6340_59 Repair Manual.pdf

TI 634O.59

CONTROLLED

DOCUMENT

F_ RNAL

-" REPAIR MANUAL

DEPOT MAINTENANCE

ARSR-4 SYSTEM

UUTs TESTED ON

COLLECTOR/PREAMP POWER

SUPPLY TEST SET

CONTRACT DTFA01-88-C-00037

CONTRACTOR

NORTHROP GRUMMAN CORPORATION

BALTIMORE, MARYLAND 21203

MADE FOR

U.S. DEPARTMENT OF TRANSPORTATION

FEDERAL AVIATION ADMINISTRATION

S-_.\ (31 JULY 1998)

TI6340.59

INTRODUCTION

This repair manual consists of four separately-bound manuals containing depot-level repair data for units tested on the Collector/Preamp Power Supply Test Set. This manual contains general repair data, specific repair data for each unit tested, and Appendix A, List of Acronyms and Abbreviations, in an 8 1/2-inch by 11-inch format. Appendix B, Assembly Drawings, is a separately-bound manual in an 11-inch by 17-inch flat-pak format. Appendix C, Parts Lists, and Appendix D, Wire Data, are separately-bound manuals in an 8 1/2-inch by 11-inch format.

(31 July 1998) Uii

TI 6340.59

" SAFETYSUMMARY

SAFETY NOTICE

The attention of operating and maintenance personnel is directed to Federal Aviation Administration (FAA) Instruction 6000.15, Maintenance of Airway Facilities, for instructions on the subject of safety precautions to be observed, and to FAA Order 3900.0, Accident Prevention Handbook for Airway Facility Personnel. Personnel must observe the safety regulations at all times.

KEEP_AWAY FROM LIVE CIRCUITS

Hazardous voltages are present within units under test. Use extreme caution when removing or installing plug-in components or making adjustments. Under certain conditions, dangerous potentials may exist in circuits with power controls in the off position due to charges retained by capacitors. To avoid casualties, always remove power, and then discharge the capacitors with a grounding rod before touching any parts.

_- WARNINGS AND CAUTIONS

Observe all warnings and cautions within this manual for maximum personnel and equipment safety.

PRECAUTIONARY NOTICE1

SEMICONDUCTOR DEVICES/INTEGRATED CIRCUITS

This equipment contains semiconductor devices that may be damaged by static discharge. Strictly adhere to the electrostatic discharge (ESD) precautionary measures within this manual before attempting to perform any procedure.

(31 Iuly 1998) iii/iv

TABLE OF CONTENTS

Paragaph Title Page

CHAPTER I - GENERAL INFORMATION

1.1 Introduction ........................................................................................................... 1-1

1.2 Depot Repairable Assemblies/Subassemblies ...................................................... 1-1

1.3 Depot Repair Facility Requirements ..................................................................... 1-4

1.4 Tools and Test Equipment .................................................................................... 1-4

1.5 Consumable Material ............................................................................................ 1-5

1.6 Related Publications ............................................................................................. 1-8

1.7 Standard Shop Practices ........................................................................................ 1-8

1.7.1 Unpacking ........................................................................................................ 1-8 1,7.1.1 Special Handling Precautions ...................................................................... 1-8

1.7.1.2 Unpacking Procedure ................................................................................... 1-9

1.7.2 Packing ............................................................................................................. 1-10

1.7.2.1 Special Handling Precautions ...................................................................... 1-10

1.7.2.2 Packing Procedure ........................................................................................ 1-10

1.7.3 Examination .......................................................................................................... 1-11

1.7.3.1 Hardware and Electrical Components .............................................................. 1-11

1.7.3.2 Cables, Wires, and Connectors ........................................................................ 1_11 1.7.3,3 Placards and Markings ..................................................................................... 1-I 1 1.7,4 Cleaning ................................................................................................................ 1-11

1.7.4.1 Cleaning Moderately Contaminated Items ....................................................... 1-11

1.7.4.2 Cleaning Highly Contaminated Items .............................................................. 1-13

1.7.5 Disassembly and Reassembly ............................................................................... 1-14

1.7.5.1 Electrostatic Discharge (ESD) Precautions ...................................................... 1_14

1.7.5.2 Component Location ........................................................................................ 1-14

1.7.5.3 Wire Removal .................................................................................................. 1-14

1.7.5.4 Component Mounting ...................................................................................... 1-14

1.7.5.5 Threaded Hardware and Component Mounting ............................................... 1-14

- 1.8 Repair Notes ......................................................................................................... 1-14

