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TM 11-6130-243-35D E P A R T M E N T O F T H E A R M Y T E C H N
I C A L M A N U A L
DIRECT SUPPORT, GENERAL SUPPORT AND
DEPOT MAINTENANCE MANUAL
POWER SUPPLY PP-4606/G
This copy is a reprint which includes current
pages from Change 1.
H E A D Q U A R T E R S , D E P A R T M E N T O F T H E A R M
Y
6 FEBRUARY 1967
-
WARNING
DANGEROUS VOLTAGES EXIST IN THIS EQUIPMENT
High voltages and currents exist in this equipment. Serious
injury ordeath may result from contact with the input and output
connections. De-energize the equiqment before connecting or
disconnecting the load to bepowered, before changing jumper
connections, and before performing anymaintenance. Discharge all
capacitors before performing maintenance.
DON’T TAKE CHANCES!
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TM 11-6130-243-35C1
CHANGE
No. 1
HEADQUARTERSDEPARTMENT OF THE ARMYWASHINGTON DC, 3 December
1981
Direct Support, General Support, AndDepot Maintenance
ManualPOWER SUPPLY PP-4606/G
(NSN 6130-00-504-0327)
TM 11-6130-243-35, 6 February 1967, is changed as follows:1.
Title of the manual is changed as shown above.2. New or changed
material is indicated by a vertical bar in the margin of the
page.3. Remove and insert pages as indicated below:
Remove Insert
None . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . A through C (FRONT OF MANUAL)
i.. . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . .i/(ii blank)
1-1 and 1-2 . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . .1-1 and 1-2
A-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . .
. . .A-1(A-2 blank)
4. File this change sheet in front of the publication for
reference purposes.
By Order of the Secretary of the Army:
Official:
ROBERT M. JOYCEBrigadier General, United States Army
The Adjutant General
E. C. MEYERGeneral, United States Army
Chief of Staff
Distribution:To be distributed in accordance with DA Form 12-31,
Direct Support and General Support Maintenance
requirements for All Fixed and Rotor Wing Aircraft.
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TM 11-6130-243-35
S A F E T Y S T E P S T O F O L L O W I F S O M E O N E
I S T H E V I C T I M O F E L E C T R I C A L S H O C K
D O N O T T R Y T O P U L L O R G R A B T H E I N D I V I D U A
L
I F P O S S I B L E , T U R N O F F T H E E L E C T R I C A L P
O W E R
I F Y O U C A N N O T T U R N O F F T H E E L E C T R I C A
L
P O W E R , P U L L , P U S H , O R L I F T T H E P E R S O N T
O
S A F E T Y U S I N G A W O O D E N P O L E O R A R O P E O
R
S O M E O T H E R I N S U L A T I N G M A T E R I A L
S E N D F O R H E L P A S S O O N A S P O S S I B L E
A F T E R T H E I N J U R E D P E R S O N I S F R E E O F
C O N T A C T W I T H T H E S O U R C E O F E L E C T R I C A
L
S H O C K , M O V E T H E P E R S O N A S H O R T D I S T A N C
E
A W A Y A N D I M M E D I A T E L Y S T A R T A R T I F I C I A
L
RESUSCITATION
Change 1 A(B blank)
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TM 11-6130-243-35
WARNINGS
DANGEROUS VOLTAGES (220 vac, and 440 vac) exist in this
equipment. When equipment is operated with coversopen or removed,
DO NOT touch exposed connections or components. SERIOUS INJURY OR
DEATH MAYRESULT. Deenergize the equipment before connecting or
disconnecting the battery to be charged, and before per-forming any
maintenance. Follow all precautions listed in TB 385-4.
Avoid personal injury. Power Supply PP-4606/G weighs 375 pounds;
be careful when moving. A mechanical lift isrequired.
Adequate ventilation should be provided while using
TRICHLOROTRIFLUOROETHANE. Prolonged breathing ofvapors should be
avoided. The solvent should not be used near heat or open flame;
the products of decomposition aretoxic and irritating. Since
TRICHLOROTRIFLUOROETHANE dissolves natural oils, prolonged contact
with skinshould be avoided. When necessary, use gloves which the
solvent cannot penetrate. If the solvent is taken
internally,consult a physician immediately.
