TM 11-6625-2978-14_Power_Supply_PP-7548_U_Tek_1106_1982

8/10/2019 TM 11-6625-2978-14_Power_Supply_PP-7548_U_Tek_1106_1982

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TM 11-6625-2978-14

T E C H N I C A L M A N U A L

OPERATORS, ORGANIZATIONAL,

DIRECT SUPPORT AND GENERAL SUPPORT

MAINTENANCE MANUAL

FOR

POWER SUPPLY PP-7549 /U

( T E K T R O N I X M O D E L 1 1 0 6 )

(NSN 6130-01-018-1226)

H E A D Q U A R T E R S , D E P A R T M E N T O F T H E A R M Y

1 8 F E B R U A R Y 1 9 8 2


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SAFETY STEPS

IS THE VICTIM

TO FOLLOW IF SOMEONE

OF ELECTRICAL SHOCK

DO NOT TRY TO PULL OR GRAB THE INDIVIDUAL

IF POSSIBLE, TURN OFF THE ELECTRICAL POWER

IF YOU CANNOT TURN OFF THE ELECTRICAL

POWER, PULL, PUSH, OR LIFT THE PERSON TO

SAFETY USING A WOODEN POLE OR A ROPE OR

SOME OTHER INSULATING MATERIAL

SEND FOR HELP AS SOON AS POSSIBLE

AFTER THE INJURED PERSON IS FREE OF

CONTACT WITH THE SOURCE OF ELECTRICAL

SHOCK, MOVE THE PERSON A SHORT DISTANCE

AWAY AND IMMEDIATELY START ARTIFICIAL

RESUSCITATION


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Th is manu al in cludes copyri ght mat eri al r eproduced by perm ission of the Tektr onix, Inc.

TM11-6625-2978-14

TE C H N I C A L M A N U A L H E A D Q U A R T E R S

DEPARTMENT OF THE ARMY

N O . 11-6625-2978-14 WASHINGTON , DC, 18 Febru ary 1982

OPERATORS, ORGANIZATIONAL, DIRECT SUPPORT,

AND GENERAL SUPPORT MAINTENANCE MANUAL

FOR

POWER SUPPLY PP-7549/U

(TEKTRONIX MODEL 1106)

(NSN 6130-01-018-1226)

REPORTING ERRORS AND RECOMMENDING IMPROVEMENTS

Yo u can h e l p i m p ro v e t h i s m an u a l . If yo u f in d an y m i s t a k es o r i f y o u k n o wo f a wa y t o i m p r o v e t h e p r o c e d u r e s , p l e a s e le t u s k n o w . Ma i l y o u r l e t t e r , DA

F o rm 2 0 2 8 (R eco m m en d ed C h an g es t o P u b l i ca t i o n s an d B l an k F o rm s ) , o r DA

F o rm 2 0 2 8 -2 l o ca t ed i n t h e b ack o f t h i s m an u a l d i r ec t t o C o m m an d er , US Ar -

m y C o m m u n i c a t i o n s - E le c t r o n i c s C o m m a n d , AT T N: D R SE L-M E -M Q, F o r t

M o n m o u t h , N J 0 7 7 0 3 .

In e i ther case , a rep ly wi l l be fu rn i shed d i rec t to you .

C H A P T E R 1 .

S ECTION

C H A P T E R 2 .S ECTION



C H A P T E R 5 .S ECTIONS ECTON

I .I I .

I I I .

I .I I .

I .I I .

I I I .

I .I I .

I .I I .

C H A P T E R 6 .

S ECTION I .

I I .

TABLE OF CONTENTS

P a r a g r a p h

INTRODUCTION

G enera l . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1Description and D at a . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

Sa fety C onsiderat ions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11

SERVICE UPON RECEIPT AND INSTALLATION

Service Upon Receipt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Inst alla tion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

OPERATING INSTRUCTIONSFunction of Contr ols and Connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Opera tion a nd I nspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3Battery Operat ion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . 3-5

THEORY OF OPERATIONCircuit D escription . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Opera tion U nder U nus ua l Condit ions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

MAINTENANCE

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

B at tery S ervice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

CALIBRATION

Genera l . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

Calibration During Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

P a g e

1-11-11-2

2-12-1

3-13-13-1

4-14-2

5-15-1

6-16-1

i


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AP P E N D I X

SECTIONSECTION

A. R EFER ENCE S . .B . MAINTENANCE

P a r a g r a p h P a g e

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1ALLOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

I . Int roduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B -1 B -1II . Maintenance Allocation Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B -3

I I I . Tool an d Test E quipment Requ irements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B -4

i i


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Fi gure 1-1.Power Supply PP-7549/ U (1106 Battery Pack) Being In stl led Un der a Port able Oscil loscope.

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CHAPTER I

INTRODUCTION

Section I.

1-1. Scope

This ma nua l describes P ower S upply P P -7549/U(fig. 1-1) and provides instructions for i ts in-stallation, operation, and maintenance. Power Sup-ply P P -7549/U is t he joint Army-Na vy nomen-

clature and type number which has been applied tothe commercially available Tektronix Model 1106B a t t e r y P a c k .

1-2. Index of Technical Publications

Refer to th e la test issue of DA P a m 310-4 to deter-mine whether there are new edit ions, changes, or ad-dit ional publications pertaining to the equipment.

