TM 11-6130-236-35DEPARTMENT OF THE ARMY TECHNICAL MANUAL

DS, GS, AND DEPOTMAINTENANCE MANUAL

CHARGER, BATTERYPP-1451/G

(NSN 6130-00-985-8157)

This copy is a reprint which includes currentpages from Change, The title was changed asshown above by Change 1.

HEADQUARTERS, DEPARTMENT OF THE ARMY27 MAY 1966

TM 11-6130-236-35

TECHNICAL MANUAL

}

HEADQUARTERSDEPARTMENT OF THE ARMY

No. 11-6130-236 WASHINGTON, DC, 27 May 1966

DS, GS, AND DEPOT MAINTENANCE MANUAL

CHARGER, BATTERY PP-1451/G(NSN 6130-00-985-8157)

REPORTING OF ERRORSYou can help improve this manual by calling attention to errors andrecommending improvements and stating your reasons for the recom-mendations. Your letter or DA Form 2028 (Recommended Changes toPublications and Blank Forms) should be mailed direct to Commander,US Army Communications and Electronics Materiel Readiness Com-mand, ATTN: DRSEL-MA-Q Fort Monmouth, NJ 07703. A reply will befurnished direct to you.

Paragraph

CHAPTER 1. FUNCTIONING OF EQUIPMENTScope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1Index of equipment publications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2Block diagram analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3Circuit analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

2. TROUBLESHOOTINGGeneral instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1Organization of troubleshooting procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2Test equipment required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3Localizing troubles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4Tests for open fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5Additional troubleshooting data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6General parts replacement techniques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7Adjustment of variable resistors R1, R2, R3, and R4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8

3. GENERAL SUPPORT TESTING PROCEDURESGeneral . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1Test equipment, tools, and materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2Physical tests and inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3Twenty-eight volt output, regulation, ripple, and efficiency test . . . . . . . . . . . . . . . . . . . . . . . . 3-4Two hundred and thirty volts, 60-cps, input power test..... . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5One hundred and fifteen volts, 400-cps, input power test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6Two hundred and thirty volts, 400-cps, input power test.... . . . . . . . . . . . . . . . . . . . . . . . . . 3-7Test data summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

4. DEPOT OVERHAUL STANDARDSApplicability of depot overhaul standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1Applicable references . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2Test facilities required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . 4-4

APPENDIX REFERENCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-11-11-11-2

2-12-12-12-22-32-32-42-4

3-13-13-33-53-73-9

3-113-12

4-14-14-14-1A-1

*This manual supersedes TM 11-6130-236-15, October 1965.

Change 1 i

TM 11-4130-236-35

CHAPTER 1

FUNCTIONING OF EQUIPMENT

1-1 Scopea. This manual contains direct support, gener-

al support, and depot maintenance instructionsfor Charger, Battery PP-1451/G (battery charg-er). It includes instructions appropriate for trou-bleshooting, testing, and repairing theequipment. It also lists tools, materials, and testequipment required for maintenance. Functionalanalysis of the equipment is covered in this chap-ter.

b. The complete technical manual for thisequipment includes TM 11-6130-236-12.

Note. For applicable forms and records, see paragraph 1-3,TM 11-6130-236-12.

1-2. Index of Equipment PublicationsRefer to the latest issue of DA Pam 310-4 to

determine whether there are new editions,changes, or additional publications pertaining tothe equipment. DA Pam 310-4 is an index ofcurrent technical manuals, technical bulletins,supply manuals (types 7, 8, and 9), supply bulle-tins, lubrication orders, and modification workorders that are available through publicationssupply channels. The index lists the individualparts (-10, -20, -35P, etc.) and the latest changesto and revisions of each equipment publication.

1-3 Block Diagram Analysis(fig. 1-1)

a. Input power of 115 volts alternating current(at) or 230 volts ac at 50 cycles per second (cps), 60cps, or 400 cps is applied to circuit breaker CB1.With CB1 at the ON position, input power isapplied through the appropriate input voltageselector linkage to transformer T1.

b. The input voltage selector consists of twoshorting links. With the linkage in the 115 acposition, the two primary windings of transform-er T1 are connected in parallel. With the linkagein the 230 ac position, the two primary windingsof transformer T1 are connected in series.

c. Blower fan motor B1 (rated at 115 volts ac,single phase) is connected across one of the pri-mary windings of T1 to insure 115-volt ac supplyregardless of input voltage linkage connections.

d. The input frequency selector linkage con-sists of four shorting links. These links are usedto connect for either 50/60 or 400 cps. All fourlinks must be in the same position (either 50/60or 400). There is one link for each of the fourmagnetic amplifiers (L1 through L4).

e. Each of two transformer T1 secondary wind-ings is connected to a full-wave bridge rectifier,with the gate windings of two magnetic amplifi-ers forming a part of each bridge in conjunctionwith two of the four diode rectifiers.