Change 1 C
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*TM 11-6130-243-35
T E C H N I C A L M A N U A L HEADQUARTERSDEPARTMENT OF THE
ARMY
No. 11-6130-243-35 WASHINGTON , DC, 6 February 1967
DIRECT SUPPORT, GENERAL SUPPORT, AND DEPOTMAINTENANCE MANUAL
POWER SUPPLY PP-4606/G(NSN 6130-00-504-0327)
ParagraphCHAPTER 1. FUNCTIONING OF EQUIPMENT
Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . 1-1lndex of Technical Publications.. . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . 1-2Block diagram . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. 1-3Input power . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . 1-4 Output circuit . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . 1-5Monitor circuit . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . 1-6
2. TROUBLESHOOTINGGeneral instructions . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . 2-1 Organization of troubleshooting
procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . 2-2 Test equipment required. . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . 2-3Localizing troubles . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-4Additional troubleshooting data... . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5Capacitor
test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-6General parts replacement techniques. . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . 2-7Replacement of diode rectifiers . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . 2-8 Adjustment of variable resistors R1 and R2 .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . 2-9
3. GENERAL SUPPORT TESTING PROCEDURESGeneral . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Test
equipment, tools, and materials. . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.Physical tests and inspections . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . .Power output, regulation, and ripple
tests at 220-volt input . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . .Insulation resistance test . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . .Output power test at
440-volt input. . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . .Test data summary . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . .
4. DEPOT OVERHAUL STANDARDSApplicability of depot overhaul
standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . .Test facilities required . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Power
output, regulation, ripple, and efficiency test at 220-volt input.
. . . . . . . . . . . . . . . . .Insulation resistance test . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.Output power test at 440-volt input.. . . . . . . . . . . . . . .
. . . . . . . . . . . . . .
3-13-23 - 33 - 43 - 53 - 63 - 7
4 - 14 - 24 - 34 - 44 - 5
APPENDIX References . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . .
Page
1-11-11-11-21-21-4
2-12-12-12-12-32-62-72-12-1
3-13-13-33-53-63-9
3-10
4-14-14-14-24-2A-1
Change 1 i/(ii blank)
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TM 11-6130-243-35
CHAPTER 1FUNCTIONING OF EQUIPMENT
1 - 1 . S c o p e
a. This manual contains direct support, general sup-port, and
depot maintenance instructions for PowerSupply PP-4606/G (power
supply). It includes instruc-tions appropriate for troubleshooting,
testing, andrepairing the equipment. It also lists tools,
materials,and test equipment required for maintenance, Func-tional
analysis of the equipment is covered in thischapter.
b. The complete technical manual for this equip-ment includes
TM11-6130-243-12.
c. You can help improve this manual. If you findany mistakes or
if you know of a way to improve theprocedures, please let us know.
Mail your letter or DAForm 2028 (Recommended Changes to
Publications andBlank Forms) direct to Commander, US
ArmyCommunications-Electronics Command, ATTN:DRSEL-ME-MQ, Fort
Monmouth, NJ 07703. In eithercase, a reply will be furnished direct
to you.
NOTEFor applicable forms and records, seeparagraph 1-3,
TM11-6130-243-12.
1-2. Index of Technical PublicationsRefer to the latest issue of
DA Pam 310-4 to determinewhether there are new editions, changes,
modificationwork orders (MWO’S) or additional publications
per-taining to the equipment.