1-3. Maintenance Forms, Records, and Reportsa. Repor ts of M ain tenance and Unsatisfactory

Equipment. Departm ent of the Army forms a ndprocedures used for equipment maintenance will bethose prescribed by TM 38-750, The Army Main-tenance Management Sys tem.b. Report of Packagin g and H and li ng Defi cien-

cies. Fill out and forward SF 364 (Report ofDiscrepancy (ROD)) as prescr ibed in AR735-11-2/D LAR 4140.55/NAVMATINS T 4355.73/AFR 400-54/MC O 4430.3E .c. Di scr epancy in Sh ipment Report (DI SREP) (SF

361). Fill out and forward Discrepancy in ShipmentReport (DISREP) (SF 361) as prescribed in AR55-38/NAVS U P INS T 4610.33B /AFR 75-18/MC O4610.19C/DLAR 4500.15.

GENERAL

1-4. Reporting Equipment Improvement

Recommendations (EIR)If y our P ower S upply P P -7549/U needs im-provement, let us know. S end us a n E IR. You, theuser , are the only one who can tel l us what you dontlike about your equipment. Let us know why youdont l ike the design. Tell us why a procedure is hardto perform. Put it on an SF 368 (Quality Deficiency

Report). Mail i t to Commander, US Army Com-munications-Electronics Command, ATTN: DR-SE L-ME -MQ, Fort Monmouth , NJ 07703. Wellsend you a reply .

1-5. Administrative Storage

Administrative storage of equipment issued to andused by Army activities will have preventive main-tenance performed in accordance with the PMCScharts before storing. When removing the equip-ment from administrative storage the PMCS shouldbe performed to assure operational readiness.Disassembly and repacking of equipment for ship-ment or limited storage are covered in paragraphs2-1 and 2-2.

1-6. Destruction of Army Electronics Materiel

Destruction of Army electronics materiel to prevent

enemy use shall be in accordance with TM750-244-2.

Section Il. DESCRIPTION AND DATA

1-7. Purpose and Use

P ower S upply P P -7549/U is a dc power sour ce foropera t ing por t a ble Osci l loscope OS -261/U

(Tektronix Model 475 Option 7) away from ac powersources. P ower Su pply P P -7549/U is sold com-

mercially as a Tektronix, Model 1106 Battery Pack.P ower Su pply PP -7549/U is a lso referred t o as t hebat tery pack throughout th is manual .

1-8. Description

P ower S upply P P -7549/U is a s elf-cont a ined por-table battery pack equipped with a dc cable for con-necting to an oscilloscope allowing operation awayfrom ac power recepticals. It also has an ac cable

which enables connection to an ac circuit forrecharging.

1-9. Use Option

a. The separate battery pack capability permits a

choice of bat tery opera tion or a c l ine opera tion.During charg ing o f the bat tery pack, theoscilloscope may be operated from the ac linew i t h o u t d e t a c h i n g t h e b a t t e r y p a c k . Theoscilloscope may be detached from the battery pack,while it is charging, and used elsewhere with eitheranother battery pack or ac l ine. The battery packand oscilloscope may be separated easily andquickly for carrying ease.

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b. Refer to the oscilloscope technical manual forinformation regarding input power switch positionwhen changing to or from battery pack operation.

1-10. Specifications

a. AC Requirements. Ac power source is requiredonly for battery charging. Standard instrument: 100to 132 Vac or 200 to 264 Vac, 50 to 400 Hz. Stan-dard instrument with an internal connection

change: 90 to 120 Vac or 180 to 240 Vac, see themaintenance section of this manual for further in-formation 50 to 400 Hz. Power line consumption is40 watts maximum at 115 Vac, 60 Hz.

b. Power Output. 22 to 24 Vdc for 7 ampere-hours. 5 A maximum.

c. Battery Operating Time. Approximately 140watt-hours from fully-charged batteries.

d. Battery Charge Time. 14 to 16 hours (0 C to40 C).

e. Temperature. Operating, 0 C to 40 C. 0 C to40 C will not noticeably reduce the batterycapacity. Storage outside this range will reduce bat-tery efficiency and capacity. Non-operating; with

batteries -40 C to +60 C; without batteries,

-55 C to +75 C.f. Physical. Weight is 16 pounds. 11.5 incheswide. 17.0 inches long, including feet and handle. 2.6inches high, including feet. Combined height of bat-tery pack and oscilloscope is approximately 8.4 in-ches.

Section Ill. SAFETY CONSIDERATIONS

1-11. Charging on a three-wire system) is not recommended, since- -

The instrument is intended to be operated from a only the Line Conductor has over-current (fuse)

single-phase ac power source having one current- protection within the instrument.

carring conductor (the Neutral Conductor) at 1-12. Power Cord Conductor Identificationground (earth) potential. Operation from powersources where both current-carrying conductors are Identification of power cord conductors is contained

live with respect to ground (such as phase-to-phase intable 1-1.

Table 1-1.Power Cord Conductor Identification

Conductor Color Alternate Color

Ungrounded (Line) Brown Black

Grounded (Neutral) Blue White

Grounding (Earthing) Green-Yellow Green-Yellow

1-13. AC Power CordThe instrument has a three-wire power cord with athree-terminal polorized plug for connection to thepower source and safety-earth. The ground (earth)terminal of the plug is directly connected to the in-strument frame. For electric-shock protection, in-sert this plug only in a mating outlet with a safetyearth contact.

1-14. Operatinga. The potential at the chassis (frame) of the bat-

tery pack is established by the oscilloscope beingpowered through the safety-earth conductorsystem. For electric-shock protection, connect theoscilloscope cabinet (frame) to a ground (earth)reference.

b. If the battery pack ac power cord is connectedto a correctly-wired ac power source, an additionalshock protection circuit is established through thesafety-earth conductor system.