1.8.1 Application of Epoxy Resin Adhesive (M53320LG) ....................................... 1-15

1.8.2 Application of Polyurethane Resin Adhesive (M53320SM) ............................ 1-16

1.8.3 Application of Polychloroprene Rubber Adhesive (PDS53314ZM) ................ 1-16

1.8.4 Application of Pressure-Sensitive Decalcomania using Rubber Base

Adhesive (MMM-A-1617) and Protective Overlay (M44723BJ) .................. 1-17

1.8.5 Application of Thread-Locking Adhesive (M53320UC or M53831NX) ........ 1-18

1.8.6 Application of Heat Sink, Silicone Compound (M53846DG) ......................... 1-18

1.9 Typical Test Procedure ......................................................................................... 1-19

1.9.1 Computer Typographic Conventions ............................................................... 1- 19

1.9.2 Test Program Initialization ............................................................................... 1-19

1.9.3 Test Program Exit ............................................................................................. 1-20 1,10 Troubleshooting .................................................................................................... 1-20

(31July1998) v

TABLE OF CONTENTS--Continued

Paragraph Title Page

CHAFI'ER 2 - COLLECTOR. POWER SUPPLY PN 3D56068G01 REPAIR

2.1 Scope ................................................................................................................. 2-1

2.2 Tools and Test Equipment .................................................................................... 2-2

2.3 Consumable Material ............................................................................................ 2-3

2.4 Disassembly and Reassembly ............................................................................... 2-6

2.4.1 Step-Start Control CCA A1 .............................................................................. 2-6

2.4.1.1 Removal ....................................................................................................... 2-6

2.4.1.2 Replacement ................................................................................................. 2-6

2.4.2 Step-Up Control CCA A2 ................................................................................ 2-7

2.4.2.1 Remo'_al ....................................................................................................... 2-7

2.4.2.2 Replacement ................................................................................................. 2-7

2.4.3 Six Capacitor CCA A3 ..................................................................................... 2-7

2.4.3.1 Removal ....................................................................................................... 2-7

2.4.3.2 Replacement ................................................................................................. 2-7

2.4.4 Eight Capacitor CCA A4 .................................................................................. 2-g

2.4.4.1 Removal ....................................................................................................... 2-8

2.4.4.2 Replacement ................................................................................................. 2-8

2.4.5 Step-Up Converter Assembly A5 ..................................................................... 2-8

2.4.5.1 Removal ....................................................................................................... 2-8

2.4.5.2 Replacement ................................................................................................. 2-9 2.4,6 Four Capacitor CCA A6, A1 I, A16, A21, or A26 ........................................... 2-9

2.4.6.1 Removal ....................................................................................................... 2-9

2.4.6.2 Replacement ................................................................................................. 2-9

2.4.7 Switcher Module Assembly AS, A13, A18, A23, or A28 ................................ 2-9

2.4.7.1 Removal ....................................................................................................... 2-9

2.4.7.2 Replacement ................................................................................................. 2-10

2.4.8 Current Sense CCA A9, A14, A19, A24, or A29 ............................................ 2-10

2.4.8.1 Removal ....................................................................................................... 2-10

2.4.8.2 Replacement ................................................................................................. 2-10

2.4.9 Output Diode Assembly A10, A15, A20, A25, or A30 ................................... 2-11

2.4.9.1 Removal ....................................................................................................... 2-11

2.4.9.2 Replacement ................................................................................................. 2-11

2.4.10 Main Control CCA A31 ................................................................................... 2-11

2.4.10.1 Removal ....................................................................................................... 2-11

2.4.10.2 Replacement ................................................................................................. 2-12

2.4.11 Switch CCA A32 .............................................................................................. 2-12

2.4.11.1 Removal ....................................................................................................... 2-12

2.4.11.2 Replacement ................................................................................................. 2-13

2.4.12 +5 Volt Regulator CCA A33 or -15 Volt Regulator CCA A34 ....................... 2-13 vi (31 July 1998)

Paragaph Title Page

2.4.12.1 Removal ....................................................................................................... 2-13

2.4.12.2 Replacement ................................................................................................. 2-13

2.4.13 +15/+12 Volt Regulator CCA A35 .................................................................. 2-13

2.4.13.1 Removal ....................................................................................................... 2-13

2.4.13.2 Replacement ................................................................................................. 2-14

2.4.14 House Control CCA A36 ................................................................................. 2-14

2.4.14.1 Removal ....................................................................................................... 2-14

2.4.14.2 Replacement ................................................................................................. 2-14

2.4.15 Switcher Control CCA A37 or A38 ................................................................. 2-15

2.4.15.1 Removal ....................................................................................................... 2-15

2.4.15.2 Replacement ................................................................................................. 2-15

