Tektronix 1106, PP-7549/U Technical Manual

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TM 11-6625-2978-14

TECHNICAL MANUAL

OPERATOR’S, ORGANIZATIONAL,

DIRECT SUPPORT AND GENERAL SUPPORT

MAINTENANCE MANUAL

FOR

POWER SUPPLY PP-7549/U

(TEKTRONIX MODEL 1106)

(NSN 6130-01-018-1226)

HEADQUARTERS, DEPARTMENT OF THE ARMY

18 FEBRUARY 1982

SAFETY STEPS

TO FOLLOW IF SOMEONE

IS THE VICTIM

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

OF ELECTRICAL SHOCK

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

This manual includes copyright material reproduced by permission of the Tektronix, Inc.

ECHNICAL MANUAL

DEPARTMENT OF THE ARMY

O. 11-6625-2978-14

OPERATOR’S, 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

You can help improve this manual. If you find any mistakes or if you know of a way to improve the procedures, please let us know. Mail your letter, DA Form 2028 (Recommended Changes to Publications and Blank Forms), or DA Form 2028-2 located in the back of this manual direct to Commander, US Army Communications-Electronics Command, ATTN: DRSEL-ME-MQ, Fort

Monmouth, NJ 07703.

In either case, a reply will be furnished direct to you.

TM11-6625-2978-14

HEADQUARTERS

ASHINGTON, DC, 18 February 1982

C HAPTER 1. S

ECTION

C HAPTER 2. S

ECTION

C HAPTER 3. S

ECTION

C HAPTER 4. S

ECTION

C HAPTER 5.

ECTION

SECTON

C HAPTER 6.

ECTION I.

II.

III.

II.

III.

II.

TABLE OF CONTENTS

Paragraph

INTRODUCTION

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Description and Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Safety Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SERVICE UPON RECEIPT AND INSTALLATION

Service Upon Receipt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OPERATING INSTRUCTIONS

Function of Controls and Connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operation and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Battery Operation THEORY OF OPERATION

Circuit Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operation Under Unusual Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

MAINTENANCE

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Battery Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CALIBRATION

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Calibration During Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . .

1-1 1-7 1-11

2-1 2-4

3-1 3-5

4-1

5-1

5-3

6-1 6-2

Page

1-1 1-1 1-2

2-1 2-1

3-1 3-1

3-1

4-1 4-2

5-1

6-1

APPENDIX S

ECTION

REFERENCES . .

MAINTENANCE

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Maintenance Allocation Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

II.

III.

Tool and Test Equipment Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ALLOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Paragraph

B-1

Page

A-1 B-1

B-3 B-4

Figure 1-1. Power Supply PP-7549/U (1106 Battery Pack) Being Instlled Under a Portable Oscilloscope.

1-0

CHAPTER I

INTRODUCTION

Section I.

1-1. Scope

This manual describes Power Supply PP-7549/U (fig. 1-1) and provides instructions for its in-

stallation, operation, and maintenance. Power Supply PP-7549/U is the joint Army-Navy nomenclature and type number which has been applied to the commercially available Tektronix Model 1106 Battery Pack.

1-2. Index of Technical Publications

Refer to the latest issue of DA Pam 310-4 to deter-

mine whether there are new editions, changes, or ad-

ditional publications pertaining to the equipment.

1-3. Maintenance Forms, Records, and Reports

a. Reports of Maintenance and Unsatisfactory

Equipment. Department of the Army forms and

procedures used for equipment maintenance will be

those prescribed by TM 38-750, The Army Main-

tenance Management System.

b. Report of Packaging and Handling Deficien-

cies. Fill out and forward SF 364 (Report of

Discrepancy (ROD)) as prescribed in AR

735-11-2/DLAR 4140.55/NAVMATINST 4355.73/

AFR 400-54/MCO 4430.3E.

c. Discrepancy in Shipment Report (DISREP) (SF

361). Fill out and forward Discrepancy in Shipment

Report (DISREP) (SF 361) as prescribed in AR

55-38/NAVSUPINST 4610.33B/AFR 75-18/MCO

4610.19C/DLAR 4500.15.

GENERAL

1-4. Reporting Equipment Improvement

If your Power Supply PP-7549/U needs im-

provement, let us know. Send us an EIR. You, the user, are the only one who can tell us what you don’t like about your equipment. Let us know why you don’t like the design. Tell us why a procedure is hard to perform. Put it on an SF 368 (Quality Deficiency Report). Mail it to Commander, US Army Communications-Electronics Command, ATTN: DR-

SEL-ME-MQ, Fort Monmouth, NJ 07703. We’ll

send you a reply.