1-3. Block Diagram(fig. 1-1)
Three-phase, wye-connected primary input power is ap-
plied to the input circuit consisting of circuit breakerswitch
CB1, the tap board, VOLTAGE ADJUST switchS2, indicator lamp DS1,
and power transformer T1. Thetap board connects the input
powerlines to the primarywindings of power transformer T1. Jumpers
are con-nected between various terminals on the tap board topermit
operation of the power supply from either 220-or 440-volt
alternating current (at) power mains. Withcircuit breaker switch
CB1 set to POWER ON, inputpower is applied through the jumpers on
the tap boardand VOLTAGE ADJUST switch S2 to the primarywindings of
stepdown power transformer T1 and in-dicator light DS1. The input
circuit to transformer Tl iswye-connected, the output circuit from
the transformeris delta-connected. VOLTAGE ADJUST switch S2
con-trols application of input power to specific taps of theprimary
windings of transformer T1. The ac outputvoltages from the
secondary windings of thetransformer is converted to a pulsating
direct current(dc) voltage by full-wave rectifiers CR1 through
CR6and filtered by the network consisting of capacitors C1through
C8 and inductor L1. Resistors R1 and R2 com-prise a load network
across the rectifiers. The powersupply current and voltage are
monitored by DIRECTCURRENT AMPERES meter M1 and DIRECT CUR-RENT
VOLTS meter M2. Resistor R3 is the ammetershunt resistor. Resistor
R4 is the meter movement seriesresistor used to establish the
deflection sensitivity of theammeter. AMMETER switch S1
(spring-loaded to theOFF position) connects the ammeter to the
output cir-cuit when depressed to the READ position.
Change1 1-1
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TM 11-6130-243-35
T M 6 1 3 0 - 2 4 3 - 3 5 - 1
1-4. Input Power(fig. 4-4).
a. The power supply is designed to operate
Figure 1-1. Power Supply PP-4606/G block diagram.
from either 220- or 440-volt, 60-cycle, 3-phasepower mains. To
provide for correct connec-tion of the power mains to the primary
wind-ings of input power transformer T1, a tapboard is provided on
the rear of the powersupply. Wire links are connected
betweenspecific terminals on the tap board, depend-ing upon the
voltage of the power mains fromwhich the power supply is to be
operated. Fig-ures 1-2 and 1-3 are simplified schematic dia-grams
that show how the primary windingsare wye-connected to the power
mains. Referto the complete schematic diagram (fig. 4-4)while
studying the two simplified schematicdiagrams. For simplicity,
VOLTAGE AD-JUST switch S2 is not shown on the simplifiedschematic
diagrams; however, assume that itis at the fully clockwise position
(HIGH) forthe discussions in b and c below.
b. When the power supply is arranged tooperate with 220-volt
input power, wire linksare connected between specific terminals
onthe tap board as shown by the short heavylines in figure 1-2. The
six primary windingsof input transformer T1 are thus
parallel-con-nected into a wye configuration which corre-sponds to
the wye configuration of the inputpower mains. When circuit breaker
switchCB1 is at POWER ON, input power is routedfrom the 220-volt
terminals of the circuitbreaker through the wire links on the
tapboard and the VOLTAGE ADJUST switch
1-2
(not shown on fig. 1-2) to each parallel-con-nected pair of
primary windings in each leg ofthe wye. VOLTAGE ADJUST switch S2
con-trols the voltage in the secondary windings oftransformer T1 by
controlling the number ofturns energized in the primary windings.
(En-ergized turns decrease and secondary windingvoltages increase
as switch S2 is turned clock-wise.)
c. When the power supply is arranged tooperate with 440-volt
input power, wire linksare connected between a different group
ofspecific terminals on the tap board as shownby the short heavy
lines in figure 1-3. Thesix primary windings of input transformer
T1are now series-connected into a wye configu-ration. When circuit
breaker switch CB1 is atPOWER ON, input power is routed from
the440-volt terminals of the circuit breakerthrough the wire links
on the terminal boardand the VOLTAGE ADJUST switch (notshown on
fig. 1-3) to each series-connectedpair of primary windings in each
leg of thewye.
1-5. Output Circuit(fig. 4-4)
a. The output circuit includes the three sec-ondary windings of
power transformer T1,diode rectifiers CR1 through CR6,
surge-sup-pressor capacitors C3 through C8, bleeder re-sistors R1
and R2, choke L1, and filter capaci-tors C1 and C2. The secondary
windings of thepower transformer are connected in a delta
-
TM6130-243-35-2
TM6130-243-35-3
TM 11-6130-243-35
Figure 1-2. Connections to power transformer primary windings
for220-volt input, simplified schematic diagram.
Figure 1-3. Connections to power transformer primary windings
for440-volt input, simplified schematic diagram.