2.4.16 Switcher Control CCA A39, A40, or A41 ....................................................... 2-15

2.4.16.1 Removal ....................................................................................................... 2-16

2.4.16.2 Replacement ................................................................................................. 2-16

2.4.17 Filter Capacitor CCA A42 ................................................................................ 2-16

2.4.17.1 Removal ....................................................................................................... 2-16

2.4.17.2 Replacement ................................................................................................. 2-16

2.4.18 Motherboard A43 ............................................................................................. 2-16

2.4.18.1 Removal ....................................................................................................... 2-16

2.4.18.2 Replacement ................................................................................................. 2-17

2.4.19 Capacitor CCA A44 ......................................................................................... 2-17

2.4.19.1 Removal ....................................................................................................... 2-17

2.4.19.2 Replacement ................................................................................................. 2-17

2.4.20 Rectifier Assembly (CR4 through CR6) .......................................................... 2-18

2.4.20.1 Removal ....................................................................................................... 2-18

2.4.20.2 Replacement ................................................................................................. 2-18

2.4.21 Rectifier Heat Sink Assembly (CR8 through CR10) ....................................... 2-18

2.4.21.1 Removal .................................................................................................... ,-- 2-18

2.4.21.2 Replacement ................................................................................................. 2-18

2.4.22 Fault Light DS1 ................................................................................................ 2-19

2.4.22.1 Removal ....................................................................................................... 2-19

2.4.22.2 Replacement ................................................................................................. 2-19

2.4.23 Three-Phase Fuseholder (F1 through F3) ......................................................... 2-19

2.4.23.1 Removal ....................................................................................................... 2-19

2.4.23.2 Replacement ................................................................................................. 2-19

2.4.24 Fuse Assembly (F4 through F9) ....................................................................... 2-20

2.4.24.1 Removal ....................................................................................................... 2-20

2.4.24.2 Replacement ................................................................................................. 2-20

2.4.25 Connector J1 ..................................................................................................... 2-20

-- 2.4.25.1 Removal ....................................................................................................... 2-20

(31July1998) vii

Paragraph Title Page

2.4.25.2 Replacement ................................................................................................. 2-21

2.4.26 Boost Inductor Assembly L1 ............................................................................ 2-21

2.4.26.1 Removal ....................................................................................................... 2-21

2.4.26.2 Replacement ................................................................................................. 2-21

2.4.27 Switch Output Inductors L2 through L6........................................................... 2-22

2.4.27.1 Removal ....................................................................................................... 2-22

2.4.27.2 Replacement ................................................................................................. 2-22

2.4.28 Inductor AssemNy L7 ...................................................................................... 2-22

2.4.28.1 Removal ....................................................................................................... 2-22

2.4.28.2 Replacement ................................................................................................. 2-23

2.4.29 Resistor Assembly (R1 through R3) and Resistor Assembly (R10 and R11) .. 2-23

2.4.29.1 Removal ....................................................................................................... 2-23

2.4.29.2 Replacement ................................................................................................. 2-23

2.4.30 Switcher Transformers T1 through T5 ............................................................. 2 23

2.4.30.1 Removal ....................................................................................................... 2-23

2.4.30.2 Replacement ......................................................................................... _....... 2-24

2.4.31 Power Transformer T6 ..................................................................................... 2-24

2.4.31.1 Removal ....................................................................................................... 2-24

2.4.31.2 Replacement ................................................................................................. 2-24

2.4.32 Inverter Transformer T7 ................................................................................... 2-24

2.4.32.1 Removal ....................................................................................................... 2-24

2.4.32.2 Replacement ................................................................................................. 2-25

2.4.33 Capacitor Discharge Device ............................................................................. 2-25

2.4.33.1 Removal ....................................................................................................... 2-25

2.4.33.2 Replacement ................................................................................................. 2-25

2.4.34 Step-Start Rectifier Assembly .......................................................................... 2-25

2.4.34.1 Removal ....................................................................................................... 2-25

2.4.34.2 Replacement ................................................................................................. 2-26

2.5 Examination and Cleaning .................................................................................... 2-26

2.6 Repair and Replacement ....................................................................................... 2-26

2.7 Test Description .................................................................................................... 2-26

2.7.1 Performance Tests ............................................................................................ 2-26

2.7.1-1 Power Up Procedure .................................................................................... 2-27

2.7.1.2 Test 100 - Resistance Tests .......................................................................... 2-27

2.7.1.3 Test 200 - Step Start Control ....................................................................... 2-27

2.7.1.4 Test 300 - Step Up Converter ...................................................................... 2-27

2.7.1.5 Test 400 - House Supply Checkout .............................................................. 2-27

2.7.1.6 Test 500 - Fuse Failure and Switcher Sync .................................................. 2-27 viii (31July1998)

