EPS PS835 CMM Rev. B 2009

Record Of Revisions
Assigned To: Location:

Rev. Insertion By Rev. Insertion By Rev. Insertion By
No. Date No. Date No. Date
Retain this record in the front of this manual. Upon receipt of a revision, insert the revised pages in this manual,
enter the revision number, date of insertion and initials on this record of revisions.
24-30-02
TP-329 Record of Revisions - Page i
Revision B, Change 1 March 31, 2005
L-3 Avionics Systems
Component Maintenance Manual
Model PS-835( ) // 501-1228-( )
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TP-329 Record of Revisions - Page ii
Revision B, Change 1 March 31, 2005
Model PS-835( ) // 501-1228-( )
Table of Contents
Section Page
Record of Revisions ............................................................................................................. i

List of Effective Pages ......................................................................................................... ii
Table of Contents ................................................................................................................. v
Introduction.......................................................................................................................... ix
Service Directives List ......................................................................................................... x
List of Figures ...................................................................................................................... xi
List of Symbols and Abbreviations...................................................................................... xii
Description and Operation

1. General ................................................................................................................................. 1
2. Purpose of Equipment .......................................................................................................... 1
3. Physical Description............................................................................................................. 1
4. Functional Description ......................................................................................................... 1
5. Continued Airworthiness ..................................................................................................... 2
6. MOD Status.......................................................................................................................... 3
7. Environmental Test Qualifications ...................................................................................... 5
8. Specifications ....................................................................................................................... 7
9. Affiliated Equipment............................................................................................................ 7
10. Charge and Discharge Performance..................................................................................... 8
A. General Battery and Cell Information................................................................... 8
B. Battery/Cell Outgassing ....................................................................................... 8
C. Storage Time and Temperature............................................................................. 9
D. Cell Current Discharge Time ................................................................................ 10
E. Cell Voltage Discharge Time................................................................................ 11
11. Operation.............................................................................................................................. 12
12. Theory of Operation............................................................................................................. 12
A. Power Input .............................................................................................................. 12
B. Heating Resistor ........................................................................................................... 13
C. Heater Control .............................................................................................................. 13
D. Over-Temperature Protection....................................................................................... 13
E. Battery Voltage Level Detection.................................................................................. 13
F. Test .............................................................................................................. 14
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TP-329 Table of Contents - Page vii
Revision B, Change 3 August 29, 2007
Model PS-835( ) // 501-1228-( )
Table of Contents (continued)

Section Page
Testing and Fault Isolation

1 General .............................................................................................................................................. 101
2 Battery Testing ................................................................................................................................ 102
3 Charging Procedures ......................................................................................................................... 102
4 Preflight Checks (Recommended) .................................................................................................... 103
5 Periodic Checks (Required 3 to 6 Months) ....................................................................................... 104
6 Capacity Testing (Required Annually) ............................................................................................. 104
7 Cell Isolation Test ............................................................................................................................. 106
8 Performance Test .............................................................................................................................. 107
9 Battery Monitor CCA Test Procedures ............................................................................................. 116
Disassembly
1. General .............................................................................................................................................. 301
2. Disassembly Procedures .................................................................................................................... 301
3. Repair ................................................................................................................................................. 303
Cleaning
1 General .............................................................................................................................................. 401
2 External Cleaning .............................................................................................................................. 401
3 Internal Cleaning ............................................................................................................................... 401
Check
1 General .............................................................................................................................................. 501
2 On-Aircraft Checks ........................................................................................................................... 501
3 Checks After Repair and During Re-Assembly ................................................................................. 501
4 Inspection After Repair and During Re-Assembly............................................................................. 502
5 Storage ............................................................................................................................................... 502
Repair
1 General ............................................................................................................................................... 601
2 Battery Cell and Pack Replacement ................................................................................................... 601
3 Circuit Card Assembly Repair............................................................................................................ 601
4 Consumable Materials ........................................................................................................................ 601
5 Special Tools ...................................................................................................................................... 602
6 Moisture and Fungus Proofing ........................................................................................................... 603
7 Performance Test................................................................................................................................ 603
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Revision B, Change 4 January 24, 2008
Model PS-835( ) // 501-1228-( )
Assembly
1 General…… ....................................................................................................................................... 701
2 Assembly Tools, Fixtures, and Consumables..................................................................................... 701
3 Assembly Procedures ......................................................................................................................... 702
4 Performance Test................................................................................................................................ 705
5 PS-835 Storage ................................................................................................................................... 705
Fits and Clearances

1 General ............................................................................................................................................... 801
2 Emergency Power Supply Location ................................................................................................... 801
3 Pre-Installation Inspection and Preparation ....................................................................................... 801
4 Post Installation Check ....................................................................................................................... 801
5 Affiliated Equipment .......................................................................................................................... 803
6 Installation Kits .................................................................................................................................. 805
7 Interconnect Diagrams ....................................................................................................................... 805
Special Tools, Fixtures, Test Equipment and Consumables

1 General ............................................................................................................................................... 901
2 Load Resistor...................................................................................................................................... 901
3 Connector Alignment Gage................................................................................................................ 901
Illustrated Parts List

1 General ............................................................................................................................................. 1001
2 Numerical Index ............................................................................................................................... 1001
3 Part Reference Designator Index...................................................................................................... 1004
4 Detailed Parts List … ....................................................................................................................... 1005
Service Bulletin Information
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TP-329 Table of Contents - Page x
Model PS-835( ) // 501-1228-( )
Introduction
This Component Maintenance Manual with Illustrated Parts List has been prepared by the Technical
Publications Department of Avionics Systems. It provides information needed to operate, maintain,
and repair specific avionics equipment. Block diagrams, schematic diagrams, and exploded views
are used and referenced within this manual to present the information. An Illustrated Parts List is
included to provide information for ordering replacement parts.
Common system maintenance procedures are not presented in the interest of clarity. The best-
established shop and line practices should be used where no specific procedures are given. When
direct current polarities are not defined with a given voltage value, the voltage is assumed to be
positive with respect to ground. Abbreviations and symbols used in this manual are defined in the
List of Symbols and Abbreviations. All weights and measurements in the manual are in English
units, unless otherwise stated.
This manual contains all practical information for the Operation, Testing, Disassembly/Assembly,
and Service and Repair of all variations of the PS-835( ) Emergency Power Supply. The manual in
published according to ATA-100 Specification for Manufacturer’s Technical Data for aviation
product manuals, to include style, format and content.
The manual is partitioned into sections, with tables, illustrations, and cross-references to information
located in other sections.
Section Page Group

Description and Operation 1-98
Testing and Fault Isolation 101-198
Disassembly 301-398
Cleaning 401-498
Check 501-598
Repair 601-698
Assembly 701-798
Fits and Clearances 801-898
Special Tools, Fixtures and Equipment 901-998
Illustrated Parts List 1001-1098
Service Letters and Bulletins
Comments, corrections, deletions, additions, clarifications or other pertinent information should be

directed to the Technical Publications Department, Avionics Systems, 5353 52nd Street S.E., Grand
Rapids, Michigan, USA 49512-9704, phone number [1-800-253-9525 or (616) 949-6600].
Avionics Systems maintains this manual to insure correct and current information by means of
revision notices, Service Letters and Service Bulletins. Follow the instructions provided with
revision notices concerning page replacement and notations to the Record of Changes page (page i).
See www.as.l-3com.com for revision levels on all Avionics Systems Technical Publications.
24-30-02
TP-329 Introduction - Page xi
Model PS-835( ) // 501-1228-( )
Service Directives List
Directive Numbers
Service Bulletins
SB501-1228-1( )
SB501-1228-2( )
SB501-1228-3( )
SB501-1228-4( )
SB501-1228-5( )
SB501-1228-6( )
SB501-1228-7 ALERT
SB501-1228-8( )
SB501-1228-9( )
SB501-1228-10( )
SB501-1228-11( )
SB501-1228-12( )
SB501-1228-13( )
SB501-1228-14( )
SB501-1228-15( )
Service Letters
SL-48( )
SL-59()
SL-64( )
SL-80( )
SL-84( )
SL-85( )
SL-105()
SL-109( )
The Service Bulletins listed above have been incorporated into this manual, in so much as it is
possible, at the revision levels current at the publishing date. PS-835 Emergency Power Supplies
will exist in the field in various levels of modification, so a complete library to all the Service
Bulletins that pertain to the PS-835 at their latest revisions will be necessary. See Description
section, chapter 6. MOD Status for detailed descriptions of the associated Service Bulletins.
See www.as.l-3com.com, Service Section, Technical Publications Page for the Publications
Index to get up-to-date listing of all Avionics Systems technical publications and directives.
Or contact Avionics Systems Customer 1-800-453-0288.
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TP-329 Service Directives - Page xii
Model PS-835( ) // 501-1228-( )
List of Figures
Figure Title Page