Change 1 1-1

TM 11-4130-236-35

f. The two magnetic amplifiers are used inpush-pull as control for each full-wave rectifier.The first and second control windings of eachmagnetic amplifier are used in conjunction withregulating diodes as part of the regulation cir-cuit. Changes in current flow in the first andsecond control windings cause proportional im-pedance changes in the gate windings to controlthe rectifier output voltage.

g. The output of each bridge rectifier appearsacross filter networks consisting of half a dualwinding choke, L5 (sections A and B), and fivefilter capacitors. Protective fuses are used toprevent equipment damage due to filter capaci-tor failure (shorting).

h. The outputs of the filter networks are con-nected to bleeder resistors. The bleeder resistorsare connected to switch 28V-S2-56V. Withswitch 28V-S2-56V set to the 28V position, thebleeder resistors are connected in parallel. Withswitch 28V–S2-56V set to the 56V position, thebleeder resistor are connected in series.

i. In the bleeder resistor circuit, VOLTAGEADJUST control R8 is used to feed back a controlcurrent through a Zener diode to the first controlwinding of the magnetic amplifiers. A fuse isused to prevent excessive current through theZener diode. Variation of the control currentthrough the first control windings will cause aproportional change in the output voltage.

j. The outputs of each filter network are fed tothe input of a contractor. The coils of the contrac-tors are energized by the output of full-wavebridge rectifier CR10 through CR13 in a thirdsecondary winding of transformer T1.

k. When the contractors are energized, the fil-tered output of each rectifier is connected to theoutput voltage selector linkage. With the linkageset to 28V, the two outputs are connected inparallel. With the linkage set to 56V, the twooutputs are connected in series. The output volt-age selector linkage consists of two shortinglinks.

l. The positive output is coupled through OUT-PUT CURRENT meter Ml shunt to the + OUT-PUT terminal on the front panel. (PRESS TOREAD switch S3 must be actuated to determinethe current output of the battery charger.)

m. OUTPUT VOLTAGE meter M2 is connectedacross the contacts of the output voltage selectorlinkage so that the output voltage may be moni-tored.

n. Separate regulating circuits are provided forvoltage variations due to load. With NORMALCHARGE switch S1 set to NORMAL, theregulating circuit detect changes in the voltagedrop across the filter choke. These voltage changescause current variations in a control winding tomaintain the selected voltage at a maximumoutput current of 50 amperes for 28-volt operation,or 25 amperes for 28-volt operation, or 25 amperesfor 56-volt operation. With NORMAL-CHARGEswitch S1 set to CHARGE, the maximum currentoutput is between 70 and 80 amperes for 28-voltoperation, or between 35 and 40 amperes for 56-volt operation.

1-4. Circuit Analysis(fig. 4-4)

a. Power Supply. Charger, Battery PP-1451/Gcan be operated from either a 115-volt or 230-voltac source, at 50, 60, or 400 cps. The input power isconnected to pins A and B of J1 and appliedthrough dual power switch and circuit breakerCB1A and CB1B to the two primaries of powertransformer T1. Power switch and circuit breakerCB1 is the power switch for the equipment and, inaddition, provides overload protection. The twoprimaries of T1 are interconnected through linksat T1A and T1B to enable parallel connection (115volts ac) or series connection (230 volts at). Blowerfan motor B1 is connected across pins 3 and 4 of theprimary of T1 and provides cooling for the interiorareas of the battery charger. Capacitor Cl permitsB1 to be self-starting. Capacitors C18, C19, C20, andC21 are used to suppress radiofrequencies thatmay be generated within the power supply.Terminal C on J1 provides a common (ground)connection for the input power.

1-2

Figure 1–1. Block diagram

1 - 3

TM 11-6130-236-35

(5)

(2)

(3)

(4)

1 4

115-volt operation to provide 60 am-peres of overload protection. For230-volt input power, the links o fT1A and T1B connect both primarywindings of T1 in series. Both 30-ampere circuit breakers are nowplaced to provide 30 amperes ofoverload protection.The ac output of T1 is steppeddown to approximately 42 volts ac.The ac voltage at terminals 5 and6 of T1 is applied to a full-wavebridge rectifier consisting of CR1through CR4 and toroid gate wind-ings of magnetic amplifiers L1 andL2. The ac voltage at terminals 7and 8 of T1 is applied to a secondfull-wave bridge rectifier consistingof CR5 through CR8 and the gatewindings of magnetic amplifiers L3and L4. A third winding of T1, ter-minals 9 and 10, provide 30 volts acto full-wave bridge rectifier CR10through CR13.The pulsating dc voltage output ofrectifiers CR1 through CR4 is ap-plied to a filter network consistingof choke L5A and filter capacitorsC6, C7, C8, C13, and C14. Theoutput of CR5 through CR8 is ap-plied to a filter network consistingof choke L5B and filter capacitorsC9, C10, C11, C15, and C16. T h eoutput of CR10 through CR13 doesnot require filtering. Fuses F1through F4 and F6 through F9 (30-ampere rating) are used to preventoverload damage to equipment.The filtered dc output of CR1through CR4 is connected to ableeder resistor network consistingof R5, R6, and R7, to a contact ofswitch 28V-S2-56V and to contactsof relay K1. The filtered dc outputof CR5 through CR8 is connected tobleeder resistor network R8, R9, andR10, to a second contact switch 28V–S2–56V and to contacts of relay K2.The output of CR10 through CR13is applied to indicator lamp DS1 andto the coils of K1 and K2.

(6)

The two filtered dc outputs of t h efull-wave bridge rectifiers can b econnected in series (56-volt dc op-eration) or in parallel (28-volt dcoperation). This is accomplished bypositioning both 28 DC OUTPUT 56links to the correct 28 or 56 posi-tion. The 28V–S2–56V switch mustbe set to agree with the position se-lected for the 28 DC OUTPUT 56links. With the 28V–S2–56V switchset to 56V, all bleeder resistors areconnected in series. With 28V-S2-56V switch set to 28V, bleeder resis-tors R5, R6, and R7 are connectedin parallel with bleeder resistor R8,R9, and R10.