1-5. Administrative Storage

Administrative storage of equipment issued to and used by Army activities will have preventive main-

tenance performed in accordance with the PMCS

charts before storing. When removing the equip-

ment from administrative storage the PMCS should

be performed to assure operational readiness.

Disassembly and repacking of equipment for ship-

ment or limited storage are covered in paragraphs

2-1 and 2-2.

1-6. Destruction of Army Electronics Materiel

Destruction of Army electronics materiel to prevent

enemy use shall be in accordance with TM

750-244-2.

Recommendations (EIR)

Section Il. DESCRIPTION AND DATA

1-7. Purpose and Use

Power Supply PP-7549/U is a dc power source for operating portable Oscilloscope OS-261/U (Tektronix Model 475 Option 7) away from ac power sources. Power Supply PP-7549/U is sold commercially as a Tektronix, Model 1106 Battery Pack. Power Supply PP-7549/U is also referred to as the

battery pack throughout this manual.

1-8. Description Power Supply PP-7549/U is a self-contained por-

table battery pack equipped with a dc cable for connecting to an oscilloscope allowing operation away from ac power recepticals. It also has an ac cable

which enables connection to an ac circuit for

recharging.

1-9. Use Option

a. The separate battery pack capability permits a choice of battery operation or ac line operation. During charging of the battery pack, the oscilloscope may be operated from the ac line without detaching the battery pack.

oscilloscope may be detached from the battery pack,

while it is charging, and used elsewhere with either another battery pack or ac line. The battery pack and oscilloscope may be separated easily and quickly for carrying ease.

The

1-1

b. Refer to the oscilloscope technical manual for information regarding input power switch position when changing to or from battery pack operation.

1-10. Specifications

a. AC Requirements.

Ac power source is required only for battery charging. Standard instrument: 100 to 132 Vac or 200 to 264 Vac, 50 to 400 Hz. Standard instrument with an internal connection change: 90 to 120 Vac or 180 to 240 Vac, see the maintenance section of this manual for further information 50 to 400 Hz. Power line consumption is 40 watts maximum at 115 Vac, 60 Hz.

b. Power Output. 22 to 24 Vdc for 7 ampere-

hours. 5 A maximum.

Section Ill. SAFETY CONSIDERATIONS

c. Battery Operating Time. Approximately 140

watt-hours from fully-charged batteries.

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

40° C).

e. Temperature.

Operating, 0° C to 40° C. 0° C to 40° C will not noticeably reduce the battery capacity. 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 inches

wide. 17.0 inches long, including feet and handle. 2.6 inches high, including feet. Combined height of battery pack and oscilloscope is approximately 8.4 inches.

1-11. Charging

The instrument is intended to be operated from a

single-phase ac power source having one currentcarring conductor (the Neutral Conductor) at ground (earth) potential. Operation from power

sources where both current-carrying conductors are

live with respect to ground (such as phase-to-phase

Table 1-1. Power Cord Conductor Identification

Conductor Ungrounded (Line)

Grounded (Neutral) Grounding (Earthing)

Brown Blue Green-Yellow

1-13. AC Power Cord

The instrument has a three-wire power cord with a

three-terminal polorized plug for connection to the

power 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 safety

earth contact.

on a three-wire system) is not recommended, since only the Line Conductor has over-current (fuse) protection within the instrument.

1-12. Power Cord Conductor Identification

Identification of power cord conductors is contained in table 1-1.

Color

Alternate Color Black White

Green-Yellow

1-14. Operating

a. The potential at the chassis (frame) of the battery pack is established by the oscilloscope being powered through the safety-earth conductor system. For electric-shock protection, connect the oscilloscope cabinet (frame) to a ground (earth) reference.

b. If the battery pack ac power cord is connected to a correctly-wired ac power source, an additional shock protection circuit is established through the safety-earth conductor system.

1-2

CHAPTER 2

SERVICE UPON RECEIPT AND INSTALLATION

Section I. SERVICE UPON RECEIPT

2-1. Packaging Data

a. Power Supply PP-7549/U may arrive packed

for either domestic or overseas shipment.

b. When Power Supply PP-7549/U is packed for overseas shipment it is placed in a lightweight packing material and is placed in a corrugated carton. The carton is sealed with gummed tape. The

boxed equipment is then placed in a moisturevaporproof barrier, which is heat-sealed, and this package is placed in a waterproof corrugated carton. The technical manuals are placed under the lid and

the carton is sealed with waterproof tape. The

packaged battery pack is placed in a wooden shipping container with a waterproof case liner. The wooden container is reinforced with flat metal straps.