1-3
-
TM6130-243-35-4
TM 11-6130-243-35
configuration as shown in the simplified sche-matic diagram (A,
fig. 1-4). Each secondarywinding applies an ac voltage to a bridge
rec-tifier circuit consisting of four of the sixdiodes CR1 through
CR6. The middle sec-ondary winding of transformer T1 (fig. 4-3)
isassociated with the bridge rectifier consistingof diodes CR2,
CR3, CR5, and CR6 as shownin the simplified schematic diagram (B,
fig.1-4). Similarly, the top secondary winding oftransformer T1 is
associated with diodes CR1,CR2, CR4, and CR5 while the bottom
wind-ing is associated with diodes CR1, CR3, CR4,and CR6. The
simplified schematic diagram(fig. 1-4) shows only those diodes
associatedwith the middle winding.
b. When the half-cycle of the ac voltage oc-curs, making
secondary winding terminal 9positive with respect to terminal 10
(B, fig.1-4), diodes CR3 and CR5 become forward-biased and diodes
CR2 and CR6 become re-verse-biased. Electrons flow from terminal
10through diode CR3, resistors R1 and R2 diodeCR5, terminal 9, and
to terminal 10. The cur-rent pulse thus produced causes a dc
voltageof the polarity indicated on figure 1-4 to ap-pear across
resistors R1 and R2. During theother half-cycle, diodes CR2 and CR6
becomeforward-biased and diodes CR3 and CR5 be-come reverse-biased.
Electrons flow from ter-minal 9 through diode CR2, resistors R1
andR2, diode CR6, terminal 10, and to terminal 9.This current pulse
also causes a dc voltageof the same polarity to appear across
resistorsR1 and R2.
c. The dc voltage pulses appearing acrossresistors R1 and R2 are
applied to the choke-input filter consisting of inductor L1 and
ca-pacitors C1 and C2. The filter networksmoothes the ripple and
assists in power sup-ply regulation. AS a result, the output
volt-age approaches the average value of voltageproduced by the
bridge rectifiers. Bleeder re-sistors R1 and R2 also provide a
dischargepath for capacitors C1 and C2.
Figure 1-4. Power supply output circuit, simplifiedschematic
diagram.
1-6. Monitor Circuit(fig. 4-4)
DIRECT CURRENT VOLTS meter M2 isconnected across the output of
the power sup-ply and monitors the output voltage. DIRECTCURRENT
AMPERES meter M1 monitorsoutput current whenever spring-loaded
AM-METER switch S1 is set to the READ (de-pressed) position. With
switch S1 de-pressed, load current flowing through low-re-sistance
shunt resistor R3 produces a smallvoltage drop which is
proportional to the cur-rent. Although the scale of DIRECT CUR-RENT
AMPERES meter M1 is marked to in-dicate amperes, the meter is
actually a milli-voltmeter which measures the voltage acrossshunt
R3. Resistor R4 is a calibrating resistorfor meter M1. When AMMETER
switch S1 isreleased to the OFF position, the switchcreates a short
circuit across R3, R4, and M1.
1-4
-
TM 11-6130-243-35
CHAPTER 2
TROUBLESHOOTING
Warning: When servicing the power supply, be extremely careful
of the high voltages.
2-1. General Instructions
Troubleshooting at the direct support,general support, and depot
maintenance cate-gories includes all the techniques outlined
fororganizational maintenance and any special oradditional
techniques required to isolate a de-fective part. Paragraph 2-4d
provides thetroubleshooting chart to be used by the re-pairman.
2-2. Organization of TroubleshootingProcedures
a. General. The first step in servicing a de-fective power
supply is to localize the fault,which means tracing the fault to
defective cir-cuit responsible for the abnormal indication.The
second step is to isolate the fault, whichmeans locating the
defective part or parts.Some defective parts, such as burned
resis-tors and shorted transformers, can often belocated by sight,
smell, and hearing. Most de-fective parts, however, must be
isolated bychecking voltages and resistance.
b. L.ocalization and Isolation. The first stepin tracing trouble
is to locate the circuit orpart at
(1)
(2)
fault by the following methods:Visual inspection. The purpose
ofvisual inspection is to locate faultswithout testing or measuring
cir-cuits. All meter indications or othervisual signs should be
observed andan attempt made to localize the faultto a particular
part.Operational test. Operational testsfrequently indicate the
general loca-tion of trouble. In many instances,the test will help
in determining the
(3)
(4)
exact nature of the fault. The op-erator’s daily preventive
maintenanceservices inspection chart (TM11-6130-243-12) contains a
good oper-ational test.
