (572) to pin sockets J2-1 and J2-2 (535 and 540). Refer to paragraph 3, above. CAUTION: INSERT A PIECE OF INSULATING MATERIAL BETWEEN PIN SOCKETS J2-1 AND J2-2 (535 AND 540) TO PREVENT SHORTING DURING MAINTENANCE. (7) Insert a piece of insulating material (tape, paper, etc.) between pin sockets J2-1 and J2-2 (535 and 540). (8) Solder the rear links to the applicable battery (575) tabs. Refer to Figure 701. (9) Rotate each group of three batteries (575) inward, tucking the intermediate solder tabs behind the integral insulators in the top half case (565A). Loop the rear wire braid (572) inward between the batteries. (10) Install the 1/4 turn fasteners (450A) and the retraction springs (465) in the pockets in the top half case (565A). Install the Teflon flat washers (460A) on the fasteners inside the case. CAUTION: MAKE SURE THERE IS NO CONTACT BETWEEN PIN SOCKETS J2-1 AND J2-2 OR ANY OTHER OPPOSITE CHARGED COMPONENT BEFORE THE INSULATING MATERIAL IS REMOVED. (11) Remove the insulating material from between pin sockets J2-1 and J2-2 (535 and 540). (12) Install the bottom half case (570A), with the integral insulator inserted between pin sockets J2-1 and J2-2 (535 and 540). The Teflon washers (460A) must be installed between the top and bottom half cases. The 1/4 turn fasteners (450A) must extend through the matching holes in the bottom half case.

Copyright 2004 by: Radiant Power Corp., a HEICO Company

25-65-02

Page 706 Aug 2009

RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER BPS7 CAUTION: DO NOT OVERTIGHTEN THE SCREWS (490A) AND THE NUTS (500A). THE BATTERY CASE IS MADE OF A LIGHTWEIGHT PLASTIC MATERIAL THAT CAN CRACK. (13) Install the screws (490A), the flat washers (495A), and the nuts (500A) to secure the top and bottom half cases (565A and 570A) together. Tighten the nuts snug but not enough to damage the battery case. (14) Bond the fuse retainer pad (525) to the top half case (565A), as follows: CAUTION: DO NOT USE SOLVENT CLEANERS ON THE TOP HALF CASE (565A). SOLVENTS CAN DAMAGE THE LEXAN MATERIAL. (a)

Clean the mounting area on the top half case with isopropyl alcohol and lint-free cloths (Table 701).

(b)

Bond the fuse retainer pad (525) to the top half case (565A) with adhesive (Table 701).

CAUTION: DO NOT LIFT BATTERY ASSEMBLY BT1 AFTER MATING THE PIN CONTACTS AND SOCKETS. DOING SO CAN DAMAGE THE PIN CONTACTS ON PCB ASSEMBLY A2. (15) Install battery assembly BT1 (445A), as follows: (a)

Insert battery assembly BT1 (445A) into the chassis assembly (400).

(b)

If the electronics assembly (40) is installed, press battery assembly BT1 (445A) against the chassis and carefully slide it inward to insert pin contacts J3-1 and J3-2 on PCB assembly A2 (205) into pin sockets J2-1 and J2-2 (535 and 540).

(c)

If the electronics assembly (40) is not installed, press battery assembly BT1 (445A) against the chassis and carefully slide it inward to a position over the receptacles (420) in the chassis brackets.

CAUTION: DO NOT TURN THE 1/4 TURN FASTENERS PAST THE DETENT (d)

C.

Turn the 1/4 turn fasteners (450A) clockwise approximately 90° to the stop. An audible click will be heard when the stop is reached. The fasteners should compress the retraction springs (465).

Assemble and install battery assembly BT1 (445), as follows: NOTE: Battery assembly BT1 (445) is obsolete and should be replaced by item (445A). Battery assembly BT1 (445A) incorporates design improvements to increase the life of the unit. Battery assembly BT1 (445) can be used if desired, however, on both the BPS7-2 and BPS7-3 battery power supplies. (1) (Refer to REPAIR to replace adhesive-backed labels (580, 585 and 590).

Copyright 2004 by: Radiant Power Corp., a HEICO Company

25-65-02

Page 707 Aug 2009

RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER BPS7 CAUTION: DO NOT SOLDER THE REAR WIRE BRAID (572) ON THE END OF THE BATTERY PACK OPPOSITE PIN SOCKETS J2-1 AND J2-2 (535 AND 540) UNTIL THE SOCKETS ARE CONNECTED AND INSULATED. (2) Solder the batteries (575) in series as shown in Figure 701. Do not connect the wire braid (572) opposite pin sockets J2-1 and J2-2 (535 and 540) until the pin sockets are soldered and insulated (step (6), below). NOTE: Replacement batteries (575) are shipped with integral solder tabs. All six batteries should be replaced if any one battery is damaged or corroded. (3) Cut two 2-inch (5.1 cm) lengths of wire braid (572). Slide 1 inch (2.5 cm) lengths of shrink tubing (571) over the wire braids and solder the wire braids to the connectors (555) and the positive and negative tabs on the battery pack. Refer to IPL Figure 1, Sheet 5. CAUTION: DO NOT OVERTIGHTEN THE NUTS (550). THE BATTERY HOLDER IS MADE OF A LIGHTWEIGHT PLASTIC MATERIAL THAT CAN CRACK. (4) Install a grommet (530) through each pin socket (535 and 540) mounting hole in the bottom battery holder (570). Insert the pin sockets through the grommets and install the inside set of nuts (550). Do not overtighten the nuts. (5) Install the batteries (575) in the bottom battery holder (570). CAUTION: INSERT A PIECE OF INSULATING MATERIAL BETWEEN PIN SOCKETS J2-1 AND J2-2 (535 AND 540) AND DO NOT ALLOW THE CONNECTORS (555) TO TOUCH, SO AS TO PREVENT SHORTING DURING MAINTENANCE. (6) Insert a piece of insulating material (tape, paper, etc.) between pin sockets J2-1 and J2-2 (535 and 540). (7) Install three layers of 2-Inch (5.1 cm) long glass tape (573) on the top of each battery (575). Refer to IPL Figure 1, Sheet 5. (8) Slide the connectors (555) onto pin sockets J2-1 and J2-2 (535 and 540). Install the star washers (545) and the outer nuts (550). NOTE: The connector (555) from the positive battery pack terminal connects to red pin socket J2-1 (535). The connector from the negative terminal connects to black pin socket J2-2 (540). (9) Loop any slack in the wire braids (572) back along the nearest battery (575), and secure it in place with glass tape (573). (10) Install the insulating paper (552) between pin sockets J2-1 and J2-2 (535 and 540). (11) Solder the rear wire braid (572) to the applicable battery (575) tabs. (12) Install the top battery holder (565). (13) Install the front band (510), as follows:

Copyright 2004 by: Radiant Power Corp., a HEICO Company

25-65-02

Page 708 Aug 2009

RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER BPS7 (a)

Wrap the front band (510) around the battery holder assembly (560). Install the screw (485) and the square washer (495).

(b)

Install the support block (480) in the pocket in the top battery holder (565).

(c)

Hold the top and bottom battery holders (565 and 570) together, push up on the screw (485), and install the square washer (495) and the nut (500).

(14) Install the middle band (515), as follows: (a)

Wrap the middle band (515) around the battery holder assembly (560). Insert the screw (485) and the square washer (495).

(b)

Install the support block (505) in the pocket in the top battery holder (565).

(c)

Hold the top and bottom battery holders (565 and 570) together, push up on the screw (485), and install the square washer (495) and the nut (500).

(15) Install the rear band (520), as follows: (a)

Wrap the rear band (520) around the batter holder assembly (560). Insert the screw (490) and the square washer (495).

(b)

Hold the top and bottom battery holders (565 and 570) together, push up on the screw (490), and install the square washer (495) and the nut (500).

(16) Install the rear support block (480) in the pocket in the top battery holder (565). (17) Install the screw (470), the flat washers (475), and the nut (500). (18) Install the 1/4 turn fasteners (450) and the retraction springs; (465) in the pockets in the top battery holder (565). Install the split ring retainers (460) under the bottom battery holder (570). CAUTION: MAKE SURE THERE IS NO CONTACT BETWEEN PIN SOCKETS J2-1 AND J2-2 OR ANY OTHER OPPOSITE CHARGED COMPONENT BEFORE THE INSULATING MATERIAL IS REMOVED. (19) Remove the insulating material from between pin sockets J2-1 and J2-2 (535 and 540). (20) Bond the fuse retainer pad (525) to the bottom battery holder (570), as follows: CAUTION: DO NOT USE SOLVENT CLEANERS ON THE BOTTOM BATTERY HOLDER (570). SOLVENTS CAN DAMAGE THE LEXAN MATERIAL. (a)

Clean the mounting area on the bottom battery holder with isopropyl alcohol and lintfree cloths (Table 701).

(b)

Bond the fuse retainer pad (525) to the bottom battery holder (570) with adhesive (Table 701).

Copyright 2004 by: Radiant Power Corp., a HEICO Company

25-65-02

Page 709 Aug 2009

RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER BPS7 CAUTION: DO NOT LIFT BATTERY ASSEMBLY BT1 AFTER MATING THE PIN CONTACTS AND SOCKETS. DOING SO CAN DAMAGE THE PIN CONTACTS ON PCB ASSEMBLY A2. (21) Install battery assembly BT1 (445), as follows: (a)

Insert battery assembly BT1 (445) into the chassis assembly (400).

(b)

If the electronics assembly (40) is installed, press battery assembly BT1 (445) against the chassis and carefully slide it inward to insert pin contacts J3-1 and J3-2 on PCB assembly A2 (205) into pin sockets J2-1 and J2-2 (535 and 540).

(c)

If the electronics assembly (40) is not installed, press battery assembly BT1 (445) against the chassis and carefully slide it inward to a position over the receptacles (420) in the chassis brackets.