2-2. Unpacking

a. For unpacking overseas shipment equipment,

proceed as follows:

(1) Cut the metal straps with a suitable cutting tool, or twist them with pliers until the straps break. Remove the straps.

(2)

Remove the nails from the top and one side of the wooden case. Do not attempt to pry off the sides and top. Such action may damage the equipment.

(3) Remove the corrugated filler from the packing case and lift the packaged equipment out of the case.

the sealed moisture-vaporproof barrier. Lift out the inner corrugated carton.

remove the battery pack. Read and observe the charging instructions fully before connecting the battery pack to an oscilloscope.

packing cases. The instructions given in a above, also apply to unpacking domestic shipments. If heavy wrapping paper has been used, remove it carefully and take out the battery pack.

2-3. Check Unpacked Equipment

during shipment. If the equipment has been damaged, report the damage on SF 964 (para 1-3b).

the packing slip.

Report all discrepancies in accordance with paragraph 1-3. The equipment should be placed in service even though a minor assembly or part that does not affect proper functioning is missing.

modified. Modified equipment will have the MWO number on the front panel near the nomenclature plate. Check also to see whether all currently applicable MWO’s have been applied. (Current MWO’s are listed in DA Pam 310-4).

checked, clean with a soft cloth.

(4) Open the outer corrugated carton and break

(5) Open the inner corrugated carton and

b. The battery pack may be received in domestic

a. Inspect

b. Check the equipment for completeness against

c. Check to see if the equipment has been

d. After the equipment has been thoroughly

the equipment for damage incurred

Section II. INSTALLATION

2-4. Attaching The Battery Pack

a. The battery pack is equipped with four permanently attached clamps that are designed to fit and attach to the feet of the portable Oscilloscope OS-261 (Tektronix Model 475 Option 7). Set the oscilloscope on the battery pack and observe that the 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 the oscilloscope. Refer to chapter 3 prior to placing the

battery pack into operation.

c. The ac power cord to the battery pack is not used while the battery pack is in operation. Store this ac cord in a method so that it will not incur damage during movement of the oscilloscope and battery pack from one working area to the next.

d. It may be advantageous to use the battery

pack and the oscilloscope as separate units as each item is equipped with its own carrying handle. With care, the two units may be carried short distances by two persons without disconnecting the dc power cord while still in the operational mode, thus realizing the full portability of these two units.

2-1

CHAPTER 3

OPERATING INSTRUCTIONS

Section I. FUNCTION OF CONTROLS AND CONNECTORS

3-1. Battery Level

Meter indicates the approximate state of charge of the batteries while under load.

3-2. Charger

a. Mode Switch.

(1) Full. Permits the maximum safe charging rate. Charge rate should be changed to the tricklecharge rate when the batteries have received a full charge.

(2) Trickle. Reduces the charging rate to main-

tain fully-charged batteries. Charging occurs as long as the battery pack is con-

nected to the ac power line. operation. oscilloscope external dc input. charger circuit only, as long as the ac line is con-

netted.

Section Il. OPERATION AND INSPECTION

3-3. First-Time Operation

The instrument may be operated with less than fully charged batteries.

however, charge the batteries at the full-charge rate

for 14 to 16 hours.

3-4. Attaching the Battery Pack

Attach the battery pack to an oscilloscope with Option 7 as follows (see fig. 1-1):

a. Open the latches on the battery pack by pulling them outward. Set the oscilloscope on top of the battery pack with the feet in the holes in the latches. Push the latches in until they lock in the feet of the

For first-time

operation,

oscilloscope. Check each corner to verify that each

foot has been latched to the battery pack. connect the battery pack output to the oscilloscope

(Option 7) dc input. Turn the oscilloscope on. Check

that the battery pack powers the oscilloscope. Observe the BATTERY LEVEL meter. The meter

reading is only indicative of the remaining charge if

the battery pack if powering an oscilloscope. Under no-load conditions, the battery pack will read full,

even if it is almost discharged.

th) reference before using.

b. ON Position. Lamp indicates charger is on.

c. Line Selector. Select 115 Vac or 230 Vac d. DC Output (Attached Cord). Connects to the e. AC Input. Allows ac operation of the battery

b. Set the oscilloscope for 24 Vdc operation and

c. Connect the oscilloscope frame to a ground (ear-

Section III.

WARNING

The nickel-cadmium (NiCd) cells used in this instrument are capable of delivering a large amount of current in a short time. Care must be taken not to short-circuit the cells. The battery pack is fused at 6 amperes.

Operating Time

3-5.

Battery operating time depends on the load

BATTERY OPERATION

selected and the charge-discharge temperatures. Op-

timum charge and discharge is obtained when the batteries are operating at temperatures between 20° C to 30° C. Relative capacities for other tem-

peratures are shown in table 3-1. Battery pack

discharge 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.

