CMM 52-11-01 1mxa1 15417738

RADIANT POWER CORP.
COMPONENT MAINTENANCE MANUAL

PART NUMBER BPAS10
HOLDERS OF COMPONENT MAINTENANCE MANUAL 52-11-01, REVISION 8
REVISION NO. 9, DATED DEC 01/2014
HIGHLIGHTS
The pages that have been added or revised are outlined below, together with the highlights of the
revision.
Chapter/Section and Page No. Description of Change

Title Page: T-1 REFLECT Revision 9
CHANGED export statement from “…ECCN: 9A991.D…”
Record of Revisions: RR-1 ADDED Revision 9
Service Bulletin List: SB-1 ADDED SB 52-01 & SB 52-02
List of Effective Pages: LEP-1 & LEP-2 UPDATED the effective date for all applicable pages
Table of Contents: TC-1 & TC-2 ADDED Section Repair-1, Figures 602R & 603R and Table 3
Introduction
Page Intro-1: Section 1: NOTE ADDED
Pages Intro-2 to Intro-4 CHANGED due to addition
Description and Operation

Page 3: Section 6 ADDED
Page 7: Table 2, Part Number ADDED BPAS10-5 MOD A
Page 8: Table 3 ADDED
Testing and Fault Isolation

Page 102: Table 101 CORRECTED current probe part number from MA200
Page 103: Section 2.D. CHANGED from “…50 VDC. Turn on…”
Page 108: Section 4.A.6, first bullet DELETED “Apply power to the Unit Under Test by setting switch
SW1 to ON.”
Page 108: Section 4.A.7, first bullet CHANGED from “…milliamps (not charging).”
Page 108: Section 4.A.8, first bullet CHANGED from “…be between 25 milliamps (fully charged
battery) and 75 milliamps (fully discharged battery).”
Page 108: Section 4.A.9, first bullet CHANGED from “…The current reading on V1…”
Page 108: Section 4.A.10 CHANGED from “…“OFF”. Do not…”
Page 109: Section 4.B.1 CHANGED from “…by turning on SW1.”
Repair
Page 604: Table 601, Test switch CHANGED from 08-70-0073 & 10-01-4024
socket & receptacle housing
Page 604: Table 601 CHANGED insertion/extraction tool from MS24256R12
Page 609: Table 602 SWITCHED P4-1 & P4-2 in “From” column
Repair-1 (Maintenance)
Page 601R: Section 1 CHANGED from “Battery Maintenance”
Page 601R: Section 2 ADDED
Page 602R: Figure 602R ADDED
Page 604R: Figure 603R ADDED
Highlights-1
Copyright 2004 by: Radiant Power Corp., a HEICO Company 52-11-01 Dec 01/2014
RADIANT POWER CORP.
PART NUMBER BPAS10
Chapter/Section and Page No. Description of Change

Illustrated Parts List
Pages 1007-1008 ADDED 53253-0270, FM08A125V1/2AT, FM08A125V5AT &
FM08A125V10AT
Page 1009 ADDED L7812CV-DG
Pages 1011-1013 ADDED 50212-8100, 51065-0200 & 53253-0270
Page 1024: Items 130A, 135A & ADDED
140A
Page 1030: IPL Figure 6 UPDATED connector
Page 1030: Item 10 SUPSD BY ITEM 10A
Page 1030: Items 10A & 15A ADDED
Page 1031: IPL Figure 7 UPDATED connector
Page 1031: Items 20A & 25A ADDED
Pages 1035-1037: Item 45A & 55A ADDED
Highlights-2
RADIANT POWER CORP.
PART NUMBER BPAS10
CAGE CODE: 1MXA1
RADIANT POWER CORP.

7135 16th Street East, Suite 101
Sarasota, FL 34243
PH: (941) 739-3200
Fax: (941) 739-3201
Component Maintenance Manual

With
Illustrated Parts List
Standby Instrument Battery
Part Number: BPAS10-5
THIS MANUAL CONTAINS PROPRIETARY INFORMATION OF RADIANT POWER

CORP., AND IS TENDERED SUBJECT TO THE CONDITION THAT NO COPY OR
OTHER REPRODUTION BE MADE IN WHOLE OR IN PART, AND THAT NO OTHER
USE BE MADE OF SUCH INFORMATION WITHOUT EXPRESS WRITTEN
PERMISSION OF RADIANT POWER CORP. REVISION 9
INFORMATION SUBJECT TO EXPORT CONTROL LAWS