CAUTION: DO NOT TURN THE 1/4 TURN FASTENERS PAST THE DETENT (d)

D.

Turn the 1/4-turn fasteners (450) clockwise approximately 90° to the stop. An audible click will be heard when the stop is reached. The fasteners should compress the retraction springs (465).

Assemble the electronics assembly (40), as follows: NOTE: With exception of the SIT components identified in the IPL, Radiant Power Corp. recommends that PCB assemblies A1 and A2 be returned to Radiant Power Corp. for repair by technicians familiar with the layout and function of the cards. Radiant Power Corp does not assume responsibility for any repairs and/or maintenance performed and parts and/or sub-assemblies which is not in accordance to procedures described in this manual. A point-to-point wire list is given in Table 702. A schematic diagram showing all connections is given in DESCRIPTION AND OPERATION, Figure 3. (1) Install resistors R1 and R2 (375), as follows: (a)

Solder the wire leads to resistor R1 and/or R2 (375). Refer to paragraph 3, above.

(b)

Lightly coat the threads of the screws (380) with thread lock compound (Table 701). Secure the resistors to the bracket assemblies (390 and 395) with the screws (380), the washers (383), and the nuts (385).

(2) Install transistor Q2 (350), as follows: (a)

Solder the wire leads between transistor Q2 (350) and the solder lug (370) and PCB assembly A2 (205). Refer to paragraph 3, above.

(b)

Lightly coat both sides of a new mica insulator (360) with thermal compound (Table 701). Secure transistor Q2 (350), the mica insulator, and an insulator strip (365) to

Copyright 2004 by: Radiant Power Corp., a HEICO Company

25-65-02

Page 710 Jan 2012

RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER BPS7 the bracket assembly (390) with the screws (340) and the nuts (345). Install the solder lug (370) under the upper nut as shown in IPL Figure 1, Sheet 3 NOTE: Install a new mica insulator (360) at each overhaul. (3) Install transistor Q1 (355), as follows: (a)

Solder the wire leads between transistor Q1 (355), the solder lug (370), and PCB assembly A2 (205). Refer to paragraph 3, above.

(b)

Solder the wire lead from transistor Q1 (355) emitter to resistor R2 (375).

(c)

Lightly coat both sides of a new mica insulator (360) with thermal compound (Table 701). Secure transistor Q1 (355), the mica insulator, and an insulator strip (365) to the bracket assembly (395) with the screws (340) and the nuts (345). Install the solder lug (370) under the upper nut as shown in IPL Figure 1, Sheet 3. NOTE: Install a new mica insulator (360) at each overhaul.

(4) Install transistor Q3 (245) on PCB assembly A2 (205), as follows: (a)

Refer to REPAIR to replace the damaged clinch nuts (226).

(b)

Lightly coat both sides of a new mica insulator (230) with thermal compound (Table 701). Secure transistor Q3 (245), the mica insulator, the bracket assembly (215), and an insulator strip (235) to the swaged standoffs on PCB assembly A2 (205) with the screws (220) and the washers (225). NOTE: Install a new mica insulator (230) at each overhaul.

(5) Solder the wire leads between PCB assembly A1 (85) and PCB assembly A2 (205). Refer to paragraph 3, above. (6) Solder the connector J1 (55A) wire leads to the PCB assemblies (85 and 205). (7) Solder the wire leads between TEST switch SW1 (70) and PCB assembly A1 (85). (8) Solder the wire lead from connector J1 (55A) to the solder lug (75). (9) Visually examine all solder connections, wire leads, and wire routing. Refer to Table 702 and Figure 3 in DESCRIPTION AND OPERATION.

Copyright 2004 by: Radiant Power Corp., a HEICO Company

25-65-02

Page 711 Jan 2012

RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER BPS7 WARNING: THE CONFORMAL COATING CAN IRRITATE YOUR EYES AND NOSE. APPLY THE COATING ONLY IN A WELL VENTILATED AREA. FLUSH IRRITATED EYES WITH WATER. CAUTION: THE WORK AREA AND BRUSH MUST BE CLEAN TO PREVENT CONTAMINATION. (10) Touch-up the conformal coating (Table 701) on the electronics assembly (40) as given below. NOTE: This step applies conformal coating to the electronics assembly using a synthetic fiber brush. This is the preferred method for repairs over aerosol sprays or dipping the assembly in a dip tank. (a)

Fold open the circuit boards and other components as needed to access the conformal coated surfaces.

(b)

Use a stiff bristle brush, plastic blade, or an equivalent tool to remove loose particles, ridges of coating material, and other defects in the conformal coating. The coated areas must have no visible blisters, cracking, peeling, pin holes or wrinkles. There must be no bubbles in contact with or bridging conductive surfaces.

(c)

Flood the area with isopropyl alcohol (Table 701) to wash off particles and soluble contamination.

(d)

Allow the electronics assembly to air dry for 30 minutes.

(e)

Examine the electronics assembly under black, ultraviolet light. Identify bare areas, other than solder connections, where the conformal coating has been worn through or scraped off.

(f)

Pour the necessary amount of Humiseal conformal coating (Table 701) from the sealed container into a temporary container. NOTE: The Humiseal conformal coating must be stored in a sealed container or it will form a skin of solid material after approximately four hours. The skin can be dissipated by pouring a 1/16 to 1/8 inch layer of thinner, Humiseal No. 20, over the material and covering the container with a tightly fitting cover.

(g)

Apply the conformal coating material with a synthetic (not natural) fiber brush. Coat all solder connections and the nonconductive areas of the PCB assemblies, including both sides of the printed circuit board, all board mounted components and their leads, and all exposed conductors. Do not coat electrical and mechanical mating surfaces, such as connector contact points, screw threads, bearing surfaces, etc. Mask the surfaces and components before application of the coating material, and carefully remove any tape residue and other contamination after the material has been applied. The coating must be 0.001 to 0.003 inch (0.025 to 0.076 mm) thick, when measured on a flat, unobstructed surface.

(h)

The coated areas must have no visible blisters, cracking, peeling, pin holes or wrinkles. There must be no bubbles in contact with or bridging conductive surfaces.

Copyright 2004 by: Radiant Power Corp., a HEICO Company

25-65-02

Page 712 Aug 2009

RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER BPS7 (i)

Examine the electronic assembly under black, ultraviolet light. Identify bare areas that require conformal coating. Reapply conformal coating to cover defective or bare areas, as required.

(j)

Allow the conformal coating to cure in accordance with the manufacturer's instructions.

(11) Lightly coat the threads of switch SW1 (70) with thread lock compound (Table 701). Install the switch through the solder lug (75) and the front panel (45) with the hex nut provided. (12) Lightly coat the threads of the screws (210) with thread lock compound. Secure PCB assembly A2 (205) to the mounting brackets (390 and 395) with the screws and the washers (213). NOTE: Install the insulating washers (213) on both sides of the printed circuit board. Install new washers at each overhaul. (13) Lightly coat the threads of the screws (90) with thread lock compound. Secure PCB assembly A1 (85) to the mounting brackets (390 and 395) with the screws and the washers (93) NOTE: Install the insulating washers (93) on both sides of the printed circuit board. Install new washers at each overhaul. (14) Install connector J1 (55A) in the front panel (45) with the screws (60) and the nuts (65). (15) Secure the front panel (45) to the mounting brackets (390 and 395) with the screws (50). CAUTION: DO NOT LIFT THE ELECTRONICS ASSEMBLY AFTER MATING THE PIN CONTACTS AND SOCKETS. DOING SO CAN DAMAGE THE PIN CONTACTS ON PCB ASSEMBLY A2. E.

Install the electronics assembly (40), as follows: (1) Lightly coat the bottoms of the transistor mounting brackets (215, 390 and 395) with thermal compound (Table 701). (2) Insert the electronics assembly (40) into the chassis assembly (400). (3) Press the electronics assembly (40) against the chassis and carefully slide it inward to insert pin contacts J3-1 and J3-2 on PCB assembly A2 (205) into pin sockets J2-1 and J22 (535 and 540) in battery assembly BT1 (445 or 445A). (4) Lightly coat the threads of the screws (35) with thermal compound (Table 701). Install the screws through the chassis assembly (400) and into the electronics assembly (40).

F.

Refer to REPAIR to replace the adhesive-backed nameplates (25, 30 and 32) or the silkscreen markings, as applicable.

G.

Install the cover assembly (10A or 10B) with the screws (15).

Copyright 2004 by: Radiant Power Corp., a HEICO Company

25-65-02

Page 713 Aug 2009

RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER BPS7 NOTE: Cover assembly, P/N 2010-2, has superseded cover assembly, P/N 2010-1. However, both can be used interchangeably. The preferred spare is P/N 2010-2. H. 5.

Refer to TESTING AND FAULT ISOLATION to bench test the BPS.

Packaging Instructions Protect the BPS from humidity and shock by packaging the unit when it is not in use or for transport. Repack the BPS in the original shipping container when possible. CAUTION: THE PCB ASSEMBLIES CONTAIN ESD SENSITIVE DEVICES. REFER TO REPAIR FOR ESD SAFE HANDLING PROCEDURES. THE BPS CONTAINS SENSITIVE ELECTRONIC COMPONENTS THAT CAN BE DAMAGED BY ROUGH HANDLING AND EXPOSURE TO HIGH HUMIDITY, WATER OR OTHER LIQUIDS, CIGARETTE SMOKE, AND OTHER CONTAMINATION. USE THE BPS IN AN ENVIRONMENT SUITABLE FOR ELECTRONIC COMPONENTS AND HANDLE THE UNIT WITH CARE TO PREVENT DAMAGE. A.

Refer to REPAIR for ESD safe handling procedures.

B.