The voltage output of the batterycharger is indicated on OUTPUTVOLTAGE meter M2 with a rangeof 0 to 75 volts dc. The currentoutput is indicated on OUTPUTCURRENT meter Ml with a rangeof 0 to 75 amperes. PRESS TOREAD switch S3 must be depressedto obtain a reading on Ml.

b. Balance and Regulation Circuits (S1 Setto NORMAL Position).

(1)

(2)

Variable resistor R1 is adjusted t obalance the outputs of both full-wave bridge rectifiers by balancingthe differences in impedance amongthe four control windings (terminals4 and 5 of L1 through L4). Vari-able resistor R2 is adjusted to bal-ance the outputs of both full-wavebridge rectifiers by balancing t h edifferences in impedance among thefour control windings (terminals 6and 7 of L1 through L4).

Output voltage regulation is achievedby initially setting VOLTAGE AD-JUST R8 for the desired outputvoltage of the battery charger. Thissetting will bias the Zener diodeCR15 for conduction with the mini-mum point set by R8 resulting in aminimum flow of current throughCR15 to a maximum point set by R8

TM 11-6130-236-35

resulting in a higher value of cur-rent flow through CR15. A decreasein the load to the battery chargerwill result in an increase of outputvoltage, and the potential acrossZener diode CR15 increases. Thisincrease in potential across CR15will cause a rise in current f1owthrough CR15 and control windingterminals 4 and 5. Simultaneously,an increase in current flows throughCR14 and control winding terminals6 and 7. The current increasethrough the control winding ter-minals 4 and 5 and 6 and 7 will in-crease its impedance and cause a de-crease of current flow through t h egate winding terminals 1, 2, and 3.The gate windings are a part of thefull-wave bridge rectifiers; thereforethe decrease of current through thegate windings results in a decreaseof voltage output of the full-wavebridge rectifiers to the voltage valueinitially set on VOLTAGE ADJUSTR8. An increase in the load to thebattery charger will result in a de-crease of output voltage and t h epotential across Zener diode CR15decreases. This decreases in poten-tial across CR15 will cause a de-crease in current flow t h r o u g hCR15 and control winding terminals4 and 5. Simultaneously, a decreasein current flows through CR14 andcontrol winding terminals 6 and 7.The d e c r e a s e in current throughcontrol winding terminals 4 and 5and 6 and 7 will decrease its imped-ance and cause an increase of cur-rent to flow through gate windingterminals 1, 2, and 3. The gatewindings are a part of the full-wavebridge rectifiers; therefore the in-crease of current through the gatewindings results in an increase ofvoltage output o f the fu l l -wavebridge rectifiers to the voltage value

initially set on VOLTAGE ADJUSTR8.

(3) Capacitors C2 and C4 in full-wavebridge rectifiers CR1 through CR4,and capacitors (23 and C5 in full-wave bridge rectifiers CR5 throughCR8 are used to bypass the highfrequency harmonics generated inthe magnetic amplifiers (LI throughL4). If these harmonics are not by-passed, a slight reduction in the out-put gain of the magnetic amplifiersmay result. Capacitors C22, C23,C24, and C25 are used to suppressthe switching transients of CRIthrough CR8.

c. Balance, Regulation, and Current Limit-ing Circuits (S1 Set to CHARGE Position).The balance and regulation circuits are thesame as discussed in b above, except for re-moval of variable resistor R4 and diode CR14from the series circuit of control winding ter-minals 6 and 7. Instead, variable resistor R3and diode CR9 are used in the series circuitof control winding terminals 6 and 7. Withno load applied to the battery charger, diodeCR9 is biased to cutoff and no current flowsthrough control winding terminals 6 and 7.With a load applied to the battery charger,diode CR9 is forward biased and currentflows through control winding terminals 6and 7. This circuit permits output currentsconsiderably higher than 50 amperes for 28-volt operation and 25 amperes for 56-vo1t op-eration (maximum current output with S1 setto the NORMAL position). With S1 set tothe CHARGE position, the maximum outputcurrent can be as high as 75 to 80 amperesfor 28-volt operation and 37.5 to 40 amperesfor 56-volt operation. Under this condition,the high current flowing through controlwinding terminals 6 and 7 will increase theimpedance of gate winding terminals 1, 2,and 3 and result in an output voltage thatis too low (approach 0 volt) to be useful.Capacitor C12 bypasses the ac voltage super-imposed on the dc voltage and prevents theac voltage from affecting regulation.

1-5

TM 11-6130-236-35

CHAPTER 2

TROUBLESHOOTING

Warning: When servicing the battery charger, beextremely careful of the high voltages.

2-1. General Instructions

Troubleshooting at the direct support, generalsupport, and depot maintenance level includes allthe techniques outlined for organizational main-tenance and any special or additional techniquesrequired to isolate a defective part. Paragraph2-4d provides the troubleshooting chart to be usedby the repairman.