Troubleshooting chart. The trou-bleshooting chart (para 2-4d)
listssymptoms of common troubles andgives corrective measures (or
refer-ences). Such a chart cannot includeall trouble symptoms that
may oc-cur; therefore, the repairman shoulduse this chart as a
guide in analyzingsymptoms that may not be listed.
Resistor and capacitor color codediagrams. Color code diagrams
forresistors and capacitors (figs. 4-2and 4-3) provide pertinent
resist-ance, voltage rating, and toleranceinformation.
2-3. Test Equipment Required
The following chart lists test equipmentrequired for
troubleshooting Power SupplyPP-4606/G and the associated technical
man-uals.
Test equipment Technical manual
Multimeter TS-352B/U --- TM 11-5527Analyzer ZM-3A/U ------ TM
11-5043-12
2-4. Localizing Troubles
c. General. The troubleshooting chart (dbelow) outlines
procedures for localizingtroubles and for isolating troubles
within
2-1
-
TM 11-6130-243-35
the various circuits of the power supply. Re-fer to figures 2-1
through 2-4 for parts loca-tion. Refer to the schematic diagram
(fig. 4-4) to identify circuit components. Voltageand resistance
measurements are given inparagraph 2-5. Depending on the nature
ofthe operational symptoms, one or more of thelocalizing procedures
will be necessary. Whentrouble has been localized to a particular
cir-cuit, use voltage and resistance measurementsto isolate the
trouble to a particular part.
b. Use of Chart. When an abnormal symp-tom is observed in the
equipment, look for adescription of the symptom in the
Symptomcolumn and perform the corrective measure inthe Corrective
measures column.
c. Conditions to Test. All checks outlinedin the troubleshooting
chart are to be con-ducted with the power supply connected to a220-
or 440-volt power source, with the tapboard wired for use. The
output cables shouldbe connected to a load.
d. Troubleshooting Chart.
2-2
-
TM6130-243-35-6
TM 11-6130-243-35
Figure 2-1. Power supply, rear oblique view of right sidewith
right side panels removed.
2-5. Additional Troubleshooting Data
a. Voltage Outputs of Power TransformerT1. The voltage output
data of power trans-former T1 is provided as an aid to
trouble-shooting. The transformer has three second-ary windings,
designated by terminals 9 and10 for each secondary winding. Each
second-ary winding voltage for both 220- and 440-volt ac input and
for each setting of theVOLTAGE ADJUST switch is listed below:
2-3
-
TM6130-243-35-7
TM 11-6130-243-35
Figure 2-2. Power supply, rear view with rear panels
removed.
2-4
-
TM6130-243-35-8
TM 11-6130-243-35
Figure 2-3. Power supply, front view with bottom front panel
removed.
b. Dc Resistance of Transformers and power supply and when the
circuit breakerCoils. The dc resistance data ((3) below) is switch
is at POWER ON. Place the circuitprovided as an aid to
troubleshooting. When breaker switch to off (down) andusing the
data, observe the following: the input power cord.
Caution: Do not measure resistance of the (1) Before making
resistancewindings when input power is applied to the ments of the
windings,
disconnect
measure-determine
2-5
-
TM6130-243-35-9
TM 11-6130-243-35
Figure 2-4. Power supply, heat sink assembly removed from
unit.
that faulty operation is probablycaused by a faulty transformer
orcoil. To do this, follow the trouble-shooting procedures in
paragraph 2-4d.
(2) Do not use the resistance measure-ments as the sole basis
for discard-ing a transformer or coil as defective.Resistances may
vary from one trans-former or coil to another because ofbroad
winding tolerances duringmanufacture. The values given inthe chart
((3) below) are typicalaverage values for all groups oftransformer
windings and coils.
(3) Dc resistances of transformers andcoils are as follows:
2-6 Capacitor Test
Filter capacitors C1 and C2 are rated at10,000 microfarads (µf),
50 volts dc; capaci-tors C3 through C8 are rated at 2 µf, 100volts
dc. Test each capacitor (figs. 2-3 and2-4 with Analyzer ZM-3A/U.