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CHAPTER 2

SERVICE UPON RECEIPT AND INSTALLATION

Section I. SERVICE UPON RECEIPT

2-1. Packaging Data

a. P ower S upply P P -7549/U ma y a rrive pa ckedfor either domest ic or overseas shipment .b. When P ower S upply P P -7549/U is pa cked for

overseas shipment it is placed in a lightweightpacking material and is placed in a corrugated car-ton. The carton is sealed with gummed tape. Theboxed equipment is then placed in a moisture-vaporproof barrier, which is heat-sealed, and thispackage is placed in a waterproof corrugated carton.The technical manuals are placed under the lid andthe carton is sealed with waterproof tape. Thepackaged battery pack is placed in a wooden ship-

ping conta iner wit h a wa terproof case liner. Thewooden container is reinforced with flat metals t r a p s .

2-2. Unpacking

a. For unpacking overseas shipment equipment,proceed as follows:

(1) Cut the metal straps with a suitable cuttingtool , or twist them with pliers unt il the straps break.Remove the straps.

(2) Remove the nails from the top and one sideof the wooden case. Do not attempt to pry off thesides a nd top. Such a ction ma y da ma ge the equip-

m e n t .(3) Remove the corrugated filler from the

packing case and lift the packaged equipment out ofthe case.

(4) Open the outer corrugated carton and breakthe sealed moisture-vaporproof barrier. Lift out theinner corrugated carton.

(5) Open the inner corrugated carton andremove the bat tery pa ck. Read a nd observe thecharging instructions fully before connecting thebattery pack to an oscilloscope.b. The battery pack may be received in domestic

packing cases. The instructions given in a above,also apply to unpacking domestic shipments. Ifheavy wrapping paper has been used, remove itcarefu l ly and t ake out the ba t tery pack .

2-3. Check Unpacked Equipment

a. Inspect the equipment for damage incurredduring shipment. If the equipmen t has beendamaged, repor t the damage on SF 964 (para 1-3b).b. Check the equipment for completeness against

the packing slip .Report all discrepancies in accordance withparagraph 1-3.The equipment should be placed inservice even though a minor assembly or part thatdoes not affect proper functioning is missing.c. Check to see if the equipment has been

modified. Modified equipment will have the MWOnumber on t he front panel near the nomencla ture

plate. Check also to see whether all currently ap-plicable MWOs have been applied. (Current MWOsare l isted in DA Pam 310-4).d. After the equipment has been thoroughly

checked, clean with a soft cloth.

Section II. INSTALLATION

2-4. Attaching The Battery Pack

a. The ba tt ery pa ck is equipped w ith four per-manently attached clamps that are designed to f itand attach to the feet of the portable Oscilloscope

OS-261 (Tektronix Model 475 Option 7). Set theoscilloscope on the battery pack and observe thatthe oscilloscope feet seat properly in the clamps.Press the moveable part of the clamp inward until a

positive fit is accomplished.b. The dc power cord attached to the battery pack

is to be plugged into the dc socket of theoscilloscope. Refer to chapter 3 prior to placing thebattery pack into operation.

c. The a c pow er cord t o the ba tt ery pa ck is notused while the battery pack is in operation. Storethis a c cord in a m ethod so tha t it w ill not incurdamage during movement of the oscilloscope and

battery pack from one working area to the next.d. I t may be advantageous to use the battery

pack and the oscilloscope as separate units as eachitem is equipped with its own carrying handle. With

care, the tw o units ma y be ca rried short distan cesby two persons without disconnecting the dc powercord while still in the operational mode, thusrealizing the full portability of these two units.

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CHAPTER 3

OPERATING INSTRUCTIONS

Section I. FUNCTION OF CONTROLS AND CONNECTORS

3-1. Battery Level tain fully-charged batteries.Meter indicates the approximate state of charge of b. ON Posit ion. Lamp indicates charger is on.

the bat teries while under load. Charging occurs as long as the battery pack is con-nected to the ac power line.

3-2. Charger c. Li ne Sel ector. Select 115 Vac or 230 Vac

a. Mode Swi tch.opera t ion .

(1) Ful l . Permits the maximum safe charging d. DC Output (Attached Cord). Connects to the

rate. Charge rate should be changed to the trickle- oscilloscope external dc input.

charge rate when the batteries have received a full e. AC I nput . Allows ac operation of the battery

c ha r g e . charger circuit only, as long as the ac line is con-

(2) Trickle. Reduces the charging rate to main- n e t t e d .

Section Il. OPERATION AND INSPECTION

3-3. First-Time Operation

The ins t rument may be opera ted wi th less than fu l lycharged bat teries. For first-time opera t ion ,however , charge the batter ies at the full-charge ratefor 14 to 16 hours.

3-4. Attaching the Battery Pack

Attach the battery pack to an oscilloscope with Op-

tion 7 as follows (see fig. 1-1):a. Open the latches on the battery pack by pulling

them outward. Set the oscil loscope on top of the bat-tery pack with the feet in the holes in the la tches.Push the latches in until they lock in the feet of the

oscilloscope. Check each corner to verify that eachfoot has been latched to the battery pack.b. Set the oscilloscope for 24 Vdc operation and

connect the battery pack output to the oscilloscope(Option 7) dc input. Turn the oscilloscope on. Checkthat the battery pack powers the oscilloscope. Ob-serve the BATTERY LEVEL meter. The meterreading is only indicative of the remaining charge ifthe battery pack if powering an oscilloscope. Underno-load conditions, the battery pack will read full,even i f i t is almost discharged.

c. Connect the oscil loscope frame to a ground (ear-th) reference before using.

Section III. BATTERY OPERATION

3-5.

a .

