A17.2_90258634-02687-Appendix_B_PRELIMINARY_8577105(-)_Package_Circuit_Boards.pdf

PDF 293 KB Posted May 15, 2019

Attached to: Printed Circuit Boards (PCB) Design Federal contract opportunity
Solicitation number: N4523A19R1312
Issued by: Department of the Navy Naval Sea Systems Command

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Appendix B

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A17.4_90258634-02687-9025-8634_SIMULATION_RESULTS_DI-SESS-81938_REV_12-18-2018.pdf	PDF	May 15, 2019
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A17.7_90258634-02687-9025-8634_DD1423-2_ENGINEERING_DRAWINGS_DI-SESS-81000E_10-18-2018.pdf	PDF	May 15, 2019
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A17.9_90258634-02687-9025-8634_CERTIFICATION_OF_COMPLIANCE-CONFORMANCE_DI-MISC-81356_REV_10-18-2018.pdf	PDF	May 15, 2019
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N4523A19R1312_Solicitation.pdf	PDF	May 15, 2019
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DEPARTMENT OF THE NAVY

NAVAL SEA SYSTEMS COMMAND

WASHINGTON NAVY YARD, WASHINGTON DC 20376

SIZE CAGE WT GP DRAWING NO REV

SCALE: NONE

53711

PACKAGE CIRCUIT BOARDS

ECI 15-5091E

FABRICATION, WIRING, OPERATION

STD 8577105 -

CODE 126.3

SHEET 1 OF 11

AND ARRANGEMENT DIAGRAM

PREPARER DATE

CHECKER

CONCURRENCE

BRANCH HEAD

DIVISION HEAD

PROJECT MGR

TECHNICAL DIR

CONFIGURATION MGT

AUTHORITY

PUGET SOUND NAVAL

SHIPYARD & INTERMEDIATE

MAINTENANCE FACILITY

BREMERTON, WA 98314

CAGE CODE 82522

B. BENTON 11/1/2018

CR 15-5091

DATE

TEMPLATE VERSION 1.01

UNCLASSIFIED//FOR OFFICIAL USE ONLY

DISTRIBUTION STATEMENT D: DISTRIBUTION AUTHORIZED TO DEPARTMENT OF DEFENSE AND U.S. DOD CONTRACTORS ONLY; CRITICAL TECHNOLOGY NOVEMBER 2018. OTHER REQUESTS WILL BE REFERRED TO

THE NAVSEA ADVANCED UNDERSEA SYSTEMS PROGRAM OFFICE, PMS 394.

WARNING: THIS DOCUMENT CONTAINS TECHNICAL DATA WHOSE EXPORT IS RESTRICTED BY THE ARMS EXPORT CONTROL ACT (TITLE 22, U.S.C. SEC 2751 ET SEQ) OR THE EXPORT ADMINISTRATION ACT OF 1979, AS AMENDED, TITLE 50, U.S.C., APP. 2401 ET SEQ. VIOLATIONS OF THESE EXPORT LAWS ARE SUBJECT TO SEVERE CRIMINAL PENALTIES. DISSEMINATE IN ACCORDANCE WITH THE PROVISIONS OF DOD DIRECTIVE 5230.25.

DESTRUCTION NOTICE: FOR UNCLASSIFIED, LIMITED DISTRIBUTION DOCUMENTS, DESTROY BY ANY METHOD THAT WILL PREVENT DISCLOSURE OF CONTENTS OR RECONSTRUCTION OF THE DOCUMENT. NO PUBLIC RELEASES OR PUBLIC DISPLAYS OF ANY KIND ARE AUTHORIZED WITHOUT THE EXPRESS WRITTEN CONSENT

OF NAVSEA (PMS394) OR HIGHER AUTHORITY.

4 3 2 1

HOLE TOLERANCES

DIAMETER TOLERANCE

≤ .125

> .125 ≤ .250

> .250 ≤ .500

> .500 ≤ .750

> .750 ≤ 1.000

+ .005 -.001

+ .006 -.001

+ .008 -.002

+ .009 -.002

+ .010 -.003

TOLERANCES

DIM ARE IN INCHES

DIM & TOL IAW ASME Y14.5-2009

FRAC

DEC

ANGLES

DIM

UNLESS OTHERWISE SPECIFIED

.XX .XXX

< 6"

6" - 24"

> 24" u 1/16 u 1/32 u 1/64 u .1 u .01 u .005 u .02 u .1 u .1 u .03 u .010 u .015

0v 30'