3-1

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

Charge Temperature

-15° C

0° C

+20° C to +30° C

+40° C

c. The approximate battery pack operating time may be roughly estimated using figure 3-1. For in- manual. dividual oscilloscope times see the Option 7

40% 65%

40%

Specification portion of the oscilloscope technical

Operating Temperature

+20°

C to +

60%

100%

65%

30° C

+55° C

50% 85%

55%

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

NOTE

High discharge rates or high ambient temperatures may raise the battery tem-

The batteries may be damaged by over-charging for long periods (in excess of 24 hours). Repeated over-

charging shortens the useful life of the batteries. perature enough to lower their 140 watthour capability.

cell in the battery pack acquires a slightly different

charge characteristic. To provide the best overall

3-6. Battery Discharge

Extensive discharge of the batteries may cause one or more of the cells to reverse polarity. Repeated reversal shortens the useful life of the batteries. The oscilloscope with the Option 7 has a circuit to cut off its inverter when the external dc source drops below approximately 22 Vdc. This prevents the battery

operation and maximum operating life, the charge

on the individual battery cells should be equalized

periodically. This can be done without damage to

the battery cells by charging the batteries at the

full-charge rate for 24 hours. Charging should be

done after every 15 charge-discharge cycles or every

30 days, whichever occurs first.

from going into deep discharge.

mode switch to trickle charge if the battery pack is

3-7. Battery Charge

a. A thermal cutout in the battery pack protects the batteries from overheating during charge time. The batteries normally become warmer as they

to remain connected to the ac line. This maintains fully-charged batteries and prevents overcharging.

3-8. Battery Pack Storage

reach full charge potential. If the temperature surrounding the batteries exceeds the safe operating level, a thermal cutout switches the charge rate from 620 milliamperes full-charge to the 60-milliampere trickle-charge rate. When the temperature returns to a safe operating level, the thermal cutout returns the charge rate to the 620-milliampere level.

be stored in a charged condition. For best shelf life, when storing the battery pack for long periods of time, remove fuse F131 (which may be stored by placing it in the dc power cord clip on the rear panel). Fully recharge the batteries about every three months.

EL6RK002

b. During normal usage or storage, each battery

c. Once the batteries are fully charged, change the

a. The batteries used in the battery pack should

3-2

b. Charge retention characteristics of nickelcadmium batteries vary with the storage temperature and humidity. The battery pack may be

stored at ambient temperatures between —40° C

and +60° C without damage, either in the instrument or as a separate unit. The self-discharge rate increases with an increase in ambient tem-

perature. For example, cells stored at +20° C will

lose about 50% of their stored charge in three mon-

ths, but when stored at +50° C, they will be almost

completely self-discharged in only one month. High

humidity also increases the rate of self-discharge.

3-9. Maintenance

Additional data regarding maintenance and repair

of the battery pack and the NiCd cells can be found in the maintenance section of this manual.

310. Battery Charge Level

a. Meter indication of battery charge level may be false during the first several minutes of battery operation. This is due to a battery characteristic.

b. When the battery pack is turned on, a residual battery charge may give a meter indication of a high state-of-charge even though a low, partial charge is all that remains. The battery pack may operate

several 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 instrument turned off. It may also show up after the instrument has been stored in temperatures significantly below

25° C, then brought to room temperature for

operation.

d. If unsure of the state of the battery charge,

recharge at the proper temperature for the full recharge time given in the battery operation section.

3-3

CHAPTER 4

THEORY OF OPERATION

Section I. CIRCUIT DESCRIPTION

4-1. General

a. The battery pack provides a 24 Vdc power

source. The charger circuit will charge, at either fullcharge or trickle-charge rates, as long as the battery pack is connected to the correct ac line. The meter circuit is always on. The output voltage is always available at the DC OUT plug. The batteries may be disconnected 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 Circuit

a. From the secondary of transformer T101, ac voltage is applied to full-wave bridge rectifier CR115. The rectified voltage goes to filter C115 and through CR121 to resistor R121 and transistor Q124. VR123 sets the bias for Q124. This bias is about 5.6V across the R123 and the emitter-base

junctions of Q124, a Darlington transistor. The drop across the two emitter-base junctions reduces this voltage to about 4.3 V across R123.

b. In parallel with R123 is the series combination

of CR125, S125, S130, and R131. The charge rate switch S130 is shown in the FULL CHG position (closed). Under normal battery temperatures, thermal cut-out S125 is closed and the 4.3 V is across R131 (in series with CR125). This limits the charge current to about 620 milliamperes.

c. Battery temperature rises as the batteries reach full charge. S125 opens, removing resistor R131 from the circuit. The charging current is now limited to about 60 milliamperes by the 4.3 V being

applied only across R123. The same current reduction occurs when the charge rate switch (S130) is set to TRICKLE CHG (open).