WARNING

The nickel-cadmium (NiCd) cells used inthis instrument are capable of delivering

a l a rge amount o f cur rent in a shor t t ime .Care must be taken not to short-circuitthe cells. The battery pack is fused at 6amperes .

Operating Time

Battery operating time depends on the load

selected and the charge-discharge temperatures. Op-t imum charge and discharge is obtained when thebat ter ies are opera t ing a t tempera tures be tween 20 C to 30 C. Relative capacities for other tem-pera tures ar e shown in table 3-1. Bat tery packdischarge curves are given in figure 3-1.b. Optimum operating time is obtained by having

the battery pack vertical (handle on top) during bat-tery charging.

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Table 3-1.Typical Battery Charge Capacity (referenced to charge-discharge at +20 C to +30 C)

Charge Temperature Operating Temperature

-15 C +20C to +30 C +55 C

0 C 40% 60% 50%

+20 C to +30 C 65% 100% 85%

+40 C 40% 65% 55%

c. Th e a p p r o x im a t e b a t t e r y p a c k o p er a t i n g t i m e S p e c i f i c a t i o n p o r t i o n o f t h e o s c i l l o s c o p e t e c h n i c a lm a y b e r o u g h l y e s t i m a t e d u s i n g f i g u r e 3 - 1 . F or i n - m a n u a l .

d i v i d u a l o s c i l l o s c o p e t i m e s s e e t h e O p t i o n 7

EL6RK002

Figure 3-1. Typical Battey-Pack Discharge Curves.

NOTEHigh discha rge rat es or high a mbienttemperatures may raise the battery tem-

perature enough to lower their 140 watt-hour capabili ty .

3-6. Battery Discharge

Extensive discharge of the batteries may cause oneor more of the cells to reverse polarity. Repeatedreversal shortens the useful life of the batteries. Theoscilloscope with the Option 7 has a circuit to cut offits inverter when the external dc source drops belowapproximately 22 Vdc. This prevents the batteryfrom going into deep discharge.

3-7. Battery Charge

a. A thermal cutout in the battery pack protectsthe batteries from overheating during charge time.The batteries normally become warmer as theyreach full charge potential . If the temperature

surrounding the bat teries exceeds the sa fe operat inglevel, a therma l cutout switches the cha rge rat e

from 620 milliamperes full-charge to the 60-milliam-pere trickle-char ge ra te. When t he tempera tur ereturns to a sa fe operat ing level, the thermal cutoutreturns the charge rate to the 620-milliampere level.

3- 2

The batteries may be damaged by over-charging forlong periods (in excess of 24 hours). Repeated over-charging shortens the useful l i fe of the bat teries.

b. During normal usage or storage, each batterycell in the battery pack acquires a slightly differentcharge characteristic. To provide the best overalloperation and maximum operating life, the chargeon the individual battery cells should be equalizedperiodically. This can be done without damage tothe battery cells by charging the batteries at thefull-charge rate for 24 hours. Charging should bdone after every 15 charge-discharge cycles or every30 days, whichever occurs first .c. Once the batteries are fully charged, change t

mode switch to trickle charge if the battery pack is

to remain connected to the ac line. This maintains

fully-charged bat teries and prevents overcharging.

3-8. Battery Pack Storage

a. The batteries used in the battery pack shouldbe stored in a charged condition. For best shelf life,when storing the battery pack for long periods oftime, remove fuse F131 (which may be stored byplacing it in the dc power cord clip on the rear panel).Fully recharge the bat teries about every three

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b. Charge retention characteristics of nickel-cadmium bat teries vary wi th the storage tem-perature and humidity. The battery pack may be

stored at ambient temperatures between 40 Can d + 60 C w ithout da mage, ei ther in the in-strument or as a separate unit. The self-dischargera te increases wi th a n increase in a mbient tem-

pera ture. For exam ple, cells stored at + 20 C w illlose about 50%of their stored charge in three mon-

ths, but wh en stored at + 50 C, they will be almostcompletely self-discharged in only one month. Highhumidity also increases the rate of self-discharge.

3-9. Maintenance

Additional data regarding maintenance and repairof the battery pack and the NiCd cells can be foundin the maintenance sec t ion o f th is manual .

310. Battery Charge Level

a. Meter indication of battery charge level may befalse during the first several minutes of batteryoperation. This is due to a battery character ist ic .b. When the battery pack is turned on, a residual

bat tery charge may g ive a meter ind ica t ion o f a h ighstate-of-charge even though a low, partial charge isal l tha t rema ins. The bat t ery pack may operateseveral minutes, under load, before this partial

charge is depleted.c. This characteristic may show up after the bat-

tery pack has been discharged and the instrumentturned o f f . I t may a lso show up a f te r the ins t rumenthas been stored in temperatures significantly below25 C, then brought to room temperature foropera t ion .d . I f unsure of the sta te of the bat tery charge,

recharge at the proper temperature for the fullrecharge t ime given in the battery operation section.

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CHAPTER 4

THEORY OF OPERATION

Section I. CIRCUIT DESCRIPTION

4-1. General

a. The battery pack provides a 24 Vdc powersource. The charger circuit will charge, at either full-charge or tr ickle-charge rates, as long as the batterypack is connected to the correct ac line. The metercircuit is always on. The output voltage is alwaysavailable at the DC OUT plug. The batter ies may bedisconnected from the meter and charger circuitry

by removing fuse F131.b. Refer to the complete schematic in chapter 6

throughout the following circuit description.