ELECTROSTATIC DISCHARGE

CONTROL DRAWING

SIZE CAGE WT GP DRAWING NO REV

53711 STD 8577105

CODE 126.3

SHEET 2

UNCLASSIFIED//FOR OFFICIAL USE ONLY

4 3 2 1

SCALE: NONE

INDEX

SH TITLE REV

1 COVER SHEET -

2 INDEX -

3 REFERENCES -

4 REVISIONS & RESERVATIONS -

5 NOTES -

5A NOTES -

6 LIST OF MATERIALS -

6A LIST OF MATERIALS -

6B LIST OF MATERIALS -

6C LIST OF MATERIALS -

6D LIST OF MATERIALS -

6E LIST OF MATERIALS -

6F LIST OF MATERIALS -

7 TRANSFORMER J-BOX ELECTRONICS PCB -

7A TRANSFORMER J-BOX ELECTRONICS PCB -

7B TRANSFORMER J-BOX ELECTRONICS PCB -

7C TRANSFORMER J-BOX ELECT PCB OPERATIONAL DESCRIPTION

7D TRANSFORMER J-BOX ELECTRONICS PCB MODEL VIEWS -

INDEX

SH TITLE REV

7E TRANSFORMER J-BOX ELECTRONICS PCB LAYER VIEWS -

8 TY2 V3 BATTERY J-BOX ELECTRONICS PCB -

8A TY2 V3 BATTERY J-BOX ELECTRONICS PCB OPERATIONAL DESCRIPTION

8B TY2 V3 BATTERY J-BOX ELECTRONICS PCB MODEL VIEWS -

8C TY2 V3 BATTERY J-BOX ELECTRONICS PCB LAYER VIEWS -

9 GTK BATTERY J-BOX ELECTRONICS PCB1 -

9A GTK BATTERY J-BOX ELECTRONICS PCB1 OPERATIONAL DESCRIPTION

9B GTK BATTERY J-BOX ELECTRONICS PCB1 MODEL VIEWS -

9C GTK BATTERY J-BOX ELECTRONICS PCB1 LAYER VIEWS -

10 GTK BATTERY J-BOX ELECTRONICS PCB2 -

10A GTK BATTERY J-BOX ELECTRONICS PCB2 OPERATIONAL DESCRIPTION

10B GTK BATTERY J-BOX ELECTRONICS PCB2 MODEL VIEWS -

10C GTK BATTERY J-BOX ELECTRONICS PCB2 LAYER VIEWS -

11 STAND ALONE DC-DC CONVERTER PCB -

11A STAND ALONE DC-DC CONVERTER ASSEMBLY OPERATIONAL DESCRIPTION

11B STAND ALONE DC-DC CONVERTER PCB MODEL VIEWS -

11C STAND ALONE DC-DC CONVERTER PCB LAYER VIEWS -

CODE 126.3

SHEET 3

UNCLASSIFIED//FOR OFFICIAL USE ONLY

4 3 2 1

SCALE: NONE

REFERENCES

NO TITLE CAGE IDENT

1 GENERIC STANDARDS ON PRINTED BOARD DESIGN IPC-2221

2 QUALIFICATION AND PERFORMANCE SPECIFICATION FOR RIGID PRINTED BOARDS IPC-6012D

3 DOCUMENTATION REQUIREMENTS FOR PRINTED BOARDS, ASSEMBLIES, AND SUPPORT DRAWINGS IPC-D-325A

4 REQUIREMENTS FOR SOLDERED ELECTRICAL AND ELECTRONIC ASSEMBLIES J-STD-001F

5 REQUIREMENTS FOR ELECTRONIC GRADE SOLDER ALLOYS AND FLUXED AND NON-FLUXED SOLID SOLDERS FOR ELECTRONICS J-STD-006C

6 TRANSFORMER J-BOX ELECTRONICS PCB PIT 82522 TE25670

7 TY2 V3 BATTERY J-BOX ELECTRONICS PCB PIT 82522 TE25671

8 GTK BATTERY J-BOX ELECTRONICS PCB PIT 82522 TE25672

9 DC-DC CONVERTER PCB PIT 82522 TE25673

10 PACKAGES PCB SYSTEM REQUIREMENTS DOCUMENT (SRD) 53711 8577164

11 PCB CIRCUIT SCHEMATICS, ELECTRICAL CHARACTERISTICS, AND OPERATIONAL DETAILS 53711 8577152

12 PACKAGE PRINTED WIRE ASSEMBLIES FABRICATION AND DETAILS 53711 8516396

CODE 126.3

SHEET 4

UNCLASSIFIED//FOR OFFICIAL USE ONLY

4 3 2 1

SCALE: NONE

REVISION HISTORY

REV SHT DESCRIPTION DATE APPROVED

- ALL INITIAL ISSUE - SEE SH 1

NO. SHT DESCRIPTION

R1 7C, 8A, 9A, 10A, 11A PCB MODEL VIEWS NEED TO BE ADDED

R2 7D, 8B, 9B, 10B, 11B PCB LAYER VIEWS NEED TO BE ADDED

R3 6 PCB COPPER TRACE REQUIREMENTS TBD

RESERVATIONS

CODE 126.3

SHEET 5

UNCLASSIFIED//FOR OFFICIAL USE ONLY

4 3 2 1

SCALE: NONE

GENERAL NOTES

1.0 ADMINISTRATIVE

1.1. INTERPRET DIMENSIONS AND TOLERANCING PER ASME Y14.5-2009.

1.2. ABBREVIATIONS, ACRONYMS AND SYSMBOLS ARE IN ACCORDANCE WITH ASME

Y14.38 AND IEEE 315, EXCEPT AS FOLLOWS:

EIA = ELECTRONIC INDUSTRIES ALLIANCE

GEF-F = GLASS FABRIC BASE, EPOXY RESIN, FLAME RESISTANT, ELECTRICAL GRADE

HASL = HOT AIR SOLDER LEVELING

J-BOX = JUNCTION BOX

PCB = PRINTED CIRCUIT BOARD

SMOBC = SOLDER MASK OVER BARE COPPER

SN = SERIAL NUMBER

SSR = SOLID STATE RELAY

TVS = TRANSIENT VOLTAGE SUPPRESSION

VSENSE = VOLTAGE SENSE

XFMR = TRANSFORMER

2.0 FABRICATION

2.1. SOLDERING SHALL CONFORM TO J-STD-006.

2.2. FABRICATE CIRCUIT BOARDS IAW IPC-6012, CLASS 3. FINISHED BOARDS MUST MEET

QUALITY CONFORMANCE TESTING AND INSPECTION IAW IPC-6012.

2.3. PCB CONSTRUCTION TO BE SMOBC. APPLY TO PRIMARY AND SECONDARY SIDES

IAW IPC-SM-840 (TYPE B, CLASS 3). USE APPROPRIATE SOLDER MASK ARTWORK

FOR EACH SIDE OF THE BOARD. PUNCTURING OF TENTED HOLES IS NOT

PERMISSIBLE.

2.4. SOLDER MASK MISREGISTRATION SHALL NOT EXCEED + .004 IN. SOLDER MASK

OVERLAP PERMITTED ON CIRCULAR LANDS ONLY AND SHALL NOT EXCEED .001 IN.

NO OVERLAP PERMITTED ON SURFACE MOUNT DEVICE RECTANGULAR LANDS.

2.5. A CERTIFICATE OF COMPLIANCE WITH IPC-6012, CLASS 3, SHALL BE SUBMITTED

WITH EACH PCB LOT.

2.6. PLATE ALL HOLES AS REQUIRED. COVERAGE AND SOLDERABILITY SHALL MEET THE

REQUIREMENTS OF J-STD-001.

2.7. EXPOSED PCB LANDS TO BE COATED USING HASL.

2.8. BOW AND TWIST SHALL NOT EXCEED .0075 IN. PER IN. MEASURED IAW IPC-TM-650,

METHOD 2.4.22.

2.9. SILKSCREEN PRIMARY SIDE (TOP) AND SECONDARY SIDE (BOTTOM) OF BOARD

USING WHITE EPOXY BASE INK PER MIL-I-43533, TYPE II, AND APPROPRIATE

ARTWORK.

2.10. SOLDER MASK TO BE DARK BLUE IN COLOR AND TRANSPARENT.

2.11. BARE BOARDS SHALL BE ELECTRICALLY TESTED FOR CONTINUITY AND INSULATION

RESISTANCE IN COMPLIANCE WITH IPC-6012, CLASS 3. INSULATION TEST VOLTAGES

SHALL BE BETWEEN 200 AND 300 VOLTS.

2.12. INSULATION MATERIAL SHALL BE IAW MIL-I-24768/27-S-7, TYPE GEE-F,

THERMOSETTING FIBERGLASS EPOXY-RESIN.

2.13. ITEMS REFERRING TO THIS NOTE ARE ELECTROSTATIC DISCHARGE SENSITIVE

(ESDS). TAKE PRECAUTIONARY MEASURES IN ACCORDANCE WITH ESD

REQUIREMENTS OF GUIDELINE 75 OF MIL-HDBK-454, AND THE ESD CONTROL

PROGRAM PER MIL-STD-1686 WHEN HANDLING ESD SENSITIVE EQUIPMENT. ITEMS

SENSITIVE TO ESD ARE ALSO IDENTIFIED WITH THIS SYMBOL 7.

2.14. APPLY SERIAL NUMBER USING FORMAT YYDDD-SS, WHERE YY IS THE YEAR, DDD IS

THE JULIAN DATE, AND SS IS A SEQUENTIAL SERIAL NUMBER. FOR EXAMPLE, THE

FIRST SEQUENTIAL UNIT ON JANUARY 1, 2019 SHALL BE LABELED 19001-01. USE

EITHER OF THE FOLLOWING METHODS:

2.14.1. PRIOR TO COMPONENT POPULATION, APPLY CHARACTERS USING WHITE INK

AND COVER CHARACTERS WITH CLEAR POLYURETHANE BASED COATING.

2.14.2. PRINT SERIAL NUMBER ON LABEL, AFFIX LABLE ON ASSEMLBY WHERE IT IS

CLEARLY VISIBLE, AND COAT LABEL WITH A CLEAR POLYURETHANE BASED

COATING. LABEL SHALL NOT INTERFERE WITH COMPONENT POPULATION

OR ASSEMBLY OPERATION.

CODE 126.3

SHEET 5A

UNCLASSIFIED//FOR OFFICIAL USE ONLY

4 3 2 1

SCALE: NONE

6.0 TESTING

6.1. EACH PCB ASSEMBLY SHALL BE PRE-INSTALLATION TESTED INCLUDING A

HYDROSTATIC TEST, TO VERIFY SATISFACTORY OPERATION PRIOR TO USE.