1 Service Bulletins and Modifications 3
2 Environmental Qualifications 5
3 PS-835 Emergency Power Supply 6
4 Specifications 7
5 Cell Storage Time vs. Temperature 9
6 Typical Discharge Time for Cells 10
7 Discharge Curves 11
8 Schematic for Models E and F 15/16
9 Schematic for Models E and F 17/19
10 Schematic for Models A through D 19/20
11 Schematic for Models A through D 21/22
12 Schematic for Models C and D 23/24
13 Schematic for Models A and B 25/26
101 Test Equipment and Fixtures 107
102 PS-835 Test Setup Schematic 108
103 Connector Pin Continuity Table 109
104 PS-835 Access Panel 112
105 Individual Cell Monitor LED's 116
106 Circuit Cart Assembly Test Setup 117
401 Modified Acid Brush 402
601 Consumable Materials 601
602 Special Tools and Equipment 602
603 Wire List for Models A, B, C, and D 603
604 Wire List for Models E and F 604
701 Tools and Consumables 701
702 Solder Pad Locations 703
801 Affiliated Equipment 804
802 Typical Interconnections for Models A through 806
803 Typical Interconnections for Models E and F 807
804 Interconnections for AC Indicators 808
805 Interconnections for DC Indicators 808
806 Installation Drawing for Models E and F 809/810
807 Installation Drawing for Models A through D 811/812
901 Special Tools and Equipment 901
IPL 1 Emergency Power Supply 1007/1008
IPL 2 Battery Circuit Card Assembly 1011/1012
IPL 3 Battery Monitor CCA 1017
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TP-329 List of Figures - Page xiii
Model PS-835( ) // 501-1228-( )
List of Symbols and Abbreviations
The following is a compilation of abbreviations and symbols used in this manual. Every effort has
been made to insure that this list is complete. Wire color symbols are not listed, as they are universal
throughout the industry.
A Ampere
AC Alternating Current
awg American Wire Gauge
AMP Ampere
AR As Required
CH Chemical Hazard
CCA Circuit Card Assembly
CCW Counterclockwise
CW Clockwise
DC Direct Current
Hz Hertz (frequency)
″ inch
lbs pounds
in-lbs Inch-Pounds (torque)
Max maximum
MSDS Material Safety Data Sheet
PWB Printed Wiring Board
RPM revolutions per minute
UUT unit under test
Vdc Volts direct current
Vac Volts alternating current
± + (plus) or – (minus)
° Angular Degree
F° Temperature Fahrenheit
C° Temperature Celsius
Ω Ohm
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TP-329 Symbols and Abbreviations - Page xiv
Model PS-835( ) // 501-1228-( )
6. MOD Status
The PS-835 Emergency Power Supply is a venerable design that has experienced numerous
improvements. This manual offers information in a manner that recognizes the various levels of
modification at which a unit may exist in the field. All the schematics (see Figures 8 through 13)
and components in the Illustrated Parts Listing that have been affecting by the various
modifications applied to PS-835 Emergency Power Supplies are included in this manual.
NOTE: It is highly recommended that SB501-1228-8( ) be applied to all PS-835 model A and
B units.
The table below lists all Service Bulletins that pertain to the PS-835 Emergency Power Supply up to
the date of this publication.
Modification Kits and

Model and Part
Service Bulletin MOD # Purpose part required for
Number
Modification
SB501-1228-1( ) A-501-1228-01 1 Wiring modification to
B-501-1228-02 prevent connector J2 arcing
during extreme vibrations.
SB501-1228-2( ) A-501-1228-01 2 Replace Thermal Resistor to MOD Kit 504-1637-01
B-501-1228-02 reduce shorting possibility.
SB501-1228-3( ) B-501-1228-02 3 Add insulation plate to prevent MOD Kit 504-1638-01
shorting possibility between
cell BT12 and chassis.
SB501-1228-4( ) A-501-1228-01 3 Modify wiring to prevent MOD Kit 504-1642-01
B-501-1228-02 4 CCA damage because loss of
grounding isolation between
battery and chassis.
SB501-1228-5( ) A-501-1228-01 4 Additional instructions to (Pervious MOD 3 and 4
B-501-1228-02 5 insure previous MOD's 3 and instructions failed to
4 are properly applied. instruct soldering wire
back onto lug)
SB501-1228-6( ) A-501-1228-01 5 Replace and reposition MOD Kit 504-1648-01
B-501-1228-02 6 resistors A2R1 and A2R7 on
Battery Monitor CCA.
SB501-1228- A-501-1228-01 6 Modify wiring to provide self-
7ALERT B-501-1228-02 7 testing capability for fuse
C-501-1228-03 1 failure.
D-501-1228-04 1
SB501-1228-8( ) A-501-1228-01 N/A Modifies Models A and B into MOD Kit 504-1745-01
B-501-1228-02 Models C and D to meet DO- Re-identifies CCA A2
160A voltage spike test. from 542-1634-01 to
(Factory only) 542-1495-01
Figure 1: Service Bulletins and Modifications
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TP-329 Description - Page 3
Revision B February 28/2004
Model PS-835( ) // 501-1228-( )
Modification Kits and

Model and Part
Service Bulletin MOD # Purpose part required for
Number
Modification
SB501-1228-9( ) A-501-1228-01 7 Replace Battery Monitor CCA Replace CCA A2 part
B-501-1228-02 8 to improve Heater Circuit number 542-1495-01
C-501-1228-03 2 performance. with CCA A2 part
D-501-1228-04 2 number 542-1521-01.
SB501-1228-10( ) A-501-1228-01 Modify wiring to circumvent MOD Kit 504-1746-01
B-501-1228-02 fuse for emergency operation. (All previous MOD's to
C-501-1228-03 Re-identifies Models C and D A, B, C, and D must
D-501-1228-04 into Models E and F. first have been
performed)
SB501-1228-11( ) A-501-1228-01 8 Prevent possible shorting MOD Kit 504-1811-01
C-501-1228-03 3 between cells and chassis.
E-501-1228-05 1
SB501-1228-12( ) A-501-1228-01 9 Prevent possible shorting MOD Kit 504-1839-01
B-501-1228-02 9 between cells and chassis.
C-501-1228-03 4
D-501-1228-04 3
E-501-1228-05 2
F-501-1228-06 1
SB501-1228-13( ) A-501-1228-01 10 Modify wiring to prevent
B-501-1228-02 10 improper charging.
C-501-1228-03 5
D-501-1228-04 4
E-501-1228-05 3
F-501-1228-06 2
SB501-1228-14( ) D-501-1228-04 5 Prevent shorting of cell leads
Serial No's by correcting wire routing and
8647 and improved soldering of cell
higher. terminals.
SB501-1228-15() A-501-1228-01 11 To add warning instructions Warning Label (p/n
B-501-1228-02 11 for proper care and 535-1873-01)
C-501-1228-03 6 maintenance of battery pack to
D-501-1228-04 6 prevent voiding warranty.
E-501-1228-05 4
F-501-1228-06 3
Figure 1: Service Bulletins and Modifications (Cont.)
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Revision B, Change 2 February 3/2006
Model PS-835( ) // 501-1228-( )
C. Storage Time and Temperature
NOTE: Avionics Systems Service Letter SL-64 contains additional information on Lead
Acid Battery out-gassing and Service Letter SL-80 contains additional information
for Float (Trickle) Charging Emergency Power Supplies during storage.
If a ready condition is required of a power supply being stored, recharge batteries every 4 months
for 1 hour at 28 to 30Vdc input. Do not store where temperature may exceed 85°F (29°C).
Low storage temperatures on fully charged cells lessen the rate of self-discharge, thus
increasing shelf life. There is no danger of damage to cells since they will not freeze even at
temperatures of -75° F. On the other hand, high storage temperatures will accelerate self-
discharge of the cells and storage under such conditions is not recommended. Refer to Figure 5.
Figure 5: Cell Storage Time vs. Temperature
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Model PS-835( ) // 501-1228-( )
D. Cell Current Discharge Time
The rate of energy being withdrawn from a cell affects the amount of energy that can be
obtained over time. For example, at low current rates the energy in a cell lasts longer than at
high current rates. The actual hours of service (Amp-hours, or Ah) from fully charged "D" or
"X" cells can be determined from Figure 6 below.
Figure 6: Typical Discharge Time for Sealed Lead Acid Cells
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Model PS-835( ) // 501-1228-( )
The 28 Vdc input through *A2CR1 (**A2CR6) or the TEST SWITCH (A1S1) provides the
operating voltage at pin 4 of A2U1 and U2.
B. Heating Resistor (A1HR1)
Heating Resistor (A1HR1) provides heat to the battery cells and functions as the internal 7.5Ω
nominal test load. When 28 Vdc is applied to J1 connector pin J1-10 and the unit temperature is
19C° (66°F) or less, or when the TEST SWITCH (A1S1) is pressed, A2U2-pin 1 is placed in a
high state which turns on HEATER ON LED A2DS17 and transistor *A2Q5 (**A2Q2)
allowing current flow through A1HR1, so long as the temperature remains less than 55 C.
C. Heater Control
Temperature Transducer (A1U1) is a temperature sensitive device that varies current flow
through potentiometer A2R8, TEMP CONTROL. If the power supply temperature is 19° to 27°
C (63° to 81° F) or more current flow through A2R8 is heavy, forcing A2U2-pin 1 into a low
output cutting off LED A2DS17, transistor *A2Q5 (**A2Q2), and heating resistor A1HR1. If
the unit temperature should drop to 19° C (66° F) or less, the current flow through A2R8 would
not be sufficient to hold A2U2- pin 1 in a low state, the high output would turn on LED
A2DS17, transistor *A2Q5 (**A2Q2), and heating resistor A1HR1.
D. Over-Temperature Protection
Thermal Resistor A1RT1 is a temperature sensitive device that changes resistance rapidly (to
over 1 Megohm) if the temperature of the surface where it is mounted exceeds +55° C (131° F).
During normal operation or test, the potential applied to the inverting input pin 6 of *A2U1
(**A2U1-13) is such that *A2U1 output pin 7 (**A2U1-14) is high, turning ON transistor
*A2Q6 (**A2Q3).
If the temperature exceeds +55° C, Thermal Resistor A1RT1 will change value reducing the
conduction current and applying a high positive voltage to the inverting inputs of *A2U1-pin 6
(**A2U1-pin 13). This causes *A2U1-pin 7 (**A2U1-pin 14) to go low, OVER 55° C LED
A2DS18 to go on, and turning off transistor *A2Q6 (**A2Q3), thereby preventing heating
resistor operation. The circuit will remain in this state until the temperature of Thermal Resistor
A1RT1 is low enough to again permit conduction.
E. Battery Voltage Level Detection
The outputs of *A2U1-pins 1, 8 and 14 (**pins 1, 7 and 8) and A2U2-pin 8 are normally high
due to the voltage applied to the non-inverting inputs by *A2Q7 (**A2Q1), resistor *A2R18
(**A2R21) and the voltage applied to the inverting inputs from voltage divider network
resistors *A2R19 through A2R22, A2R24 and A2R25 (**A2R5, A2R6, A2R12, A2R17,
A2R22 and A2R23).
The potentiometer *A2R25 (**A2R5) is adjusted so that OUTPUT VOLTAGE MONITOR