4-2. Battery Charger C ircuit

a. From the secondary of transformer T101, acvoltage is applied to full-wave bridge rectifierCR115. The rectified voltage goes to filter C115 andthrough CR121 to resistor R121 and transistorQ124. VR123 sets the bias for Q124. This bias isabout 5.6V across the R123 and the emitter-basejunctions of Q124, a Darlington transistor. The dropacross the two emitter-base junctions reduces thisvoltag e to a bout 4.3 V across R123.b. In parallel with R123 is the series combination

of CR125, S125, S130, and R131. The charge rateswitch S130 is shown in the FULL CHG posit ion(closed). Under normal battery temperatures, ther-mal cut-out S125 is closed and the 4.3 V is acrossR131 (in series with CR125). This limits the chargecurrent to about 620 mill iamperes.c. Bat tery tempera ture r ises as the ba t ter ies

rea ch full cha rge. S 125 opens, removing r esistorR131 from the circuit. The charging current is nowlimited to about 60 milliamperes by the 4.3 V beingapplied only across R123. The same current reduc-tion occurs when the charge rate switch (S130) is setto TRICKLE CHG (open).

4-3. Charger Circuit Protection

a. Power dissipated by Q124, in the full-chargemode, is reduced for high line or low battery con-ditions by the circuitry involving C117, CR111,

CR112, R125, and T101.

b. At low line, CR111 and CR112 are reversebiased. An increase in line voltag e increases t hepotential from the -DC OUT line to the collector ofQ124 and also to CR112 and CR111. Q124 providesa constant current to a fixed load (R123 and R131).The increased potential, therefore, appears across

Q124, increasing its dissipation.c. At some point the increased line voltage causes

CR111 and CR112 to conduct. This point is deter-mined by the taps on T101. Once CR111 and CR112

conduct, they maintain a voltage at the plus side ofC117 tha t is a bout 70% of the voltage a t t he plus sideof C115 (with respect to the -DC OUT line). As thevoltage across C117 increases, current throughR125 increases. There is a corresponding decrease incurrent supplied by Q124. This current reduction inQ124 decreases the power dissipated in Q124. Sincethe current through R125 is supplied from a lowervoltage source than is the current through Q124,there is a reduction in to tal power .d. A low charge on the ba tt er ies w il l have the

same effect on the circuit as an increase in linevo l tage . Ba t te r ies wi th a low charge and wi th a h ighac l ine may receive near ly al l o f the charging currentthrough CR111, CR112, and R125.e. CR125 prevents the current, during high line

condit ions, from bypassing the charge rate switchwhen it is in the TRICKLE CHG mode. CR 121

prevents C115 from charging through Q124. Thissituat ion can exist if the ba ttery pack has been offfor a long time, a dead battery is replaced, F131 isreplaced, or a similar condition exists that permitsC115 to discharge, then apply voltage across the+ DC OU T line.

4-4. Meter Circuit

The voltage reference for the meter circuit is set byR127 and VR131. The other side of the meter is con-nected to voltage divider R128, R133, and R136.R133 is set for a meter reading at the junction of thered and green portions of the meter scale (a readingat the lef t end dot for ear ly SN instruments) .

4- 1


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Section Il. OPERATION UNDER UNUSUAL CONDITIONS

4-5. Operation in Arctic Climates

Subzero temperatures and climatic conditionsassociated with cold weather may hamper the ef-ficient operation of electronic equipment. In-structions and precautions for operation under suchadverse conditions follow:

a. Keep the equipment warm and dry . I f theequipment is not kept in a heated enclosure, con-struct an insula ted box for i ts protect ion.b. Make certain the equipment has been warmed

up sufficiently before use. This may take 15 to 30minutes, depending on the temperature of the

surrounding a ir .c. When equipment which has been exposed to

the cold is brought into a warm room, it will sweat

until it reaches room temperature. When the equip-ment has reached room temperature, dry i tthoroughly.

4-6. Operation in Tropical Climates

In t ropical climates, electronic equipment may be in-sta l led in tents, huts or , when necessary , in un-derground dugouts. When equipment is installed

below ground, and when i t i s se t up in swamp a reas ,danger of moisture damage is more acute than nor-

mal in the tropics. Ventilation is usually very poor,and the high relative humidity cuases condensationon the equipment whenever i ts temperaturebecomes lower than the ambient air. To counteractthis condition, place lighted electric bulbs under theeq u ip m en t .

4-7. Operation in Desert Climates

The main problem with electronic equipment indesert areas is the large amount of sand and dusttha t lodges in t he moving parts a nd mecha nicalassemblies. Cleaning and servicing intervals shouldbe shortened according to local conditions.

4-2


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CHAPTER 5

MAINTENANCE

Section I. TROUBLESHOOTING

5-1. General

The first step in servicing a defective battery pack isto sectionalize the fault. Sectionalization meanstracing the fault to the major circuit responsible forthe abnormal operation. The second step is tolocalize the fault . Localization means tracing thefault to a particular stage or network within one ofthe major circuits. The third step is to isolate thefault. Isolation means tracing the fault to the defec-tive part responsible for the abnormal condition.Some faults, such as burned-out resistors, arcingan d shorted t ra nsformers, can often be located bysight, smell , and hearing. The majority of faults,however, must be isolated by checking voltages and

r es i s t a n c es .

5-2. Component Sectionalization, Localization,

and IsolationListed below is a sequence of tests a rra nged toreduce unnecessa ry w ork a nd a id in tra cing the

trouble to a specific component.a. Visual I nspecti on. Through inspection alone,

the trouble may frequently be discovered or the cir-cuit in which the trouble exists may be determined.