• FOR ASSEMBLY A1 – SEE REFERENCE 6

• FOR ASSEMBLY A2 – SEE REFERENCE 7

• FOR ASSEMBLY A3 – SEE REFERENCE 8

• FOR ASSEMBLY A4 – SEE REFERENCE 8

• FOR ASSEMBLY A5 – SEE REFERENCE 9

9.0 OPERATIONAL

9.1. TO SET THE STAND ALONE DC-DC CONVERTER OUTPUT VOLTAGE, PLACE THE

JUMPER ACROSS THE APPROPRIATE PINS:

• FOR 26VDC – JUMPER PINS C TO C1

• FOR 48VDC – JUMPER PINS B TO B1

• FOR 60VDC –JUMPER PINS A TO A1

CODE 126.3

SHEET 6

UNCLASSIFIED//FOR OFFICIAL USE ONLY

4 3 2 1

SCALE: NONE

FIND

QTY DESCRIPTION

MATERIAL

SPECIFICATION

CAGE

PART NUMBER

REMARKS

1 AR GEE-F MIL-I-24768 NOTE 2.13

2 AR COPPER, TBD OZ R3

3 AR COPPER, TBD OZ R3

4 AR COPPER, TBD OZ R3

5 AR COPPER SHEET, .125" ASTM B152 COPPER 110 SHT .125X12X24

6 AR COPPER SHEET, .25" ASTM B187 COPPER 110 SHT .25X.75X12

7 AR COPPER SHEET, 16OZ ASTM B370 COPPER 110 SHT .021X12X24

8 AR COPPER SHEET, 32OZ ASTM B370 COPPER 110 SHT .043X12X24

LIST OF MATERIALS

CODE 126.3

SHEET 6A

UNCLASSIFIED//FOR OFFICIAL USE ONLY

4 3 2 1

SCALE: NONE

FIND

QTY DESCRIPTION

MATERIAL

SPECIFICATION

CAGE

PART NUMBER

REMARKS

A1 1 TRANSFORMER J-BOX ELECTRONICS PCB ASSEMBLY 7 VARIOUS

53711

8577105-A1-00

NOTE 6.1, SEE SHT 7 THRU 7E

A1.1 4 FUSE, SMD, 20A, 100VDC, FAST, F1-F4 COMMERCIAL 0456020.ER

A1.2 6 FUSE, SMD, 30A, 100VDC, FAST, F5-F10 COMMERCIAL 0463030.ER

A1.3 1 TERMINAL BLOCK, 12 POS, 300V, 58A, 6-20AWG, THRU HOLE, TB1 COMMERCIAL 691256610012

A1.4 2 TERMINAL BLOCK, 10 POS, 300V, 18A, 12-26AWG, THRU HOLE, TB2/TB3 COMMERCIAL 1935242

A1.5 1 TERMINAL BLOCK, 4 POS, 300V, 18A, 12-26AWG, THRU HOLE, TB4 COMMERCIAL 1935187

A1.6 14 DIODE, SHOTTKY, SMD, 45V, 15A, TO277B, D1-D12 COMMERCIAL DST1545S

A1.7 5 RESISTOR, SMD, 3.9KΩ, 1%, 3W, 2512, R1-R5 COMMERCIAL 35223K9FT

A1.8 8 RESISTOR, SMD, 91Ω, 1%, 1W, 2512, R6-R13 COMMERCIAL AC2512FK-0791RL

A1.9 9 RESISTOR, SMD, 1.2KΩ, 1%, 1W, 2512, R14-R22 COMMERCIAL CRCW20101K20FKEFHP

A1.10 22 LED, SMD, GREEN, CLEAR, DS1-DS22 COMMERCIAL APD3224ZGC-F01

A1.11 2 RELAY CIRCUIT, NORMALLY CLOSED, NC-1/NC-2 VARIOUS

53711

8577152-A1-00

SEE REEFERENCE 11

A1.12 3 RELAY CIRCUIT, NORMALLY OPEN, NO-1/NO-2/NO-3 VARIOUS

53711

8577152-A2-00

SEE REEFERENCE 11

A1.13 1 SSR CONTROL CIRCUIT, SSRC-1 VARIOUS

53711

8577152-A5-00

SEE REEFERENCE 11

A1.14 1 EMBEDDED DC-DC CONVERTER CIRCUIT, DC-1 VARIOUS

53711

8577152-A6-00

SEE REEFERENCE 11, 26VDC OUTPUT

A1.15 1 PCB, CUSTOM, TRANSFORMER J-BOX ELECTRONICS BARE BOARD VARIOUS

53711

8577105-A1.15-00

CODE 126.3

SHEET 6B

UNCLASSIFIED//FOR OFFICIAL USE ONLY

4 3 2 1

SCALE: NONE

FIND

QTY DESCRIPTION

MATERIAL

SPECIFICATION

CAGE

PART NUMBER

REMARKS

A2 1 TY2 V3 BATTERY J-BOX ELECTRONICS PCB ASSEMBLY 7 VARIOUS

53711

8577105-A2-00

NOTE 6.1, SEE SHT 8 THRU 8C

A2.1 2 FUSE, SMD, 30A, 100VDC, FAST, F1-F2 COMMERCIAL 0463030.ER

A2.2 1 TERMINAL BLOCK, 4 POS, 300V, 58A, 6-20AWG, THRU HOLE, TB1 COMMERCIAL 691256610004

A2.3 2 TERMINAL BLOCK, 4 POS, 300V, 18A, 12-26AWG, THRU HOLE, TB2/TB5 COMMERCIAL 1935187

A2.4 2 TERMINAL BLOCK, 2 POS, 300V, 58A, 6-20AWG, THRU HOLE, TB3/TB4 COMMERCIAL 691256610002

A2.5 1 TERMINAL BLOCK, 2 POS, 300V, 18A, 12-26AWG, THRU HOLE, TB6 COMMERCIAL 1935310

A2.6 2 RESISTOR, SMD, 3KΩ, 1%, 2W, 2512, R1/R6 COMMERCIAL 35213K0FT

A2.7 1 RESISTOR, SMD, 3.9KΩ, 1%, 3W, 2512, R4 COMMERCIAL 35223K9FT

A2.8 3 RESISTOR, SMD, 91Ω, 1%, 1W, 2512, R2/R3/R5 COMMERCIAL AC2512FK-0791RL

A2.9 1 RESISTOR, SMD, 1.2KΩ, 1%, 1W, 2512, R7 COMMERCIAL CRCW20101K20FKEFHP

A2.10 1 RESISTOR, SMD, 820Ω, 1%, .5W, 0805, R8 COMMERCIAL ERJ-P6WF8200V

A2.11 8 LED, SMD, GREEN, CLEAR, DS1-DS8 COMMERCIAL APD3224ZGC-F01

A2.12 1 RELAY CIRCUIT, NORMALLY OPEN, NO-1 VARIOUS

53711

8577152-A2-00

SEE REFERENCE 11

A2.13 1 LATCHING RELAY CIRCUIT, LR-1 VARIOUS

53711

8577152-A3-00

SEE REFERENCE 11

A2.14 1 ORING CIRCUIT, OR-1 VARIOUS

53711

8577152-A4-00

SEE REFERENCE 11

A2.15 1 EMBEDDED DC-DC CONVERTER CIRCUIT, DC-1 VARIOUS

53711

8577152-A6-00

SEE REFERENCE 11, 26VDC OUTPUT

A2.16 1 PCB, CUSTOM, TY2 V3 BATTERY J-BOX ELECTRONICS BARE BOARD VARIOUS

53711

8577105-A2.16-00

CODE 126.3

SHEET 6C

UNCLASSIFIED//FOR OFFICIAL USE ONLY

4 3 2 1

SCALE: NONE

FIND

QTY DESCRIPTION

MATERIAL

SPECIFICATION

CAGE

PART NUMBER

REMARKS

A3 1 GTK BATTERY J-BOX ELECTRONICS PCB1 ASSEMBLY 7 VARIOUS

53711

8577105-A3-00

NOTE 6.1, SEE SHT 9 THRU 9C

A3.1 2 FUSE, SMD, 80A, 75VDC, F1/F2 COMMERCIAL 0881080.UR

A3.2 2 TERMINAL BLOCK, 4 POS, 300V, 58A, 6-20AWG, THRU HOLE, TB1/TB5 COMMERCIAL 691256610004

A3.3 2 TERMINAL BLOCK, 2 POS, 300V, 58A, 6-20AWG, THRU HOLE, TB4/TB6 COMMERCIAL 691256610002