THE TECHNICAL DATA IN THIS DOCUMENT (OR FILE) IS CONTROLLED FOR EXPORT UNDER THE EXPORT
ADMINISTRATION REGULATIONS (EAR), 15 CFR PARTS 730-774, ECCN: 9E991.D. VIOLATIONS OF THESE LAWS
MAY BE SUBJECT TO FINES AND PENALTIES UNDER THE EXPORT ADMINISTRATION ACT.
Copyright 2004 by: Radiant Power Corp., a HEICO Company Page T-1
Original Issue: Jan 05/2001
52-11-01 Rev. 9: Dec 01/2014
RADIANT POWER CORP.
PART NUMBER BPAS10
THIS PAGE INTENTIONALLY LEFT BLANK
T-2
Copyright 2004 by: Radiant Power Corp., a HEICO Company 52-11-01 Jun 27/2012
RADIANT POWER CORP.
PART NUMBER BPAS10
RECORD OF REVISIONS
REVISION REVISION DATE BY REVISION REVISION DATE BY

NUMBER DATE FILED NUMBER DATE FILED
1 Jan 05/01 Jan 05/01 A. Ieraci
2 Apr 26/01 Apr 26/01 R. Francavilla
3 Jan 22/02 Jan 31/02 P.VanWormer
4 Oct 08/02 Oct 08/02 R. Francavilla
5 Jul 2006 Jul 2006 A.Lustenberger
6 Aug 2009 Aug 2009 T. Meyer
7 Jun 27/12 Jun 27/12 T. Meyer
8 Jan 07/13 Jan 07/13 T. Meyer
9 Dec 01/14 J. Densmore
Page RR-1
RADIANT POWER CORP.
PART NUMBER BPAS10
Page RR-2
RADIANT POWER CORP.
PART NUMBER BPAS10
RECORD OF TEMPORARY REVISIONS
REVISION REVISION DATE BY REVISION REVISION DATE BY

NUMBER DATE FILED NUMBER DATE FILED
Page TR-1
RADIANT POWER CORP.
PART NUMBER BPAS10
Page TR-2
RADIANT POWER CORP.
PART NUMBER BPAS10
SERVICE BULLETIN LIST
SERVICE DATE DATE BY SERVICE DATE DATE BY

BULLETIN ISSUE FILED BULLETIN ISSUE FILED
SB 52-01 Dec 12/12 DJD
SB 52-02 Feb 13/13 DJD
Page SB-1
RADIANT POWER CORP.
PART NUMBER BPAS10
Page SB-2
RADIANT POWER CORP.
PART NUMBER BPAS10
LIST OF EFFECTIVE PAGES
Subject Page Date Subject Page Date
Title Page T-1 Dec 01/14 Disassembly 301 Jan 07/13

T-2 Jun 27/12 302 Jun 27/12
303 Jan 07/13
Record of Revisions RR-1 Dec 01/14 304 Jan 07/13
RR-2 Jun 27/12 305 Jun 27/12
306 Jan 07/13
Record of Temporary TR-1 Jun 27/12 307 Jun 27/12
Revisions TR-2 Jun 27/12 308 Jun 27/12
Service Bulletin List SB-1 Dec 01/14 Cleaning 401 Jun 27/12
SB-2 Jun 27/12 402 Jun 27/12
List of Effective Pages LEP-1 Dec 01/14 Check 501 Jun 27/12
LEP-2 Dec 01/14 502 Jun 27/12
503 Jan 07/13
Table of Contents TC-1 Dec 01/14 504 Jun 27/12
TC-2 Dec 01/14
Repair 601 Jan 07/13
Introduction Intro-1 Dec 01/14 602 Jun 27/12
Intro-2 Dec 01/14 603 Jun 27/12
Intro-3 Dec 01/14 604 Dec 01/14
Intro-4 Dec 01/14 605 Jun 27/12
606 Jun 27/12
Description and 1 Jun 27/12 607 Jun 27/12
Operation 2 Jun 27/12 608 Jun 27/12
3 Dec 01/14 609 Dec 01/14
4 Jun 27/12 610 Jun 27/12
5 Jun 27/12
6 Jun 27/12 Repair-1 (Maintenance) 601R Dec 01/14
7 Dec 01/14 602R Dec 01/14
8 Dec 01/14 603R Dec 01/14
604R Dec 01/14
Testing and Fault 101 Jun 27/12
Isolation 102 Dec 01/14 Assembly (including 701 Jun 27/12
103 Dec 01/14 Storage) 702 Jun 27/12
104 Jun 27/12 703 Jan 07/13
105 Jun 27/12 704 Jun 27/12
106 Jan 07/13 705 Jan 07/13
107 Jan 07/13 706 Jun 27/12
108 Dec 01/14 707 Jun 27/12
109 Dec 01/14 708 Jun 27/12
110 Jan 07/13 709 Jun 27/12
111 Jan 07/13 710 Jun 27/12
112 Jan 07/13
113 Jan 07/13 Special Tools, Fixtures, 901 Jun 27/12
114 Jan 07/13 and Equipment 902 Jun 27/12
115 Jan 07/13
116 Jan 07/13 Illustrated Parts List 1001 Jun 27/12
117 Jan 07/13 1002 Jun 27/12
118 Jan 07/13 1003 Jun 27/12
1004 Jun 27/12
Page LEP-1
RADIANT POWER CORP.
PART NUMBER BPAS10
Subject Page Date Subject Page Date
Illustrated Parts List 1005 Jun 27/12