TI 6340_59

Paragraph Title Page

2.7.1.7 Test 600 - Output Overvoltage ..................................................................... 2-27

2.7.1.8 Test 700 - Switcher High Power ......................................... : ........................ 2-27

2.7.1.9 Test 800 - Fine Charge Control .................................................................... 2-27

2.7.1.10 Test 900 - Bus Regulator Interface Tests ..................................................... 2-27

2.7.1.10.1 Reference Voltage In Test ....................................................................... 2-27

2.7.1.10.2 Bus Voltage In Test ................................................................................. 2-27

2.7.1.10.3 Current Sample 1 Pulse Width Test ........................................................ 2-28

2.7.1.10.4 Current Sample 1 Peak Amplitude Test .................................................. 2-28

2.7.1.10.5 Current Sample 2 Pulse Width Test ........................................................ 2-28

2.7.1.10.6 Current Sample 2 Peak Amplitude Test .................................................. 2-28

2.7.1.10.7 Current Sample 2 Step Voltage Peak Amplitude Test ............................ 2-28 2.7.1A0.8 Current Sample 3 Pulse Width Test ........................................................ 2-28

2.7.1.10.9 Current Sample 3 Voltage Peak Amplitude Test .................................... 2-28

2.7.1.11 Test 1000 - Regulation Performance ........................................................... 2-28

2.7.1.12 Test 1100 - Covers On Performance Test .................................................... 2-28

2.7.2 Diagnostic Tests ............................................................................................... 2-33

2.8 Test Procedure ...................................................................................................... 2-33

2.9 Troubleshooting .................................................................................................... 2-33

2.10 Assembly Drawings and Parts Lists ...................................................................... 2-33

2.11 Wire Data .............................................................................................................. 2-33

CHAPTER_ 3 - PREAMPLIFIER POWER SUPPLY PN 3D56068G02 REPAIR

3.1 Scope ................................................................................................................. 3-1

3.2 Tools and Test Equipment .................................................................................... 3-2

3.3 Consumable Material ............................................................................................ 3-3

3.4 Disassembly and Reassembly ............................................................................... 3-6 --- 3.4.1 Step-Start Control CCA A1 .............................................................................. 3-6

3.4.1.1 Removal ....................................................................................................... 3-6

3.4.1.2 Replacement ................................................................................................. 3-6

3.4.2 Step-Up Control CCA A2 ................................................................................ 3-7

3.4.2.1 Removal ....................................................................................................... 3-7

3.4.2.2 Replacement ................................................................................................. 3-7

3.4.3 Six Capacitor CCA A3 ..................................................................................... 3-7

3.4.3.1 Removal ....................................................................................................... 3-7

3.4.3.2 Replacement ................................................................................................. 3-7

3.4.4 Eight Capacitor CCA A4 .................................................................................. 3-8

3.4.4.1 Removal ....................................................................................................... 3-8

- 3.4.4.2 Replacement ................................................................................................. 3-8

(31July1998) ix

Paragraph Title Page

3.4.5 Step-Up Converter Assembly A5 ....................................................... .............. 3-8 3.4.5,1 Removal ....................................................................................................... 3-8

3,4.5.2 Replacement ......................................................... ........................................ 3-9

3.4.6 Four Capacitor CCA A6, AI 1, A16, A21, or A26 ........................................... 3-9 3.4.6,1 Removal ....................................................................................................... 3-9

3.4.6.2 Replacement ................................................................................................. 3-9

3.4.7 Switcher Module Assembly A8, A13, A18, A23, or A28 ................................ 3-9

3.4.7.1 Removal ....................................................................................................... 3-9

3.4.7.2 Replacement ................................................................................................. 3-10 3,4_8 Current Sense CCA A9, A14_ A19, A24, or A29 ............................................ 3-10

3.4.8.1 Removal ....................................................................................................... 3-10

3.4.8.2 Replacement ................................................................................................. 3-10

3.4.9 Output Diode Assembly A10, A15, A20, A25, or A30 ................................... 3-11 3,4.9.1 Removal ....................................................................................................... 3-11 3.4.9,2 Replacement ................................................................................................. 3-11

3.4.10 Main Control CCA A31 ................................................................................... 3-11

3.4.10.1 Removal ....................................................................................................... 3-11

3.4.10.2 Replacement ................................................................................................. 3-12 -_

3.4.11 Switch CCA A32 .............................................................................................. 3-12

3.4.11.1 Removal ....................................................................................................... 3-12