A3.4 1 TERMINAL BLOCK, 4 POS, 300V, 18A, 12-26AWG, THRU HOLE, TB2 COMMERCIAL 1935187

A3.5 1 TERMINAL BLOCK, 5 POS, 300V, 18A, 12-26AWG, THRU HOLE, TB3 COMMERCIAL 1935190

A3.6 2 RESISTOR, SMD, 3KΩ, 1%, 2W, 2512, R1/R6 COMMERCIAL 35213K0FT

A3.7 1 RESISTOR, SMD, 3.9KΩ, 1%, 3W, 2512, R4 COMMERCIAL 35223K9FT

A3.8 3 RESISTOR, SMD, 91Ω, 1%, 1W, 2512, R2/R3/R5 COMMERCIAL AC2512FK-0791RL

A3.9 1 RESISTOR, SMD, 1.2KΩ, 1%, 1W, 2512, R7 COMMERCIAL CRCW20101K20FKEFHP

A3.10 1 RESISTOR, SMD, 820Ω, 1%, .5W, 0805, R8 COMMERCIAL ERJ-P6WF8200V

A3.11 1 DIODE, SHOTTKY, SMD, 150V, 35A, SLIMDPAK, D1 COMMERCIAL V35PWM15HM3/I

A3.12 1 DODE, TVS, SMD, 90VCR, 146VCL, D0-214AC, D2 COMMERCIAL SMAJ90A

A3.13 8 LED, SMD, GREEN, CLEAR, DS1-DS8 COMMERCIAL APD3224ZGC-F01

A3.14 1 RELAY CIRCUIT, NORMALLY OPEN, NO-1 VARIOUS

53711

8577152-A2-00

SEE REFERENCE 11

A3.15 1 LATCHING RELAY CIRCUIT, LR-1 VARIOUS

53711

8577152-A3-00

SEE REFERENCE 11

A3.16 1 ORING CIRCUIT, OR-1 VARIOUS

53711

8577152-A4-00

SEE REFERENCE 11

CODE 126.3

SHEET 6D

UNCLASSIFIED//FOR OFFICIAL USE ONLY

4 3 2 1

SCALE: NONE

FIND

QTY DESCRIPTION

MATERIAL

SPECIFICATION

CAGE

PART NUMBER

REMARKS

A3 1 GTK BATTERY J-BOX ELECTRONICS PCB1 ASSEMBLY 7 VARIOUS

53711

8577105-A3-00

NOTE6.1, SEE SHT 9 THRU 9C

A3.17 1 EMBEDDED DC-DC CONVERTER CIRCUIT, DC-1 VARIOUS

53711

8577152-A6-00

SEE REFERENCE 11, 26VDC OUTPUT

A3.18 1 PCB, CUSTOM, GTK BATTERY J-BOX ELECTRONICS BARE BOARD 1 VARIOUS

53711

8577105-A3.17-00

CODE 126.3

SHEET 6E

UNCLASSIFIED//FOR OFFICIAL USE ONLY

4 3 2 1

SCALE: NONE

FIND

QTY DESCRIPTION

MATERIAL

SPECIFICATION

CAGE

PART NUMBER

REMARKS

A4 1 GTK BATTERY J-BOX ELECTRONICS PCB2 ASSEMBLY 7 VARIOUS

53711

8577105-A4-00

NOTE 6.1, SEE SHT 10 THRU 10C

A4.1 1 TERMINAL BLOCK, 2 POS, 300V, 58A, 6-20AWG, THRU HOLE, TB7 COMMERCIAL 691256610002

A4.2 1 TERMINAL BLOCK, 4 POS, 300V, 18A, 12-26AWG, THRU HOLE, TB8 COMMERCIAL 1935187

A4.3 2 TERMINAL BLOCK, 4 POS, 300V, 58A, 6-20AWG, THRU HOLE, TB9/TB10 COMMERCIAL 691256610004

A4.4 3 RESISTOR, SMD, 3KΩ, 1%, 2W, 2512, R12/R14/R15 COMMERCIAL 35213K0FT

A4.5 2 RESISTOR, SMD, 3.9KΩ, 1%, 3W, 2512, R13/R16 COMMERCIAL 35223K9FT

A4.6 2 RESISTOR, SMD, 91Ω, 1%, 1W, 2512, R10/R11 COMMERCIAL AC2512FK-0791RL

A4.7 2 DIODE, SHOTTKY, SMD, 150V, 35A, SLIMDPAK, D3, D4 COMMERCIAL V35PWM15HM3/I

A4.8 2 DIODE, SHOTTKY, SMD, 45V, 15A, D7, D8 COMMERCIAL DST1545S

A4.9 2 DODE, TVS, SMD, 90VCR, 146VCL, D0-214AC, D5, D6 COMMERCIAL SMAJ90A

A4.10 7 LED, SMD, GREEN, CLEAR, DS10-DS16 COMMERCIAL APD3224ZGC-F01

A4.11 3 RELAY CIRCUIT, NORMALLY OPEN, NO-2/NO-3/NO-4 VARIOUS

53711

8577152-A2-00

SEE REFERENCE 11

A4.12 3 EMBEDDED DC-DC CONVERTER CIRCUIT, DC-1 THRU DC-4 VARIOUS

53711

8577152-A6-00

SEE REFERENCE 11, 60VDC OUTPUT, CURRENT SHARE

A4.13 1 PCB, CUSTOM, GTK BATTERY J-BOX ELECTRONICS BARE BOARD 2 VARIOUS

53711

8577105-A4.13-00

SEE REFERENCE 11

CODE 126.3

SHEET 6F

UNCLASSIFIED//FOR OFFICIAL USE ONLY

4 3 2 1

SCALE: NONE

FIND

QTY DESCRIPTION

MATERIAL

SPECIFICATION

CAGE

PART NUMBER

REMARKS

A5 1 STAND ALONE DC-DC CONVERTER ASSEMBLY 7 VARIOUS

53711

8577105-A5-00

NOTE 6.1, 9.1, SEE SHT 11 THRU 11C

A5.1 2 RESISTOR, SMD, .01Ω, 1%, 3W, 3015, R1/R5 COMMERCIAL FCSL76R010FER

A5.2 1 RESISTOR, SMD, 23.2kΩ, 1%, .5W, 1210, R2 COMMERCIAL ERJ-14NF2322U FOR 26V OUTPUT

A5.3 1 RESISTOR, 9.1kΩ, 5%, .5W, 0805, R3 COMMERCIAL ERJ-P06J912V FOR 48V OUTPUT

A5.4 1 RESISTOR, SMD, 5.62kΩ, 1%, .5W, 1206, R4 COMMERCIAL RNCP1206FTD5K62 FOR 60V OUTPUT

A5.5 4 CAPACITOR, RADIAL, CERAMIC, 100µF, 100V,C1-C4 COMMERCIAL KTD101B107M99A0B00

A5.6 1 DIODE, TVS, 78V , 124V CLAMPING, UNI-DIRECTION, D1 COMMERCIAL SMBJ78D-M3/H

A5.7 1 DC-DC CONVERTER, DC-DC1 7 COMMERCIAL NQ90W90HGV26NRF-G

A5.8 1 JUMPER, JMP1 COMMERCIAL 881545-2

A5.9 1 PCB HEADER, HDR1 COMMERCIAL 10897060

A5.10 1 CONNECTOR, PCB, J1 COMMERCIAL PET-04-02-L-RA-SD

A5.11 1 RECEPTACLE, ES5 SERIES, SINGLE PIN, J2 COMMERCIAL ES5S001JF1R5500

A5.12 1 PCB, CUSTOM, DC-DC CONVERTER BARE BOARD VARIOUS

53711

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CODE 126.3

SHEET 7

UNCLASSIFIED//FOR OFFICIAL USE ONLY

4 3 2 1

SCALE: NONE

(LVDC +)

(LVDC -)

TB1-1

TB1-2

(J9-UCM GPIO1)

TB2-4

(J10-UCM RET)

(J10-UCM GPIO1)

TB2-2

TB2-1

(J9-UCM RET)

TB2-3

(J5-1)

TB1-3

(J5-2)

TB1-4

(J4-5)

TB1-5

(J4-6)

TB1-6

VOUT +

VOUT -

VIN +

VIN -

CS +/-

LOAD +

LOAD -

LOAD +

LOAD -

PWR +

PWR -

PWR +

PWR -

CS +/-

NC-1

NC-2

DC-1 (26V)

DS1

R14

DS14

DS2

LVDC + / -

(7A-4D)

J9/J10 Ret (7A-2D), (7B-3C)

DS6

DS7

A1 SHT 6A: TRANSFORMER J-BOX ELECTRONICS

PCB CIRCUIT SCHEMATIC

PCB INPUTS/OUTPUTS SHOWN IN PARENTHESIS

NODE 3

(17.03A)