(cont) 1006 Jun 27/12
1007 Dec 01/14
1008 Dec 01/14
1009 Dec 01/14
1010 Jun 27/12
1011 Dec 01/14
1012 Dec 01/14
1013 Dec 01/14
1014 Jun 27/12
1015 Jun 27/12
1016 Jun 27/12
1017 Jun 27/12
1018 Jun 27/12
1019 Jun 27/12
1020 Jun 27/12
1021 Jun 27/12
1022 Jun 27/12
1023 Jun 27/12
1024 Dec 01/14
1025 Jun 27/12
1026 Jun 27/12
1027 Jun 27/12
1028 Jun 27/12
1029 Jun 27/12
1030 Dec 01/14
1031 Dec 01/14
1032 Jan 07/13
1033 Jun 27/12
1034 Jun 27/12
1035 Dec 01/14
1036 Dec 01/14
1037 Dec 01/14
1038 Jun 27/12
1039 Jun 27/12
1040 Jun 27/12
Page LEP-2
RADIANT POWER CORP.
PART NUMBER BPAS10
TABLE OF CONTENTS
Subject Page
Description and Operation 1

Testing and Fault Isolation 101
Automatic Test Requirements Not Applicable
Disassembly 301
Cleaning 401
Check 501
Repair 601
Repair-1 (Maintenance) 601R
Assembly (Including Storage) 701
Fits and Clearances Not Applicable
Special Tools, Fixtures, and Equipment 901
Illustrated Parts List 1001
LIST OF FIGURES
Figure Page
1 BPAS10-5 Primary Components 3

2 Pin-out for Electrical Connector 4
3 Schematic Diagram 5
101 STC500 Test Cable Assembly 103
102 Test Fixture Set-up 105
103 Schematic for Test Fixture, BPAS10-5 106
601 Test Setup Centering & Actuation Tests 607
602 Arm/ Disarm Switch Assembly (140, IPL Figure 1) 608
601R Charging Cable RP-3300 (Repair-1) 601R
602R Discharging Setup 602R
603R Charging Setup 604R
701 Arm/ Disarm Switch Assembly Wire Leads 709
702 Tiedown Strap Placement 710
IPL1 Emergency Door Power Assist Battery Pack 1015
IPL2 Heatsink Cabled Assembly 1021
IPL3 Heatsink PCB Assembly 1026
IPL4 Chassis Assembly 1028
IPL5 Connector Assembly 1029
IPL6 Test Switch Assembly 1030
IPL7 LED/ PCB Assembly 1031
IPL8 EMI PCB Assembly 1032
IPL9 Main PCB Assembly 1033
IPL10 Arm/Disarm Switch Assembly 1038
LIST OF TABLES
Table Page
1 Electrical Connector Pin Assignment 4

2 Technical Properties 7
3 Unit Modification 8
101 Test Equipment and Materials 101
102 Troubleshooting 112
103 Fault Isolation Procedures 115
TC-1
RADIANT POWER CORP.
PART NUMBER BPAS10
LIST OF TABLES (CONT)
Table Page
401 Cleaning Materials 401

501 Check Procedures 501
601 Repair Tools and Materials 604
602 Assembly Wire List 609
701 Assembly Tools and Materials 702
702 Packaging and Storage Materials 708
901 Special Tools, Fixtures, and Equipment 901
1001 Vendor Names and Addresses 1005
REFERENCE DESIGNATOR INDEX 1007
NUMERICAL INDEX 1010
IPL FIGURE 1 PARTS LIST 1017
TC-2
RADIANT POWER CORP.
PART NUMBER BPAS10
INTRODUCTION
1. Scope
This Component Maintenance Manual (CMM) contains maintenance instructions and lists
replacement parts to assist qualified repair personnel in off-aircraft maintenance of Emergency
Door Open Power Assist System (EPAS) Battery Pack, part number BPAS10-5. The EPAS
battery pack is manufactured by Radiant Power Corporation of Sarasota, Florida.
NOTE: This CMM covers maintenance of the BPAS10-5 and BPAS10-5 MOD A
configurations.
Configuration Serial Numbers