This inspection helps to avoid additional damage tothe equipment as a result of improper servicingmethods .b. In term it tents. It is possible that some external

connections may cause the trouble. Test wiring forloose connections and move wires and components

with an insulated tool. This may indicate thelocation of a faulty connection or component.c. Vol ta ge Checks. Refer to figures 6-2, 6-3, and

6-4 for t roubleshooting volta ge checks, symbols,and schemat ic d iagram.

Section II. BATTERY SERVICE

5-3. Tools and Test Equipment Required

The following is a list of common tools and test

equipment required for general support main-

tenance.a. Mu lt imet er M E -451/U , NS N 6625-01-

060-6804.

b. B a tt ery C ha rger P P -6241/U , NS N 6130-00-106-6445.c. Tool Kit , E lectr onic E qu ipmen t TK-100/G ,

NSN 5180-00-605-0079.

5-4. Batteries

a. The battery pack contains twenty 1.25 VNickel-Ca dmium (NiCd ) cells, in groups of four,strapped together. Background information regar-ding these cells is given in chapter 3, sect ion I I I ba t-

tery operation and should be read before any ser-vicing is performed on the bat tery pack.b. If one group of cells is defective and fails while

the rest of the battery pack is stil l quite new, thatgroup may be replaced without undue concern. TheTektronix Field Representative or Office should be

consulted before cells are replaced, i f the warranty isstill in effect.c. Gas evolution and recombination takes place

during battery charging. This creates a pressurewithin t he cells which th ey normally can w ithsta nd.

If a cell becomes defective, or a circuit failure causes

the recommended charge rate to be exceeded, ex-cessive pressure builds up. The pressure may rup-ture a relief vent, exha usting t he ga s. This a ctionmay shorten the life of the cell, and will coat thesurrounding areas with a corrosive substance.

5-5. Battery Removal

Remove the six screws from the sides of the batterypack. Remove the cover. Remove fuse F131.Remove the two screws from the battery clamps.Unsolder the wires a t the bat teries.

5-6. Cell Replacement

a. When necessary, a group of four cells can beremoved and replaced by cutting the straps that

connect the two ends of the cell group to the pack,

and soldering a new group of four cells. Single cellreplacement should not be attempted. The cell type

specified must be used. Other types may not func-tion properly. They may prove to be a hazard to theinstrument and to personnel. Operat ing t ime or tem-perature performance may be degraded. The bat tery

5-1


15/31

pack should be charged for 24 hours after cells are variation in input voltage as may exist in certain

rep laced. condit ions or geographical areas. The wires on t ran-b. All cells in the battery pack should be made by sformer T101 may be changed to accept line

the sa me manufa cturer. Include this informa tion, variation. Proper wiring of the input will result in

with the other information required, when ordering satisfactory battery pack charging.

replacement cells.

5-7. Line voltage Selection Wiring

a The battery pack can be wired

b. Refer to figure 5-1 for line voltage selectwiring. For nominal 115 Vat, use the 100 to 132VAC

-diagram. For nominal 105 Vat, use the 90 to

to accept a 120 VAC diagram.

100 TO 132 VAC

90 TO 120 VAC

E L 6 R K 0 0 3

Figure 5-1.Line Voltage Section Wiring.

5-2


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CHAPTER 6

CALIBRATION

Section I. GENERAL

6-1. Terms and Definition b. Calibration, in accordance with AR 750-25-1

a. Calibration, in accordance with maintenance (US Army Calibration System), is a periodic checkpractices, is the checking of voltages, current, of the total accuracy of each parameter as compared

resistances, etc., through each section or stage, and to calibrated standards at a ratio of 4 to 1. Upon

the adjusting and alignment of variable components completion of this type of calibration a Department

within ea ch sect ion or sta ge. I t is almost alw ays of the Army DA Label 80 is affixed to the accepted

necessary to perform this type of calibration while unit. All in format ion regarding cal ibra t ion

the equipment is being electrically repaired or as requirements for the maintenance of Army materiel

parts are being replaced. Common maintenance test is contained in TB 43-180 and TM 38-750.

equipment is used for this type of cal ibration.

Section II.

6-2. Battery Pack Disassembly

CALIBRATION DURING MAINTENANCE

lift the cover.

a. For calibration during maintenance, remove b. For further mechanical disassembly see the ex-

the six screws from the sides of the battery pack and ploded view in figure 6-1.

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Figur e 6-1.Battery Pack PP-75/ U, Exploded View.

WARNINGDa ngerous potential a nd high current

capabilities exist at several points.Disconnect power cord, remove fuseF131, and unsolder batteries beforereplacing parts.

6-3. Equipment Required

DC Milliammeter: 620 mA and 60mA. Voltmeter:/VDC a nd 5 ,000

Variable DC Power Source: 21 to 24 V at 10 mA.

NOTEThe battery pack is calibrated at the fac-tory using a power supply permitting ac-

6-4.

a .

curate setting of the meter zero. Becausethis type of power supply may not beavailable, an alternate method is given.The accuracy of the equipment requireddepends on how critically the user wantsthe meter zero to coincide with the cut-offpoint in the Option 7 circuitry.

Calibration Procedure

Charge.

(1) Remove fuse F131, (figure 6-2). Connect the

ammeter across the terminals for F131. Connect thebattery pack to the correct ac l ine. Set the modeswitch to FULL CHG.

6-2


18/31

Voltmeter: 20,000 / and 5,000 / mult imeter.

Voltage readings will vary with line voltage and battery

charge level.

Battery charged

Line Selector: Correct line voltage

Mode Switch: FULL CHG

Fi gure 6-2.Battery Pack PP-7549/ U, Cir cuit Board, wi th Test Voltages and Condit ions.

(2) Current should be approximately 620 mA.