NODE 2

(13.3A)

FN ID VALUE

A1.1 F1-F2 20A A1.2 F5-F6 30A

A1.3 TB1 6-20AWG

A1.4 TB2 12-26AWG

A1.7 R2 3.9KΩ

A1.8 R6-R7 91Ω

A1.9 R14 1.2KΩ

A1.10 DS2, DS6-DS7, DS14 GRN

A1.12 NO-1, NO-2, NO-3 REF. 11

COMPONENT LIST

LVDC RECTIFIER #1/#2

CODE 126.3

SHEET 7A

UNCLASSIFIED//FOR OFFICIAL USE ONLY

4 3 2 1

SCALE: NONE

(J9-UCM GPIO2)

TB2-5

(J10-UCM GPIO2)

TB2-6

(J9-UCM GPIO3)

TB2-7

(J10-UCM GPIO3)

TB2-8

(J9-UCM GPIO4)

TB2-9

(J10-UCM GPIO4)

TB2-10

(J4-1)

TB1-7

(J4-2)

TB1-8

(J4-7)

TB1-9

(J4-8)

TB1-10

(J4-3)

TB1-11

(J5-4)

TB1-12

F10

LOAD +

LOAD -

LOAD +

LOAD -

LOAD +

LOAD -

PWR +

PWR -

PWR +

PWR -

PWR +

PWR -

CS +/-

NO-1

NO-2

NO-3

DS3

DS4

DS5

LVDC +/-

(7-3B)

J9/J10 RET

(7-2B)

DS9

DS8

R10

DS10

R13

DS13

R11

DS11

R12

DS12

A1 SHT 6A: TRANSFORMER J-BOX ELECTRONICS

PCB CIRCUIT SCHEMATIC

PCB INPUTS/OUTPUTS SHOWN IN PARENTHESIS

GTK T/S HPU

(17.28A)

GTK NODE 4

(12.75A)

GTK UMS 1HP HPU

(23.64A)FN ID VALUE

A1.1 F3-F4 20A A1.2 F7-F10 30A

A1.3 TB1 6-20AWG

A1.4 TB2 12-26AWG

A1.6 D1-D6 SHOTTKY

A1.7 R3-R5 3.9KΩ

A1.8 R8-R13 91Ω

A1.10 DS3-DS5, DS8-DS13 GRN

A1.12 NO-1, NO-2, NO-3 REF. 11

CODE 126.3

SHEET 7B

UNCLASSIFIED//FOR OFFICIAL USE ONLY

4 3 2 1

SCALE: NONE

(LEAK DETECT)

(J10-A/D)

TB3-10

TB3-9

(J9-A/D)

TB3-7

TB3-8

RET -

PWR +

CS2

CS1

CTRL1 +

CTRL1 -

CTRL2 +

CTRL2 -

(SSR2-4) (RET)

TB4-2

(SSR2-3)

TB4-1

(SSR1-4) (RET)

TB4-4

(SSR1-3)

TB4-3

R16

DS16

R15

DS15

(J10-UCM 26V )

TB3-2

(J9-UCM 26V)

TB3-1 D7

(J10-UCM D/A(A))

(J9-UCM D/A(A))

(J9-UCM D/A(B))

(J10-UCM D/A(B))

R20

DS20

R19

DS19

TB3-6

TB3-5 D11

D12

R18

DS18

R17

DS17

TB3-4

TB3-3 D9

D10

R21

DS21

R22

DS22

SSRC-1

A1 SHT 6A: TRANSFORMER J-BOX ELECTRONICS

PCB CIRCUIT SCHEMATIC

PCB INPUTS/OUTPUTS SHOWN IN PARENTHESIS

FN ID VALUE

A1.4 TB3 12-26AWG

A1.5 TB4 12-26AWG

A1.6 D7-D12 SHOTTKY

A1.9 R15-22 1.2KΩ

A1.10 DS15-DS22 GRN

A1.13 SSRC-1 REF. 11

COMPONENT LIST

J9/J10 RET

(7-2B)

(.05A)

CODE 126.3

SHEET 7C

UNCLASSIFIED//FOR OFFICIAL USE ONLY

4 3 2 1

SCALE: NONE

OPERATIONAL DESCRIPTION

THE PURPOSE OF THE TRANSFORMER J-BOX ELECTRONICS PCB IS TO ALLOW CONTROL

THE DISTRIBUTION OF LVDC POWER TO DOWNSTREAM COMPONENTS VIA A PAIR OF J-

BOX UNIVERSAL CONTROL MODULES (UCM).

TWO NORMALLY CLOSED (NC) RELAY CIRCUITS DISTRIBUTE LVDC POWER TO PACKAGE

NODES 2 AND 3 AS LONG AS POWER IS AVAILABLE TO THE PACKAGE. THIS ALLOWS

EITHER NODE TO TAKE CONTROL OF THE PACKAGE FOR OPERATION. WITHOUT THESE

RELAY CIRCUITS THE PACKAGE WOULD REQUIRE EXTERNAL STIMULATION TO POWER ON

THE NODES. THE RELAY CIRCUITS ARE CONTROLLED VIA UCM, J9 OR J10: J9 CONTROLS

NC-2 AND NODE 2; J10 CONTROLS NC-1 AND NODE 3. ONLY THE NODE THAT IS NOT

CONTROLLING THE XFMR J-BOX IN THE PACKAGE GUI CAN BE ISOLATED.

THE POWER FROM NC-1 IS ROUTED THRU A PAIR OF 20A FUSES (+ /-) AND A DC-DC

CONVERTER WHERE IT IS STEPPED DOWN TO 26VDC. IT IS THEN ROUTED OUT OF THE J-

BOX TO NODE 3 VIA RECEPTACLE J5.

THREE NORMALLY OPEN (NO) RELAY CIRCUITS ALSO DISTRIBUTE LVDC TO OTHER

DOWNSTREAM COMPONENTS VIA 30A FUSE PAIRS TO J-BOX RECPTACLE J5: NODE 2 VIA

J5-5/6, GTK NODE 4 VIA J5-7/8, GTK UMS 1 HP HPU VIA J5-3/4, GTK TOOL SKID 1HP HPU VIA

J5-1/2. THE NO RELAY CIRCUITS ARE ALSO CONTROLLED BY J9 & J10 UCMS. THE SIGNALS

FROM EACH UCM ARE DOUBLED TO PROVIDE REDUNDANT CONTROL OF THE COMPONENT

INCASE OF LOSS OF A NODE. THESE SIGNALS HAVE DIODES IN LINE TO PREVENT

FEEDBACK BETWEEN NODES.

THE REMAINING CIRCUIT ON THE PCB IS THE SOLID STATE RELAY CONTROL (SSRC)

CIRCUIT. THIS CIRCUIT IS USED TO PREVENT PREMATURE TURN ON OF A PAIR OF SSRS

CONTROLLING DISTRIBUTION OF HVDC TO AN EXTERNAL MOTOR CONTROLLER. UCM

26VDC AND D/A SIGNALS ARE USED TO CONTROL THE SSRS: 26VDC IS CONTINUOUSLY

ROUTED TO SSR POSITIVE TERMINALS (3); THE D/A SIGNALS ARE ROUTED THRU A PAIR OF

IDENTICAL DIFFERENCE AMPLIFIERS. UNTIL THE D/A SIGNAL LEVELS GET ABOVE

APPROXIMATELY 20VDC, THE OUTPUT OF EACH CIRCUITS IS THE RAIL VOLTAGE OF

26VDC, WHICH IS ROUTED TO THE SSR CONTROL NEGATIVE TERMINAL (4). WITHOUT A

DIFFERENCE OF POTENTIAL AT THE SSR CONTROL TERMINALS, THE SSRS REMAIN OFF.

ONCE THE D/A SIGNAL LEVELS INCREASE PAST 20V, THE CIRCUIT OUTPUTS ARE DRIVEN

LOW AND THE SSR IS TURNED ON ALLOWING HVDC TO BE ROUTED OUT OF THE J-BOX VIA

RECEPTACLE J3.