4-3. Charger Circuit Protection

a. Power dissipated by Q124, in the full-charge

mode, is reduced for high line or low battery conditions by the circuitry involving C117, CR111, CR112, R125, and T101.

biased. An increase in line voltage increases the potential from the -DC OUT line to the collector of Q124 and also to CR112 and CR111. Q124 provides a constant current to a fixed load (R123 and R131). The increased potential, therefore, appears across Q124, increasing its dissipation.

CR111 and CR112 to conduct. This point is determined by the taps on T101. Once CR111 and CR112 conduct, they maintain a voltage at the plus side of C117 that is about 70% of the voltage at the plus side of C115 (with respect to the -DC OUT line). As the voltage across C117 increases, current through R125 increases. There is a corresponding decrease in current supplied by Q124. This current reduction in Q124 decreases the power dissipated in Q124. Since the current through R125 is supplied from a lower voltage source than is the current through Q124, there is a reduction in total power.

same effect on the circuit as an increase in line

voltage. Batteries with a low charge and with a high ac line may receive nearly all of the charging current through CR111, CR112, and R125.

conditions, from bypassing the charge rate switch when it is in the TRICKLE CHG mode. CR 121 prevents C115 from charging through Q124. This situation can exist if the battery pack has been off for a long time, a dead battery is replaced, F131 is replaced, or a similar condition exists that permits C115 to discharge, then apply voltage across the

+DC OUT line.

4-4. Meter Circuit

The voltage reference for the meter circuit is set by R127 and VR131. The other side of the meter is connected to voltage divider R128, R133, and R136. R133 is set for a meter reading at the junction of the red and green portions of the meter scale (a reading

at the left end dot for early SN instruments).

b. At low line, CR111 and CR112 are reverse

c. At some point the increased line voltage causes

d. A low charge on the batteries will have the

e. CR125 prevents the current, during high line

4-1

Section Il. OPERATION UNDER UNUSUAL CONDITIONS

4-5. Operation in Arctic Climates

Subzero temperatures and climatic conditions associated with cold weather may hamper the efficient operation of electronic equipment. Instructions and precautions for operation under such adverse conditions follow:

a. Keep the equipment warm and dry. If the equipment is not kept in a heated enclosure, construct an insulated box for its protection.

b. Make certain the equipment has been warmed up sufficiently before use. This may take 15 to 30 minutes, depending on the temperature of the surrounding air.

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 equipment has reached room temperature, dry it thoroughly.

4-6. Operation in Tropical Climates

In tropical climates, electronic equipment may be installed in tents, huts or, when necessary, in underground dugouts. When equipment is installed below ground, and when it is set up in swamp areas, danger of moisture damage is more acute than normal in the tropics. Ventilation is usually very poor, and the high relative humidity cuases condensation on the equipment whenever its temperature becomes lower than the ambient air. To counteract this condition, place lighted electric bulbs under the equipment.

4-7. Operation in Desert Climates

The main problem with electronic equipment in desert areas is the large amount of sand and dust that lodges in the moving parts and mechanical assemblies. Cleaning and servicing intervals should be shortened according to local conditions.

4-2

CHAPTER 5

MAINTENANCE

Section I. TROUBLESHOOTING

5-1. General

The first step in servicing a defective battery pack is to sectionalize the fault. Sectionalization means

tracing the fault to the major circuit responsible for the abnormal operation. The second step is to localize the fault. Localization means tracing the fault to a particular stage or network within one of

the major circuits. The third step is to isolate the fault. Isolation means tracing the fault to the defec-

tive part responsible for the abnormal condition.

Some faults, such as burned-out resistors, arcing and shorted transformers, can often be located by

sight, smell, and hearing. The majority of faults,

however, must be isolated by checking voltages and resistances.

5-2. Component Sectionalization, Localization,

Listed below is a sequence of tests arranged to reduce unnecessary work and aid in tracing the trouble to a specific component.

the trouble may frequently be discovered or the circuit in which the trouble exists may be determined. This inspection helps to avoid additional damage to the equipment as a result of improper servicing methods.

connections may cause the trouble. Test wiring for loose connections and move wires and components with an insulated tool. This may indicate the location of a faulty connection or component.

6-4 for troubleshooting voltage checks, symbols, and schematic diagram.