LED DS15 will go out when the voltage at J1 connector pin J1-11 is below 24 Vdc. When this
requirement has been met, the remaining OUTPUT VOLTAGE MONITOR LED's will go on or
off when their representative voltage levels are present at J1 connector pin J1-11.
24-30-02
Model PS-835( ) // 501-1228-( )
F. Test
Depressing the remote or unit TEST SWITCH applies the battery output voltage through J1
connector pins J1 pins 2 and 6 to diode *A2CR4 (**A2CR3), to pin J1-4 of A2U1 and A2U2;
through diode *A2CR3 (A2CR4) to diode *A2CR11 (**A2CR2) and resistor *A2R5
(**A2R3) to bypass the heater turn-off system. While the TEST SWITCH is being held, the
internal heater A1HR1 is turned on, placing the batteries under an approximate 7.5Ω load. The
voltage level detection system analyzes the battery voltage level at this time and will cause the
appropriate LED's (DS13 through DS16) to go on.
NOTE: If unit TEST SWITCH or Remote Test Switch is depressed at a battery ambient
temperature of 55° C or greater, the unit internal heater will not turn on to
provide a test load for the unit battery.
When a remote test is being performed, the Remote Battery-Voltage Level Lamp will go on,
provided the loaded battery voltage level is greater than 24 Vdc.
NOTE: INDIVIDUAL CELL MONITOR LED's (DS1 through DS12) function as

GO/NO GO indicators when testing PS-835 lead acid cells. In case of low output
capacity, these LED's will indicate which cell or cells have failed. The
brightness of the LED's may vary and does not indicate cell condition.
24-30-02
Model PS-835( ) // 501-1228-( )
J1 Connector
506-2090B
Figure 8: PS-835 Models E and F Schematic Diagram
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TP-329 Description
Description - Page
- Page 9
15/16
Model PS-835( ) // 501-1228-( )
This schematic represents Models E and F after

conversion from Models C and D as prompted by
SB501-1228-10( ). See Service Bulletin table Figure 1
* Note relocation of Fuse F1
506-1622C
Figure 9: PS-835 Models E and F Schematic Diagram
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TP-329 Description
Description - Page
- Page 10
17/18
Model PS-835( ) // 501-1228-( )
This schematic represents Models A, B, C, and D

after replacement of A2 CCA 542-1495-01 with
542-1521-01. See Service Bulletin table Figure 1
and SB501-1228-9( ).
506-1512G
Figure 11: PS-835 Models A, B, C, and D Schematic Diagram
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TP-329 Description
Description - Page
- Page 12
21/22
Model PS-835( ) // 501-1228-( )
This schematic represents Models A and B that have been converted to 506-1486E
Model C and D with the re-identification of A2 CCA from 542-1364-
01 to 542-1495-01. See Service Bulletin table Figure 1 and SB501-
1228-8( ). Models C and D that include the A2 CCA's (542-1495-xx)
are obsolete and are no longer supported.
Figure 12: PS-835 Models C and D Schematic Diagram
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TP-329 Description
Description - Page
- Page 13
23/24
Model PS-835( ) // 501-1228-( )
This schematic includes wiring changes prompted by MOD 1 to both 506-1287L

Model A and B and MOD 6 for Model A and MOD 7 for Model B. See
Service Bulletin table Figure 1. Models A and B that include the A2
CCA (542-1495-01) are obsolete and are no longer supported.
Figure 13: PS-835 Models A and B Schematic Diagram
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TP-329 Description
Description - Page
- Page 14
25/26
Model PS-835( ) // 501-1228-( )
Testing and Fault Isolation
1. General
This section of the manual provides the following procedures; bench test, battery charging, periodic
testing, performance tests and circuit card tests for the PS-835 Emergency Power Supply.
NOTE: Read these procedures thoroughly before proceeding with any testing.
These instructions will offer reference to supporting Illustrated Parts List illustrations that will
appear in parenthesis identifying figure and item number (sample 1-50). In addition, electronic
components will include Reference Designator identification in parenthesis indicating the major
assembly and component reference number that is listed or identified on the appropriate schematic
(sample A1R8). Schematic drawings are located in the Description and Operation section.
A. Battery/Cell Out-gassing (Venting)
CAUTION: SOME OF THE TYPES OF GASSES THAT MAY VENT FROM A CELL ARE TOXIC AND
SHOULD NOT BE CONTAINED IN A CLOSED, NON-VENTED AREA.
CAUTION: CELL/BATTERY CORROSION IS EVIDENCE OF THE LOSS OF SEAL, LIKELY CAUSED BY

OUT GASSING. CELLS MUST BE REPLACED WHEN CORROSION IS APPARENT.
All lead-acid cells and batteries produce gasses during charging. The amount and type of gas
produced depends on state of charge, rate of charge, chemical composition of the electrolyte,
and general condition of the battery. Normally, gasses produced are recombined within the
cells to form oxides and water.
Venting occurs when excessive charge rates are placed on the battery or because of a defective
cell(s), which will subject the remaining good cells to excessive charge rates. Venting may also
result from battery abuse or neglect.
If the odor of rotten eggs becomes apparent in the cockpit, pull the aircraft Emergency Power
Supply circuit breaker. The rotten egg odor is evidence that the lead-acid cells vent due to
prolonged high rate overcharging. Although the possibility of toxic levels is extremely remote,
the precaution of pulling the circuit breaker will prevent increased discomfort from the odor.
Venting is an indication that the Power Supply in not controlling the charging process. If
venting occurs, the factory recommends that the Power Supply be removed from the aircraft,
and tested to identify and replace defective cell(s).
NOTE: With proper maintenance and periodic testing, the likelihood of any battery
developing undetected problems is very remote.
24-30-02
TP-329 Test & Fault - Page 101
Model PS-835( ) // 501-1228-( )
2. Battery Testing
NOTE: Test functions should be performed only with the main buss not providing power to
the unit (OFF of disconnected).
Toggling the unit TEST SWITCH (Figure 104, Item 4) on the power supply front panel bypasses the
thermostatic heat control system. That, in-turn, applies the battery voltage to the internal battery
heater. While in the TEST mode, the batteries are placed under an approximate 7.5Ω load. The
voltage level detection system will then analyze the battery voltage level and will cause the
appropriate OUTPUT VOLTAGE MONITOR LED's (Figure 104, Item 2) to illuminate.
NOTE: Ensure Test Switch is returned to normal position and all LED's are extinguished.
NOTE: If the unit TEST SWITCH or Remote Test Switch is depressed at a battery ambient
temperature of 55°C or greater, the unit internal heater will not turn ON to provide a
test load for the unit battery. This is not an ideal condition for battery state of charge
tests and should not be considered valid.
If the remote test is being performed, the Remote Battery-Voltage Level Lamp will momentarily
illuminate, provided the internally loaded battery voltage level is greater than 24Vdc.
NOTE: After testing, it is possible that the lamp will not illuminate again until the batteries
are recharged.
The INDIVIDUAL CELL MONITOR LED's (Figure 104, Item 1) function as GO/NO GO indicators
for each of the PS-835 lead acid cells. In case of low output capacity, these LED's will indicate
which cell or cells have failed. Any variation of brightness does not indicate cell condition.
3. Charging Procedures
A. Constant-Voltage Charging Method

Locally manufacture a power cable using 16AWG wire and the appropriate mating connector
See Figure 101, Item 7 & 8. Include a Diode (15 ADC (min), 50.0 PIV or greater, See Figure
101, Item 6) to prevent battery discharge in case of loss of power from the power source.
Using the external power supply (Figure 101, Item 1), apply 29.0 ± 0.5 Vdc (10A maximum
current limited) to J1 connector pins 11 (+) and 7 (-) and charge the unit for 16 hours. The
batteries should reach 80% capacity within 1 hour and full charge at 16 hours.
J1 pin 11 +
PS-835 (16AWG conductors)
Power Supply Power Supply
J1 pin 7 (ground)
_
NOTE: Pin J1-11 is used instead of Pin J1-10 (during the Constant-Voltage Charging
Method) because applying power to J1-10 may activate the internal heater blanket.
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Model PS-835( ) // 501-1228-( )
Connector Pins
From (+) To ( - ) Correct Results
All Models
J1-1 J1-7 Open
J1-1 J2-2 Short
J1-2 J1-7 33KΩ min.
J1-3 J1-7 Open
J1-3 J2-7 Short
J1-4 J1-7 Open
J1-4 J2-15 Short
J1-5 J2-8 Short
J1-5 J1-7 Open
J1-6 J1-7 1MΩ min.
J1-8 J1-7 Open
J1-10 J1-7 20KΩ min.
J1-11 J1-7 CAUTION: DO NOT MEASURE
J1-11 J2-9 Short
J1-12 J1-7 Short
J1-12 J2-5 Short
J1-12 J2-13 Short
J1-12 Chassis Short
J2-8 J2-3 Short
J3-2 J3-5 40-100 Ω (see step 5. d.(3))
J3-24 J3-25 7.4±0.5 Ω
Model A and B
J1-9 J1-7 Open
J1-9 or J1-13 J1-4 or J1-9 or J1-11 Short
Model C & D
J1-1 J1-5 Open
J1-1 J1-11 Open
J1-1 J2-1 Open
J1-3 J1-5 Open
J1-5 J1-13 Open
J1-9 J1-7 Open
J1-12 J1-13 Open
Model E & F
J1-9 J1-7 or J1-12 CAUTION: DO NOT MEASURE
J1-11 J1-9 Short (through F1 fuse)
J1-13 J2-4 or J2-11 Short
Figure 103: Connector Pin Continuity Table
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Model PS-835( ) // 501-1228-( )
2) Voltage Test
Use the Digital Voltmeter (Figure 101, Item 2) independent leads to measure the voltage
between J1 connector pin J1-11 and the chassis of the unit. The voltage must be 25Vdc
(nominal).
3) Battery Monitor CCA Calibration Procedure
NOTE: The Battery Monitor CCA MUST be correctly calibrated to insure

successful Battery Charging and Capacity Testing Procedures.
NOTE: If calibration cannot be successfully achieved, remove the Battery Monitor