THE PCB PROVIDES INDICATION OF INCOMING AND OUTGOING SIGNALS TO PROVIDE

VISUAL VERIFICATION OF CIRCUIT OPERATION.

INPUT/OUTPUT TABLE

PARAMETER VALUE

LVDC 74 – 90 VDC

UCM GPIO OUTPUT 5 – 5.6 VDC

UCM GPIO OUTPUT .025 ADC

UCM D/A OUTPUT MAX 30 VDC

UCM D/A OUTPUT MAX .04 ADC

UCM A/D INPUT MAX 32 VDC

CODE 126.3

SHEET 7D

UNCLASSIFIED//FOR OFFICIAL USE ONLY

4 3 2 1

SCALE: NONE

R1 FOR XFMR J-BOX ELECTRONICS PCB MODEL VIEWS

CODE 126.3

SHEET 7E

UNCLASSIFIED//FOR OFFICIAL USE ONLY

4 3 2 1

SCALE: NONE

R2 FOR TRANSFORMER J-BOX ELECTRONICS PCB LAYER VIEWS

CODE 126.3

SHEET 8

UNCLASSIFIED//FOR OFFICIAL USE ONLY

4 3 2 1

SCALE: NONE

CS +/-

(J5-UCM RET)

TB2-4

(J2-1)

TB1-5

(J2-4)

TB1-6

V_A +

PWR +

PWR -

CS +/-

V_B + D2

V_A -

V_B -

VOUT +

VOUT -

VSEN +

VSEN -

LOAD +

LOAD -

PWR +

PWR -

LOAD +

LOAD -

(J4-1)

TB1-7

(J4-2)

TB1-8

VOUT +

VOUT -

VIN +

VIN -

(J5 A/D) (.001A)

TB6-5

CS +

CS -

(J5 GPIO2)

(.025A)

TB2-2

(J5 GPIO3)

(0.25A)

TB2-3

(D/A (B)) (.04A)

TB5-1

TB5-3

(J5 HE)

TB6-1

(J5 +5V)

(.1A) TB6-3

TB1-2

(J5 GPIO1)

TB2-1

LR-1

OR-1

NO-1

DC-1 (26V)

TB5-2

TB5-4

(J2-2)

(J2-3)

TB6-2

TB6-4

(LEAK DETECT)

DS5

DS4

DS8

DS7

DS6 (LVDC +) (J1-5)

(10.2A)

(LVDC -) (J1-6)

TB1-1

DS3

DS2

(BATT +)

(18.94A)

TB1-3

(BATT -)

TB1-4

DS1

A2 SHT 6B: TY2 V3 BATTERY J-BOX ELECTRONICS

PCB CIRCUIT SCHEMATIC

PCB INPUTS/OUTPUTS SHOWN IN PARENTHESIS

FN ID VALUE FN ID VALUE

A2.1 F1-F2 30A A2.9 R7 1.2KΩ

A2.2 TB1 6-20AWG A2.10 R8 820Ω

A2.3 TB2, TB5 12-26AWG A2.11 DS1-DS8 GRN

A2.4 TB3, TB4 6-20AWG A2.12 NO-1 REF. 11

A2.5 TB6 12-26AWG A2.13 LR-1 REF. 11

A2.6 R1, R6 3KΩ A2.14 OR-1 REF. 11

A2.7 R4 3.9KΩ A2.15 DC-1, 26V REF. 11

A2.8 R2, R3, R5 91Ω

COMPONENT LIST

BU HPU

(.04A)

UCM RET

VSENSE

BU HPU

(5.77A @ LVDC)

(10.71A @ BATT)

NODE 2

(13.3A)

CODE 126.3

SHEET 8A

UNCLASSIFIED//FOR OFFICIAL USE ONLY

4 3 2 1

SCALE: NONE

OPERATIONAL DESCRIPTION

THE PURPOSE OF THE TY2 V3 BATTERY J-BOX ELECTRONICS PCB IS TO PROVIDE THE

CAPABILITY TO SEAMLESSLY SWITCH BETWEEN PRIMARY AND BACKUP POWER AND

CONTROL THE DISTRIBUTION OF THAT POWER TO DOWNSTREAM COMPONENTS VIA A J-

BOX UNIVERSAL CONTROL MODULE (UCM).

PRIMARY POWER (LVDC 74-90V) IS BROUGHT ONTO THE PCB VIA J-BOX RECEPTACLE J1.

THE POWER SWITCHING IS ACCOMPLISHED BY THE OR-ING CIRCUIT (OR-1), WHICH

OUTPUTS THE HIGHER VOLTAGE LEVEL BETWEEN PRIMARY AND BACKUP. UPON LOSS OF

PRIMARY POWER, THE CIRCUIT AUTOMATICALLY SWITCHES TO BACKUP POWER WITHOUT

CAUSING NODE 2 TO POWER OFF THUS MAINTAINING CONTROL OF THE PACKAGE. ONCE

PRIMARY POWER IS RESTORED THE CIRCUIT SEAMLESSLY SWITCHES TO PRIMARY

POWER, AGAIN WITHOUT CAUSING NODE 2 TO POWER OFF.

THE OR-ING CIRCUIT ALSO HAS A VOLTAGE SENSE (VSENSE) SUB-CIRCUIT THAT

CONDITIONS (32/100) BOTH PRIMARY AND BACKUP VOLTAGE LEVELS AND SWITCHES

(1/SEC) SENDING ONE OUTPUT AT A TIME TO THE J-BOX UCM A/D MODULE FOR

MEASUREMENT. THESE LEVELS ARE ULTIMATELY PROVIDED IN THE GUI FOR DISPLAY.

ONE NORMALLY OPEN (NO) RELAY CIRCUIT (NO-1) DISTRIBUTES THE OR-ING CIRCUIT

OUTPUT (EITHER PRIMARY OR BACKUP POWER) TO THE BACKUP HPU VIA J-BOX

RECPTACLE J2.

THE LATCHING RELAY CIRCUIT (LR-1) PROVIDES CONSTANT BATTERY VOLTAGE TO THE

OR-ING CIRCUIT. THE CIRCUIT IS TURNED ON VIA THE GUI. THE GUI CONTROL SIGNAL IS A

MOMENTARY SIGNAL, BUT THE RELAY CIRCUIT REMAINS “LATCHED” IN THE CLOSED

STATE UNTIL A FOLLOW-ON SIGNAL IS RECEIVED AT WHICH POINT IT WILL OPEN AND

ISOLATE THE BATTERY BANK. THE CIRCUIT, AS DESCRIBED BY REF. 15, POWERS ON IN

THE UNLATCHED OPEN STATE. BATTERY POWER (+ / -) IS FUSED PRIOR TO LR-1 AT 30A.

THE DC-1 CIRCUIT CONVERTS EITHER PRIMARY OR BACKUP POWER TO 26VDC FOR

POWER TO NODE 2 VIA J-BOX RECEPTACLE J4.

UCM OUTPUT D/A (B) IS USED TO SUPPLY 0-5VDC TO THE BACKUP HPU FOR OPERATION.

THE LEAK DETECT CIRCUIT IS SIMPLY A DISCONNECT POINT BETWEEN THE UCM AND THE

LEAK DETECT WIRES FOR EASE OF MAINTENANCE.

THE PCB PROVIDES INDICATION OF INCOMING AND OUTGOING SIGNALS TO PROVIDE

VISUAL VERIFICATION OF CIRCUIT OPERATION.