2-2. Organization of TroubleshootingProcedures

a. General. The first step in servicing a defectivebattery charger is to localize the fault. Localiza-tion means tracing the fault to a defective circuitresponsible for the abnormal condition. The sec-ond step is isolation. Isolation means the locatingof the defective part or parts. Some defectiveparts, such as burned-out resistors and arcingtransformers, can oft in be located by sight, smell,or hearing. Most defective parts, however, mustbe isolated by checking voltages and resistance.

b. Localization and Isolation. The first step intracing trouble is to localize the defective stage byone of the following methods:

(1)

(2)

Visual inspection. The purpose of visualinspection is to locate faults without test-ing or measuring circuits. All meter indi-cations or other visual signs should beobserved and an attempt made to localizethe fault to a particular part.Voltage and resistance measurements. Usethe voltage and resistance values given inparagraph 2-6 and compare them withreadings taken.

(3)

(4)

(5)

Operational test. Operational test fre-quently indicate the general location oftrouble. In many instances, the test willhelp in determining the exact nature ofthe fault. The daily preventive mainte-nance checks and services chart (TM11-6130-236-12) contains a good oper-ational test.Troubleshooting chart. The troubleshoot-ing chart (para 2–4d) lists symptoms ofcommon troubles and gives (or references)corrective measures. Such a chart obvi-ously cannot include all trouble symptoms that may occur. The repairmanshould use this chart as a guide in analyz-ing symptoms that may not be listed.Resistor and color code diagrams. Colorcode diagrams for resistors and capacitors(figs. 4-1 and 4-2) provide pertinent resist-ance, voltage rating, and tolerance infor-mation.

2-3. Test Equipment RequiredNote. Continue using the test equipment listed below until

new test equipment, listed in the latest Maintenance Alloca-tion Chart (MAC) of TM 11-6130-236-12, becomes available.

a. Multimeter TS-352/U and Analyzer ZM-3/Uare required for troubleshooting. MultimeterTS-352/U is used for continuity tests, resistancemeasurements, and ac or dc voltage measure-ments. Analyzer ZM-3/U is used to test thecapacitors.

b. The following test equipment and materialsare required to perform the adjustment proce-dures given in paragraph 2-8:

(1) Multimeter ME-87/U (2 required), Feder-al stock No. 6625-223-5248.

Change 1 2-1

TM 11-6130-236-35

(2)

(3)

(4)

(5)

(6)

Toggle switch (2 required), Federal stockNo. 5930-823-2041.Knife switch (2 required), Federal stockNo. 5930-224-4928.Resistance element, 0.58-ohm, 3,350-watt,Federal stock No. 5905-280-0374.Resistance element, 0.86 ohm, 2,150-watt,Federal stock No. 5905-185-8450.Resistance element, 1.36 ohm, 2,150-watt,Federal stock No. 5905-186-8451.

2—4. Localizing Troubles

a. General. Procedures for localizing and iso-lating troubles within the various circuits of thebattery charger are given in the troubleshootingchart (d below). Refer to figure 4-3 for componentlocations. Refer to the schematic diagram (fig.4-4) to identify circuit components. Voltage andresistance measurements are given in paragraph2-6. Depending on the nature of the operational

symptoms, one or more of the localizing proce-dures will be necessary. When trouble has beenlocalized to a particular circuit, use resistanceand voltage measurements to isolate the troubleto a particular part.

b. Use of Chart. The troubleshooting chart isdesigned to supplement the operational checksdetailed in TM 11-6130-236-12. If previous oper-ational checks have resulted in reference to aparticular item of this chart, go directly to thereferenced item. If no operational symptoms areknown, start with item 5 of the daily preventivemaintenance checks and services chart (TM11-6130-236-12) and proceed until a troublesymptom appears.

c. Conditions to Tests. All checks outlined inthe troubleshooting chart are to be conductedwith the battery charger connected to a powersource. Always remove input power before mak-ing any continuity checks with ohmmeter.

d. Troubleshooting Chart.

Symptom

1. Indicator lamp DS1 does notlight and fan motor B1 doesnot start when power switchand circuit breaker CB1 isset to ON.

2. Indicator lamp DS1 lights andfan motor B1 does not opera-ate.

3. Fan motor B1 operates andindicator lamp DS1 does notlight.

4. Indicator lamp DS1 lights butno output voltage is present.

5. Erratic output with S1 inNORMAL position. Correctoutput with S1 in CHARGEposition.

Probable trouble

DO ac power is applied to batterycharger.

Defective CB1.

Defective B1.

Power transformer T1 secondarywinding terminals 9 and 10open.

Defective full-wave bridge rectifierdiodes CR1O through CR13.

Open in output circuit.

Defective power transformer T1.Defective magnetic amplifiers L1

through L4.

Defective resistor R4.

Defective diode CR14.

Corrective measures

Check for input voltage.

Check CB1; replace if defective.

Replace B1.

Check for continuity across termi-nals 9 and 10 of T1. ReplaceT1 if necessary.

Check CR1O through CR13. Re-place defective diode.

Check for loose connections,broken lead, or faulty compon-ent.

Replace power transformer T1.Replace defective magnetic amplif-

ier L1 through L4. (Defectivemagnetic amplifiers must be replaced in matched pairs. L1 andL3 are one matched pair. L2and L4 are another matchedpair.

Replace R4.

Replace CR14.

2 - 2

TM 11-6130-236-35

Symptom Probable trouble Corrective measure.

6. Erratic output output with S1 inCHARGE position. Correctoutput with S1 in NORMALposition.

7. Battery charger cannot bebalanced during adjustmentprocedure (para 2–8).

2-5. Tests for Open Fuses

a.. When to Check.

Defective resistor R3.

Defective diode CR9.

Defective capacitor C12.Defective variable resistor R1.