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 maintenance.

a. Multimeter ME-451/U, NSN 6625-01-

060-6804.

b. Battery Charger PP-6241/U, NSN 6130-00-

106-6445.

c. Tool Kit, Electronic Equipment TK-100/G,

NSN 5180-00-605-0079.

5-4. Batteries

a. The battery pack contains twenty 1.25 V Nickel-Cadmium (NiCd) cells, in groups of four, strapped together. Background information regarding these cells is given in chapter 3, section III battery operation and should be read before any servicing is performed on the battery pack.

b. If one group of cells is defective and fails while the rest of the battery pack is still quite new, that group may be replaced without undue concern. The Tektronix Field Representative or Office should be consulted before cells are replaced, if the warranty is still in effect.

c. Gas evolution and recombination takes place

during battery charging. This creates a pressure within the cells which they normally can withstand.

If a cell becomes defective, or a circuit failure causes the recommended charge rate to be exceeded, excessive pressure builds up. The pressure may rup-

ture a relief vent, exhausting the gas. This action

may shorten the life of the cell, and will coat the

surrounding areas with a corrosive substance.

5-5. Battery Removal

Remove the six screws from the sides of the battery pack. Remove the cover. Remove fuse F131.

Remove the two screws from the battery clamps. Unsolder the wires at the batteries.

5-6. Cell Replacement

removed 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 cell replacement 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 the

instrument and to personnel. Operating time or tem-

perature performance may be degraded. The battery

and Isolation

a. Visual Inspection. Through inspection alone,

b. Intermittents. It is possible that some external

c. Voltage Checks. Refer to figures 6-2, 6-3, and

a. When necessary, a group of four cells can be

5-1

pack should be charged for 24 hours after cells are replaced.

b. All cells in the battery pack should be made by the same manufacturer. Include this information, with the other information required, when ordering replacement cells.

5-7. Line voltage Selection Wiring

a The battery pack can be wired

to accept a

100 TO 132 VAC

variation in input voltage as may exist in certain conditions or geographical areas. The wires on transformer T101 may be changed to accept line variation. Proper wiring of the input will result in satisfactory battery pack charging.

b. Refer to figure 5-1 for line voltage selection

wiring. For nominal 115 Vat, use the 100 to 132

VAC

diagram. For nominal 105 Vat, use the 90 to

120 VAC diagram.

90 TO 120 VAC

EL6RK003

Figure 5-1. Line Voltage Section Wiring.

5-2

CHAPTER 6

CALIBRATION

Section I. GENERAL

6-1. Terms and Definition

a. Calibration, in accordance with maintenance practices, is the checking of voltages, current, resistances, etc., through each section or stage, and the adjusting and alignment of variable components within each section or stage. It is almost always

necessary to perform this type of calibration while

the equipment is being electrically repaired or as

parts are being replaced. Common maintenance test equipment is used for this type of calibration.

Section II.

6-2. Battery Pack Disassembly

a. For calibration during maintenance, remove

the six screws from the sides of the battery pack and

CALIBRATION DURING MAINTENANCE

(US Army Calibration System), is a periodic check of the total accuracy of each parameter as compared

to calibrated standards at a ratio of 4 to 1. Upon

completion of this type of calibration a Department

of the Army DA Label 80 is affixed to the accepted

unit. requirements for the maintenance of Army materiel

is contained in TB 43-180 and TM 38-750.

lift the cover. ploded view in figure 6-1.

b. Calibration, in accordance with AR 750-25-1

All information regarding calibration

b. For further mechanical disassembly see the ex-

6-1

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

WARNING

Dangerous potential and high current capabilities exist at several points. Disconnect power cord, remove fuse F131, and unsolder batteries before replacing parts.

6-3. Equipment Required

DC Milliammeter: 620 mA and 60mA. Voltmeter:

/VDC and 5,000

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

NOTE

The battery pack is calibrated at the factory using a power supply permitting ac-

6-2

curate setting of the meter zero. Because this type of power supply may not be available, an alternate method is given. The accuracy of the equipment required depends on how critically the user wants the meter zero to coincide with the cut-off point in the Option 7 circuitry.

Calibration Procedure

6-4.

Charge.

(1) Remove fuse F131, (figure 6-2). Connect the ammeter across the terminals for F131. Connect the battery pack to the correct ac line. Set the mode

switch to FULL CHG.

Voltmeter: 20,000 Ω/ς∆Χ and 5,000 Ω/ςΑΧ multimeter.

Voltage readings will vary with line voltage and battery charge level.

Battery charged

Line Selector: Correct line voltage

Mode Switch: FULL CHG

Figure 6-2. Battery Pack PP-7549/U, Circuit Board, with Test Voltages and Conditions.