Refer to the
2-6
-
schematic diagram (fig. 4-4) for connectionof the
capacitors.
2-7. General Parts ReplacementTechniques
All power supply parts, except diode recti-fiers, can be reached
and replaced easilywithout special procedures. The six
dioderectifiers must be replaced in accordance withthe specialized
procedure given in paragraph2-8. Refer to figures 2-1 through 2-4
for thelocation of all parts. Connect replaced itemsaccording to
the schematic diagram (fig. 4-4).
2-8. Replacement of Diode Rectifiers
a. The following chart lists the tools re-quired to replace the
diode rectifier in thepower supply.
b. The six diode rectifiers are mounted on aheat sink assembly
(fig. 2-4). When a diodeis removed, the replacement diode must be
ofthe same type and mounted with the same ori-entation as the
removed part. Diodes CR1,CR2, and CR3 are type 1N4587; diodesCR4,
CR5, and CR6 are type 1N4587R.
c. Replace any diode rectifier as follows:(1)
(2)
(3)
(4)
Before proceeding, make sure that thecircuit breaker switch is
in the off(down) position and that the inputpower cable is
disconnected from thepower mains.Remove the hardware that secures
thediode pigtail and capacitor pigtail tothe bus bar on the heat
sink. Do notdiscard hardware.Make note of the diode type;
diode1N4587 is color-coded white anddiode 1N4587R is color-coded
violet.Remove a defective diode by re-moving the nut and lockwasher
thatsecure the diode to the bus bar.
(5)
(6)
TM 11-6130-243-35
Apply a coating of Dow CorningHeat Sink Compound No. 340 tothe
mating flat surfaces on the heatsink only and replace the diode
withone of the same type. Install themounting hardware and torque
to 30inch-pounds; use the crowfootwrench and torsion wrench.Secure
the pigtail lug of the diodeand the pigtail of the capacitor tothe
bus bar on the heat sink; usethe hardware previously removed.
2-9. Adjustment of Variable ResistorsR1 and R2
a. With no load connected to the powersupply and VOLTAGE ADJUST
switch S2set to NOM. set the circuit breaker switchto POWER ON.
b. Check to see that DIRECT CURRENTVOLTS meter indicates 28.5
volts. If the in-dication is not 28.5 volts, set the circuit
break-er switch to off and perform the proceduresin c through h
below.
Warning: Do not touch the interior com-ponents of the power
supply unless the circuitbreaker switch is set to the off (down)
posi-tion.
c. Remove the top left side panel of thepower supply to gain
access to resistors R1and R2.
d. Loosen the sliding contacts on resistorsR1 and R2.
e. Reposition the sliding contacts slightly.
f. Set the circuit breaker switch to POWERON and check to see
whether DIRECT CUR-RENT VOLTS meter M2 indicates 28.5 volts.
g. Repeat the procedures in e and f aboveuntil DIRECT CURRENT
VOLTS meter in-dicates 28.5 volts; always turn the power sup-ply
off before adjusting resistor sliding con-tacts.
h. Set the circuit breaker switch to the offposition. Tighten
the sliding contacts on re-sistors R1 and R2; replace top left
panel ofthe power supply.
2-7
-
TM 11-6130-243-35
CHAPTER 3
GENERAL SUPPORT TESTING PROCEDURES
3-1. General
a. Testing procedures are prepared for useby field maintenance
shops and service organi-zations responsible for general support
main-tenance of electronic equipment to determinethe acceptability
of repaired equipment. Theseprocedures set forth specific
requirements thatrepaired equipment must meet before it is
re-turned to the using organization. These pro-cedures may also be
used as a guide for test-ing equipment that has been repaired at
directsupport, if the proper tools and test equip-ments are
available. A summary of the per-formance standards is given in
paragraph 3-7.
b. Comply with the instructions precedingeach chart before
proceeding to the chart. Per-
a. Test Equipment.
form each step in sequence. Do not vary thesequence. For each
step, perform all theactions required in the control
settingscolumns; then perform each specific test pro-cedure and
verify it against its performancestandard.