CCA and perform the Battery Monitor CCA Test Procedures, Step 8.
a. Check Transducer (A1U1) (2-210) ensure that it is not grounded. Repair if necessary
before proceeding with calibration.
b. Check Thermo Resistor (A1RT1) (2-215) to ensure that it is adequately grounded to

the unit chassis. Repair if necessary before proceeding with calibration.
c. Battery Heater Adjustment (Perform only if Battery Monitor CCA not previously
calibrated)
(1) Set External Power Supply to 28 to 30Vdc, open Test Setup switch S4 to prevent
application of load to J1 connector pin J1-11, close Test Setup switch S3 to apply
power to J1 connector pin J1-10.
(2) Find Temperature Control resistor (A2R8) located on the Battery Monitor CCA
(A2) and adjust resistor to so to discover the resistor setting that turns ON the
HEATER ON LED at the current room temperature.
(3) From that point, rotate the resistor adjustment 2 complete turns clockwise to
establish the approximate 20°C Heater setting.
WARNING: ADHESIVE (F-900 TORQUE SEAL) HAS BEEN IDENTIFIED AS HAVING A

DEGREE OF HAZARD IN HEALTH, FLAMMABILITY, AND REACTIVITY.
CONSULT THE APPLICABLE MATERIAL SAFETY DATA SHEET PRIOR TO
USE OR ASSOCIATION WITH THIS PRODUCT.
(4) Apply Torque Seal (Figure 701 Item 11) to resistor A2R8 screw head.
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Figure 106: Circuit Card Assembly Test Setup
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Model PS-835( ) // 501-1228-( )
B. Battery Monitor CCA Performance Test (542-1521-xx, 542-2625-xx, 542-2635-xx)
NOTE: Obsolete Battery Monitor CCA's 542-1495-xx and 542-1364-xx have no

Performance Tests available. See Service Bulletin and Modification table,
Figure 1.
1) Connect the Battery Monitor CCA (A2) to the CCA Test Setup connector J3.
2) Open (OFF) switches SW2, SW3, and SW6 and close (ON) switch SW4. Position switch
S1 to OFF.
3) Energize and set the External Power Supply to 28 Vdc.
4) Turn switch S1 to position 1.
5) Measure and record voltage at J3 connector pin J3-8 (TP 1). Voltage must be 12.6 ±7% Vdc.
6) Adjust resistor A2R13 CW so that Test Setup LED CR1 just goes OFF.
WARNING: ADHESIVE (F-900 TORQUE SEAL) HAS BEEN IDENTIFIED AS HAVING A DEGREE OF
HAZARD IN HEALTH, FLAMMABILITY, AND REACTIVITY. CONSULT THE APPLICABLE
MATERIAL SAFETY DATA SHEET PRIOR TO USE OR ASSOCIATION WITH THIS
PRODUCT.
7) Apply Digital Voltmeter test lead to J3 connector pin J3-25 (TP 2) and Set External Power
Supply to 24± 0.01 Vdc. Adjust CW resistor A2R5 until OUTPUT MONITOR LED DS15
and Test Setup LED CR3 just goes OFF.
a. Apply Torque Seal (Figure 701 Item 11) to resistor A2R5 screw head.
8) Increase External Power Supply (measured at TP 2) to 28 Vdc. INDIVIDUAL CELL

MONITOR LED's DS13 through DS16 and Test Setup LED CR3 must go ON.
9) Gradually decrease External Power Supply to 19.8 Vdc, observe and record voltage values
that each LED, DS13 through DS16 and Test Setup LED CR3, go OFF. LED's must go
OFF at:
LED Voltage
DS13 27± 0.27 Vdc
DS14 25± 0.25 Vdc
DS15 24± 0.10 Vdc
CR3 (TP 2) 24± 0.10 Vdc
DS16 20± 0.20 Vdc
10) Close (ON) Test Setup switch SW3, observe and confirm that HEATER ON LED DS17 is
still OFF. Apply the Digital Voltmeter test lead to pin 19 (TP 3) and set the External Power
Supply to 26.07± 0.01 Vdc.
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Model PS-835( ) // 501-1228-( )
11) Slowly adjust resistor A2R13 CCW until Test Setup LED CR1 goes ON.
a. It is easy to overshoot the adjustment, that is to continue rotation to some degree after
the Test Setup LED CR1 goes ON. In that case, back-up the adjustment (CW) about a
full rotation. Quickly toggle the Test Setup switch S6 close/open (ON/OFF) to reset
the circuit.
b. Repeat the slow and deliberate adjustment of resistor A2R13 CCW until Test Setup
LED CR1 goes on.
c. Raise the input voltage at J3 connector pin J3-19 (slow and deliberate to avoid
overshoot) to 27.75± 0.01 Vdc. Test Setup LED CR1 must turn OFF at or before
reaching this voltage.
WARNING: ADHESIVE (F-900 TORQUE SEAL) HAS BEEN IDENTIFIED AS HAVING A DEGREE
OF HAZARD IN HEALTH, FLAMMABILITY, AND REACTIVITY. CONSULT THE
APPLICABLE MATERIAL SAFETY DATA SHEET PRIOR TO USE OR ASSOCIATION
WITH THIS PRODUCT.
d. Apply Torque Seal (Figure 701 Item 11) to resistor A2R13 screw head.
12) Open (OFF) Test Setup switch SW3, close (ON) SW6, and adjust External Power Supply
to 28 Vdc as measured at J3 connector pin J3-19 (TP 3).
13) Adjust resistor A2R8 CCW until HEATER ON INDICATOR LED DS17 goes ON, then
close (ON) the Test Setup switch SW3 which must result in cell HEATER ON
INDICATOR LED DS17 to go OFF.
14) Close (ON) switch SW2 and apply Digital Voltmeter lead to pin 24 (TP 4). With switch
SW3 still closed (ON) the voltage reading at pin 24 (TP 4) must be 28 Vdc. Open (OFF)
switch SW3 and voltage reading must be less than 2.5 Vdc.
15) Apply, again, the Digital Voltmeter lead to J3 connector pin J3-19 (TP 3). Open (OFF) Test
Setup switch SW3, close (ON) SW6, and adjust External Power Supply to 26 Vdc.
16) Adjust resistor A2R8 CCW and confirm that HEATER ON INDICATOR LED DS17
remains OFF.
17) Close (ON) switch SW2 and apply Digital Voltmeter lead to pin 24 (TP 4). Close (ON)
switch SW3, voltage reading at J3 connector pin J3-24 (TP 4) must be 26 Vdc. Open
(OFF) switch SW3 and voltage reading must continue to be 26 Vdc.
18) Return External Power Supply to 28 Vdc and open (OFF) Test Setup switch SW3. Open
(OFF) Test Setup switch SW4, observe and confirm the OVER 55° LED DS18 goes ON
and Test Setup LED CR2 goes OFF.
19) Apply the Digital Voltmeter lead to J3 connector pin J3-19 (TP 3) and adjust External
Power Supply to 28 Vdc. Close (ON) Test Setup switches SW2, SW3, and SW4. Place
Test Setup switch SW1 to position 2. Apply Digital Voltmeter lead to pin 24 (TP 4). Open
(OFF) Test Setup switch SW4. The Digital Voltmeter must read 28 Vdc.
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Model PS-835( ) // 501-1228-( )
20) Place Test Setup switch SW1 to position 3. The Digital Voltmeter must read 28 Vdc.
WARNING: ADHESIVE (F-900 TORQUE SEAL) HAS BEEN IDENTIFIED AS HAVING A DEGREE OF
PRODUCT.
21) Apply Torque Seal (Figure 701 Item 11) to resistor A2R8 screw head.
C. Post Test Procedures
Return the Battery Monitor CCA into the unit and perform the Test Procedures for the LRU.
Perform the Charging Procedures and Capacity Test Procedures as required to return the unit to
service.
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Model PS-835( ) // 501-1228-( )
Disassembly
1. General
CAUTION: READ ALL THE INFORMATION IN THIS SECTION BEFORE ANY ATTEMPT TO DISASSEMBLE THIS
UNIT.
Disassembly procedures are listed in descending order to allow for successive accessibility to sub-
assemblies and components. These procedures are intended to cover most aspects of disassembly.
De-soldering of components and wires, and the replacement of items such as switches, fasteners, and
other simple operations are not covered explicitly. Technicians working on avionics equipment of
this type should have adequate knowledge of avionics shop practices before attempting any repairs.
Whenever a disassembly procedure involves disconnecting wires from components and/or connector
J1, it is best to tag, mark, or identify the wires that are cut, de-soldered, or otherwise removed. If
wires are cut, do so in a manner that provides an adequate wire for re-connections.
Disassemble the PS-835 Emergency Power Supply only to the level necessary to repair the unit as
revealed in the procedures of the Fault Isolation and Test section.
Any disassembly of the PS-835 for repair or cleaning will require functional testing after re-
assembly and before installation. See the Testing and Fault Isolation section for functional test
procedures and wiring diagrams.
WARNING: SEVERE (3RD DEGREE) BURNS AND MELTED METAL PARTS CAN RESULT THROUGH
IMPROPER HANDLING OF THE LRU AND SUBASSEMBLIES. THE BATTERIES CONTAINED
WITHIN THE PS-835 ARE CAPABLE OF PRODUCING AND SUSTAINING LARGE CURRENTS (OVER
50 AMPS) FOR SEVERAL MINUTES. REMOVE ALL JEWELRY WHEN WORKING ON THIS
EQUIPMENT.
Place the PS-835 on a stable, flat surface with appropriate lighting. Anticipate placing fasteners and
other small components into containers to prevent loss.
NOTE: Components and assemblies listed in these instructions include IPL Figure and Item
numbers in parenthesis. Use the Illustrated Parts List section to assist in the
disassembly process.
2. Disassembly Procedures
A. Cover Removal
1) Remove Screws (1-10), Washers (1-15 and 1-20), and Nuts (1-25) from rear of Cover
Assembly (1-5).
2) Grasp Front Panel Handle (1-55) while holding Cover Assembly (1-5), separate cover from
unit by pulling cover rearward.
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B. Front Panel Removal