(2) Current should be approximately 620 mA. (3) Change mode switch to TRICKLE CHG.

junction of the red and green portions of the scale (or near the left end dot for SN below B022417).

(4) Current should be approximately 60 mA.

b. Zero Adjust.

(1) Disconnect the battery pack from the ac

line. Disconnect the external milliammeter but do

reading at the junction of the red and green portions

of the scale (for SN below B022417 adjust R133 for a meter reading at the left end dot).

not install F131. Connect a 23 V power source to the

DC OUT connector (for SN below B022417 use a 22

F131.

V source).

(2) Battery level meter should read near the

manner as disassembled in paragraph 6-2.

(3) Adjust Meter Level (R133) (fig. 6-2) for a

(4) Remove the dc power source and install fuse (5) Reassemble the battery pack in the opposite

6-3

CIRCUIT BOARD ILLUSTRATION, DIAGRAM, AND

PARTS 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).

Resistors = 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 manufacturer’s data.

Values less than one are

in microfarads (µF).

Logic symbols depict the Iogic function performed

Internal Screwdriver Adjustment Test Voltage Plug to E.C. Borad Panel Adjustment

Plug Index Modified Component–See Parts List

Refer to Waveform Refer to Diagram Number

Coaxial Connector

Panel Connector

Assembly Number

Board Name

Etched Circuit Board

Figure 6-3.

Schematic Name and Number

Battery Pack PP-7549/U, Vertical Amplifier Schematic with Explanation of Electrical Symbols.

6-4

NOTE:

DENOTES COMMON NEGATIVE RETURN

Figure 6-4. Battery Pack PP-7649/U, Schematic Diagram.

6-5

APPENDIX A

REFERENCES

DA Pam 310-4 TB 43-180 TB 43-0118

TM 11-6130-351-14

TM 11-6625-2953-14 TM 38-750

TM 740-90-1

TM 750-244-2

Index of Technical Publications. Calibration Requirements for the Maintenance of Army Materiel. Field Instructions For Painting and Preserving Electronics Command Equip-

ment Including Camouflage Pattern Painting of Electrical Equipment Shelters.

Operator’s, Organizational, Direct Support, and General Support Main-

tenance Manual Including Repair Parts and Special Tools Lists (Including Depot Maintenance Repair Parts and Special Tools) for Battery Charger PP-6241/U.

Operator’s, Organizational, Direct Support, and General Support Main-

tenance Manual for Multimeter AN/USM-451. The Army Maintenance Management System (TAMMS). Administrative Storage of Equipment. Procedures for Destruction of Electronics Materiel to Prevent Enemy Use

(Electronics Command).

A-1/(A-2 Blank)

APPENDIX B

MAINTENANCE ALLOCATION

Section I. INTRODUCTION

B-1. General

This appendix provides a summary of the main-

tenance operations for the PP-7549/U. It authorizes categories of maintenance for specific maintenance

functions on repairable items and components and

the tools and equipment required to perform each function. This appendix may be used as an aid in

planning maintenance operations.

B-2. Maintenance Function

Maintenance functions will be limited to and defined as follows:

a. Inspect. To determine the serviceability of an

item by comparing its physical, mechanical, and/or

electrical characteristics with established standards through examination.

b. Test. To verify serviceability and to detect in-

cipient failure by measuring the mechanical or elec-

trical characteristics of an item and comparing those characteristics with prescribed standards.

c. Service. Operations required periodically to keep an item in proper operating condition, i.e., to clean (decontaminate), to preserve, to drain, to paint, or to replenish fuel, lubricants, hydraulic fluids, or compressed air supplies.

d. Adjust. To maintain, within prescribed limits, by bringing into proper or exact position, or by setting the operating characteristics to the specified parameters.

e. Align. To adjust specified variable elements of an item to bring about optimum or desired performance.

f. Calibrate. To determine and cause corrections to be made or to be adjusted on instruments or test measuring and diagnostic equipments used in precision measurement. Consists of comparisons of two instruments, one of which is a certified standard of known accuracy,

discrepancy in the accuracy of the instrument being compared.

g. Install. The act of emplacing, seating, or fixing

into position an item, part, module (component or assembly) in a manner to allow the proper func-

tioning of the equipment or system.

h. Replace. The act of substituting a serviceable

like type part, subassembly, or module (component

or assembly) for an unserviceable counterpart.

i. Repair. The application of maintenance ser-

to detect and adjust any

vices (inspect, test, service, adjust, align, calibrate, replace) or other maintenance actions (welding, grinding, riveting, straightening, facing, remachining, or resurfacing) to restore serviceability to an item by correcting specific damage, fault, malfunction, or

failure in a part, subassembly, module (component

or assembly), end item, or system. vice/action) necessary to restore an item to a com-

pletely prescribed by maintenance standards (i.e., DMWR) in appropriate technical publications. Overhaul is normally the highest degree of maintenance performed by the Army. Overhaul does not normally return an item to like new condition.

necessary for the restoration of unserviceable equipment to a like new condition in accordance with original manufacturing standards. Rebuild is the highest degree of materiel maintenance applied to Army equipment. The rebuild operation includes the act of returning to zero those age measurements (hours, miles, etc.) considered in classifying Army equipments/components.