3.4.11.2 Replacement ................................................................................................. 3-13

3.4.12 +5 Volt Regulator CCA A33 or -15 Volt Regulator CCA A34 ....................... 3-13

3.4.12.1 Removal ....................................................................................................... 3-13

3.4.12.2 Replacement ................................................................................................. 3-13

3.4.13 +15/+12 Volt Regulator CCA A35 .................................................................. 3-13

3.4.13.1 Removal ....................................................................................................... 3-13

3.4.13.2 Replacement ................................................................................................. 3-14

3.4.14 House Control CCA A36 ................................................................................. 3-14

3.4.14.1 Remo_ral ....................................................................................................... 3-14

3.4.14.2 Replacement ................................................................................................. 3-14

3.4.15 Switcher Control CCA A37 or A38 ................................................................. 3-15

3.4.15.1 Removal ....................................................................................................... 3-15

3.4.15.2 Replacement ................................................................................................. 3-15

3.4.16 Switcher Control CCA A39, A40, or A41 ....................................................... 3-15

3.4.16.1 Removal ....................................................................................................... 3-16

3.4.16.2 Replacement ................................................................................................. 3-16

3.4.17 Filter Capacitor CCA A42 ................................................................................ 3-16

3.4.17.1 Removal ....................................................................................................... 3-16

3.4.17.2 Replacement ................................................................................................. 3-16

3.4.18 Motherboard A43 ............................................................................................. 3-16 x (31July1998)

Paragraph Title Page

3.4,18.1 Removal ....................................................................................................... 3-16

3.4,18.2 Replacement ................................................................................................. 3-17

3.4.19 Capacitor CCA A44 ......................................................................................... 3-17

3.4.19.1 Removal ....................................................................................................... 3-17

3.4.19.2 Replacement ................................................................................................. 3-17

3.4.20 Rectifier Assembly (CR4 through CR6) .......................................................... 3-18

3.4.20.1 Removal ....................................................................................................... 3-18

3.4.20.2 Replacement ................................................................................................. 3-18

3.4.21 Rectifier Heat Sink Assembly (CR8 through CR10) ....................................... 3-18

3.4.21.1 Removal ....................................................................................................... 3-18

3.4.21.2 Replacement ................................................................................................. 3-18

3.4.22 Fault Light DSI ................................................................................................ 3-19

3.422.1 Removal ....................................................................................................... 3-19

3.4.22.2 Replacement ................................................................................................. 3-19

3.4.23 Three-Phase Fnseholder (F1 through F3) ......................................................... 3-19

3.4.23.1 Removal ....................................................................................................... 3 19

3.4.23.2 Replacement ................................................................................................. 3-19

3.4.24 Fuse Assembly (F4 through F9) ....................................................................... 3-20

3.4.24.1 Removal ....................................................................................................... 3-20

3,4.24.2 Replacement ................................................................................................. 3-20

3.4.25 Connector J 1..................................................................................................... 3-20

3.4.25.1 Removal ....................................................................................................... 3-20

3.4.25.2 Replacement ................................................................................................. 3-21

3.4.26 Boost Inductor Assembly L1 ............................................................................ 3-21 3A.26.1 Removal ....................................................................................................... 3-21

3.4.26.2 Replacement ................................................................................................. 3-21

3.4.27 Switch Output Inductors L2 through L6 ........................................................... 3-22

3.4.27.1 Removal ....................................................................................................... 3-22

-- 3,4,27,2 Replacement ................................................................................................. 3-22

3.4.28 Inductor Assembly L7 ...................................................................................... 3-22 3,4.28.1 Removal ....................................................................................................... 3-22

3.4.28.2 Replacement ................................................................................................. 3-23

3.4.29 Resistor Assembly (R1 through R3) and Resistor Assembly _10 and R11)., 3 23

3.4.29.1 Removal ....................................................................................................... 3-23

3.4.29.2 Replacement ................................................................................................. 3-23 3,4.30 Switcher Transformers T 1 through T5 ............................................................. 3-23 3.4,30,1 Removal ....................................................................................................... 3-23

3.4.30.2 Replacement ................................................................................................. 3-24

3.4.31 Power Transformer T6 ..................................................................................... 3-24

" 3.4.31.1 Removal ....................................................................................................... 3-24

(31July1998) xi

--4

TABLE OF CONTENTS--Continued

Paragraph Title Page

3.4.31.2 Replacement ................................................................................................. 3-24

3.4.32 Inverter Transformer T7 ................................................................................... 3-24

3.4.32.1 Removal ....................................................................................................... 3-24

3.4.32.2 Replacement ................................................................................................. 3-25