3-2. Test Equipment, Tools, and Materials
All test equipment, tools, and materials re-quired to perform
the testing proceduresgiven in this chapter are listed in a, b, and
c,below and are authorized under TA 11-17,Signal Field Maintenance
Shops; and TA11-100(11-17), Allowances of Signal CorpsExpendable
Supplies for Signal Field Mainte-nance Shops, (Continental United
States).
b. Tools. All the tools required are in-cluded in Tool Kit,
Electronic Equipment TK-100/G and Tool Kit, Electronic
EquipmentTK-105/G.
c. Materials.
3-1
-
3-3. Physical Tests and Inspections
a. Test Equipment and Materials. None re-quired.
b. Test Connections and Conditions. No
TM 11-6130-243-35
connections are necessary. Remove power sup-ply left and right
side panels.
c. Procedure.
3-3
-
TM6130-243-35-10
TM 11-6130-243-35
Figure 3-1. Connection diagram for power output, regulation, and
rippletests at 220-volt input.
3-4
-
3-4.
TM
11-6130-243-35
3-5
-
TM 11-6130-243-35
3-5. Insulation Resistance Test
a. Test Equipment. The only test equip-ment required is Ohmmeter
ZM-21A/U.
b. Test Connections and Conditions. Thistest is performed with
the PP-4606/G discon-nected from the ac power source. This
testchecks the insulation resistance of the primarywindings of
power transformer T1. The testis written for the PP-4606/G strapped
for220-volt ac operation.
c. Procedure.
(2) Connect the line lead of the ZM-21A/U to any terminal 1 of
the tapboard on the rear of the PP-4606/G.
(3) Operate the ZM-21A/U and ob-serve the indication on the
ZM-21A/U meter. The PP-4606/U meetsthe performance standard if the
ZM-21A/U meter reading is greaterthan 10 megohms.
(1) Connect the ground lead of theZM-21A/U to the frame of the
PP- (4) Disconnect the ZM-21A/U from the4606/G. PP-4606/G.
3 - 6
-
Figure 3-2.
TM
6130-243-35-11
TM
11-6130-243-35
3-8
-
3-6.
TM
11-6130-243-35
3-9
-
TM 11-6130-243-35
3-7. Test Data Summary
a. Input.(1) Voltage ----------220 or 440 volts.(2) Frequency
----------60 cps.(3) Phase -------------- Three, wye-connected.(4)
Current (each leg 18 amperes maximum for
at full load) 220-volt input or 9 am-peres for 440-volt
input.
b. Output.
(1) Voltage (VOLT- 28.5 volts dc + 2.5.AGE ADJUSTswitch S2 set
toNOM)
(2) Current (maxi- 200 amperes + 15.mum)
(3) Ripple voltage 5 percent maximum.(4) Regulation 9 percent
maximum.
c. Formulas Used.
Where:E is dc output voltage measured under no-load
NLconditions.
E is dc output voltage measured under full-loadL
conditions.E is the measured ripple voltage.
RMSE is the measured dc output voltage.
DC
3-10
-
TM 11-6130-243-35
CHAPTER 4
DEPOT OVERHAUL STANDARDS
4-1. Applicability of Depot Overhaul b. Technical Publication.
The technical pub-Standards lication applicable to the equipment to
be
The tests outlined in this chapter are de- tested is
TM11-6130-243-12.
signed to measure the performance capabil- C. Modification Work
Orders. Perform allity of a repaired equipment. Equipment that
modification work orders applicable to thisis to be returned to
stock should meet the equipment before making the tests
specified.standards given in these tests. DA Pam 310-4 lists all
available MWO’s.
a. Repair Standards. Applicable proce-dures of the depots
performing these tests 4-2. Test Facilities Requiredand the general
standards for repaired elec-tronics equipment given in TB SIG
355-1, TB
The following items are required for de-
SIG 355-2, and TB SIG 355-3 form a part ofpot testing.
the test requirements. a. Test Equipment.
b. Materials.
4-3. Power Output, Regulation, Ripple,and Efficiency Test at
220-Volt Input
a. With 220-volt, 3-phase, 60-cps inputpower, connect the
equipment as shown in fig-ure 4-1.
b. With no load connected to the powersupply, set the PP-4606/G
VOLTAGE AD-
JUST switch to NOM and the circuit breakerswitch to POWER ON.