INPUT/OUTPUT TABLE

PARAMETER VALUE

LVDC 74–90 VDC

BATT VOLTAGE 42-56VDC

UCM GPIO OUTPUT 5 – 5.6 VDC

UCM GPIO OUTPUT .025 ADC

UCM D/A OUTPUT MAX 30 VDC

UCM D/A OUTPUT MAX .04 ADC

UCM HE INPUT MAX 8.5 VDC

CODE 126.3

SHEET 8B

UNCLASSIFIED//FOR OFFICIAL USE ONLY

4 3 2 1

SCALE: NONE

R1 FOR TY2 V3 BATTERY J-BOX ELECTRONICS PCB MODEL VIEWS

CODE 126.3

SHEET 8C

UNCLASSIFIED//FOR OFFICIAL USE ONLY

4 3 2 1

SCALE: NONE

R2 FOR TY2 V3 BATTERY J-BOX ELECTRONICS PCB LAYER VIEWS

CODE 126.3

SHEET 9

UNCLASSIFIED//FOR OFFICIAL USE ONLY

4 3 2 1

SCALE: NONE

V_A +

PWR +

PWR -

CS +/-

V_B + D2

V_A -

V_B -

VOUT +

VOUT -

VSEN +

VSEN -

LOAD +

LOAD -

(J3-1)

TB6-1

(J3-2)

TB6-2

VOUT +

VOUT -

VIN +

VIN -

(BATT + FROM FB1-2)

(58.93A)

TB1-1

(J6 A/D)

(.001A)TB3-5

CS +

CS -

(J6 GPIO2)

(.025A)

TB3-2

(J6 HE)

TB2-1

(J6 +5V)

TB2-2

(LVDC +) (J2-5)

(3.54A)

TB4-1

(LVDC -) (J2-6)

TB4-2

(J6 GPIO1)

(.025A)

TB3-1

CS +/-

(J5-1)

TB5-3

(J5-2)

TB5-4

PWR +

PWR -

LOAD +

LOAD -

(J6-UCM RET)

TB3-3

(J6 D/A(A)) (.04A)

TB3-4

(LVDC -) (J2-8)

TB5-2

(PCB2 TB7)

(43.9A)

NO-1LR-1

OR-1

DC-1 (26V)

TB1-3

TB1-4

TB2-3

(LEAK DETECT)

TB2-4

DS1

DS2

DS3

DS4

(BATT - FROM FB2-2)

TB1-2

DS5

DS6

DS7

DS8

(LVDC +) (J2-7)

(20A)

TB5-1

DS9

A3 SHT 6C/6D:GTK BATTERY J-BOX ELECTRONICS

PCB1 CIRCUIT SCHEMATIC

PCB INPUTS/OUTPUTS SHOWN IN PARENTHESIS

S/R J-BOX TO NODE 4

(20A @ LVDC)

(8.45A @ BATT)

NODE 2

(9.94A)

FN ID VALUE FN ID VALUE

A3.1 F1-F2 30A A3.9 R7 1.2KΩ

A3.2 TB1, TB5 6-20AWG A3.10 R8 820Ω

A3.3 TB4, TB6 6-20AWG A3.11 D1 150V

A3.4 TB2 12-26AWG A3.12 D2, TVS 90VR, 146VCL

A3.5 TB3 12-26AWG A3.13 DS1-DS8 GRN

A3.6 R1, R6 3KΩ A3.14 NO-1 REF. 11

A3.7 R4 3.9KΩ A3.15 LR-1 REF. 11

A3.8 R2, R3, R5 91Ω A3.16 OR-1 REF. 11

A3.17 DC-1, 26V REF. 11

CODE 126.3

SHEET 9A

UNCLASSIFIED//FOR OFFICIAL USE ONLY

4 3 2 1

SCALE: NONE

OPERATIONAL DESCRIPTION

THE PURPOSE OF THE GTK BATTERY J-BOX ELECTRONICS PCB1 IS TO PROVIDE THE

CAPABILITY TO SEAMLESSLY SWITCH BETWEEN PRIMARY AND BACKUP POWER AND

CONTROL THE DISTRIBUTION OF THAT POWER TO DOWNSTREAM COMPONENTS USING A

J-BOX UNIVERSAL CONTROL MODULE (UCM).

PRIMARY POWER (LVDC 74-90V) VIA J-BOX RECEPTACLE J2 IS BROUGHT ONTO THE PCB AT

TB5. BATTERY POWER FROM THE BATTERY BANK IS BROUGHT ONTO THE PCB AT TB1.

THE POWER SWITCHING IS ACCOMPLISHED BY THE OR-ING CIRCUIT (OR-1), WHICH

OUTPUTS THE HIGHER VOLTAGE LEVEL BETWEEN PRIMARY AND BACKUP. UPON LOSS OF

PRIMARY POWER, THE CIRCUIT AUTOMATICALLY SWITCHES TO BACKUP POWER WITHOUT

CAUSING NODE 2 TO POWER OFF THUS MAINTAINING CONTROL OF THE PACKAGE. ONCE

PRIMARY POWER IS RESTORED THE CIRCUIT SEAMLESSLY SWITCHES TO PRIMARY

POWER, AGAIN WITHOUT CAUSING NODE 2 TO POWER OFF.

THE OR-ING CIRCUIT ALSO HAS A VOLTAGE SENSE (VSENSE) SUB-CIRCUIT THAT

CONDITIONS (32/100) BOTH PRIMARY AND BACKUP VOLTAGE LEVELS AND SWITCHES

(1/SEC) SENDING ONE OUTPUT AT A TIME TO THE J-BOX UCM A/D MODULE FOR

MEASUREMENT. THESE LEVELS ARE ULTIMATELY PROVIDED IN THE GUI FOR DISPLAY.

ONE NORMALLY OPEN (NO) RELAY CIRCUIT (NO-1) DISTRIBUTES BACKUP POWER TO NODE

4 VIA J-BOX RECPTACLE J5. PRIMARY POWER IS ALSO ROUTED TO THESE TWO

RECEPTACLES; THE HIGHER OF THE TWO VOLTAGES DOMINATES AND IS THE ONE THAT IS

SENT OUT. PRIMARY POWER INPUTS HAVE DIODES TO PREVENT FEEDBACK FROM

BATTERY POWER.

THE LATCHING RELAY CIRCUIT (LR-1) PROVIDES CONSTANT BATTERY VOLTAGE TO THE

OR-ING CIRCUIT. THE CIRCUIT IS TURNED ON VIA THE GUI. THE GUI CONTROL SIGNAL IS A

MOMENTARY SIGNAL, BUT THE RELAY CIRCUIT REMAINS “LATCHED” IN THE CLOSED

STATE UNTIL A FOLLOW-ON SIGNAL IS RECEIVED AT WHICH POINT IT WILL OPEN AND

ISOLATE THE BATTERY BANK. THE CIRCUIT, AS DESCRIBED BY REF. 15, POWERS ON IN

THE UNLATCHED OPEN STATE. BATTERY POWER (+ / -) IS FUSED PRIOR TO LR-1 AT 80A.

THE DC-1 CIRCUIT CONVERTS EITHER PRIMARY OR BACKUP POWER TO 26VDC FOR

POWER TO NODE 2 VIA J-BOX RECEPTACLE J3.

UCM OUTPUT D/A (A) IS USED TO PROVIDE THE CONTROL SIGNAL TO THE NO RELAY

CIRCUIT (NO-1).

THE LEAK DETECT CIRCUIT IS SIMPLY A DISCONNECT POINT BETWEEN THE UCM AND THE

LEAK DETECT WIRES FOR EASE OF MAINTENANCE.

THE PCB PROVIDES INDICATION OF INCOMING AND OUTGOING SIGNALS TO PROVIDE

VISUAL VERIFICATION OF CIRCUIT OPERATION.