3.4.33 Capacitor Discharge Device ............................................................................. 3-25

3.4.33.1 Removal ....................................................................................................... 3-25

3.4.33.2 Replacement ................................................................................................. 3-25

3.4.34 Step-Start Rectifier Assembly .......................................................................... 3-25

3.4.34.1 Removal ............................................................................... ........................ 3-25

3.4.34.2 Replacement ................................................................................................. 3-26

3.5 Examination and Cleaning .................................................................................... 3-26

3.6 Repair and Replacement ....................................................................................... 3-26

3.7 Test Description .................................................................................................... 3-26 3.7,1 Performance Tests ............................................................................................ 3-26

3.7.1.1 Power Up Procedure .................................................................................... 3-27 3.7,1.2 Test 100 - Resistance Tests .......................................................................... 3-27

3.7.1.3 Test 200 - Step Start Control ....................................................................... 3-27

3.7.1.4 Test 300 - Step Up Converter ...................................................................... 3-27 -

3.7.1.5 Test 400 - House Supply Checkout .............................................................. 3-27

3.7.1.6 Test 500 - Fuse Failure and Switcher Sync .................................................. 3-27 3,7.1.7 Test 600 - Output Overvoltage ..................................................................... 3-27

3.7.1.8 Test 700 - Switcher High Power .................................................................. 3-27

3.7.1.9 Test 800 - Fine Cha_ge Control .................................................................... 3-27

3.7.1.10 Test 900 - Bus Regulator Interface Tests ..................................................... 3-27

3.7.1.10.1 Reference Voltage In Test ....................................................................... 3-27

3.7.1.10.2 Bus Voltage In Test ................................................................................. 3-27 3.7A.10.3 Current Sample 1 Pulse Width Test ........................................................ 3-28

3.7.1.10.4 Current Sample 1 Peak Amplitude Test .................................................. 3-28

3.7.1.10.5 Current Sample 2 Pulse Width Test ........................................................ 3-28

3.7.1.10.6 Current Sample 2 Peak Amplitude Test .................................................. 3-28

3.7.1.10.7 Current Sample 2 Step Voltage Peak Amplitude Test ............................ 3-28

3.7.1.10.8 Current Sample 3 Pulse Width Test ........................................................ 3-28

3.7.1.10.9 Current Sample 3 Voltage Peak Amplitude Test .................................... 3-28

3.7.1.11 Test 1000 - Regulation Performance ........................................................... 3-28

3.7.1.12 Test 1100 - Covers On Performance Test .................................................... 3-28

3.7.2 Diagnostic Tests ............................................................................................... 3-33

3.8 Test Procedure ...................................................................................................... 3-33

3.9 Troubleshooting .................................................................................................... 3-33

3.10 Assembly Drawings and Parts Lists ...................................................................... 3-33

3.11 Wire Data .............................................................................................................. 3-33 xii (31 July 1998)

TABLE OF CONTENTS- Continued

Paragaph Title Page

APPENDIXES

A LIST OF ACRONYMS AND ABBREVIATIONS .............................................. A-1 B ASSEMBLY DRAWINGS ................................................................................... B-1 C PARTS LISTS ...................................................................................................... C- 1 D WIPE DATA ........................................................................................................ D-1

LIST OF ILLUSTRATIONS

Figure Title Page

1-1 Reusable Container ............................................................................................... 1-9

2-1 Current Sample 1 Waveform ................................................................................ 2-29 242 Current Sample 2 Waveform ................................................................................ 2-30 2-3 Current Sample 3 Waveform ................................................................................ 2-31 2-4 CPS Output Waveform ......................................................................................... 2-32

3-1 Current Sample 1 Waveform ................................................................................ 3-29 3-2 Current Sample 2 Waveform ................................................................................ 3-30 3-3 Current Sample 3 Waveform ................................................................................ 3-31 3-4 PPS Output Waveform .......................................................................................... 3-32 FO-1 Collector/Preamplifier Power Supply Component Locator .................................. FO-1

LIST OF TABLES

Number Tide Page

" 1-1 UUTs Tested on CPPSTS ..................................................................................... 1-2

1-2 Test Equipment and Tools Required .................................................................... 1-4 1-3 Consumable Material Required ............................................................................ 1-5 1-4 Related Publications ............................................................................................. 1-8

1 5 Cleaning Contaminated Items ............................................................................... 1-12 1-6 Common FaiIures Identified by Visual Inspection ............................................... 1-23 1-7 Resistance Checks ................................................................................................. 1-25

2-1 Test Equipment and Tools Required for PN 3D56068GO1 .................................. 2-2 2-2 Consumable Material Required for PN 3D56068G01 .......................................... 2-3