The TS-352B/Ushould indicate 28.5 volts + 2.5. If necessary,set the
VOLTAGE ADJUST switch to LOWor HIGH to obtain 28.5 volts + 2.5 on
the TS-352B/U. The DIRECT CURRENT VOLTSmeter on the PP-4606/G
should indicate with-in ±5 percent of the reading on the
TS-352B/U.
c. Set the circuit breaker switch on the PP-4606/G to off.
d. Connect the load (three each, 0.41-ohm,3,400-watt resistors
connected in parallel for atotal resistance of 0.1366 ohm). Connect
theTV-100 to measure the output current. Setthe circuit breaker
switch on the PP-4606/G
4-1
-
TM 11-6130-243-35
to POWER ON. The TS-352B/U should in-dicate within 9 percent of
the reading obtainedin b above. The TV-100 should indicate
200amperes ±15. Depress the AMMETERswitch on the PP-4606/G.
Indication on theDIRECT CURRENT AMPERES metershould be within ±5
percent of the currentreading obtained on the TV-100.
e. The ME-30(*)/U should indicate lessthan 1.3 volts.
f. Both wattmeters (TS-430/U) should in-dicate less than 7,400
watts total.
g. Set the circuit breaker switch on the PP-4606/G to OFF and
disconnect the equip-ment.
4-4. Insulation Resistance Test
The depot overhaul standards insulationresistance test
procedures are the same asthose for general support (para 3-5).
Equip-ment that meets the performance standardsstated in paragraph
3-5 will furnish satisfac-tory insulation resistance equivalent to
thatof new equipment.
4-5. Output Power Test at 440-Volt Input
The depot overhaul standards output powertest procedures at
440-volt input are the sameas those for general support (para
3-6).Equipment that meets the performancestandards stated in
paragraph 3-6 will fur-nish satisfactory output power at 440-volt
in-put equivalent to that of new equipment.
4-2
-
TM6130-243-35-12
TM 11-6130-243-35
Figure 4-1. Connection diagram for power output, regulation,
ripple,and efficiency at 220-volt input.
4-3
-
TM 11-6130-243-35
Figure 4-2. Color code markings for MIL STD resistors.
4-4
-
Figure 4-4.
TM6130-243-35-5
I
-
Figure 4-3.
-
TM 11-6130-243-35
APPENDIX
REFERENCES
DA Pam 310-4TB SIG 355-1TB SIG 355-2TB SIG 355-3TB
385-4TM11-487H-l/lTM11-2050TM11-5043-12
TM11-6130-243-12TM11-6625-320-12
TM11-6625-366-15
lndex of Technical Publications.Depot Inspection Standard for
Repaired Signal Equipment.Depot Inspection Standard for Refinishing
Repaired Signal Equipment.Depot Inspection Standard for Moisture
and Fungus Resistant Treatment.Safety Precautions for Maintenance
of Electrical/EIectronic Equipment.Military Standardization
Handbook: Electronic Test Equipment.Test Set I-48B and Ohmmeter
ZM-21A/U.Operator’s and Organizational Maintenance Manual For
Analyzers, ZM-3/U
and ZM-3A/U.Organizational Maintenance Manual: Power Supply
PP-4606/G.Operator’s and Organizational Maintenance Manual:
Voltmeter, Meter
ME-30A/U and Voltmeters, Electronic ME-30B/U, ME-30C/U,
andME-30E/U.
Operator’s, Organizational, Direct Support, General Support, and
DepotMaintenance Manual: Multimeter TS-352B/U.
Change 1 A-1/(A-2 Blank)
-
TM 11-6130-243-35
By Order of the Secretary of the Army:
Official:
KENNETH G. WICKHAM,Major General, United States Army,
TM 11-6130-243-35
HAROLD K. JOHNSON,General, United States Army,Chief of
Staff.
The Adjutant General.
Distribution:
To be distributed in accordance with DA Form 12-36, unclassified
requirements for Direct and GeneralSupport maintenance literature
for all Rotor Wing Accounts (2) plus USASESCS (60).
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P I N : 0 2 0 6 7 9 - 0 0 0
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