Defective diode CR15.Defective capacitor C17.Defective VOLTAGE ADJUST re-

sistor R8.Defective variable resistor R2.Defective diode CR14.Defective variable resistor R4.Defective winding in one of the

magnetic amplifiers (L1, L2, L3,or L4).

(1)

(2 )

When any one of fuses F1 throughF4 or F6 through F9 opens continu-ously with no load connected to thebattery charger or when there is nodc output from the battery charger.When fuse F5 opens during opera-tion (S1 in NORMAL orCHARGE position).

b. Conditions for Tests.(1) Disconnect the external] p o w e r

sources connected to receptacle J 1.(2) Disconnect any load connected to the

DC OUTPUT terminals.(3) Remove the covers and panels f o r

access to the components.

c. Tests. Make the tests and perform thecorrective measures if fuse F1, F2, F3, F4,F6, F7, F8, or F9 is open and the capacitortested is defective.

Fuse Capacitor to test Corrective measure.

F1F2F3F4F6F7F8F9

C6C7C8C13 and C14C9C10C11C15 and C16

Replace C6.Replace C7.Replace C8.Replace C13 and/or C14.Replace C9.Replace C10.Replace C1l.Replace C15 or C16.

Replace R3.

Replace CR9.

Replace C12.Check R1 and replace if necessary.

Replace CR15.Replace C17.Check R8 and replace if necessary.

Check R2 and replace if necessary.Replace CR14.Check R4 and replace if necessary.Check winding of L1, L2, L3, and

L4 (para 2-6) and replace ifnecessary. (Defective magneticamplifiers must be replaced inmatched pairs. (L1 and L3are one matched pair. L2 andL4 are the other matched pair).

d. Additional Tests. If fuse F5 is open,proceed as follows:

(1)

(2)

(3)

Test capacitor C17 and replace i fdefective.Test Zener diode CR15 and replaceif defective.

Caution: Magnetic amplifiers mustbe replaced in matched pairs. Mag-netic amplifiers L1 and L3 are onematched pair; magnetic amplifiers L2and L4 are the other matched pair.Test magnetic amplifiers L1, L2, L3,and L4 (para 2–6). If a magneticamplifier is defective, replace t h edefective magnetic amplifier.

2-6. Additional Troubleshooting Dataa. Voltage Output of Power Transformer

T1. The voltage output data of power trans-former T1 are provided as an aid to trouble-shooting. The voltages of T1 secondarywindings are listed below:

Secondary winding terminals Ac voltage indication(approx)

5-6 427–8 429-10 30

b. Dc Resistances of Transformer, FilterChokes, Relays, and Magnetic Amplifiers. Thedc resistance data ( (3) below) are provided

2-3

TM 11-6130-236-35

as an aid to troubleshooting. When using thedata, observe the following precautions:

Caution: Do not measure resistance wheninput power is applied to the battery chargerand when the power switch and circuit break-er is at ON. Disconnect the power plug andplace the power switch and circuit breaker toOFF.

(1)

(2)

(3)

Before making resistance measure-ments, determine whether faulty op-eration is caused by a faulty trans-former, filter choke, relay or magne-tic amplifier. To do this, follow thetroubleshooting procedures as out-lined in paragraph 2–4dDo not use the resistance measure-ments as the sole basis to determinethat a transformer, filter choke, re-lay, or magnetic amplifier is defec-tive. Resistances may vary from onetransformer, filter choke, relay, ormagnetic amplifier to another, be-cause of broad winding tolerancesduring manufacture. The valuesgiven in the chart ( (3) below) aretypical average values.Dc resistances of transformed, filterchokes, relays, and magnetic ampli-fiers are as follows:

Transformer, filterchokes, and relays I Terminals I Resistance (ohms}

T1 l-2 Less than 13-4 Less than 15-6 Less than 17-8 Less than 19–10 Less than 1

3-4 Less than 1L5A 1-2 Less than 1

K1 X1-X2 110K2 X1-X2 110

L1, L2, L3, 1-2 Less than 1and L4 2-3 Less than 1

4–5 376-7 3

2–7. General Parts ReplacementTechniques

The battery charger parts can be reachedand replaced without special procedures. Referto figure 4–3 for the location of parts. When

2-4

soldering connections to the diodes, solderquickly; use a heat sink (such as long-nosedpliers) between the soldered joint and thediode.

2-8. Adjustment of Variable ResistorsR1, R2, R3, and R4

(fig. 2-1)

Caution: Be sure the battery charger isconnected as specified in paragraph 2-3, TM11-6130-236-12.

Perform the procedures given below aftermajor repair of the battery charger or whenthe input power source to be used ischanged from 50/60 to 400 cps; or from400 to 50/60 cps.

a. Resistors R1 and R2, Magnetic Ampli-fiers Current Balance Adjustment.

(1)

(2)

(3)

(4)

Remove both of the 28 DC OUT-PUT 56 links and connect the nega-tive terminals of each of Multime-ters ME–87/U (ammeter) connectedas ammeters to each of the terminalsmarked 28.Connect the positive terminals ofeach of the ammeters to each of theassociated unmarked terminals a sshown in figure 2–1.Remove the shorting links fromTB1 and TB2.Connect toggle switches to TB1 andTB2 as follows:

(a.)