WARNING: USE SPECIAL CARE TO RETRIEVE THE WASHER (1-45) ASSOCIATED WITH FRONT PANEL
ASSEMBLY. RE-ASSEMBLY WITHOUT THE WASHER IN PLACE WILL CAUSE SHORTING
THAT WILL DESTROY THE UNIT AND INJURE BYSTANDERS.
1) Remove Screws (1-50 and 1-40) and Washer (1-45) from Front Panel (1-30).
2) Separate Front Panel (1-30) from Battery CCA (A1) (1-70).
C. Battery Monitor Circuit Card Assembly (A2) (CCA) Removal
1) Grasp the Battery Monitor CCA (A2) by the edges and pull straight out from Connector
(J3) (2-23)
D. Cell Removal
CAUTION: CELLS ARE CHARGED AND HAVE THE ABILITY TO INDUCE SHOCK OR BURNS WHEN
MISHANDLED.
CAUTION: CELL/BATTERY CORROSION IS EVIDENCE OF THE LOSS OF SEAL, LIKELY CAUSED BY

OUT GASSING. CELLS MUST BE REPLACED WHEN CORROSION IS APPARENT.
1) Clip all Tie-Down Straps (2-6) from the backside of the Battery CCA (A1) (1-70).
2) Pull the first (closest to Front Panel) vertical 4-cell group from Battery CCA and clip all
cell wires just above the cell terminals.
3) Repeat for the next vertical 4-cell group.
4) Pull out the last vertical 4-cell group.
5) Clip all the wires just above the cell terminals except the red wire (positive) on cell BT1
for models E and F, or the black wire (negative) for cell BT12 for models C and D. (See
IPL Figure 1 Note A)
6) De-solder and remove that wire not clipped from the cell.
7) Cut and/or shave RTV material that secures the 4-cell groups away from their associated
Insulator Plates (2-10). Save the Insulator Plates and discard cells.
8) De-solder and remove all those clipped cell wires from the solder pads located on the back
of the Battery CCA (A1).
E. Heater Element (HR1) Removal
1) De-solder and remove Heater Element wires (white) from terminals on reverse side of
Battery CCA (A1) (1-70) (see Figure 702).
2) Peel Heater Element (HR1) (2-45) from Battery CCA Chassis.
3) Remove excess adhesive from chassis.
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Model PS-835( ) // 501-1228-( )
F. Battery CCA (A1) Disassembly
NOTE: De-solder, clip, or otherwise disconnect wires from terminals to the degree
necessary to proceed with disassembly. Remember to mark or tag wires and
terminal to ensure for proper re-assembly.
1) Remove Screws (2-20 and 2-25), Washers (2-30 and 2-35), and Nut (2-40).
2) Separate Inverter Assembly Support (2-15) form Battery CCA (A1) (1-70).
3) Remove Screws (2-150 and 2-160), Washers (2-155 and 2-165)
4) Separate Battery PWB (2-145) from Battery CCA Chassis.
3. Repair
See Repair section for instructions and guidance for repair of those issues identified in the
Performance Test of the Fault and Isolation section. See Assembly section for re-assembly
instructions and guidance.
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Model PS-835( ) // 501-1228-( )
Cleaning
1. General
The PS-835, like any avionics equipment, will accumulate dust and dirt during service. Avionics
Systems has taken precautions to allow cleaning the equipment with environmentally friendly
solutions and chemicals. Procedures and suggested cleaning agents are described in this section.
2. External Cleaning
CAUTION: WATER MAY MIGRATE OR LEAK INTO THE CELL THROUGH THE CELL VENT CAUSING A
CHEMICAL CHANGE IN THE CELL RESULTING IN SHORTENED SERVICE LIFE, EVEN THOUGH
THE BATTERY CELLS ARE SUPPOSEDLY SEALED. DO NOT IMMERSE THE POWER SUPPLIES IN
A WATER BATH.
The outside surfaces and flat metal parts may be cleaned with a damp cloth containing a mild
solution of ordinary household cleaner (following manufacturer's instructions on cleaner container)
and water. Dirt and grime caught in metal corners or around screws or other fasteners may be
removed with a modified acid brush (bristles removed to 1/3 of the normal length as shown in Figure
401) and a solution of cleaner and water. Dry the unit after cleaning before reinstallation and use.
NOTE: Water in connectors can be removed using low pressure compressed air.
3. Internal Cleaning
CAUTION: CELL/BATTERY CORROSION IS EVIDENCE OF THE LOSS OF SEAL, LIKELY CAUSED BY OUT
GASSING. CELLS MUST BE REPLACED WHEN CORROSION IS APPARENT.
WARNING: ISOPROPYL ALCOHOL HAS BEEN IDENTIFIED AS HAVING A DEGREE OF HAZARD IN HEALTH
AND FLAMMABILITY. CONSULT THE APPLICABLE MATERIAL SAFETY DATA SHEET PRIOR TO
USE OR ASSOCIATION WITH THIS PRODUCT.
With exception to the circuit card assemblies (CCAs), the internal surfaces of the assembly may be
cleaned following the processes for external cleaning above. CCAs can be cleansed using Isopropyl
Alcohol and a modified acid brush. Allow CCA to dry before use.
Remove dust and dirt with a low-pressure jet of clean, dry air. If necessary, use the brush depicted in
Figure 401 to loosen hardened dirt and embedded dust balls.
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Model PS-835( ) // 501-1228-( )
Figure 401: Modified Acid Brush
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Model PS-835( ) // 501-1228-( )
Check
1. General
This section provides avionics service personnel necessary guidance for inspections to the PS-835
Emergency Power Supply, which will assist in identifying shortcomings that may result in failure of
the unit operate.
2. On Aircraft Checks
A. Pull aircraft circuit breaker to remove power from PS-835 Emergency Power Supply.
B. Place TEST SWITCH (cockpit remote test switch for aircraft so equipped) into the TEST
position.
C. View Output Voltage Monitor LED's (cockpit remote test lamp for aircraft so equipped).
Output Voltage Monitor LED for 24VDC (or the cockpit remote test lamp) must illuminate
momentarily to indicate that the unit is adequately charged.
D. Release the TEST SWITCH and reset the aircraft circuit breaker.
NOTE: Ensure Test Switch is returned to normal position and all LED's are extinguished.
3. Checks After Repair and During Re-assembly
A. Perform disassembly according to the Disassembly section.
While in progress of disassembly, check:
1) Transistors, high-wattage resistors and surrounding areas for overheating.
2) For burned, broken, or shorted parts, components, and hardware.
3) Connector and terminal posts for bent, broken, or damaged pins, screws (heads and
threads), and casings for breakage and cracking.
4) Inspect all wiring for being excessively tight or loose, chafing, fraying, burned insulation,
and breakage. Wiring insulated with Teflon should be checked closely for insulation cold-
flowing and bare conductors. This phenomenon would be most evident at wire bends and
places where wire bundles are secured or tied. Being able to see actual wire through the
insulation does not necessarily mean the wire needs replacement. An insulation breakdown
test will determine if replacement is warranted.
5) Inspect all soldered connections, even those not unsoldered during disassembly, for broken
or pitted solder, cold joints, and solder quality.
Deficiencies found during inspection should be corrected when repairing a defective unit, or
performed as a preventive maintenance measure to preclude future problems. Repair defects in
accordance with the Repair section of this manual.
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Model PS-835( ) // 501-1228-( )
4. Inspection After Repair and During Assembly
A. Perform re-assembly according to Reassembly section.
While in progress of unit re-assembly check:
1) Sufficient service loop exists between interconnected subassemblies.
2) All screws in terminal posts and CCAs are tight (not stripped).
3) Screws attaching subassemblies to chassis are tight (not stripped).
4) External hardware and nuts securing front panel to chassis are tight.
5) Appropriate modifications have been incorporated and mod numbers marked off
accordingly on modification plate.
6) Connector J1 is properly covered for storage or handling.
After assembly, perform unit performance test according to Testing and Fault Isolation
section.
5. PS-835 Storage
NOTE: Service Letter SL-64 contains additional information on Lead Acid Battery out-
gassing and Service Letter SL-80 contains additional information for Float Charging
Emergency Power Supplies during storage.
A. If a ready condition is required of a power supply being stored, recharge batteries every 4
months for 1 hour at 28 to 30Vdc input. Do not store where temperature may exceed 85°F
(29°C). See Figure 5 for storage lengths of non-ready conditions.
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6. Moisture And Fungus Proofing
WARNING: COATING MATERIAL FROM HUMISEAL 1A34, AND HUMISEAL 1B31 HAVE BEEN IDENTIFIED AS
HAVING A DEGREE OF HAZARD IN HEATH AND FLAMMABILITY. CONSULT THE APPLICABLE
MATERIAL SAFETY DATA SHEET PRIOR TO USE OR ASSOCIATION WITH THIS PRODUCT.
A. Prepare coating HUMISEAL 1A34 or HUMISEAL 1B31 in accordance with manufacturer's

instructions on product. Prepare only enough coating to accomplish the task.
The original CCAs are coated at the factory with Paraxylene C. This coating may be repaired
by applying HUMISEAL 1A34 to the areas of the CCA where repair was accomplished.
HUMISEAL 1A34 may be used on all CCAs, but is expressly used for military qualified units.
HUMISEAL 1B31 is the preferred alternate coating if 1A34 is unavailable for CCAs not
qualified for military use. It is unnecessary and inadvisable to re-coat the entire CCA.
7. Performance Test
Perform the tests cited in Testing and Fault Isolation section before returning unit into service or
storage.
Wire Number From To Wire Number From To
W1 A1E1 J1 pin 1 W23 BT12 neg AF1-2

W2 A1E2 J1 pin 2 W11 CR1 ANODE A1E12
W3 A1E3 J1 pin 4 W10 CR1 ANODE J1 pin 10
W4 A1E4 J1 pin 6 W15 E18 J1 pin 11
W5 A1E7 J1 pin 7 W42 E18 A1-22
W43 A1E7 A1E9 W1 J1 pin 1 A1E1
W6 A1E7 XF1-1 W2 J1 pin 2 A1E2
W16 A1E8 A1-24 W12 J1 pin 3 A1E14
W7 A1E9 J1 pin 12 W13 J1 pin 5 A1E15
W44 A1E9 A1E19 W4 J1 pin 6 A1E4
W8 A1E10 J1 pin 9 W5 J1 pin 7 A1E7
W9 A1E11 J1 pin 13 W8 J1 pin 9 A1E10
W11 A1E12 CR1 ANODE W10 J1 pin 10 CR1 ANODE
A12 A1E14 J1 pin 3 W15 J1 pin 11 E18
W13 A1E15 J1 pin 5 W7 J1 pin 12 A1E9
W44 A1E19 A1E9 W9 J1 pin 13 A1E11
W42 A1-22 E18 W6 XF1-1 A1E7
W16 A1-24 A1E8 W23 XF1-2 B12 neg
W14 BT1 pos A1-22
Figure 603: Wire List for PS-835 A, B, C, and D
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TP-329 Repair - Page 603
Revision B, Change 2 February 3, 2006
Model PS-835( ) // 501-1228-( )
Wire Number From To Wire Number From To
W1 A1E1 J1 pin 1 W11 CR1 ANODE A1E12