INPUT/OUTPUT TABLE

PARAMETER VALUE

LVDC 74–90 VDC

BATT 42-56VDC

UCM GPIO OUTPUT 5 – 5.6 VDC

UCM GPIO OUTPUT .025 ADC

UCM D/A OUTPUT MAX 30 VDC

UCM D/A OUTPUT MAX .04 ADC

UCM HE INPUT MAX 8.5 VDC

CODE 126.3

SHEET 9B

UNCLASSIFIED//FOR OFFICIAL USE ONLY

4 3 2 1

SCALE: NONE

R1 FOR GTK BATTERY J-BOX ELECTRONICS PCB1 MODEL VIEWS

CODE 126.3

SHEET 9C

UNCLASSIFIED//FOR OFFICIAL USE ONLY

4 3 2 1

SCALE: NONE

R2 FOR GTK BATTERY J-BOX ELECTRONICS PCB1 LAYER VIEWS

CODE 126.3

SHEET 10

UNCLASSIFIED//FOR OFFICIAL USE ONLY

4 3 2 1

SCALE: NONE

VOUT +

VOUT -

VIN +

VIN -

CS +/-

PWR +

PWR -

LOAD +

LOAD -

(5V) J6-GPIO3

(.025A)

PWR +

PWR -

LOAD +

LOAD -

TB8-1

(PCB1 TB1)

(43.9A)

VOUT +

VOUT -

VIN +

VIN -

VOUT +

VOUT -

VIN +

VIN -

PWR +

PWR -

LOAD +

LOAD -

CS +/-

GPIO3

UCM RET

GPIO3

CS +/-

UCM RET

GPIO4

TB9-3

TB9-4

TB10-1

TB10-2

TB9-1

TB9-2

TB10-3

TB10-4

NO-4

NO-3NO-2

DC-2 (60V)

DC-3 (60V)

DC-4 (60V)

TB7-1

TB7-2

A4 SHT 6E: GTK BATTERY J-BOX ELECTRONICS

PCB2 CIRCUIT SCHEMATIC

R12

DS12

R14

DS14

R13

DS13

R16

DS16

R15

DS15

ISHARE

UCM RET

TB8-3

(J6-UCM RET)

R10

DS10

(5V) J6-GPIO4

(.025A)

TB8-2

R11

DS11

GPIO4

(LVDC +) (J2-1)

(17.28A)

(LVDC -) (J2-2)

(LVDC +) (J2-3)

(23.64A)

(LVDC -) (J2-4)

(J5-3)

(J5-4)

(J4-1)

(J4-2)

PCB INPUTS/OUTPUTS SHOWN IN PARENTHESIS

S/R J-BOX TO T/S HPU

(17.28A @ LVDC)

(22.47A @ BATT)

UMS BU HPU

(23.64A @ LVDC)

(30.73A @ BATT)

FN ID VALUE

A4.1 TB7 6-20AWG

A4.2 TB8 12-26AWG

A4.3 TB9, TB10 6-20AWG

A4.4 R12, R14, R15 3KΩ

A4.5 R13, R16 3.9KΩ

A4.6 R10, R11 91Ω A4.7 D3, D4 150V

A4.8 D5, D6, TVS 90VR, 146VCL

A4.9 D7, D8 45V

A4.10 DS10-DS16 GRN

A4.11 NO-2, NO-3, NO-4 REF. 11

A4.12 DC-2, DC-3, DC-4 REF. 11

COMPONENT LIST

D5(22.47A)

(30.73A)

CODE 126.3

SHEET 10A

UNCLASSIFIED//FOR OFFICIAL USE ONLY

4 3 2 1

SCALE: NONE

OPERATIONAL DESCRIPTION

THE PURPOSE OF THE GTK BATTERY J-BOX ELECTRONICS PCB2 IS TO CONVERT BATTERY

POWER TO 60VDC AND TO DISTRIBUTE PRIMARY AND BACKUP POWER.

DC-DC CONVERTERS USE A SMALL AMOUNT OF POWER IN AN IDLE STATE. NORMALLY

OPEN (NO) RELAY CIRCUIT (NO-2) PROVIDES ISOLATION OF THE DC-DC CONVERTERS

FROM THE BATTERY BANK TO PREVENT A SLOW DISCHARGE OF THE BATTERY BANK.

TWO NORMALLY OPEN (NO) RELAY CIRCUITS (NO-3, NO-4) DISTRIBUTES BACKUP POWER

TO DOWNSTREAM COMPONENTS VIA J-BOX RECPTACLES J4 AND J5. PRIMARY POWER IS

ALSO ROUTED TO THESE TWO RECEPTACLES; THE HIGHER OF THE TWO VOLTAGES

DOMINATES AND IS THE ONE THAT IS SENT OUT. PRIMARY POWER INPUTS HAVE DIODES

TO PREVENT FEEDBACK FROM BATTERY POWER.

DC-2 THRU DC-4 CIRCUITS CONVERT BACKUP POWER TO 60VDC FOR POWER TO GTK

COMPONENTS. THE CONVERTERS USE CURRENT SHARING TO SPREAD THE HIGH POWER

LOAD BETWEEN THE THREE.

THE PCB PROVIDES INDICATION OF INCOMING AND OUTGOING SIGNALS TO PROVIDE

VISUAL VERIFICATION OF CIRCUIT OPERATION.

TERMINAL BLOCK TB7-1 AND TB7-2 PROVIDES A CONNECTION POINT BETWEEN PCB1 AND

PCB2.

INPUT/OUTPUT TABLE

PARAMETER VALUE

LVDC 74–90 VDC

BATT 42-56VDC

UCM GPIO OUTPUT 5 – 5.6 VDC

UCM GPIO OUTPUT .025 ADC

CODE 126.3

SHEET 10B

UNCLASSIFIED//FOR OFFICIAL USE ONLY

4 3 2 1

SCALE: NONE

R1 FOR GTK BATTERY J-BOX ELECTRONICS PCB2 MODEL VIEWS

CODE 126.3

SHEET 10C

UNCLASSIFIED//FOR OFFICIAL USE ONLY

4 3 2 1

SCALE: NONE

R2 FOR GTK BATTERY J-BOX ELECTRONICS PCB2 LAYER VIEWS

CODE 126.3

SHEET 11

UNCLASSIFIED//FOR OFFICIAL USE ONLY

4 3 2 1

SCALE: NONE

VIN+(VIN +) 1 8

VIN-

VOUT+ (VOUT +)

(VOUT -)

ON/OFF2

VSENSE+

VSET+

VSENSE-

VOUT-

C1 C2 C3

DC-DC1

(VIN -)

Jumper C TO C1 = 26VDC OUT Jumper B TO B1 = 48VDC OUT Jumper A TO A1 = 60VDC OUT

ISHAREC R4

(ISHARE)

A5 SHT 6F: STAND ALONE DC-DC CONVERTER

PCB CIRCUIT SCHEMATIC

HDR1

B B1

C C1

PCB INPUTS/OUTPUTS SHOWN IN PARENTHESIS

FN ID VALUE

A5.1 R1, R5 .01Ω

A5.2 R2 23.2KΩ

A5.3 R3 9.1KΩ

A5.4 R4 5.62KΩ

A5.5 C1-C4 100µF A5.6 D1 78V

A5.7 DC-DC1 NQ90

A5.8 JMP1 2-PIN

A5.9 HDR1 6-PIN

A5.10 J1 PET-04

A5.11 J2 ES5 SERIES

CODE 126.3

SHEET 11A

UNCLASSIFIED//FOR OFFICIAL USE ONLY

4 3 2 1

SCALE: NONE

OPERATIONAL DESCRIPTION

THE PURPOSE OF THE STAND ALONE DC-DC CONVERTER ASSEMBLY IS TO CONVERT

INPUT DC POWER TO A FIXED DC OUTPUT.

THE ASSEMBLY IS THE SAME AS THE PREVIOUS ASSEMBLY (REF. 11, FN 3) WITH THE

EXEPTION THAT ALL FILTERING COMPONENTS ARE INCLUDED ON THE PCB AND THE

OUTPUT VOLTAGE IS SET BY INSTALLING A JUMPER BETWEEN DESIGNATED PINS. THE

OUTPUT VOLTAGE CAN BE SET TO 26VDC, 48VDC, OR 60VDC.

INPUT/OUTPUT TABLE

PARAMETER VALUE

INPUT VOLTAGE 9–90 VDC

INPUT CURRENT 0-26 ADC

OUTPUT VOLTAGE 0–90 VDC

OUTPUT CURRENT 0-26 ADC

CODE 126.3

SHEET 11B

UNCLASSIFIED//FOR OFFICIAL USE ONLY

4 3 2 1

SCALE: NONE

R1 FOR STAND ALONE DC-DC CONVERTER MODEL VIEWS

CODE 126.3

SHEET 11C

UNCLASSIFIED//FOR OFFICIAL USE ONLY

4 3 2 1

SCALE: NONE

R2 FOR STAND ALONE DC-DC CONVERTER PCB LAYER VIEWS

File details come from the government source that posted it.