B-3. Column Entries

group numbers, the purpose of which is to identify components, modules with the next higher assembly.

contains the noun names of components, assemblies, subassemblies, and modules for which maintenance is authorized.

lists the functions to be performed on the item listed in column 2. When items are listed without maintenance functions, it is solely for purpose of having the group numbers in the MAC and RPSTL coincide.

specifies, by the listing of a “work time” figure in the appropriate subcolumn(s), the lowest level of maintenance authorized to perform the function listed in column 3. This figure represents the active time required to perform that maintenance function at the indicated category of maintenance. If the number or complexity of the tasks within the listed

j. Overhaul. That maintenance effort (ser-

serviceable/operational

k. Rebuild. Consists of those services/actions

a. Column 1, Group Number. Column 1 lists

assemblies,

b. Column 2, Component/Assembly. Column 2

c. Column 3, Maintenance Functions. Column 3

d. Column 4, Maintenance Category. Column 4

subassemblies,

condition as

and

B-1

maintenance function vary at different maintenance categories, appropriate “work time” figures will be shown for each category. The number of task-hours specified by the “work time” figure represents the average time required to restore an item (assembly, subassembly, component, module, end item or system) to a serviceable condition under typical field operating conditions. This time includes preparation time, troubleshooting time, and quality assurance/quality control time in addition to the time required to perform the specific tasks identified for the maintenance functions authorized in the maintenance allocation chart. Subcolumns of column 4 are as follows:

C–Operator/Crew O–Organizational F–Direct Support H–General Support D–Depot

e. Column 5, Tools and Equipment. Column 5 specifies by code, those common tool sets (not individual tools) and special tools, test, and support equipment required to perform the designated function.

f. Column 6, Remarks. Column 6 contains an alphabetic code which leads to the remark in section IV, Remarks, which is pertinent to the item opposite the particular code.

B-4. Tools and Test Equipment Requirements

numbers in this column coincide with the numbers used in the tools and equipment column of the MAC. The numbers indicate the applicable tool or test equipment for the maintenance functions.

column indicate the maintenance category allocated the tool or test equipment.

name and nomenclature of the tools and test equipment required to perform the maintenance functions.

lists the National/NATO stock number of the

specific tool or test equipment. turer’s part number of the tool followed by the

Federal Supply Code for manufacturers (5-digit) in

parentheses.

B-5. Remarks (Sec IV)

propriate item in section II, column 6. explanatory information necessary to clarify items

appearing in section II.

(See III)

a. Tool or Test Equipment Reference Code. The

b. Maintenance Category. The codes in this

c. Nomenclature. This column lists the noun

d. National/NATO Stock Number. This column

e. Tool Number. This column lists the manufac-

a. Reference Code. This code refers to the ap-

b. Remarks. This column provides the required

(Next

printed page is B-3)

B-2

TM 11-6625-2978-14

(I)

GROUP

NUMBER

COMPONENT/ASSEMBLY

POWER SUPPLY PP-7549/U

STORAGE BATTERY BT-131

CIRCUIT CARD ASSY (A1)

SECTION II MAINTENANCE ALLOCATION CHART

FOR

POWER SUPPLY PP-7549/U

0.1

(4)

0.5

1.0

0.1

0.2

0.1

0.5

0.2

5.0

0.5

(2)

(3)

MAINTENANCE

FUNCTION

Inspect Test Calibrate Repair Repair Overhaul

Inspect Test Replace Repair

MAINTENANCE CATEGORY

(5)

TOOLS

AND

EQPT.

1 thru 3 1 thru 3

3 1 thru 3

3 2,3 3 3

3 1 thru 3 3 3

(6)

REMARKS

DRSEL-MA Form 6031, (1 Jul 76)

B-3

HISA-FM 2314-79

TM 11-6625-2978-14

TOOL OR TEST

EQUIPMENT

REF CODE

1 2 3

MAINTENANCE

Tektronix 1106, PP-7549/U Technical Manual

Specifications and Main Features

Frequently Asked Questions

User Manual