(3) Change mode switch to TRICKLE CHG.(4) Current should be approximately 60 mA.b. Zero Ad ju st.

(1) Disconnect th e bat tery pa ck from t he a cline. Disconnect the external milliammeter but donot install F131. Connect a 23 V power source to theDC OUT connector (for SN below B022417 use a 22

V source).(2) B a tt ery level meter should read nea r t he

junction of the red and green portions of the scale (or

near the left end dot for SN below B022417).(3) Adjust Meter Level (R133) (fig. 6-2)for areading at the junct ion of the red and green port ionsof the scale (for SN below B022417 adjust R133 fora meter reading at the lef t end dot) .

(4) Remove the dc power source and install fuse

F131.(5) Reassemble the battery pack in the opposite

manner as disassembled in paragraph 6-2.

6-3


19/31

C I R C U I T B O A R D I L L U S T R A T I O N , D I A G R A M , A NPARTS LISTS

Symbols

Electrical components shown on the diagrams are in the following units unless noted otherwise:

Capacitors = Values one or greater are in picofarads (pF).

Fi gu r e 6 -3 .

Values less than one are

Resi stor s = Ohms

Symbols used on the diagrams are based on USA Standard Y32.2-1967.

Logic symbology is based on MIL-STD-8068 in terms of positive logic.

and may differ from the manufacturers data.

in microfarads (F).

Logic symbols depict the Iogic function performed

Internal Screwdriver Adjustment

Test Voltage

Plug to E.C. Borad

Panel Adjustment

Plug Index

Modified ComponentSee Parts List

Refer to Waveform

Refer to Diagram Number

Coaxial Connector

Panel Connector

Assembly Number

Board Name

Etched Circuit Board

Schematic Name and Number

Ba t t e r y Pack PP - 7549 /U , Ver t i c a l Am p l i f i e r Schema t i c w i t h Exp l an a t i o n o f E le c t r i c a l Symbo l s .

6-4


20/31

NOTE:

DENOTES COMMON

NEGATIVE RETURN

Fi gure 6-4. Batt ery Pack PP-7649/ U , Schemat ic Diagr am.

6- 5


21/31

APPENDIX A

REFERENCES

DA Pam 310-4 Index of Technical Publications.

TB 43-180 Calibra t ion Requirements for the Maintenance of Army Materiel .TB 43-0118 Field Instructions For Painting and Preserving Electronics Command Equip-

ment Including Ca mouflage Pa t tern P aint ing of Electrica l Equipment

Shelters.TM 11-6130-351-14 Opera tors , Organ izat iona l , Direct Support , an d G enera l Support Main-

tenance Manual Including Repair Parts and Special Tools Lists (Including

Depot Maintenance Repair Parts and Special Tools) for Battery ChargerP P -6241/U .

TM 11-6625-2953-14 Opera tors , Organizat iona l , Direct Support , a nd G enera l Support Main-tena nce Ma nua l for Mult imeter AN/U SM-451.

TM 38-750 The Army Maintenance Management System (TAMMS).TM 740-90-1 Administrative Storage of Equipment.TM 750-244-2 Procedures for Destruction of Electronics Materiel to Prevent Enemy Use

(Electronics Command).

A-1/(A-2 Blank)


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APPENDIX B

MAINTENANCE ALLOCATION

Section I. INTRODUCTION

B-1. GeneralThis a ppendix provides a sum ma ry of the ma in-ten a nce opera tions for th e PP -7549/U . It a ut horizescategories of maintenance for specific maintenancefunctions on repairable items and components andthe tools and equipment required to perform eachfunction. This appendix may be used as an aid inplanning maintenance opera t ions .

B-2. Maintenance Function

Maintenance functions wil l be l imited to and def inedas fo l lows:a. I nspect. To determine the serviceability of an

item by compar ing its ph ysical, mecha nical, a nd/orelectrical characteristics with established standardsthrough examinat ion .b. Test. To verify serviceability and to detect in-

cipient failure by measuring the mechanical or elec-t r ica l chara cterist ics of an i tem an d comparingthose character ist ics with prescr ibed standards.c. Ser vi ce. Operations required periodically to

keep an item in proper operating condition, i.e., toclean (decontaminate), to preserve, to drain, topaint, or to replenish fuel, lubricants, hydraulicfluids, or compressed air supplies.d. Adj ust. To maintain, within prescribed limits,

by bringing into proper or exact position, or by set-ting the operating characteristics to the specifiedp a r a m e t e r s .e. Ali gn. To adjust specified variable elements of

an item to bring about optimum or desired per-f o r ma nc e .f . Cal ibr ate. To determine and cause corrections

to be made or to be adjusted on instruments or testmeasuring and diagnostic equipments used inprecision measurement. Consists of comparisons oftwo instruments, one of which is a cer t i f ied standardof known accuracy, to detect and adjust anydiscrepancy in the accuracy of the instrument being

compared.g. I nstall . The act of emplacing, seating, or fixing

into position an item, part, module (component ora ssembly) in a ma nner t o allow the proper func-t ioning of the equipment or system.h. Repl ace. The act of substituting a serviceable

like type part, subassembly, or module (componentor assembly) for an unserviceable counterpar t .i . Repair . The a pplica tion of ma intena nce ser-

vices (inspect, test, service, adjust, align, calibrate,replace) or o ther maintenance actions (welding, gr in-ding, riveting, straightening, facing, remachining,or resurfacing) to restore serviceability to an itemby correcting specific damage, fault, malfunction, orfailure in a part, subassembly, module (componentor assembly), end i tem, or system.j . Over hau l . That maintenance effort (ser-

vice/a ction) necessa ry t o restore a n it em to a com-pletely serviceable/operat iona l condit ion asprescribed by maintenance standards (i.e., DMWR)

in appropriate technical publications. Overhaul isnormally the highest degree of maintenance per-

formed by the Army. Overhaul does not normallyreturn an i tem to l ike new condit ion.k. Rebuil d. Cons ists of th ose services/a ctions

necessary for the restorat ion of unserviceable equip-ment t o a l ike new condition in a ccordan ce w ithoriginal manufacturing standards. Rebuild is thehighest degree of materiel maintenance applied toArmy equipment. The rebuild operation includes theact of returning to zero those age measurements(hours, miles, etc.) considered in classifying Armyequipm ent s/component s.