If loose components must be shipped, pack the PCB assemblies in antistatic shipping bags. Pack all other components in clean plastic bags. The materials given below are unacceptable and prohibited from use in any packaging where they could come into direct contact with the PCB assemblies. (1) Untreated styrofoam, polyform or polystyrene sheets, black inserts, and foam filler pieces (for example, foam peanuts). (2) Untreated plastic boxes. (3) Static-generating plastic wrap, bags, or bubble pack. (4) Pink poly foam and bubble wrap that is not certified Amino-free. (5) Untreated connector plastic dust covers.

C.

If the original shipping containers are not available, pack the BPS, as follows: (1) Write the maintenance data and dates on a tag. Attach the tag to the BPS. (2) Install a protective cap (Table 703) on connector J1. (3) Overwrap the BPS in nylon film or bubble wrap to cushion the unit and prevent damage to the barrier bag. (4) Pack the BPS in a corrugated paper box. Fill all voids with cellulose wadding or brown Kraft paper. (5) Add a sufficient amount of desiccant and seal the box with packing tape.

Copyright 2004 by: Radiant Power Corp., a HEICO Company

25-65-02

Page 714 Aug 2009

RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER BPS7 (6) Write the BPS nomenclature, part number, and maintenance/test dates on the box. 6.

Storage Instructions CAUTION: THE PCB ASSEMBLIES CONTAIN ESD SENSITIVE DEVICES. REFER TO REPAIR FOR ESD SAFE HANDLING PROCEDURES. THE BPS CONTAINS SENSITIVE ELECTRONIC COMPONENTS THAT CAN BE DAMAGED BY ROUGH HANDLING AND EXPOSURE TO HIGH HUMIDITY, WATER OR OTHER LIQUIDS, CIGARETTE SMOKE, AND OTHER CONTAMINATION. USE THE BPS IN AN ENVIRONMENT SUITABLE FOR ELECTRONIC COMPONENTS AND HANDLE THE UNIT WITH CARE TO PREVENT DAMAGE A.

Refer to REPAIR for ESD safe handling procedures.

B.

Refer to ASSEMBLY, paragraph 5 to package the BPS for storage.

C.

Store the BPS in an area suitable for electronic equipment. The storage area must have adequate ventilation with low humidity, dust, and protection from direct sunlight and high heat. Storage Materials Table 703

Description

Part Number or Specification Number

Source (CAGE)*

Bag, Polyethylene

Military Specification MIL-B-117

Commercially Available

Box, Corrugated Paper

Federal Specification PPP-B-636

Commercially Available

Cover, Protective Tape, Packing

---

Protective Closures Inc. (99017)

Federal Specification JAN-P-127

Commercially Available

---

Commercially Available

Tag, Identification

*Refer to Table 1001 in the IPL for the address

Copyright 2004 by: Radiant Power Corp., a HEICO Company

25-65-02

Page 715 Aug 2009

RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER BPS7

THIS PAGE INTENTIONALLY LEFT BLANK

Copyright 2004 by: Radiant Power Corp., a HEICO Company

25-65-02

Page 716 Aug 2009

RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER BPS7

SPECIAL TOOLS, FIXTURES AND EQUIPMENT The recommended special tools, fixtures, and test equipment are given in Table 901. NOTE: Equivalent items can be used. Special Tools, Fixtures, and Equipment Table 901 (Sheet 1 of 2) Nomenclature

Part Number

Source (CAGE)*

Use

Bright Light

---

Commercially Available

To assist in the inspection of parts.

Brush, Synthetic Fiber

---

Commercially Available

Connector, Electrical

BACC45FN16- 24S or 48-16R16-24S

The Boeing Co. (81205) Amphenol Corp. (77820)

Function Generator, 5V, 0.2Amp, 30 ms Square Wave

Model 1400

Krohn-Hite Corp. (88865)

Function generator to generate squib pulses for bench tests.

Insertion/Extraction Tool, Pin Contact

MS24256R12

Commercially Available

To replace damaged pin contacts in connector J1.

Lamp, Incandescent (Test Load) (8 Required)

No. 82

General Electric Co. (0EE74)

Load to simulate emergency lights for bench tests.

Model 16449701

Quadtech Inc. (0PK96)

To measure the insulation resistance of the BPS circuits.

Megohmmeter, 100 megohms, 500 VDC, ±2% Full Scale Multimeter (Ohmmeter, Ammeter or Voltmeter can be used), 0 to 10 Amps DC (±2% Full Scale), 0 to 100 VDC (31/2 digits); 200 to 300 kilohms Oscilloscope, Digital Storage, Two Channel

8012A, 77 or 85 III

Model 8010A,

John Fluke Mfg. Co., Inc. (89536)

To apply Humiseal conformal coating. Mating connector to connect test equipment to BPS for bench tests.

To measure voltage, current, and resistance for bench tests.

34401A

Hewlett-Packard Co. (28480)

54504A-E01/910 DL1540

Hewlett-Packard Co. (28480)

Yokogawa (60336)

To measure and display the squib pulse voltage and current.

Power Supply, 0 to 12 VDC min/ 25A min (E1)

Model DCR40-25B2 Model 1692

Sorensen BK Precision (0GXY1)

DC power source E1 for bench tests.

Power Supply, 0 to 32 VDC min/ 2A min (E2)

Model DCR40-25B2 Model 1601

Sorensen BK Precision (0GXY1)

DC power source E2 for bench tests.

Press, Hydraulic or Mechanical

---

Commercially Available

To press new clinch nuts in the brackets and heatsink.

Commercially Available

Resistors for the squib pulse bench test circuit (Figure 101).

Resistor, 47.5 1W, 1% 4.75 5W, 1% 0.47 100W, 10%

RWR81S47R5FR RWR74S4R75FR RE77GR470

*Refer to Table 1001 in the IPL for the address

Copyright 2004 by: Radiant Power Corp., a HEICO Company

25-65-02

Page 901 Jan 2012

RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER BPS7 Special Tools, Fixtures, and Equipment Table 901 (Sheet 2 of 2) Nomenclature

Part Number

Source (CAGE)*

Use

Switch, Momentary Contact, SPST (S1)

---

Commercially Available

Switch for bench test setup.

Switch, Toggle SPST (S2,S3,S4) (3 Required)

---

Commercially Available

Switch for bench test setup.

Transistor

JANTX2N3055

Commercially Available

Transistor for the squib pulse bench test circuit (Figure 101).

Transistor

JANTX2N4399

Commercially Available

Transistor for the squib pulse bench test circuit (Figure, 101).

Solder Iron, LowWattage (24 to 40Watt)

---

Commercially Available

To solder wire connections to the circuit board pads and other electronic/ electrical components.

Tank or Shop Compressed Air, 20 psig (140 kPag)

---

Commercially Available

To clean and dry BPS components.

Thread Chaser

---

Commercially Available

To repair damaged threads.

BPS7-3 Battery Housing Analyzer Kit

550-13058-00

Radiant Power Corp. (1MXA1)

To perform on-aircraft testing of BPS7-3 battery and charger.

*Refer to Table 1001 in the IPL for the address

Copyright 2004 by: Radiant Power Corp., a HEICO Company

25-65-02

Page 902 Jan 2012

RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER BPS7

ILLUSTRATED PARTS LIST 1.

Introduction A.

Purpose This IPL illustrates and lists authorized replacement parts.

B.

Guide to Use of the IPL (1) If the part number is not known: (a)

Find the part in the exploded-view Illustrations.

(b)

Refer to the parts list and find the item number in the FIG. ITEM column.

(2) If the part number is known:

2.

(a)

Refer to the parts list, numerical index, or equipment designator index and find the part in the PART NUMBER column.

(b)

Refer to the exploded-view illustration to identify the attaching hardware and related assembly parts.

Manufacturer Names and Addresses The CAGE codes for the companies that make the parts, the materials, the special tools, and the test equipment referenced in this CMM are given in Table 1001. The codes are taken from Cataloging Handbook H4/H8. No code is given in the parts list when the part is made by Radiant Power Corp. or to a Radiant Source Control Drawing (SCD).

3.

Equipment Designator Index The Equipment Designator Index is an aid to find electronic and electrical components in the Detail Parts List by equipment designator. The equipment designator, the figure number, and the item number are given for each entry. The equipment designators are sorted one character at a time, from left to right. The correct sequence is (1) dash, (2) letters A through Z and (3) numerals 0 through 9.

4.

Numerical Index The Numerical Index is an aid to find the parts in the Detail Parts List by part number. The figure number, the item number, and the total quantity are given for each entry. The part numbers are sorted one character at a time, from left to right. The correct sequence is (1) dash, (2) letters A through Z, and (3) numerals 0 through 9. Manufacturer Names and Addresses

Copyright 2004 by: Radiant Power Corp., a HEICO Company

25-65-02

Page 1001 Aug 2009

RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER BPS7 Manufacturer Names and Addresses Table 1001 (Sheet 1 of 2) CAGE

Name and Address

CAGE

057Q7

ACI Electronics 500 N State College Blvd. Ste. 730 Orange, CA 92868

18565

Chromerics Inc. 77 Dragon Court Woburn, MA 01801

Adcraft Prod. Co. Inc. 1230 S. Sherman St. Anaheim, CA 92805

4T284

Clorox Co. Food Service Products Div. 1221 Broadway Oakland, CA 94612

5X895

Aeroflite Components Inc. 261 Gemini Brea, CA 92821

99109

Columbia Chase Corp. Humiseal 128 First St. Pittsburgh, PA 15238

0TBK5

Allied Electronics Inc. 10491 72nd St. N. Largo, FL 33774

6S047

Electrical Insulation Suppliers Inc. 1905 Premier Row Orlando, FL 32809-6205

77820

Amphenol Corp. Bendix Connector Operations 40-60 Delaware Ave. Sidney, NY 13838

0EE74

General Electric Co. GE Lighting Div. 4521 Highwoods Pkwy. Ste. 200 Glen Allen, VA 23060