W2 A1E2 J1 pin 2 W10 CR1 ANODE J1 pin 10
W3 A1E3 J1 pin 4 W15 E18 J1 pin 11
W4 A1E4 J1 pin 6 W50 E18 XF1-1
W49 A1E7 A1 pin 24 W12 J1 pin 3 A1E14
W7 A1E9 J1 pin 12 W13 J1 pin 5 A1E15
W44 A1E9 A1E19 W4 J1 pin 6 A1E4
W11 A1E12 CR1 ANODE W46 J1 pin 9 XF1-2
W12 A1E14 J1 pin 3 W10 J1 pin 10 CR1 ANODE
W13 A1E15 J1 pin 5 W15 J1 pin 11 E18
W44 A1E19 A1E9 W7 J1 pin 12 A1E9
W45 A1-22 XF1-1 W9 J1 pin 13 A1E11
W48 A1-24 BT12 neg W50 XF1-1 E18
W49 A1-24 A1E7 W45 XF1-1 A1-22
W47 BT1 pos XF1-2 W47 XF1-2 BT1 pos
W48 BT12 neg A1-24 W46 XF1-2 J1 pin 9
Figure 604: Wire List for PS-835 E and F
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TP-329 Repair - Page 604
Revision B, Change 2 February 3, 2006
Model PS-835( ) // 501-1228-( )
Assembly
1. General
Assembly procedures are listed in ascension order, starting at the lowest level of assembly. These
procedures are intended to cover most aspects of assembly. Soldering of components and wires, and
the replacement of items such as switches, fasteners, and other simple operations are not covered
explicitly. Technicians working on avionics equipment of this type should have adequate knowledge
of avionics shop practices before attempting any repairs.
CAUTION: READ AND UNDERSTAND ALL THE INFORMATION IN THIS SECTION BEFORE ATTEMPTING
ASSEMBLY OF THIS UNIT.
NOTE: Detailed assembly procedures for the Battery Pack(s) are listed in the Repair section.
Testing procedures are found in the Testing and Fault Isolation section of this manual.
Disassembly section procedures included encouragement to tag and/or mark wires at disconnection.
If no wire marking was performed at disassembly, take time to identify wires and appropriate
connection points before starting re-assembly process. See Description and Operation section for
Schematic Diagrams.
WARNING: SEVERE (3RD DEGREE) BURNS AND MELTED METAL PARTS CAN RESULT THROUGH
IMPROPER HANDLING OF THE LRU AND SUBASSEMBLIES. THE BATTERIES CONTAINED
WITHIN THE PS-835 ARE CAPABLE OF PRODUCING AND SUSTAINING LARGE CURRENTS (OVER
50 AMPS) FOR SEVERAL MINUTES. REMOVE ALL JEWELRY WHEN WORKING ON THIS
EQUIPMENT.
NOTE: Place the PS-835 assemblies and components on a stable, flat surface with appropriate
lighting. Take special note that storage batteries contained in the PS-835 are charged
and capable of inflicting burns and shocks. Do not proceed with assembly without
reading this entire section.
2. Assembly Tools, Fixtures and Consumables
This table lists the tools, fixtures, and consumable materials necessary to correctly assembly the PS-
835 Emergency Power Supply. Those products listed that are considered chemical hazards are
marked with a CH symbol. Material Safety Data Sheets should be on hand to determine the best
means to safely handle these products.
Item # Tools and Consumable Materials Part Number Source

Consumables:
1. Acetone CH Allied Fibris & Plst
2. Solder Wick PLATO-WICK or equivalent
3. Flux CH R or RMA
4. Solder-025"dia. SN63WRMA
5. HEATSINK COMPOUND CH #340 Dow Corning
6. TIE DOWN STRAP MS3367-4-9
7. ADHESIVE EPOXY TWO-PART FLEXIBLE CH 514-1247-01
Figure 701: Tools and Consumables
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TP-329 Assembly - Page 701
Model PS-835( ) // 501-1228-( )
Item # Tools and Consumable Materials Part Number Source
8. CELL TIE DOWN STRAPS P/N 566-1115-01

MS3368-3-9C
9. ADHESIVE SILICONE RUBBER CH 732 RTV Stabond Corp
10. ADHESIVE RUBBER BASE- CH VULCABOND V36 Stabond Corp
SCOTCHGRIP-847 ADHESIVE RUBBER BASE Preferred Alternate for
CH - 3M Co. Vulcabond V36
11. SEALING LOCKING AND RETAINING F-900 Torque Seal- Green Organic Products Co.
COMPOUND CH
12. INSULATING COMPOUND CH 1A34 or 1B31 HUMISEAL
Miscellaneous Hand/Shop Tools:
13. Screwdrivers (Phillips and Standard), Wire Cutters, Needle Nose Pliers, Applicator Brush, Cotton Swab, Toothpick,
Kim wipe, Nut Driver (various sizes), Bench Vise, Solder Iron and associated tools.
See Consumable Materials (Figure 601) and Wiring Lists (Figures 603 and 604) for wire information.
Figure 701: Tools and Consumables (Cont.)

3. Assembly Procedures
A. Heater Element (HR1) Assembly
WARNING: ADHESIVE (VULCABOND V-36) HAS BEEN IDENTIFIED AS HAVING A DEGREE OF HAZARD
IN HEALTH, FLAMMABILITY, AND REACTIVITY. CONSULT THE APPLICABLE MATERIAL
SAFETY DATA SHEET PRIOR TO USE OR ASSOCIATION WITH THIS PRODUCT.
WARNING: ADHESIVE (SCOTCHGRIP-847) HAS BEEN IDENTIFIED AS HAVING A DEGREE OF HAZARD

IN HEALTH, AND FLAMMABILITY. CONSULT THE APPLICABLE MSDS PRIOR TO USE OR
ASSOCIATION WITH THIS PRODUCT.
1) Apply Vulcabond (Scotchgrip 847) adhesive (Figure 701 Item 10) uniformly to Battery
CCA Chassis.
2) Place Heater Element (HR1) (2-45) onto Battery CCA Chassis.
3) Solder Heater Element (HR1) wires onto Battery CCA solder pads #18 and #19 (see Figure
702).
B. Cell Installation (All cells replaced assumed)
NOTE: Refer to SL-84( ) for instructions concerning the replacement of nickel cadmium
(NiCad) battery cells and packs; and lead-acid cells.
CAUTION: WHEN REPLACING CELLS WITHIN A PACK THE CELLS MUST BE THE SAME PART NUMBER
AND VENDOR AS THE CELLS BEING REPLACED. AVIONICS SYSTEMS RECOMMENDS THAT
WHEN ANY PACK HAS MORE THAN 4 DEFECTIVE CELLS, ALL 12 CELLS SHOULD BE
REPLACED.
1) Prepare cells by:

a. For models C and D, de-solder and remove the pre-installed black (negative) wire
from one of the cells. This cell now becomes BT12. See IPL Figure 1 Note A for cell
BT12 location.
b. For models E and F, de-solder and remove the pre-installed red (positive) wire from
one of the cells. This cell now becomes BT1. See IPL Figure 1 Note A for cell BT1.
24-30-02
Model PS-835( ) // 501-1228-( )
c. For models C and D, solder the black (negative) wire that passes through the rear
vertical chassis member access hole and is attached to Fuse Holder (XF1) to the
negative (-) terminal of cell BT12.
d. For models E and F, solder the red (positive) wire that passes through the rear vertical
chassis member access hole and is attached to the Fuse Holder (XF1) to the positive
(+) terminal of cell BT1.
2) Mount Insulator Plate (2-10) onto the inside surface, notch facing Heater Element, of the
Rear Vertical Chassis Member (see IPL Figure 2 Note A) using Vulcabond (Figure 701
Item 10).
3) Mount the initial cell (BT1 or BT12) into position and secure it to the Battery CCA (A1)
with a Tie-Down Strap (2-6).
4) Solder the black wire of cell BT1 for models C and D, or red wire of cell BT12 for models
E and F, onto the appropriate Battery CCA solder pad on reverse side of Battery CCA (A1).
5) Mount cells (BT2-BT4) (see IPL Figure 1 Note A), aligned with positive (+) terminals
down, onto Battery CCA (A1) by securing them with Tie-Down Straps (2-6). Solder the
cell wires to the appropriate solder pads on the reverse side of the Battery CCA (A1).
Tie-Down Strap holes are

numbered to correspond to cell
ref. designator numbers.
Example: BT12
Cell solder pads are

located adjacent to
cell Tie-Down Strap
holes. Pad polarity
designated on board
Example: BT7
Heater Element (HR1) solder

pad location
Figure 702: Solder Pad Locations
24-30-02
Revision B, Change 2 February 3/2006
Model PS-835( ) // 501-1228-( )
WARNING: ADHESIVE (VULCABOND V-36) HAS BEEN IDENTIFIED AS HAVING A DEGREE OF

PRODUCT.
6) Mount an Insulator Plate (2-10) onto the bottom surfaces of the just-mounted cells using
Vulcabond (Figure 701 Item 10).
7) Mount the next 4-cell row of cells (see IPL Figure 1 Note A), aligned with positive (+)
terminals down, by securing them with Tie-Down Straps (2-6). Solder the cell wires to the
appropriate solder pads on the reverse side of the Battery CCA (A1).
8) Mount an Insulator Plate (2-10) onto the bottom surfaces of the just-mounted cells (see IPL
Figure 1 Note A) using Vulcabond (Figure 701 Item 10).
9) Mount the next 4-cell row of cells (see IPL Figure 1 Note A), aligned with positive (+)
terminals down, by securing them with Tie-Down Straps (2-6). Solder the cell wires to the
appropriate solder pads on the reverse side of the Battery CCA (A1).
WARNING: SILICONE RUBBER ADHESIVE (DOW 732 RTV) HAS BEEN IDENTIFIED AS HAVING A
DEGREE OF HAZARD IN HEALTH AND FLAMMABILITY. CONSULT THE APPLICABLE
PRODUCT.
10) Apply RTV (Figure 701 Item 9) fillets to Cell Insulator Plate locations (see IPL Figure 1
Note A).
C. Battery Monitor CCA (A2) Installation
WARNING: HEAT SINK COMPOND (#340) HAS BEEN IDENTIFIED AS HAVING A DEGREE OF
PRODUCT.
1) Apply Heatsink Compound (Figure 701 Item 5) to Transistors Q2 and Q3.