B-3. Column Entries

a. Column 1, Gr oup N um ber . Column 1 listsgroup numbers, the purpose of which is to identifycomponents, assemblies, subassemblies, a n dmodules wi th the next h igher assembly .b. Column 2, Component / Assembl y. Column 2

conta ins the noun na mes of components , ass em-blies, subassemblies, and modules for which main-tenance is authorized.c. Colum n 3, Main tenan ce Fu nctions. Column 3

l is ts the functions to be performed on the i tem l istedin column 2. When items are listed without main-tenance functions, it is solely for purpose of havingthe group numbers in the MAC and RPSTL coin-

cide.d. Colum n 4, M ain tenan ce Categor y. Column 4

specifies, by the listing of a work time figure inthe appropriate subcolumn(s), the lowest level ofma intena nce a uth orized to perform th e functionlisted in column 3. This figure represents the activetime required to perform that maintenance function

a t t he indicated category of maintena nce. I f th enumber or complexity of the tasks within the listed

B-1


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maintenance funct ion vary a t d i f fe rent maintenancecategories, appropriate work time figures will beshown for each category. The number of task-hoursspecified by the work time figure represents theaverage time required to restore an item (assembly,

subassembly, component, module, end item orsyst em) to a serviceable condition under t ypica lfield operating conditions. This time includespreparation time, troubleshooting time, and qualitya ssura nce/qua lity cont rol time in a ddition to thetime required to perform the specific tasks iden-tified for the maintenance functions authorized inthe maintenance allocation chart. Subcolumns ofcolumn 4 are as follows:

COpera tor/Cr ewOOrganizationalFDirect SupportHGeneral SupportDDepot

e. Colu mn 5, Tool s and E qui pment . Column 5specifies by code, those common tool sets (not in-dividual tools) and special tools, test, and support

equipment required to perform the designated func-t ion .f . Column 6, Remark s. Column 6 contains an

alphabetic code which leads to the remark in sect ionIV, Remarks, which is pertinent to the item op-posite the particular code.

B-4. Tools and Test Equipment Requirements(See III)

a. Tool or Test Equ i pm ent Reference Code. Thenumbers in this column coincide with the numbers

used in the tools and equipment column of the MAC.The numbers indicate the applicable tool or testequipment for the maintenance funct ions.b. M ai nt enan ce Category. The codes in this

column indicate the maintenance category allocated

the tool or test equipment.c. N omenclat ur e. This column lists the noun

name and nomenclature of the tools and test equip-ment required to perform the maintenance func-t ions .d. Nat i onal / NA TO Stock Num ber. This column

lists t he Na tiona l/NATO st ock num ber of th especific tool or test equipment.e. Tool N um ber . This column lists the manufac-

turers part number of the tool followed by theFederal Supply Code for manufacturers (5-digit) inpa re n t he s e s .

B-5. Remarks (Sec IV)a. Reference Code. This code refers to the ap-

propriate item in section II, column 6.b. Remar ks. This column provides the required

explanatory information necessary to clarify items

appearing in sect ion II .

(Next printed page is B-3)

B-2


24/31

TM 11-6625-2978-14

(I)

GROUP

NUMBER

00

01

02

SECTION II MAINTENANCE ALLOCATION CHART

FOR

POWER SUPPLY PP-7549/U

(2)

COMPONENT/ASSEMBLY

POWER SUPPLY PP- 7549/ U

STORAGE BATTERY BT- 131

CI RCUI T CARD ASSY ( A1)

(3)

MAINTENANCE

FUNCTION

I nspectTestCali brateRepai rRepai r

Over haul

I nspectTest

Repl ace

Repai r

I nspectTestRepl aceRepai r

(4)

MAINTENANCE CATEGORY

C O

0. 1

0. 1

F H

0. 50. 5

1. 0

0. 10. 10. 2

0. 2

0. 10. 50. 2

D

5. 0

0. 5

(5)

TOOLS

AN D

EQPT.

1 thru 3

1 thru 3

3

1 thru 3

3

2, 3

3

3

3

1 thru 3

3

3

(6)

REMARKS

B- 3

DRSEL-MA Form 6031, (1 Jul 76)HISA-FM 2314-79


25/31

TM 11-6625-2978- 14

SECTI ON I I I TOOL AND TEST EQUI PMENT REQUI REMENTS

F OR

POWER SUPPLY PP- 7549/ U

TOOL OR TEST MAI NTENANCEEQUI PMENT CATEGORY

NOMENCLAT URENATI ONAL/ NATO

REF CODESTOCK NUMBER TOOL NUMBER

1 H, D MULTI METER ME- 451/ U 6625- 01-060- 6804

2 H, D BATTERY CHARGER PP- 6241/ U 6130- 00-106- 6445

3 H, D TOOL KI T, ELECTRONI C EQUI PMENT TK-100/ G 5180- 00-605- 0079

B- 4


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THE METRIC SYSTEM AND EQUIVALENTS


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