6M193

Arrow/ Zeus Electronics 2900 Westchester Ave Ste. 401 Purchase, NY 10577

9G944

General Electric Supply Co. 200 W. River Ave. Pittsburgh, PA 15212-5725

68491

Andpak-Ema Inc. - Calla Chemical Operations 400 Jarvis Rd. Morgan Hill, CA 95037

81073

Grayhill Inc. 561 Hillgrove Ave. La Grange, IL 60525-5914

0GXY1

BK Precision 84 Chenango St. S. Greene, NY 13778-0496

12405

Henkel Loctite Corp. 15051 E. Don Julian Rd. Industry, CA 91746

81205

The Boeing Company 7755 E. Marginal Way S. Seattle, WA 98108

28480

Hewlett-Packard Co. Corporate Headquarters 3000 Minuteman Rd. Andover, MA 01810

94058

Brulin and Co. Inc. 2920 Dr. Andrew J. Brown Ave. Indianapolis, IN 46205

98978

International Electronic Research Corp. 413 N. Moss St. Burbank, CA 91502

8R639

Century Fasteners Corp. 5040 Tampa W. Blvd. Tampa, FL 33634

4U744

ITT Pomona Electronics Div. 6920 Seaway Boulevard Everett, WA 98203

ADCPR*

Copyright 2004 by: Radiant Power Corp., a HEICO Company

Name and Address

25-65-02

Page 1002 Sep 2010

RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER BPS7 Manufacturer Names and Addresses Table 1001 (Sheet 2 of 2) CAGE 89536

Name and Address John Fluke Mfg. Co., Inc.

CAGE

Name and Address

07080

R. S. Hughes Company, Inc. 1162 Sonora Crt. Sunnyvale, CA 94086

6920 Seaway Boulevard Everett, WA 98203 88865

Krohn-Hite Corp. 15 Jonathan Dr. Ste. 4 Brockton, MA 02301

1MXA1

Radiant Power Corp. 7135 16th St. E., Ste. 101 Sarasota, FL 34243

4J674

Leader Tech, Inc. 12420 Race Track Rd. Tampa, FL 33626

00JU0

Sanyo Energy Corp. 2600 Network Blvd. Ste. 600 Frisco, TX 75034

75915

Littlefuse Inc. 8755 W. Higgins Rd. Ste. 500 Chicago, IL 60631

86928

Seastrom Manufacturing Co. Inc. 456 Seastrom St. Twin Falls, ID 83301

05972

Loctite Corp. 1001 Trout Brook Xing Rocky Hill, CT 06067

94222

Southco Inc. 210 N. Brinton Lake Rd. Concordville, PA 19331

83750

Markel Electric Products Co. 555 Commerce Dr. Tonawanda, NY 14150

28071

Steven Label Corp. 11926 Burke St. Santa Fe Springs, CA 90670

39425

McNab, Inc. 383 E. 29th St. Buena Vista, VA 24416

8N187

TTI, Inc. 2441 NE Pkwy. Fort Worth, TX 76106-1816

02929

Newark Electronics 4801 N Ravenswood Ave. Chicago, IL 60640-4457

1W091

Universal Semiconductor Inc. 2775 W Cypress Creek Rd. Fort Lauderdale, FL 33309

Nica Corp. 6006 Shull St. Bell Gardens, CA 90201

92218

The Wakefield Corp. 29 Foundry St. Wakefield, MA 01880-3200

Penn Engineering and Mfg. Corp. 5190 Old Eaton Road Danboro, PA 18916

14726

Wearnes Hollingsworth Corp. Crystal Park-Bldg. 4 1907 NW 40th Court Pompano Beach, FL 33064

Premier Fabricating & Stamping 232 Dunbar Ave. Oldsmar, FL 34677

79963

Zierick Mfg. Co. 131 Radio Circle Mount Kisco, NY 10549

Quadtech Inc. 5 Clock Tower Pl. Ste. 210 Maynard, MA 01754

60336

Yokogawa Corp. 12530 W. Airport Blvd. Sugarland, TX 77478

NICAC*

46384

PREMF*

0PK96

*Internal vendor code, CAGE code pending

Copyright 2004 by: Radiant Power Corp., a HEICO Company

25-65-02

Page 1003 Jan 2012

RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER BPS7 5.

Explanation of Detail Parts List Entries The Detail Parts List is arranged in general sequence of disassembly. The parts are illustrated in an exploded-view illustration and listed in the related parts list. A.

FIG. ITEM Column (1) The first number at the top of each FIG. ITEM column is the figure number of the exploded-view illustration. The number given opposite each part number is the item number given to the part in the illustration. (2) A dash (-) is put before the item number when it is not illustrated. (3) Alpha-variants A through Z (except I and O) are given to item numbers when necessary to identify added parts, alternative parts, and service bulletin modified parts.

B.

PART NUMBER Column This column contains the part number for each part, as modified to satisfy ATA 200/2000. The modifications can include: (1) Removal of blank spaces and special characters, with the possible exception of dashes. Dashes are permitted only between numeric characters. (2) Use of a shorter part number compatible with ATA 200/2000 if the part number is longer than 15 characters. The full part number is given in the NOMENCLATURE column.

C.

NOMENCLATURE Column (1) This column contains the name of each part. The column can also contain the CAGE code of the company that made the part (if it is not made by Radiant Power Corp.), the full part number (if it is longer than 15 digits or modified to ATA 200/2000), any service bulletins that apply to the part, and any obsolete part numbers. (2) The indenture system used in the NOMENCLATURE column shows how each part is related to the others, as follows: 123 End Item or Major Assembly  Detail Parts for End Item or Major Assembly  Subassemblies ATTACHING PARTS  Attaching Parts for Subassemblies ----****----

  Detail Parts for Subassemblies ATTACHING PARTS   Attaching Parts for Detail Parts ----****----

Copyright 2004 by: Radiant Power Corp., a HEICO Company

25-65-02

Page 1004 Aug 2009

RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER BPS7 (3) Assemblies, subassemblies and detail parts subject to modification, deletion, addition or replacement by an issued service bulletin are annotated to indicate both pre- and postservice bulletin configurations. The term (PRE SB XXXX) in the NOMENCLATURE column designates the original configuration, and the term (POST SB XXXX) identifies assemblies and parts after the modification has been completed. (4) The terms defined below are used when applicable to show the interchangeability of parts.

D.

Term Superseded By

Abbreviation SUPSD BY

Supersedes

SUPSDS

Replaced By

REPLCD BY

Replaces

REPLCS

Definition The part is replaced by and is not interchangeable with the item number designated in the notation The part replaces and is not interchangeable with the item number designated in the notation. The part is replaced by and is interchangeable with the item number designated in the notation. The part replaces and is interchangeable with the item number designated in the notation.

EFF CODE Column This column contains effectivity codes (A, B, etc.) to show the alternative models or configurations of the end item to which the parts apply. This column is left blank when the parts apply to all models or configurations in the parts list.

E.

UNITS PER ASSY Column The quantity given in this column shows the number of units necessary for one NHA or, when you refer to attaching parts, the quantity to attach one such item. The abbreviation RF (reference) is given to end items and subassemblies.

Copyright 2004 by: Radiant Power Corp., a HEICO Company

25-65-02

Page 1005 Aug 2009

RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER BPS7 EQUIPMENT DESIGNATOR INDEX (Sheet 1 of 3) DESIGNATOR A1 A2 BT1 C2 C3 C4 C5 C7 C8 C9 C10 C11 C12 C13 C14 C15 CR1 CR2 CR3 CR4 CR5 CR6 CR7 F1 F2 F3 F4 J1 J2-1 J2-2 Q1 Q2 Q3 Q4

PART NUMBER 2001 NONPROC1 2004-2 NONPROC2 2013-1 2013-1A CSR13E106KR CKR05BX104KR M39014/1-1553 CKR06BX105KR M39014/2-1415 CKR05BX104KR M39014/1-1553 CKR05BX104KR M39014/1-1553 CKR06BX105KR M39014/2-1415 CKR05BX104KR M39014/1-1553 CKR05BX104KR M39014/1-1553 CKR05BX104KR M39014/1-1553 CKR05BX104KR M39014/1-1553 CKR05BX104KR M39014/1-1553 M39014/2-1316 CKR05BX104KR M39014/1-1553 JANTX1N751A-1 JANTX1N5622 JANTX1N4148-1 JANTX1N751A-1 JANTX1N4148-1 JANTX1N4148-1 JANTX1N4469 276005 276005 276005 276005 MS24264R16B24PN BACC45FN16-24P 3542-2 3542-0 JANTX2N3716 JANTX2N4399 JANTX2N3741 JANTX2N2222A

Copyright 2004 by: Radiant Power Corp., a HEICO Company

FIGURE 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

25-65-02

ITEM 200 200A 335 335A 445 445A 155 145 145A 150 150A 145 145A 145 145A 150 150A 145 145A 145 145A 145 145A 145 145A 145 145A 147 263 263A 255 325 165 160 165 165 265 310 310 310 310 55 55A 535 540 355 350 245 250

Page 1006 Aug 2009

RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER BPS7 EQUIPMENT DESIGNATOR INDEX (Sheet 2 of 3) DESIGNATOR Q5 Q6 R1 R2 R3 R4 R5 R6 R7 R8 R9 R10 R11 R12 R13 R14 R15 R16 R17 R18 R19 R20 R21