2) Align pins of Battery Monitor CCA Connector (P3) to the mounting holes of Battery CCA
Connector (J3) (2-230) and insert CCA into the connector.
3) When replacing LED Diodes (3-195) place 1 or 2, as needed, Insulator Standoff's (3-240)
between CCA and LED.
D. Front Panel Installation
1) Insert Screws (1-50 and 1-40) into the appropriate mounting holes in the Front Panel (1-30).
CAUTION: USE SPECIAL CARE WHEN PLACING WASHER (1-45) ASSOCIATED WITH FRONT
PANEL ASSEMBLY. RE-ASSEMBLY WITHOUT THE WASHER IN PLACE WILL CAUSE
SHORTING THAT WILL DESTROY THE UNIT AND INJURE BYSTANDERS.
2) Align Front Panel Screws to Battery CCA (A1) and Battery Monitor CCA (A2) mounting
holes, place Washer (1-45) onto screws while inserting screws into place, and drive screws
tight.
24-30-02
Model PS-835( ) // 501-1228-( )
E. Cover Installation
1) Insert Battery CCA (A1) into the opening of the Cover (1-5).
2) Place Screws (1-10) and Washers (1-15) through Cover and Battery CCA holes. Mount
Washers (1-15 and 1-20) onto Screws and tighten.
4. Performance Test
Perform those procedures listed in the Fault Isolation and Testing section before entering unit back
into service.
5. PS-835 Storage
NOTE: Avionics Services Service Letter SL-64 contains additional information on Lead Acid
Battery out-gassing and Service Letter SL-108 contains additional information for
Float Charging Emergency Power Supplies during storage.
A. If a ready condition is required of a power supply being stored, recharge batteries every 4 months
for 1 hour at 28 to 30Vdc input. Do not store where temperature may exceed 85°F (29°C). See
Figure 5 for storage lengths of non-ready conditions.
24-30-02
Model PS-835( ) // 501-1228-( )
24-30-02
Model PS-835( ) // 501-1228-( )
Fits and Clearances
1. General
The installation information provided is for “typical” install situations, not including information for
specific aircraft. Additional information may be obtained from the original aircraft manufacturer.
2. Emergency Power Supply Location
The following steps provide general requirements for locating the Emergency Power Supply in an
aircraft.
A. The Emergency Power Supply provides limited direct-current power and 115Vac (when in
combination with Static Inverter Model SI-100) to the aircraft emergency bus equipment in case
of primary power failure. Therefore, the supply should be located in the general area of aircraft
AC and DC busses.
B. Ensure that space requirements for the supply match space available for the installation being
considered.
1) The Emergency Power Supply should be accessible for inspection, maintenance, or

removal.
2) The installation area should be free from excessive vibration and heat.
C. Consider the relative distance to associated equipment. Keep connecting cables as short as
possible.
D. The cable should not run adjacent to heaters or engine exhausts.
3. Pre-Installation Inspection And Preparation

A. Check unit for physical damage that may have occurred during shipping and handling.
B. For new-unit installation, the PS-835 Battery Pack must be charged. See Testing and Fault
Isolation section charging procedures.
C. Units installed after a maintenance action must be tested in accordance with the Performance
Test procedures listed in Testing and Fault Isolation section before installation.
4. Post Installation
Perform either the Preflight or the Periodic Check, see Testing and Fault Isolation section,
immediately after installation of the PS-835 Emergency Power Supply.
24-30-02
TP-329 Fits and Clearances - Page 801
Model PS-835( ) // 501-1228-( )
24-30-02
Model PS-835( ) // 501-1228-( )
5. Affiliated Equipment
A. SI-100 Static Inverter
The SI-100 Static Inverter provides for alteration of the PS-835 output for use of equipment that
requires alternating current (AC).
The Model SI-100A Static Inverter (Avionics Systems part number 501-1240-01) has 3Ø,
400Hz, 115Vac, 25VA output capability.
The Model SI-100B Static Inverter (Avionics Systems part number 501-1240-02) has 1Ø,
400Hz 115Vac, 75VA output capability, or 1Ø, 400Hz, 5Vac, 5VA output capability.
B. SC-841 Static Converter
The SC-841 Static Converter (Avionics Systems part number 501-1318-01) provides for direct
current conversion for 2 to 6.5 Vdc, 25 Watt output capability. See Avionics Systems
Installation Instructions TP-351 for additional information.
C. BC-815 Battery Charger
The BC-815 Battery Charger (Avionics Systems part number 501-1321-01) provides the
capability to charge the PS-835 Emergency Power Supply when not mounted on aircraft. See
Avionics Systems Installation Instructions TP-350 for additional information.
D. ATR Mounting Rack
ATR Mounting Rack (Avionics Systems part number S53001-01) for use with PS-835 in
aircraft applications.
E. Transformer (used with SI-100 Static Inverter)
For aircraft applications that require 26Vac output. (Avionics Systems part number 556-2006-
01)
F. Connector Plug for AC and DC powered Indicators
MS3126E10-16S for AC power Indicators, Avionics Systems part number 563-1013-04 for DC
powered Indicators.
G. Mating Connectors
Avionics Systems part numbers S24140-02 for PS-835 E and F, S24140-01 for PS-835 A
through D. (See Figure 806 and 807)
24-30-02
Model PS-835( ) // 501-1228-( )
Item 1
Item 2
Item 3
Figure 801: Affiliated Equipment
24-30-02
Model PS-835( ) // 501-1228-( )
(* or Microsemi P/N UES702)
Figure 803: Typical Installation Interconnections for PS-835E and F
24-30-02
Model PS-835( ) // 501-1228-( )
*If an existing installation is being converted from a PS-823 to a PS-835

and a Transformer is required, remove wire from power supply mating
connector pin 4 and connect to transformer yellow lead.
Figure 804: Interconnections to AC Powered Indicators
Figure 805: Interconnections to DC Powered Indicators
24-30-02
Model PS-835( ) // 501-1228-( )
Connector Keying for PS-835 models E and F

See Service Bulleting SB501-1228-10( )
507-1182M
Figure 806: PS-835 Models E and F Installation Drawing

24-30-02
TP-329 FitsFits
andand Clearances
Clearances - Page
Page 801
809/810
Model PS-835( ) // 501-1228-( )
Ref. Fig/ Ref. Fig/ Ref. Fig/

Designator Item Designator Item Designator Item
A2Q4 3-45 A2R19 3-75 A2R8 3-160
A2R1 3-115 A2R2 3-130 A2R9 3-155
A2R10 3-120 A2R20 3-80 A2RT1 3-10
A2R11 3-85 A2R21 3-170 A2S1 3-15
A2R12 3-115 A2R22 3-180 A2U1 3-100
A2R12 3-185 A2R23 3-170 A2U2 3-100
A2R13 3-165 A2R24 3-115 A2U3 3-105
A2R14 3-145 A2R3 3-70 A2U4 3-105
A2R15 3-95 A2R4 3-50 A2U5 3-25
A2R16 3-90 A2R5 3-165 A2VR1 3-125
A2R17 3-190 A2R6 3-175 A2VR2 3-150
A2R18 3-140 A2R7 3-65
4. Detailed Parts List
The Detailed Parts List consists of illustrations and columnar parts listing of component parts for this
equipment. All assemblies, subassemblies, and parts that can be disassembled, repaired or replaced,
and reassembled are included. The Detailed Parts List only lists and illustrates those parts attached
by means other than welding or riveting, or other generally accepted means of permanent
attachment.
Each illustration is assigned a figure number commencing with IPL Figure 1 and progressing
sequentially from there. Alpha variants A thru Z will be assigned to figure numbers when necessary
to add additional figures to show modification or configuration changes, or differences between
units.
A. Figure Number Column
This column reflects the assigned Figure number of an illustration.
B. Item Number Column
This column reflects the assigned Item number of an illustration. Items listed but not shown on
the illustration are identified with a dash (-) to the left of the item number. Alpha variants A
thru Z are assigned to existing item numbers when necessary to add items, to show
configuration changes, or multiple sources for component parts.
C. Part Number Column
Part numbers listed are MIL Standard or Goodrich Avionics Systems, Inc. part numbers
Goodrich Avionics Systems part numbers consist of a three digit family group, four digit family
number, and a two digit variant number.
24-30-02
TP-329 Illustrated Parts Listing - Page 1005
Model PS-835( ) // 501-1228-( )
D. Nomenclature Column
This column contains key and modifying words depicted within Goodrich Avionics Systems,
Inc. drawing title description blocks, modification numbers and service bulletin references, part
reference designators “if any”, military standards, plus pertinent information relative to that part
such as “Matched Parts” or Next Higher Assembly (NHA). Electrostatic discharge sensitive
components are identified with bold letters (ESDS).
E. Units Per Assembly Column
Quantities specified in this column are per item number. The letters AR appearing in this
column denote selection of parts on an As Required basis. Letters REF refer to an assembly
completely assembled on a previous illustration.
F. Effectivity Code Column
This column is used to establish parts compatibility with units or subassemblies that are
essentially the same as far as color, marking methods, etc. When no code is listed, parts are
usable on all applicable models or assemblies. At the end of each Figure Listing is a Effectivity
Code to Part Number cross reference table to assist in unit identification.
G. How To Use The Detailed Parts List
For the following examples, refer to the appropriate lists and indexes within this manual.
1) Finding the Part Number when only the physical location of the part is known:
a. Use the List of Illustrations to locate assembly page number in which the part is used.
b. Find the illustration and locate the part on the next higher assembly (e.g., if a part is
located on a PC board, the PC board is the next higher assembly). Note the part
number.
c. Refer to the Detailed Parts List for the illustration figure number.
d. Locate the part item number and the part number in the Part Number column.
2) Finding the Part Number when only the Part Reference Designator is known:
a. Find the Part Reference designation number in the Part Reference Designator Index.
b. Refer to the figure and item number column in the Detailed Parts List for part number.
3) Finding an Illustration for a known Part Number:
a. Locate the known part number in the Numerical Index. Note the figure and item
number.
b. Turn to the Detailed Parts List and locate the figure and index number for a
description of the part.
c. Turn to the illustration and locate the physical position of that part on the assembly.
24-30-02
Model PS-835( ) // 501-1228-( )
96 15 4 ea
95
10 2 ea
85
80
20 2 ea
25 2 ea
100
75 (A2)
45 CAUTION!
See Assembly section
30
5
35
A Replace Cells in the order for which they are numbered.