(b)

(c)

(d)

The center terminal of one toggleswitch to terminal 2 of TB1 andthe center terminal of the othertoggle switch to terminal 2 ofTB2.Terminal 1 on TB1 to the leftterminal of the toggle switch con-nected to TB1 and terminal 1 onTB2 to the left terminal of thetoggle switch connected to TB2.Terminal 3 on TB1 to the rightterminal of the toggle switch con-nected to TB1 and terminal 3 onTB2 to the right terminal of thetoggle switch connected to TB2.Set both toggle switches to openposition.

(5)

(6)

(7)

(8)

(9)

(10)

(11)

(12)

Set the NORMAL-CHARGE switchto NORMAL, the 28V-S2-56Vswitch to 28V, and the VOLTAGEADJUST control fully counterclock-wise.Connect the 1/4-load resistors (1.36-ohm in series with 0.86-ohm, total2.22-ohms resistance) in series withone knife switch and the full-loadresistor (0.58-ohm) in series withthe other knife switch to the +OUTPUT - terminals as shown infigure 2–1. Set both knife switchesto open position.Set the power switch and circuitbreaker to ON. After a 2-minutewarmup, apply one-quarter load byclosing the knife switch in serieswith the one-quarter load.Rotate the VOLTAGE ADJUSTcontrol for an indication of 28 voltson the OUTPUT VOLTAGE meter.Set the toggle switch connected t oTB2 to its left position. Observeand note the indication on each am-meter. Set the same toggle switchto its right position. Observe andnote the indication on each ammeter.Set the toggle switch in the posi-tion (left or right) that provides theminimum current difference betweenthe two ammeters. (For example,with the toggle switch set to theleft, one ammeter indicates 4 am-peres and the other ammeter indi-cates 8 amperes. With t h e toggleswitch set to the right, one ammeterindicates 5 amperes and the otherammeter indicates 7 amperes. F o rthis condition, the toggle switch isset to the right.) Adjust variable resister R2 until the ammeters indicatethe lowest value of imbalance.Remove the one-quarter load by set-ting the series-connected switch t othe open position. Apply full-loadby closing the switch in series withthe full-load.Readjust R2 as necessary until theammeters indicate the lowest valueof imbalance. The greatest tolerable

(13)

(14)

(15)

(16)

(17)

TM 11-6130-236-35

value of imbalance is 5 amperes ofdifference between both ammeterswith a full load applied. Repair ofthe battery charger is required if animbalance greater than 5 amperes ex-ists after adjusting R2.Remove the full load by settingthe series connected knife switch toopen position.Set the toggle switch connected toTB1 to its left position. Observeand note the indication on each am-meter. Set the same toggle switchto its right position. Observe a n dnote the indication on each ammeter.Set the toggle switch in the position(left or right) that provides theminimum current difference betweenthe two ammeters. Adjust variableresistor R1 until each ammeter indi-cates 0 current.Set the pcwer switch and circuitbreaker to OFF.Disconnect each toggle switch andreplace the shorting links across theterminals of TB1 and TB2 that wereshorted by the toggle switches forthe adjustment of R1 ( (15) above)and R2 (10) above).

b. Resistor R4 Regulation Adjustment. Af-ter performing the magnetic amplifiers cur-rent balance adjustment (a above), adjust var-iable resistor R4 as follows:

(1)

(2)

(3)

(4)

(5)

Set the power switch and circuitbreaker to ON. Rotate the VOLT-AGE ADJUST control for an indi-cation of 28 volts on the OUTPUTVOLTAGE meter.Apply a full load by closing theknife switch in series with the fullload. Adjust variable resistor R4 foran indication between 27.7 volts and27.9 volts on the OUTPUT VOLT-AGE meter.Readjust R2 as necessary for mini-mum imbalance (a ( 12) above).Remove the full load by setting theseries-connectedopen position.Set the powerbreaker to OFF.

knife switch to the

switch and circuit

2-5

TM 11-6130-236-35

(6)

(7)

(8)

Remove both ammeters from the 28DC OUTPUT 56 terminals. Replaceboth of the 28 DC OUTPUT 56links for 28-volt output power.Apply a full load by closing theknife switch in series with the fullload. If necessary, readjust R4 foran indication between 27.7 volts and27.9 volts on the OUTPUT VOLT-AGE meter.Set the power switch and c i r c u i tbreaker to OFF.

c.Resistor R3 Maximum Current forCHARGE Mode Adjustment.

(1)

(2)

(3)

Remove the one-quarter load, fullload, both knife switches, and hook-up wire from the + OUTPU’T – ter-minals.Rotate variable resistor R3 fullycounterclockwise.Connect one end of a 10-foot No. 8AWG wire to the + OUTPUT ter-minal and the other end of the No.8 AWG wire to the - OUTPUT ter-minal. (The 10-foot length of No.8 AWG wire across the + OUTPUT

– terminals is used to simulate t h erequired short circuit to adjust R3.)

(4) Set the NORMAL-CHARGE switchto CHARGE.

Caution: The procedure, given in(5) below is for CHARGE mode ofoperation only. Be sure that theNORMAL-CHARGE switch is in theCHARGE position before applying in-put power to the battery charger.

(5)

(6)

(7)

(8)

(9)

Set the power switch and circuitbreaker to ON. ( T h e O U T P U TCURRENT meter should indicatebetween 40 amperes and 50 am-peres.)Adjust variable resistor R3 for anindication of between 70 amperesand 75 amperes on the OUTPUTCURRENT meter.Set the power switch and circuitbreaker to OFF.Set the NORMAL-CHARGE switchto NORMAL.Remove the No. 8 AWG wire fromthe + OUTPUT – terminals.