" " 3-1 Test Equipment and Tools Required for PN 3D56068G02 .................................. 3-2 3-2 Consumable Material Required for PN 3D56068G02 .......................................... 3-3

(31 July 1998) xiii/xiv

CHAPTER 1

GENERAL INFORMATION

1.1 INTRODUCTION.- This repair manual contains depot-level maintenance for the Air Route Surveillance Radar-Model 4 (ARSR-4) units under test (UUTs) tested on the Collector/Preamp Power Supply Test Set (CPPSTS). The UUTs tested are collector power supply 3D56068G01, preamplifier power supply 3D56068G02, and their associated line replaceable units (LRUs). The CPPSTS automatically runs a series of performance tests which determine the operational status of the LRU under test. If the LRU fails a performance test, the operator can initiate on-line diagnostic tests or manual troubleshooting to isolate faults to a defective circuit or component. A keypad, keyboard, and display provide the operator/equipment interface. Information provided in this chapter includes a list of the LRUs tested on the CPPSTS; depot repair facility requirements; lists of tools, test equipment, and consumable materials needed to test and repair the LRUs; a list of related publications; and standard shop practices that apply to the repair of the LRUs. Also provided are procedures for initializing and exiting the tests on the CPPSTS, and general tronbleshooting information for isolating and correcting faults on defective LRUs. Specific repair data for the collector power supply and its associated LRUs are provided in chapter 2. Specific repair data for the preamplifier power supply and its associated LRUs are provided in chapter 3. Repair data provided in each chapter includes lists of tools, test equipment, and consumable material required;

information and instructions on disassembly, examination, cleaning, repair, replacement, and reassembly; operational test information; and troubleshooting information. All acronyms and abbreviations used in this manual are defined in Appendix A. Assembly drawings showing the component locations and part identification for each LRU are contained in Appendix B. Parts lists providing complete parts ordering information for each LRU are contained in Appendix C. Wiring data for applicable LRUs is contained in Appendix D. Schematic diagrams and technical descriptions for the collector and preamp power supplies and their associated LRUs are provided in chapter 46 of the ARSR-4 System Site-Replaceable LRUs Schematics and Descriptions Instruction Book, TI 6340.26.

1.2 DEPOT REPAIRABLE ASSEMI3LIES/SUBASSEMBLIES.- Table 1-1 contains a list of the

UUTs tested on the CPPSTS. The first column of the table contains the part number of the UUT.

The second column contains the ARSR-4 System reference designation of the UVT, and the third column contains the name of the UUT. The fourth column, Repair Decision, designates whether the UUT is to be repaired at the depot or discarded. Items designated for depot repair are tested on the CPPSTS, Manual Test Bench, or GenRad Test Set. Although there are no formal test or repair procedures for itemS designated as discard, manual troubleshooting techniques can be used to identify the defective component. If a defective component requires replacement, refer to the assembly drawing in Appendix B to identify the component and determine if there are any special repair or replacement criteria_ Since the UUTs are part of the collector and preamp power supplies, the part numbers and ARSR-4 System reference designations of the power supplies are listed before the UUTs. The reference designations for the UUTs are listed at the power supply level only.

(31 July 1998) 1-1

Ronald Breaux Highlight

Ronald Breaux Highlight

Table 1-1. UUTs Tested on CPPSTS

ARSR-4System Repair PartNumber RefDes Name Decision

3D56068G01 9A1PS1 - 9A1PS4, Collector Power Supply Depot

9A2PS1, (CPPSTS)

9A3PS 1 - 9A3PS4

3D56068G02 9A2PS3 Preamplifier Power Supply Depot

(CPPSTS)

159C947G01 A10, A15, A20, A25, A30 Output Diode Assembly Discard 159C950Cr01 F4- F9 FuseAssembly Discard L61C002A01 L1 BoostInductorAssembly Discard 161C085G01 R1- R3 ResistorAssembly Discard 161C170G01 CR4- CR6 RectifierAssembly Discard 161C180A01 T7 InverterTransformer Discard

161C181A01 L7 InductorAssembly Discard 161C182A01 T6 PowerTransformer Discard

161C217G01 R10,R11 ResistorAssembly Discard 161C419G01 T1 - T5 SwitcherTransformer Discard

161C420G01 L2- L6 SwitcherOutputInductor Discard 16tC459G01 CR8 - CRI0 Rectifier Heat Sink Assembly Discard 3D56547GO1 A5 Step-Up Converter Assembly Depot

(CPPSTS)