Note:
50 3 ea
Arrange Cells to align terminals vertically with positive (+) terminal on bottom.
Invert the position of the Tie-Down Straps for the top row of Cells.
Apply RTV into the shaded areas. Note location of cells BT1 and BT12 for sake of
Disassembly and Assembly wiring instructions.
BT10 BT11 BT12
70 (A1)
BT8 BT7
40 BT9
BT4 BT5 BT6
60 2 ea
91 65 2 ea BT3 BT2 BT1

90
IPL Figure 1: PS-835 Emergency Power Supply
24-30-02
TP-329 Illustrated
Illustrated Parts Parts Listing
Listing - Page- 1007/1008
Page 1001
Model PS-835( ) // 501-1228-( )
5
220
195 13 ea
10
190
15
185
20 180
170
2 ea
175
25 100
165
30 2 ea
35
3 ea 160
155
40
9 ea
105
45
185 190
50 180
135 140 145 150
115
120
115 105
115
125 110 100
120
130 2 ea 542-1521-01
542-1521-01
30 95
90
195 85 80
75
55
65 70
60
2 ea
200
225
2 ea
205 2 ea
2 ea
215
210
IPL Figure 3: Battery Monitor CCA 542-2635-01, 542-2625-01, and 542-1521-01

24-30-02
Model PS-835( ) // 501-1228-( )
Fig- Nomenclature Units/ Eff.

Part Number
Item 123456 Assy Code
BATTERY MONITOR CCA (A2)
3-1 542-2635-01
(See IPL Figure 1 for next higher assembly.)
542-2625-01 BATTERY MONITOR CCA (A2) *Obsolete E,F
542-1521-01 A,B,C,
BATTERY MONITOR CCA (A2) *Obsolete
E,F
542-1495-01 BATTERY MONITOR CCA (A2) *Obsolete 1 C,D
542-1495-02 BATTERY MONITOR CCA (A2) *Obsolete 1 C,D
542-1364-01 BATTERY MONITOR CCA (A2) *Obsolete 1 A,B
*See Service Bulletins and Modifications table Figure 1.
5 536-2594-01 • PRINTED WIRING BOARD 1

10 551-1300-05 THERMAL RESISTOR (RT1) 12
15 561-1018-01 • SWITCH, ROCKER DIP (S1) 1
20 563-1033-03 • CONNECTOR, ELECTRICAL (P3) 1
25 551-1211-06 • RESISTOR NETWORK 42.2K 1W 2% SIP8 (U5) 1
30 554-1108-03 • DIODE, LED GREEN 90MA T1-3/4 (DS13 and 2
DS17)
35 554-1108-02 • DIODE, LED YELLOW 60MA T1-3/4 (DS14 ,DS15, 3
DS16)
40 JANTX1N4148-1 • DIODE, FAST 75V 150MA DO-35 (CR1-CR5, CR7- 9
CR10)
45 553-1069-01 • TRANSISTOR (Q4) 1
50 RN55C9092F • RESISTOR, 90.9K .1W 1% (R4) 1
55 JAN1N5618 • DIODE, FAST 600V 1A DO-204AP (CR6) 1
60 553-1047-01 • TRANSISTOR (Q2,Q3) 2
65 551-1217-34 • RESISTOR, WIRE WOUND 50Ω 2.2W 1% (R7) 1
70 RLR07C5601GS • RESISTOR, 5.60K .25W 2% (R3) 1
75 551-1217-14 • RESISTOR, WIRE WOUND 2.00K 2.2W 1% (R19) 1
80 RLR05C2700GS • RESISTOR, 270 OHM .125W 2% (R20) 1
90 RLR07C2001GS • RESISTOR, 2.0K .25W 2% (R16) 1
95 RN55C1004F • RESISTOR, 1 MEG .1W 1% (R15) 1
100 577-1019-01 • QUAD OP AMP (U1,U2) 2
105 551-1211-04 • RESISTOR, NETWORK (U3,U4) 2
110 M39003/01-2362 • CAPACITOR (C1) 1
115 RN55C1001F • RESISTOR, 1.00K .1W 1% (R1,R12,R24) 3
120 RN55C5623F • RESISTOR, 562K .1W 1% (R10) 1
24-30-02
Model PS-835( ) // 501-1228-( )
Fig- Nomenclature Units/ Eff.

Part Number
Item 123456 Assy Code
3-125 1N829A • DIODE, 6.2V 250MW 5% DO-34 (VR1) 1
130 RN55C8250F • RESISTOR, 825 OHM .1W 1% (R2) 1
135 553-1060-01 • TRANSISTOR, N-CHANNEL FET (Q1) 1
150 1N4751A • DIODE, 30V 1W 5% DO-204 (VR2) 1
160 551-1022-11 • RESISTOR, VARIABLE (R8) 1
165 551-1022-13 • RESISTOR, VARIABLE (R13,R5) 2
170 RN55C1002F • RESISTOR, 10.0K .1W 1% (R21,R23) 2
180 RN55C2001F • RESISTOR, 2.00K .1W 1% (R22)
195 554-1171-01 • DIODE, LED RED 5V 7MA T1-3/4 (DS1-D12,D18) 13
200 528-1036-01 • HEATSINK AND NUT ASSY 1

ATTACHING PARTS
205 568-1566-06 • SPACER 2
210 569-1137-07 • WASHER SHOULDERED NON-METALLIC 2
215 580-1513-02 • STANDOFF P.C. BD. 2
220 580-1513-09 • STANDOFF P.C. BD. 1
225 MS24693C5 • SCREW MACHINE FLAT COUNTERSUNK HEAD 2
***
230 S23044-13 • INSULATOR STANDOFF 24

235 S43003-07 • INSULATOR SEMICONDUCTOR MOUNTING 2
240 S23044-24 • INSULATOR STANDOFF 18
24-30-02
Model PS-835( ) // 501-1228-( )
24-30-02

EPS PS835 CMM Rev. B 2009

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Record of Revisions ............................................................................................................. i

Description and Operation

Table of Contents (continued)

Testing and Fault Isolation

Fits and Clearances

Special Tools, Fixtures, Test Equipment and Consumables

Illustrated Parts List

Service Bulletin Information

This page intentionally blank.

Section Page Group

Comments, corrections, deletions, additions, clarifications or other pertinent information should be

Service Directives List

Figure Title Page

List of Symbols and Abbreviations

Modification Kits and

Figure 1: Service Bulletins and Modifications

Modification Kits and

Figure 1: Service Bulletins and Modifications (Cont.)

C. Storage Time and Temperature

Figure 5: Cell Storage Time vs. Temperature

D. Cell Current Discharge Time

Figure 6: Typical Discharge Time for Sealed Lead Acid Cells

B. Heating Resistor (A1HR1)

E. Battery Voltage Level Detection

The potentiometer *A2R25 (**A2R5) is adjusted so that OUTPUT VOLTAGE MONITOR

NOTE: INDIVIDUAL CELL MONITOR LED's (DS1 through DS12) function as

Figure 8: PS-835 Models E and F Schematic Diagram

This schematic represents Models E and F after

This schematic represents Models A, B, C, and D

Figure 11: PS-835 Models A, B, C, and D Schematic Diagram

This schematic includes wiring changes prompted by MOD 1 to both 506-1287L

Testing and Fault Isolation

CAUTION: CELL/BATTERY CORROSION IS EVIDENCE OF THE LOSS OF SEAL, LIKELY CAUSED BY

A. Constant-Voltage Charging Method

3) Battery Monitor CCA Calibration Procedure

NOTE: The Battery Monitor CCA MUST be correctly calibrated to insure

NOTE: If calibration cannot be successfully achieved, remove the Battery Monitor

b. Check Thermo Resistor (A1RT1) (2-215) to ensure that it is adequately grounded to

WARNING: ADHESIVE (F-900 TORQUE SEAL) HAS BEEN IDENTIFIED AS HAVING A

Figure 106: Circuit Card Assembly Test Setup

B. Battery Monitor CCA Performance Test (542-1521-xx, 542-2625-xx, 542-2635-xx)

NOTE: Obsolete Battery Monitor CCA's 542-1495-xx and 542-1364-xx have no

3) Energize and set the External Power Supply to 28 Vdc.

4) Turn switch S1 to position 1.

8) Increase External Power Supply (measured at TP 2) to 28 Vdc. INDIVIDUAL CELL

C. Post Test Procedures

B. Front Panel Removal

2) Separate Front Panel (1-30) from Battery CCA (A1) (1-70).

C. Battery Monitor Circuit Card Assembly (A2) (CCA) Removal

CAUTION: CELL/BATTERY CORROSION IS EVIDENCE OF THE LOSS OF SEAL, LIKELY CAUSED BY

3) Repeat for the next vertical 4-cell group.

4) Pull out the last vertical 4-cell group.

E. Heater Element (HR1) Removal

2) Peel Heater Element (HR1) (2-45) from Battery CCA Chassis.

3) Remove excess adhesive from chassis.

F. Battery CCA (A1) Disassembly

3) Remove Screws (2-150 and 2-160), Washers (2-155 and 2-165)

4) Separate Battery PWB (2-145) from Battery CCA Chassis.

This page intentionally blank.

Figure 401: Modified Acid Brush