R22 R23 R24 R25 R26 R27 R28

R29 R31 R32 SW1 VR1 Z1 Z2

PART NUMBER JANTX2N2222A JANTX2N2222A RER60F14R0R RER60F14R0R RWR80S4020FR RLR07C4702GR RLR07C4703GR RLR07C4702GR RWR81S1R00FR RLR07C68R0GR RLR07C1001GR RLR07C1001GR RLR07C2401GR RLR07C4703GR RNC55H3742FR RLR07C1004GR RLR07C2203GR RLR07C4702GR RNC55H1002FR RLR07C4703GR RLR07C4702GR RLR07C4702GR RNC55H7870FR RNC55H7680FR RNC55H7500FR RNC55H8060FR RNC55H5110FR RLR07C4702GR RNC55H4022FR RLR07C1000GR RLR07C4702GR RLR07C4703GR RCR07G915JS RCR07G625JS RCR07G755JS RCR07G825JS RLR07C9104GP RLR07C6204GP RLR07C7504GP RLR07C8204GP RLR07C4702GR RLR07C4703GR RLR07C4703GR 39-1 V33ZA1 LM139J/883 2026 SG1503Y/883B

Copyright 2004 by: Radiant Power Corp., a HEICO Company

FIGURE 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

25-65-02

ITEM 250 250 375 375 270 95 110 95 275 280 285 100 105 110 125 170 115 95 130 110 95 95 300 300A 300B 300C 305 290 120 295 95 110 140 140A 140B 140C 140D 140E 140F 140G 95 110 110 70 260 175 180 180A

Page 1007 Aug 2009

RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER BPS7 EQUIPMENT DESIGNATOR INDEX (Sheet 3 of 3) DESIGNATOR Z3 Z4 Z5

PART NUMBER MC14011B/883 CD4011B/883 MM54C14J883 CD40106BF3A CD4085BF/883

Copyright 2004 by: Radiant Power Corp., a HEICO Company

FIGURE 1 1 1 1 1

25-65-02

ITEM 185 185A 190 190A 195

Page 1008 Aug 2009

RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER BPS7 NUMBERICAL INDEX (Sheet 1 of 5) PART NUMBER

AIRLINE STOCK NO.

B1530B-1/8-4 BACC45FN16-24P BACN10JC04 BACN10JC06 BACR15BA4AD4 BBI-03G BBI-066G BMS160ATYPE1 CD40106BF3A CD4011B/883 CD4085BF/883 CKR05BX104KR CKR06BX105KR CSR13E106KR DBX-101 DM101 FEO-440

FE-440 HS-105 HT105-3-16 JANTX1N4148-1 JANTX1N4469 JANTX1N5622 JANTX1N751A-1 JANTX2N2222A JANTX2N3716 JANTX2N3741 JANTX2N4399 LM139J/883 M39014/1-1553 M39014/2-1316 M39014/2-1415 MC14011B/883 MM54C14J883 MS21043-06 MS24264R16B24PN MS24693-C1 MS24693-1 MS24693C1 MS3367-4-9

Copyright 2004 by: Radiant Power Corp., a HEICO Company

FIGURE

ITEM

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

240 55A 65A 500B 430 365 235 525 190A 185A 195 145 263 150 155 360A 360 226 248 394 398 415 417 582 571 165 265 325 160 255 250 355 245 350 175 145A 263A 147 150A 185 190 373 55 42 35A 35 399

25-65-02

TTL REQ 2 1 4 3 4 2 1 1 1 1 1 8 1 2 1 2 2 2 2 4 4 8 4 AR AR 3 1 1 1 1 3 1 1 1 1 8 1 1 2 1 1 4 1 6 6 6 AR

Page 1009 Sep 2010

RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER BPS7 NUMBERICAL INDEX (Sheet 2 of 5) PART NUMBER

AIRLINE STOCK NO.

MS35489-1 MS35649-224 MS51957-3 MS51957-12 MS51957-13

MS51957-27 MS51957-28 MS51957-29 MS51957-31 MS51957-32 MS51957-34 NAS549FL4 NAS620C2 NAS620C416 NAS620C6

NAS620C8 NAS679C04M NAS679C06

P212

R1903X RCR07G625JS RCR07G755JS RCR07G825JS RCR07G915JS RER60F14R0R RLR07C1000GR RLR07C1001GR RLR07C1004GR RLR07C2203GR RLR07C2401GR RLR07C4702GR

RLR07C4703GR RLR07C6204GP RLR07C68R0GR

Copyright 2004 by: Radiant Power Corp., a HEICO Company

FIGURE

ITEM

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

530 385 380 15 50 60 90 210 340 220 372 340A 470 485 490 490A 93 213 383 455 225 475 495A 545A 65 345 500 500A 27 202 574 555 140A 140B 140C 140 375 295 100 285 170 115 105 95 290 135 110 140E 280

25-65-02

TTL REQ 2 4 4 4 4 4 4 4 4 2 4 4 1 2 1 3 8 8 4 2 2 2 6 2 4 4 4 3 AR AR AR 2 1 1 1 1 2 1 1 1 1 1 1 7 1 6 1 1

Page 1010 Sep 2010

RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER BPS7 NUMBERICAL INDEX (Sheet 3 of 5) PART NUMBER

AIRLINE STOCK NO.

RLR07C7504GP RLR07C8204GP RLR07C9104GP RNC55H1002FR RNC55H3742FR RNC55H4022FR RNC55H5110FR RNC55H7500FR RNC55H7680FR RNC55H7870FR RNC55H8060FR RTV102 RWR80S4020FR RWR81S1R00FR SOS440-4

SOS440-6

SG1503Y/883B TA2402A V33ZA1 081-001-006 10-8008-2-03 120-2 146-001-002 156 2001 2003 2004-2 2006 2006-1 2006-2 2007 2007-1 2007-2 2007-3 2007-4 2007-5 2007-6 2007-10 2008 2009 2010 2010-1 2010-2

Copyright 2004 by: Radiant Power Corp., a HEICO Company

FIGURE

ITEM

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

140F 140G 140D 130 125 120 305 300B 300A 300 300C 527 270 275 393 397 405 392 396 410 180A 230 260 550 330 605 545 320 200 85 335 205A 205B 205 400 425 390 395 435 395A 391 433 45 215 10 10A 20 10B

25-65-02

TTL REQ 1 1 1 1 1 1 1 1 1 1 1 AR 1 1 2 2 4 2 2 4 1 1 1 4 2 AR 2 2 1 1 1 1 1 1 1 2 1 1 1 1 1 4 1 1 1 1 1 1

Page 1011 Sep 2010

RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER BPS7 NUMBERICAL INDEX (Sheet 4 of 5) PART NUMBER

AIRLINE STOCK NO.

2010-3 2011 2011-1 2011-2 2012-1 2013-1 2013-1A 2015 2017 2018 2019 2020 2021 2022 2025 2026 2027-1 2027-2 2027-3 2028 2031-1 2031-2 2032 2033 2034 2035 2037 2042 2042-1 2042-2 2044 2045 2050 2339 251005 276005 3-331272-5 3542-0 3542-2 39-1 3M69 5607-88 5612-26-31 7-156-BA 7831 805-144 805-169

Copyright 2004 by: Radiant Power Corp., a HEICO Company

FIGURE

ITEM

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

20A 560 570 565 5 445 445A 40 575 25 440 595 590 465 80 180 510 515 520 30 505 480 580 495 552 585 3 32 560A 570A 565A 580A 593 25A 525A 310A 310 315 540 535 70 573 530A 460A 320A 600 370 75

25-65-02

TTL REQ 1 1 1 1 1 1 1 1 6 1 1 1 2 1 1 1 1 1 1 1 2 1 6 1 1 1 1 1 1 1 1 1 1 4 4 8 1 1 1 AR 4 2 2 AR 2 1

Page 1012 Jan 2012

RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER BPS7 NUMBERICAL INDEX (Sheet 5 of 5) PART NUMBER

AIRLINE STOCK NO.

82-19-1040-16 82-19-800-16 82-32-101-20 82-35-307-55 8654 8654-1-8FLAT

Copyright 2004 by: Radiant Power Corp., a HEICO Company

FIGURE

ITEM

1 1 1 1 1 1

450A 450 460 420 572A 572

25-65-02

TTL REQ 2 2 2 2 2 3

Page 1013 Aug 2009

RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER BPS7

THIS PAGE INTENTIONALLY LEFT BLANK

Copyright 2004 by: Radiant Power Corp., a HEICO Company

25-65-02

Page 1014 Aug 2009

RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER BPS7

Notes: 1. Cut two pieces of tape (27) 1.5±.25” and apply on the inside of cover (20A) on each side between mounting holes. 2. When mounting electronics assy (40), use thermal compound (605) between the brackets (215, 390 & 395) and chassis assy (400). Battery Power Supply IPL Figure 1 (Sheet 1 of 6)

Copyright 2004 by: Radiant Power Corp., a HEICO Company

25-65-02

Page 1015 Aug 2009

RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER BPS7

Notes: 1. Cut two pieces of tape (27) 1.5±.25” and apply on the inside of cover (20A) on each side between mounting holes. 2. When mounting electronics assy (40), use thermal compound (605) between the brackets (215, 390 & 395) and chassis assy (400). Battery Power Supply IPL Figure 1 (Sheet 2 of 6)

Copyright 2004 by: Radiant Power Corp., a HEICO Company

25-65-02

Page 1016 Jan 2012

RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER BPS7

Section A Notes: 1. Use cable ties (399) to bundle wiring inside electronics assy (40). 2. Apply thermal compound (605) under resistors (375) and transistors (350 & 355) before mounting. Battery Power Supply IPL Figure 1 (Sheet 3 of 6)

Copyright 2004 by: Radiant Power Corp., a HEICO Company

25-65-02

Page 1017 Sep 2010

RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER BPS7

Battery Power Supply IPL Figure 1 (Sheet 4 of 6)

Copyright 2004 by: Radiant Power Corp., a HEICO Company

25-65-02

Page 1018 Aug 2009

RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER BPS7

Section F Notes: 1. Approximately 1.0” of heatshrink (582) should cover tabs between cells (4 places). No heatshrink required between rear battery connections. Battery Power Supply IPL Figure 1 (Sheet 5 of 6)