2-6

Figure 2-1. Adjustment of variable resistor R1, R2, R3, and R4 connection diagram.

2 - 7

TM 11-6130-236-35

CHAPTER 3

GENERAL SUPPORT TESTING PROCEDURES

3-1. General

a. Testing procedures are prepared for use bySignal Field Maintenance Shops and Signal Serv-ice Organizations responsible for general supportmaintenance of electronic equipment to deter-mine the acceptability of repaired equipment.These procedures set forth specific requirementsthat repaired equipment must meet before it isreturned to the using organization. These proce-dures may also be used as a guide for testingequipment which has been repaired at directsupport level if the proper tools and test equip-ment are available. A summary of the perform-ance standards is given in paragraph 3-8.

b. Comply with the instructions preceding eachchart before proceeding to the chart. Performeach step in sequence. Do not vary the sequence.For each step, perform all the actions required in

the Control settings column; then perform eachspecific test procedure and verify it against itsperformance standard.

3-2. Test Equipment, Tools, andMaterials

All test equipment, tools, and materials re-quired to perform the testing procedures given inthis chapter are listed in a, b, and c, below and areauthorized under TA 11-17, (Signal Field Mainte-nance Shops); and TA 11-100 (11–17), (Allowancesof Signal Corps expendable Supplies for SignalField Maintenance Shops).

Note. Continue using the test equipment listed below untilnew test equipment, listed in the latest Maintenance Alloca-tion Chart (MAC) of TM 11-6130-236-12, becomes available.

Change 1 3-1

TM 11-6130-236-35

a. Test Equipment.

Nomenclature

Multimeter TS-352/U (2 required)Wattmet.er TS-430/UTransformer, Variable Power

TF-171A/UVoltmeter, Meter ME30A/ULow Voltage Circuit Tester

TV-loo

Federal stock No.

6625-242-50236625-649-53935950-503-0632

6625-669-07424910-092-9136

b. Tools. All the tools required are included inTool Kit, Radio and Radar Repairman TK-87/U.

c. Materials.

Nomenclature

Wire, electrical, stranded;#10 AWG

Resistance Element,0.58-ohm, 3,350-watt(load for 28-volttests)

Federal stock No.

6145-160-5110

5905-280-0374

Technical manual

TM 11-5527NoneNone

TM 11-6625-320-12None

Nomenclature

Resistance Element,1.36-ohm, 2,150-watt(part of bad for56-volt tests)

Resistance Element,0.86+hm, 2,150-watt(part of load for 56-Volt tests)

Knife switch (60-ampere)

Federal stock No.

5905-186-8451

5905-186-8450

5930-224-4928

3-2 Change 1

TM 11-6130-236-35

3–3. Physical Tests and Inspections b. Test Connections and Conditions. NO

connections necessary. Remove panels a n da. Test Equipment and Materials. None covers as necessary for visual and actual ac-

required. eess to all components.

c. Procedures.

StepNo.

1

2

3

Control settings

‘I’est equipment Equipment undertest

None

None

None

Controls may bein any position,

Controls may bein any position.

Controls may bein any position.

Test procdure

a. Inspect case and chassis fordamage, missing parts, andcondition of paint.

Note. Touchup painting isrecommended in lieu of refin-ishing whenever practical; screw-heads, binding posts, receptacles,and other plated parts will not bepainted or polished with abrasives.b. Inspect all controls and mechan-

ical assemblies for loose ormissing screws, bolts, andnuts.

c. Inspect all connectors, recepta-cles, meters, and fuseholdersfor looseness, damage, ormissing parts.

a. Rotate all panel controlsthrough their limits of travel.

b. Operate all switches.

Manually turn fan blades ofmotor B1.

Performance standard

a. No damage evident or partsmissing. External surfaces in-tended to be painted do notshow bare metal. Panellettering will be legible.

b. Screws, bolts, and nuts aretight. None missing.

c. No loose parts or damage,missing parts.

No

a. Controls rotate freely withoutbinding or excessive loose-ness.

b. Switches operate properly.

Fan blades turn freely withoutbinding.

3-3

TM 11-6130-236-35

Figure 3-1. Twenty-eight Volt output, regulation, ripple, and efficiency testconnection diagram.

3-4

CHAPTER 4

DEPOT OVERHAUL STANDARDS

4-1. Applicability of Depot OverhaulStandards

The tests outlined in this chapter are designedto measure the performance capability of a re-paired equipment. Equipment that is to be re-turned to stock should meet the standards givenin these tests.

4-2. Applicable References

a. Repair Standards. Applicable procedures ofthe depots performing these tests and the generalstandards for repaired electronic equipment

give in TB SIG 355-1, TB SIG 355-2, and TB SIG355-3 form a part of the test requirements.

b. Technical Publication. The technical publi-cation applicable to the equipment to be tested isTM 11-6130-236-12.

c. Modification Work Orders. Perform all modi-fication work orders applicable to this equipmentbefore making the tests specified. DA Pam 310-4lists all available MWO’s.

4-3. Test Facilities Required

The following items are required for depottesting:

a. Test Equipment.

Note. Continuing using the test equipment listed below until new test equipment, listed in the latest MaintenanceAllocation Chart (MAC) of TM 11-6130-236-12, becomes available.