3D57541G01 A6, A11, A16, A21, A26 Four Capacitor Circuit Card Discard

Assembly 3D57543GOI A3 Six Capacitor Circuit Card Discard

Assembly 3D57574G01 A1 Step-StartControlCircuitCard Depot

Assembly (CPPSTS) 3D57576G01 A2 Step-UpControlCircuitCard Depot

Assembly (Test Fixtures/ Bench)

3D57580G01 A36 HouseControlCircuitCard Depot Assembly (Test

Fixtures/

Bench) 3D59038G01 A13, A18, A23 Switcher Module Assembly Depot

(CPPSTS)

3D59038G02 A8, A28 SwitcherModuleAssembly Depot

(CPPSTS)

1-2 (31July1998)

Table 1-1. UUTs Tested on CPPSTS--Continued

ARSR-4System Repair PartNumber RefDes Name Decision

3D59073G01 Step-StartRectifierAssembly Depot

(CPPSTS)

3D59344G01 A42 FilterCapacitorCircuitCard Discard Assembly

3D60027G01 A9, A14, A19, A24, A29 Current Sense Circuit Card Depot Assembly (CPPSTS)

3D60029G01 A4 EightCapacitorCircuitCard Discard Assembly

3D60213G01 A32 SwitchCircuitCardAssembly Depot

(CPPSTS)

3D60215GO1 A33 +5 VoltRegulatorCircuitCard Depot Assembly (CPPSTS)

3D60217G01 A34 -15 Volt Regulator Circuit Card Depot Assembly (CPPSTS)

3D60219G01 A35 +15/+12 Volt Regulator Circuit Depot CardAssembly (CPPSTS)

3D60262G01 A5A1 Up ConverterSensorCircuit Depot CardAssembly (CPPSTS)

3D60297GOl* A31 CPS Main Control Circuit Card Depot Assembly (GenRad

Test Set)

3D60316G01** A31 PPS Main ControlCircuit Card Depot Assembly (GenRad

Test Set) 3D60418G01 A44 CapacitorCircuitCardAssembly Discard 3D60525G01* A37 - A41 Switcher ControlCircuit Card Depot

Assembly (GenRad Test Set)

3D60525G02** A37 - A41 Switcher Control Circuit Card Depot Assembly (GenRad

Test Set) 706J613G01 A43 MotherboardCircuitCard Discard

Assembly F02B250V1/8A F1 - F3 Fuse Discard

* Applies to collector power supply only.

** Applies to preamphfier power supply only.

(31July1998) 1-3

1.3 DEPOT REPAIR FACILITY REQUIREMENTS.- There are no special depot repair facility requirements unique to any of the UUTs. Testing shall be performed at an ambient temperature of 25 (+15, -5)°C, barometric pressure of 30(+.+.2)inches of mercury, and relative humidity of up to 90 percent room ambient.

1.4 TOOLS AND TEST EQU/PMENT.- The tools and test equipment required for testing, troubleshooting, and maintenance of all U-tJTs are listed in table 1-2. Equivalent tools and test equipment may be substituted, Common hand tools are not listed.

Table 1-2. Test Equipment and Tools Required

Part Number/ Manufacturer

Qty Name Type/Model/Spec. (CAGE) Remarks

Test Equipment

1 Collector/preamp KA422100 Northrop Grumman Used for UUT test and powersupplytest (18323) repair set

1 Adapter, self test 129622 Transistor Devices Used for UUT test and

(09004) repair 4 Coaxial cable BNC-C-36 1TT Pomona Used for UUT test and

(05276) repatr 1 Console assembly SPS4233 Transistor Devices Used for UUT test and

(09004) repair 1 Cover, interface 310-113-154 Virginia Panel Used for UUT test and

(18117) repatr 1 Cover, interface 410-112-299 Virginia Panel Used for UUT test and testadapter (18117) repmr 4 Currentprobe TCP202 Tektronix Usedfor UUTtest and

(80009) repair 1 High voltage P5200 Tektronix Used for UUT test and differentialprobe (80009) repmr 1 Interface test AD422077 Northrop Gmmman Used for UUT test and adapter (18323) repaar 4 Probe interface 012-1372-00 Tektronix Used for UUT test and cable (80009) repatr 1 Shield, left 400730 Transistor Devices Used for UUT test and

(09004) repmr 1 Shield, right 400731 Transistor Devices Used for UUT test and

(09004) repaar

I-4 (31July1998)

Table 1-2. Test Equipment and Tools Required--Continued

Part Number/ Manufacturer

Qty Name Type/ModeYSpec. (CAGE) Remarks

Tools

1 Calibrator adapter 015-0672-50 Tektronix Used for…