Copyright 2004 by: Radiant Power Corp., a HEICO Company

25-65-02

Page 1019 Aug 2009

RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER BPS7

Section H Notes: 1. Approximately 1.0” of heatshrink (582) should cover tabs between cells (4 places). No heatshrink required between rear battery connections. Battery Power Supply IPL Figure 1 (Sheet 6 of 6)

Copyright 2004 by: Radiant Power Corp., a HEICO Company

25-65-02

Page 1020 Sep 2010

RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER BPS7 Battery Power Supply, IPL Figure 1 PARTS LIST FIGURE ITEM

PART NUMBER

AIRLINE STOCK NO

NOMENCLATURE 1234567

EFF CODE

UNITS PER ASSY

A

RF

B

RF

1-1

BPS7-2

-1A

BPS7-3

-3 5 -10 10A 10B

15

-20 20A

2037 2012-1 2010 2010-1 2010-2

MS51957-12

2010-1 2010-3

25

2018

25A

2050

27

P212

30

2028

32

2037

35

MS24693C1

-35A

MS24693-1

40

2015

-42

MS24693C1

45

2008

BATTERY POWER SUPPLY (BOEING SCD S283T014-2) (V1MXA1) (SUPSD BY ITEM 1A) BATTERY POWER SUPPLY (BOEING SCD S283T014-3) (V1MXA1) (SUPSDS ITEM 1)  LABEL, FAA-PMA (ADHESIVEBACKED) (V1MXA1) (SUPSDS ITEM 32)  CHARGER ASSY, BATTERY (V1MXA1)   COVER ASSY (SUPSD BY ITEM 10B)   COVER ASSY (SUPSD BY ITEM 10B)   COVER ASSY (V1MXA1) (SUPSDS ITEMS 10 AND 10A) ATTACHING PARTS   SCREW, MACHINE-PAN HEAD (V8R639) ----****---   COVER (SUPSD BY ITEM 20A)    COVER (V4J674) (SUPSDS ITEM 20)    NAMEPLATE (USED ON 2010-1) (ADHESIVE-BACKED) (SUPSD BY ITEM 25A)    LABEL, WIRING DIAGRAM (VADCPR) (SUPSDS ITEM 25)    TAPE, ADHESIVE BACKED GLASS (V6S047)   NAMEPLATE, ESD WARNING (USED ON 2010-1) (ADHESIVEBACKED)   LABEL, FAA-PMA (ADHESIVEBACKED) (V1MXA1) (SUPSD BY ITEM 3)   SCREW FLAT-COUNTERSUNK HEAD (V8R639) (SUPSD BY ITEM 42)   SCREW, FLAT-COUNTERSUNK HEAD (V8R639) (SUPSD BY ITEM 42)   ELECTRONICS ASSY (V1MXA1) ATTACHING PARTS   SCREW FH (MS24693C1 IS REF CODE FOR MS24693-C1) (4-40x.25L) (V8R639) (SUPSDS ITEMS 35 AND 35A) ----****---   PANEL, FRONT (V4J674)

1

A A

1 1 1 1

4

A

1 1

A

1

1 AR A

1

1 6 6 1 6

1

Dashed (-) items not illustrated

Copyright 2004 by: Radiant Power Corp., a HEICO Company

25-65-02

Page 1021 Aug 2009

RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER BPS7 Battery Power Supply, IPL Figure 1 PARTS LIST FIGURE ITEM

PART NUMBER

AIRLINE STOCK NO

NOMENCLATURE 1234567

EFF CODE

UNITS PER ASSY

150

MS51957-12

55

MS24264R16B24 PN BACC45FN1624P

-55A

60

MS51957-13

65

NAS679C04M

-65A

BACN10JC04

70

39-1

75 80

805-169 2025

85

2003

90

MS51957-13

93

NAS549FL4

95

RLR07C4702GR

100

RLR07C1001GR

105

RLR07C2401GR

110

RLR07C4703GR

115

RLR07C2203GR

120

RNC55H4022FR

125

RNC55H3742FR

130

RNC55H1002FR

ATTACHING PARTS    SCREW, MACHINE-PAN HEAD (V8R639) ----****---   CONNECTOR, 24 PIN (J1) (V5X895) (SUPSD BY ITEM 55A)    CONNECTOR, 24 PIN (J1) (V5X895) (SUPSDS ITEM 55) ATTACHING PARTS    SCREW, MACHINE-PAN HEAD (V8R639)    NUT, HEX SELF-LOCKING (V8R639)    NUT, HEX SELF-LOCKING (V8R639) (ALT TO ITEM 65) ----****---   SWITCH, PUSHBUTTON (V81073) (SW1)    LUG, SOLDER (V79963)    LABEL, TEST SWITCH (ADHESIVEBACKED) (V28071)    PCB ASSY (A1) (V1MXA1) ATTACHING PARTS    SCREW, MACHINE-PAN HEAD (V8R639)    WASHER, NONMETALLIC INSULATING (V8R639) ----****---    RESISTOR (47K, 2PCT, 1/4W) (R4, R6, R16, R19, R20, R26, R29) (V8N187)     RESISTOR (1K, 2PCT, 1/4W) (R10) (V8N187)     RESISTOR (2.4K, 2PCT, 1/4W) (R11) (V6M193)     RESISTOR (470K, 2PCT, 1/4W) (R5, R12, R18, R27, R31, R32) (V8N187)     RESISTOR (220K, 2PCT, 1/4W) (R15) (V8N187)     RESISTOR (40.2K, 1PCT, 1/10W) (R24) (P/N CORRECTION) (V6M193)     RESISTOR (37.4K, 1PCT, 1/10W) (R13) (V6M193)     RESISTOR (10K, 1PCT, 1/10W) (R17) (V6M193)

4

1 1

4 4 4

1 1 1 1 4 8

7

1 1 6 1 1 1 1

Dashed (-) items not illustrated

Copyright 2004 by: Radiant Power Corp., a HEICO Company

25-65-02

Page 1022 Aug 2009

RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER BPS7 Battery Power Supply, IPL Figure 1 PARTS LIST FIGURE ITEM

PART NUMBER

AIRLINE STOCK NO

NOMENCLATURE 1234567

EFF CODE

UNITS PER ASSY

1135 140

RLR07C4702GR RCR07G915JS

-140A

RCR07G625JS

-140B

RCR07G755JS

-140C

RCR07G825JS

-140D

RLR07C9104GP

-140E

RLR07C6204GP

-140F

RLR07C7504GP

-140G

RLR07C8204GP

145

CKR05BX104KR

-145A

M390141-1553

147

M390142-1316

150

CKR06BX105KR

-150A

M390142-1415

155

CSR13E106KR

160

JANTX1N751A

DELETED     RESISTOR, S.I.T. (9.1M, 5PCT, 1/4W) (SELECT FROM R28) (SUPSD BY ITEM 140D)     RESISTOR, S.I.T. (6.2M, 5PCT, 1/4W (SELECT FROM R28) (SUPSD BY ITEM 140E)     RESISTOR, S.I.T. (7.5M, 5PCT, 1/4W) (SELECT FROM R28) (SUPSD BY ITEM 140F)     RESISTOR, S.I.T. (8.2M, 5PCT, 1/4W) (SELECT FROM R28) (SUPSD BY ITEM 140G)     RESISTOR, S.I.T. (9.1M, 2PCT, 1/4W) (SELECT FROM R28) (V8N187) (SUPSDS ITEM 140)     RESISTOR, S.I.T. (6.2M, 2PCT, 1/4W) (SELECT FROM R28) (V8N187) (SUPSDS ITEM 140A)     RESISTOR, S.I.T. (7.5M, 2PCT, 1/4W) (SELECT FROM R28) (V8N187) (SUPSDS ITEM 140B)     RESISTOR, S.I.T. (8.2M, 2PCT, 1/4W) (SELECT FROM R28) (V8N187) (SUPSDS ITEM 140C)     CAPACITOR (.1MF, 50V) (C3, C5, C7, C9-C13) (SUPSD BY ITEM 145A)     CAPACITOR (M390141-1553 IS REF CODE FOR M39014/1-1553) (.1MF, 50V) (C3, C5, C7, C9-C13) (V8N187) (SUPSDS ITEM 145)     CAPACITOR, S.I.T. (M3901421316 IS REF CODE FOR M39014/2-1316) (.22MF, 50V) (C14) (V8N187)     CAPACITOR, 1MF, 50V (C4, C8) (SUPSD BY ITEM 150A)     CAPACITOR (M390142-1415 IS REF CODE FOR M39014/2-1415) (1MF, 50V) (C4, C8) (V8N187) (SUPSDS ITEM 150)     CAPACITOR (10MF, 50V) (C2) (V6M193)     DIODE, ZENER (JANTX1N751A IS REF CODE FOR JANTX1N751A-1) (5V) (CR4) (V057Q7)

1

1

1

1

1

1

1

1

8 8

1

2 2

1 1

Dashed (-) items not illustrated

Copyright 2004 by: Radiant Power Corp., a HEICO Company

25-65-02

Page 1023 Aug 2009

RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER BPS7 Battery Power Supply, IPL Figure 1 PARTS LIST FIGURE ITEM