Item

Multimeter TS-352/U (2 required)Wattmeter TS-430/UTransformer, Variable Power

TF-171A/UVoltmeter, Meter ME-30A/ULow Voltage Circuit Tester

TV-l00

b. Materials

Federal stock No. Technical manual

6625-242-5023 TM 11-55276625-649-5393 None5950-503-0632 None

6625-669-0742 TM 11-6625-320-124910-092-9136 None

Nomenclature

Wire, electrical stranded;#10 AWG

Resistance Element, 0.53-ohm, 3,350-watt (loadfor 23-volt tests)

Resistance Element, 1.36-ohm, 2,150-watt (part ofload for 56-volt tests)

Resistance Element, 0.36

Federal stock No.

6145-160-5110

5905-280-0374

5905-186-3451

5905-136-3450

Nomenclature Federal duck No.

ohm, 2,150-watt (part ofload for 56 vote tests)

Knife switch (60 ampere) 5930-224-4928

4-4 TestsThe depot overhaul standards test procedures

are the same as those for general support (para3-4 through 3-7). Equipment that meets the per-formance standards stated in these tests willfurnish satisfactory operation equivalent to thatof new equipment.

Change 1 4-1

TM 11-6130-236-35

COLOR CODE MARKING FOR MILITARY STANDARD RESISTORS

*If B and D is omitted, the resistor tolerance is .+. 20%, and the resistor is not Mil-Std.

Figure 4–1. Color code marking for MIL STD resistors.

4 - 2

TM 11-6130-236-35

APPENDIX

REFERENCES

DA Pam 310-4

TA 11-17TA 11-100 (11-17)

TM 11-487H-1/1TM 11-5043-12

TM 11-5527TM 11–6130-236-12TM 11-6130-236-25P

TM 11–6625–320-12

Index of Technical Manuals, Technical Bulletins, Supply Manuals (types7, 8, and 9), Supply Bulletins, Lubrication Orders, and ModificationWork Orders.

Signal Field Maintenance Shops.Allowances of Signal Corps Expendable Supplies for Signal Field Main-

tenance Shops.Electronic Test Equipment.Operator’s and Organizational Maintenance Manual: Analyzers ZM–3/U

and ZM–3A/U.Multimeters TS-352/U, TS-352A/U, and TS–352B/U.organizational Maintenance Manual: Charger, Battery PP–1451/G.organizational, DS, GS, and Depot Maintenance Repair Parts and Special

Tool Lists: Charger, Battery PP-1451/G.organizational Maintenance Manual: Voltmeter, Meter ME–30A/U and

Voltmeters, Electronic ME–30B/U, ME–30C/U, and ME–30E/U.

A-1

By Order of the Secretary of the Army:

Official:

J. C. LAMBERT,Major General, United States Army,The Adjutant Genenal.

Distribution:

Active Army:

USASA (2)CNGB (1)CC-E (7)Dir of Tram (1)CofEngrs (1)TSG (1)CofSptS (1)USAAESWBD (5)USAAVNTBD (5)USACDCEA (1)USACDCCBRA (1)USACDCCEA (1)USACDCCEA:

Ft Huachuca (1)USACDCOA (1)USACDCQMA (1)USACDCTA (1)USACDCADA (1)USACDCARMA (1)USACDCAVNA (1)USACDCARYTA (1)USACDCSWA (1)USAMC (5)USCONARC (5)ARADCOM (5)ARADCOM Rgn (2)OS Maj Comd (4)LOGCOMD (2)USAMICOM (4)USASMC (2)USASCC (4)MDW (1)Armies (2)Corps (2)USAC (3)507th USASA Gp (2)508th USASA Gp (2)318th USASA Bn (2)319th USASA Bn (2)

NG: State AG (3).

320th USASA Bn (2)177th USASA Co (2)182nd USASA Co (2)183rd USASA Co (2)184th USASA Co (2)251st USASA Co (2)102nd USASA Det (2)104th USASA Det (2)Svc Colleges (2)Br Svc Sch (2) except

USATSCH (5)USA Tng Cen & Sch (5)

Sig FLDMS (2)AMS (1)USMA (5)GENDEP (2)Sig Sec GENDEP (5)Sig Dep (12)A Dep (2) except

LBAD (14)SAAD (30)TOAD (14)FTWOAD (10)LEAD (7)SHAD (3)NAAD (5)SVAD (5)CHAD (3)ATAD (10)SEAD (7)

USASTC (2)USATC Armor (2)USATC Engr @)USATC Inf (2)Army Pic Cen (2)USACDCEC (10)USATTC (5)USAJFKCENSPWAR (5)Instl (2) except

USAR: None.

For explanation of abbreviations used, see AR 320-50.

HAROLD K. JOHNSON,General, United States Army.Chief of Staff.

Ft Monmouth (70)Ft Hancock (4)Ft Gordon (10)Ft Huachuca (10)Ft Carson (21)Ft Knox (12)Ft Ritchie (5)

WSMR (5)WRAMC (1)USAERDAA (2)USAERDAW (13)USACRREL (2)USARSG (5)Units org under fol TOE:

(2 copies each)11-611-3511-3711–3811-3911–5611–5711-9711-9811–11711–15511–15611–15711–15811–22511–22611–35811-500 (AA-AC)11-58711–59211–59729–5629–134

*U.S. GOVERNMENT: PRINTING OFFICE : 1989 0 - 242-451 (6027)Text

P I N : 0 2 0 6 6 8 - 0 0 0