PART NUMBER

AIRLINE STOCK NO

NOMENCLATURE 1234567

EFF CODE

UNITS PER ASSY

1165

JANTX1N4148-1

170

RLR07C1004GR

175

LM139J883

180

2026

-180A

SG1503Y883B

185

MC14011B883

-185A

CD4011B883

190

MM54C14J883

-190A

CD40106BF3A

195

CD4085BF883

200

2001

202

P212

-200A 205

NONPROC1 2006-2

-205A

2006

-205B

2006-1

    DIODE (CR3, CR5, CR6) (V1W091)     RESISTOR (1M, 1PCT) (R14) (V8N187)     COMPARAT0R, I.C. (LM139J883 IS REF CODE FOR LM139J/883) (Z1) (V6M193)     VOLTAGE REFERENCE (Z2) (SUPSD BY ITEM 180A)     VOLTAGE REFERENCE (SG1503Y883B IS REF CODE FOR SG1503Y/883B) (Z2) (V1W091) (SUPSDS ITEM 180)     GATE, DUAL INPUT NAND (MC14011B883 IS REF CODE FOR MC14011B/883) (Z3) (V6M193) (OPT ITEM 185A)     GATE, DUAL INPUT NAND (CD4011B883 IS REF CODE FOR CD4011B/883) (Z3) (OPT ITEM 185)     INVERTER, SCHMITT TRIGGER (Z4) (SUPSD BY ITEM 190A)     INVERTER, SCHMITT TRIGGER (Z4) (V6M193) (IF Z4 REPLACED, REPLACE C14 WITH ITEM 147) (SUPSDS ITEM 190)     GATE, DUAL AND/OR INVERTER (CD4085BF883 IS REF CODE FOR CD4085BF/883) (Z5) (V6M193)     BOARD, A1 PRINTED CIRCUIT (SUPSD BY ITEM 200A)     TAPE, ADHESIVE BACKED GLASS (V6S047)     BOARD, A1 PRINTED CIRCUIT (SUPSDS ITEM 200)    PCB ASSY (A2) (V1MXA1) (SUPSDS ITEMS 205A AND 205B)    PCB ASSY (A2) (V1MXA1) (SN 001 THRU 376) (PRE SB 25-BPS7-2-1) (SUPSD BY ITEM 205)    PCB ASSY (A2) (V1MXA1) (SN 377 THRU 710) (SUPSD BY ITEM 205)

3 1 1

1 1

1

1

1 1

1

1 AR 1 1 1

1

Dashed (-) items not illustrated

Copyright 2004 by: Radiant Power Corp., a HEICO Company

25-65-02

Page 1024 Sep 2010

RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER BPS7 Battery Power Supply, IPL Figure 1 PARTS LIST FIGURE ITEM

PART NUMBER

AIRLINE STOCK NO

NOMENCLATURE 1234567

EFF CODE

UNITS PER ASSY

1210

MS51957-13

213

NAS549FL4

215

2009

220

MS51957-27

225 -226

NAS620C6 FEO440

230

TA2402A

235

BBI066G

240

B1530B18-4

245

JANTX2N3741

248

FEO440

250 255

JANTX2N2222A JANTX1N751A

260 263

V33ZA1 CKR05BX104KR

-263A

265 270

M390141-1553

JANTX1N4469 RWR80S4020FR

ATTACHING PARTS    SCREW, MACHINE-PAN HEAD (V8R639)    WASHER, NONMETALLIC INSULATING (V8R639) ----****---    BRACKET ASSY, TRANSISTOR MOUNTING (VPREMF) ATTACHING PARTS     SCREW, MACHINE-PAN HEAD (V8R639)     WASHER, FLAT (V8R639)     NUT, CLINCH, SELF-LOCKING (P/N CORRECTION) (FEO440 IS REF CODE FOR FEO-440) (V46384) (SUPSD BY ITEM 248)     INSULATOR, MICA (0.002 INCH THICK) (V18565)     STRIP, INSULATOR (P/N CORRECTION) (BBI066G IS REF CODE FOR BBI-066G) (V39425)     STANDOFF, SWAGE-MOUNT (B1530B18-4 IS REF CODE FOR B1530B-1/8-4) (.125 LG) (V8R639)     TRANSISTOR (Q3) (V057Q7) ----****---     NUT, CLINCH, SELF-LOCKING (P/N CORRECTION) (FEO440 IS REF CODE FOR FEO-440) (V46384) (SUPSDS ITEM 226)     TRANSISTOR (Q4-Q6) (V6M193)     DIODE, ZENER (JANTX1N751A IS REF CODE FOR JANTX1N751A-1) (5V) (CR1) (V057Q7)     VARISTOR (V6M193) (VR1)     CAPACITOR (.1MF, 50V) (C15) (SUPSD BY ITEM 263A)     CAPACITOR (M390141-1553 IS REF CODE FOR M39014/1-1553) (.1MF, 50V) (C15) (V8N187) (SUPSDS ITEM 263)     DIODE, ZENER (CR7) (V057Q7)     RESISTOR (402 OHMS, 1PCT, 2W) (R3) (V8N187)

4 8

1

2 2 2

1 1

2

1 2

3 1

1 1 1

1 1

Dashed (-) items not illustrated

Copyright 2004 by: Radiant Power Corp., a HEICO Company

25-65-02

Page 1025 Sep 2010

RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER BPS7 Battery Power Supply, IPL Figure 1 PARTS LIST FIGURE ITEM

PART NUMBER

AIRLINE STOCK NO

NOMENCLATURE 1234567

EFF CODE

UNITS PER ASSY

1275

RWR81S1R00FR

280

RLR07C68R0GR

285

RLR07C1001GR

290

RLR07C4702GR

295

RLR07C1000GR

300

RNC55H7870FR

-300A

RNC55H7680FR

-300B

RNC55H7500FR

-300C

RNC55H8060FR

305

RNC55H5110FR

310

276005

-310A

251005

315 320 -320A

325 330 335

3-331272-5 156 7-156BA

JANTX1N5622 10-8008-2-03 2004-2

-335A

NONPROC2

340

MS51957-13

    RESISTOR (1 OHM, 1PCT, 1W) (R7) (V8N187)     RESISTOR (68 OHMS, 2PCT, 1/4W) (R8) (V6M193)     RESISTOR (1K, 2PCT, 1/4W) (R9) (V8N187)     RESISTOR (47K, 2PCT, 1/4W) (R23) (V8N187)     RESISTOR (100 OHMS, 2PCT, 1/4W) (R25) (V8N187)     RESISTOR, S.I.T. (787 OHMS, 1PCT, 1/10W) (SELECT FROM R21) (V8N187)     RESISTOR, S.I.T. (768 OHMS, 1PCT, 1/10W) (SELECT FROM R21) (V8N187)     RESISTOR, S.I.T. (750 OHMS, 1PCT, 1/10W) (SELECT FROM R21) (V8N187)     RESISTOR, S.I.T. (806 OHMS, 1PCT, 1/10W) (SELECT FROM R21) (V8N187)     RESISTOR (511 OHMS, 1PCT, 1/10W) (R22) (V8N187)     FUSE, SUBMINIATURE (5A, 125V) (F1-F4) (V75915) (SUPSD BY ITEM 310A)     FUSE, SUBMINIATURE (5A, 125V) (F1-F4) (V75915) (SUPSDS ITEM 310)     SOCKET, FUSE (V8N187)     HEATSINK (SUPSD BY ITEM 320A) (V98978)     HEATSINK (7-156BA IS REF CODE FOR 7-156-BA) (SUPSDS ITEM 320) (V98978)     DIODE, ZENER (CR2) (V057Q7)     PIN (.08 DIA X .40 LG) (V81205)     BOARD, A2-2 P.C. (SUPSD BY ITEM 335A)     BOARD, A2-2 P.C. (SUPSDS ITEM 335)    SCREW, MACHINE-PAN HEAD (V8R639) (SUPSD BY ITEM 372)

1 1 1 1 1 1

1

1

1

1 4

4

8 2 2

1 2 1 1 4

Dashed (-) items not illustrated

Copyright 2004 by: Radiant Power Corp., a HEICO Company

25-65-02

Page 1026 Sep 2010

RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER BPS7 Battery Power Supply, IPL Figure 1 PARTS LIST FIGURE ITEM

PART NUMBER

AIRLINE STOCK NO

NOMENCLATURE 1234567

EFF CODE

UNITS PER ASSY

1-340A

MS51957-29

345

NAS679C06

350 355

JANTX2N4399 JANTX2N3716

360

DM101

-360A

DBX101

365

BBI03G

370 -372

805-144 MS51957-28

-373

MS21043-06

375

RER60F14R0R

380

MS51957-3

383 385

NAS620C2 MS35649-224

390 391

2007-2 2007-6

-392

SOS440-6

-393

SOS440-4

   SCREW, MACHINE-PAN HEAD (V8R639) (SUPSD BY ITEM 372)    NUT, HEX SELF-LOCKING (V8R639) (POST SB 25-BPS7-2-1 FOR SN 001 THRU 620) (SUPSD BY ITEM 373)    TRANSISTOR (Q2) (V1W091)    TRANSISTOR (Q1) (V057Q7) ATTACHING PARTS    INSULATOR, MICA (SUPSD BY ITEM 360A) (V18565)    INSULATOR, THERMAL PAD (DBX101 IS REF CODE FOR DBX-101) (V8R639) (SUPSDS ITEM 360)    STRIP, INSULATOR (P/N CORRECTION) (BBI03G IS REF CODE FOR BBI-03G) (V39425)    LUG, SOLDER (V79963)    SCREW, MACHINE-PAN HEAD (V8R639) (SUPSDS ITEMS 340 AND 340A)    NUT, HEX SELF-LOCKING (V8R639) (POST SB 25-BPS7-2-1 FOR SN 001 THRU 620) (SUPSDS ITEM 345) ----****---   RESISTOR (14 OHMS, 1PCT, 5W) (R1, R2) (V6M193) ATTACHING PARTS    SCREW, FLAT-COUNTERSUNK HEAD (V8R639)    WASHER, FLAT (V8R639)    NUT, PLAIN HEX (V8R639) ----****---   BRACKET ASSY, Q2 (V4J674)     BRACKET, Q2 MOUNT (ORDER NHA)     STANDOFF, SELF-CLINCHING (P/N CORRECTION) (V46384) (ORDER NHA)     STANDOFF, SELF-CLINCHING (P/N CORRECTION) (V46384) (ORDER NHA)

4 4

1 1 2 2

2

2 4

4

2

4 4 4 1 1 2

2

Dashed (-) items not illustrated

Copyright 2004 by: Radiant Power Corp., a HEICO Company

25-65-02

Page 1027 Sep 2010

RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER BPS7 Battery Power Supply, IPL Figure 1 PARTS LIST FIGURE ITEM

PART NUMBER

AIRLINE STOCK NO

NOMENCLATURE 1234567

EFF CODE

UNITS PER ASSY

1-394

FEO440

395

2007-3

395A

2007-5

-396

SOS440-6

-397

SOS440-4

-398

FEO440

-399 -400 405

MS3367-4-9 2007 SOS440-4

410

SOS440-6

415

FEO440

417

FE440

420

82-35-307-55

425

2007-1

430

BACR15BA4AD4

433

2007-10

435 440

2007-4 2019

    NUT, CLINCH, SELF-LOCKING (P/N CORRECTION) (FEO440 IS REF CODE FOR FEO-440) (V46384) (ORDER NHA)    BRACKET ASSY, Q1 TRANSISTOR MOUNTING (V4J674)     BRACKET, Q1 MOUNT (ORDER NHA)     STANDOFF, SELF-CLINCHING (P/N CORRECTION) (V46384) (ORDER NHA)     STANDOFF, SELF-CLINCHING (P/N CORRECTION) (V46384) (ORDER NHA)     NUT, CLINCH, SELF-LOCKING (P/N CORRECTION) (FEO440 IS REF CODE FOR FEO-440) (V46384) (ORDER NHA)    CABLE TIE, MINIATURE (V8R639)   CHASSIS ASSY (VPREMF)    STANDOFF, SELF-CLINCHING (P/N CORRECTION) (V46384) (ORDER NHA) (SUPSD BY ITEMS 393 AND 397)    STANDOFF, SELF-CLINCHING (P/N CORRECTION) (V46384) (ORDER NHA) (SUPSD BY ITEMS 392 AND 396)    NUT, CLINCH, SELF-LOCKING (P/N CORRECTION) (FEO440 IS REF CODE FOR FEO-440) (V46384) (ORDER NHA) (QTY 4 SUPSD BY ITEM 394) (QTY 4 SUPSD BY ITEM 398)    NUT, CLINCH, SELF-LOCKING (FE440 IS REF CODE FOR FE-440) (V46384) (ORDER NHA)    RECEPTACLE (V94222) (ORDER NHA)    BRACKET, BATTERY MOUNTING (VPREMF) ATTACHING PARTS    RIVET (1/8 X 1/4, SOLID) (V81205) ----****---   PAD, DAMPER (NOT USED WITH ITEM 445A)    CHASSIS (ORDER NHA)   NAMEPLATE, CHASSIS (V1MXA1)

4

1 1 2

2

4

AR 1 4

4

8

4

2 2

4 4 1 1

Dashed (-) items not illustrated

Copyright 2004 by: Radiant Power Corp., a HEICO Company

25-65-02

Page 1028 Sep 2010

RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER BPS7 Battery Power Supply, IPL Figure 1 PARTS LIST FIGURE ITEM

PART NUMBER

AIRLINE STOCK NO

NOMENCLATURE 1234567

EFF CODE

UNITS PER ASSY

1445 445A

2013-1 2013-1A

450

82-19-800-16

450A

82-19-1040-16

455

NAS620C416

460

82-32-101-20

460A

5612-26-31

465 470

2022 MS51957-31

475

NAS620C6

480

2031-2

485

MS51957-32

490

MS51957-34

490A

MS51957-34

495

2033

495A

NAS620C6

500

NAS679C06

-500A

NAS679C06

500B

BACN10JC06

505

2031-1

510 515

2027-1 2027-2

 BATTERY ASSY, 6 NI-CD SERIES CELL (BT1) (V1MXA1)  BATTERY ASSY, 6 NI-CD SERIES CELL (BT1) (V1MXA1) (PREF ALT TO ITEM 445)   FASTENER, 1/4 TURN (V94222) (USED ON ITEM 445)   FASTENER, 1/4 TURN (V94222) (USED ON ITEM 445A)   WASHER, FLAT (V8R639) (USED ON ITEM 445)   RETAINER, SPLIT RING (V94222) (USED ON ITEM 445)   WASHER, FLAT, TEFLON (V86928) (USED ON ITEM 445A)   SPRING, RETRACTION (V8R639)   SCREW, MACHINE-PAN HEAD (V8R639) (USED ON ITEM 445)   WASHER, FLAT (V8R639) (USED ON ITEM 445)   BLOCK, SUPPORT (USED ON ITEM 445)   SCREW, MACHINE-PAN HEAD (V8R639) (USED ON ITEM 445)   SCREW, MACHINE-PAN HEAD (V8R639) (USED ON ITEM 445)   SCREW, MACHINE-PAN HEAD (V8R639) (USED ON ITEM 445A)   WASHER, SQUARE (USED ON ITEM 445)   WASHER, FLAT (V8R639) (USED ON ITEM 445A)   NUT, SELF-LOCKING HEX (V8R639) (USED ON ITEM 445)   NUT, SELF-LOCKING HEX (V8R639) (SUPSD BY ITEM 500B) (USED ON ITEM 445A)   NUT, SELF-LOCKING HEX (V8R639) (SUPSDS ITEM 500A (USED ON ITEM 445A)   BLOCK, SUPPORT (USED ON ITEM 445)   BAND, FRONT (USED ON ITEM 445)   BAND, MIDDLE (USED ON ITEM 445)

1 1

2 2 2 2 2 2 1 2 2 2 1 3 6 6 4 3

3

1 1 1

Dashed (-) items not illustrated

Copyright 2004 by: Radiant Power Corp., a HEICO Company

25-65-02

Page 1029 Sep 2010

RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER BPS7 Battery Power Supply, IPL Figure 1 PARTS LIST FIGURE ITEM

PART NUMBER

AIRLINE STOCK NO

NOMENCLATURE 1234567

EFF CODE

UNITS PER ASSY

1520 525

2027-3 BMS160ATYPE1

-525A

2339

-527 530 530A

RTV102 MS35489-1 5607-88

535 540

3542-2 3542-0

545

146-001-002

545A

NAS620C8

550 552

081-001-006 2034

555

R1903X

560

2011

560A

2042

565

2011-2

565A

2042-2

570

2011-1

570A

2042-1

571

HT105-3-16

572

8654-1-8FLAT

-572A

8654

573 574

3M69 P212

  BAND, REAR (USED ON ITEM 445)   PAD, FUSE RETAINER, GRADE B (SUPSD BY ITEM 525A)   PAD, FUSE RETAINER, GRADE B (V4J674) (SUPSDS ITEM 525)   ADHESIVE, SILICONE (V07080)   GROMMET (USED ON ITEM 445)   WASHER, SHOULDER (V86928) (USED ON ITEM 445A)   SOCKET, PIN (RED) (J2-1) (V4U744)   SOCKET, PIN (BLACK) (J2-2) (V4U744)   WASHER, STAR (V4U744) (USED ON ITEM 445)   WASHER, FLAT (V8R639) (USED ON ITEM 445A)   NUT, HEX (V4U744)   PAPER, INSULATING (USED ON ITEM 445)   CONNECTOR (V14726) (USED ON ITEM 445)   HOLDER ASSY, BATTERY (USED ON ITEM 445)   CASE ASSY, BATTERY (VNICAC) (USED ON ITEM 445A)    CASE, TOP HALF (USED ON ITEM 560)    CASE, TOP HALF (USED ON ITEM 560A)    HOLDER, BATTERY, BOTTOM (USED ON ITEM 560)    CASE, BOTTOM HALF (USED ON ITEM 560A)   TUBING, SHRINK (USED ON ITEM 445)   BRAID, WIRE (SUPSD BY ITEM 572A)   BRAID, WIRE (V0TBK5) (SUPSDS ITEM 572)   TAPE, GLASS (USED ON ITEM 445)   TAPE, ADHESIVE BACKED GLASS (V6S047)

1 1 1 AR 2 4 1 1 2 2 4 1 2 1 1 1 1 1 1 AR 3 2 AR

AR

Dashed (-) items not illustrated

Copyright 2004 by: Radiant Power Corp., a HEICO Company

25-65-02

Page 1030 Sep 2010

RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER BPS7 Battery Power Supply, IPL Figure 1 PARTS LIST FIGURE ITEM

PART NUMBER

AIRLINE STOCK NO

NOMENCLATURE 1234567

EFF CODE

UNITS PER ASSY

1575 580

2017 2032

580A

2044

-582

HS105

-585

2035

-590

2021

-593 595 -600 -605

2045 2020 7831 120-2

  BATTERY   LABEL, REMOVAL WARNING (ADHESIVE-BACKED) (V00JU0) (USED ON ITEM 445)   LABEL, BATTERY HOLDER (ADHESIVE-BACKED) (V1MXA1) (USED ON ITEM 445A)   TUBING, HEATSHRINK (HS105 IS REF CODE FOR HS-105) (V0TBK5)   LABEL, BAND WARNING (ADHESIVE-BACKED) (USED ON ITEM 445)   NAMEPLATE, BATTERY HOLDER (ADHESIVE-BACKED) (USED ON ITEM 445) DELETED   DELETED  COMPOUND, LOCKING (V07080)  THERMAL COMPOUND (V02929)

6 1

1

AR 1

1

AR AR

Dashed (-) items not illustrated

Copyright 2004 by: Radiant Power Corp., a HEICO Company

25-65-02

Page 1031 Jan 2012

RADIANT POWER CORP. COMPONENT MAINTENANCE MANUAL PART NUMBER BPS7

THIS PAGE INTENTIONALLY LEFT BLANK

Copyright 2004 by: Radiant Power Corp., a HEICO Company

25-65-02

Page 1032 Sep 2010