BPAS10-5 0001 thru 2183
BPAS10-5 (MOD A) 2184 and subsequent
2. Product Support Services
A. Repair and overhaul services, replacement parts, technical documentation, and other
product support services are available from Radiant Power Corp. Please contact our
Sales Department at:
Radiant Power Corp. Telephone: (941) 739-3200
7135 16th Street East, Suite 101 FAX: (941) 739-3201
Sarasota, FL. 34243
USA
3. Usage Guide
A. Refer to the Table of Contents to find the necessary maintenance procedures or other
data. This CMM is written to ATA 100 and AECMA Simplified English.
(1) Description and Operation describes the purpose, primary components, and
technical properties of the EPAS battery pack.
(2) Testing and Fault Isolation contains bench test and fault isolation procedures.
(3) Disassembly contains procedures to disassemble the EPAS battery pack for repair
or part replacement.
(4) Maintenance contains information on proper storage and electrical conditioning of

the batteries.
(5) Cleaning contains procedures to clean the EPAS battery pack.
(6) Check contains procedures to check parts for damage.
(7) Repair contains procedures to refinish and rework parts to serviceable condition.
(8) Assembly contains procedures to reassemble and store the EPAS battery pack.
Page Intro-1
RADIANT POWER CORP.
PART NUMBER BPAS10
(9) Illustrated Parts List contains the information necessary to order replacement
parts. An equipment designator index, a numerical index, and exploded-view
drawings are provided to help find and identify the parts. The introduction to the IPL
gives more data.
B. The recommended tools and materials are given in each section. Equivalent items can
be used.
C. WARNINGS, CAUTIONS and NOTES
(1) WARNINGS are provided before potentially dangerous procedures, materials,

methods, and processes which must be followed precisely to avoid injury.
(2) CAUTIONS are provided before procedures, materials, methods, and processes
which must be followed precisely to avoid equipment damage.
(3) NOTES are provided after applicable procedure steps when necessary to highlight
or clarify information.
4. General Safety Precautions
The following general safety precautions must be observed during all phases of operation,
service, and repair of the EPAS battery pack.
ELECTROSTATIC DISCHARGE All Integrated Circuits (ICs), surface mounted devices,

and many semiconductors are susceptible to
Electrostatic Discharge (ESD). Careless handling
during repair can drastically decrease the component
life.
Follow the PCB handling procedures given in REPAIR

to avoid ESD damage.
GROUNDING Connect equipment and personnel to electrical ground

to minimize shock hazards. When handling PCB
assemblies, place them on a grounded workbench.
EXPLOSIVE ENVIRONMENT Do not operate the EPAS battery pack in the presence
of flammable gas or fumes.
LIVE CIRCUITS The EPAS battery pack contains high voltage electrical
circuits. Do not service the unit with the power on. To
avoid injury, always disconnect power and discharge
the circuits before maintenance.
DO NOT SERVICE OR ADJUST Maintenance personnel must be familiar with high
ALONE voltage equipment safety guidelines. Another person
capable of providing first aid and resuscitation must be
present.
DO NOT SUBSTITUTE PARTS OR Do not alter or add to the mechanical or electrical
design of the EPAS battery pack. Design changes and
Page Intro -2
RADIANT POWER CORP.
PART NUMBER BPAS10
MODIFY EQUIPMENT additions can alter safety characteristics and create a

hazard. Any design alterations or additions will void the
warranty. Do not install substitute parts or do any
unauthorized modifications to the equipment.
SHOCK To prevent electrical discharge, do not expose the

equipment to rain or high humidity.
Visually check for pinched, out of place, or frayed

wiring during maintenance. Components and/or wiring
that appear to have overheated or are otherwise
damaged should be replaced with components that
meet the original specifications.
Do a safety check of the entire unit before returning

the equipment for operation.
5. Verification Dates
Procedure Date
Testing/Fault Isolation Dec 21/96
Disassembly Dec 21/96
Assembly Dec 21/96
6. Revision Service
Revised pages will be issued when necessary to correct errors or to add new configurations.
The revised part of the page will be identified by a change bar or capital R in the left margin.
7. Abbreviations and Unit Symbols
Abbreviations and unit symbols used in this manual are defined below. All weights and
measurements are given first in English standard units followed by the metric equivalent in
parentheses.
AC Alternating Current EFF Effectivity

Assy Assembly EMI Electromagnetic Interference
ATA Air Transport Association EPAS Emergency Door Open Power
AWG American Wire Gage Assist System
C degree Celsius ESD Electrostatic Discharge
C Capacitor F degree Fahrenheit
CAGE Commercial And Government Fig. Figure
Entity HIRF High Intensity Radio Frequency
cm centimeter Hz Hertz
CMM Component Maintenance IC Integrated Circuit
Manual ID Inner Diameter
D Diode IPL Illustrated Parts List
DC Direct Current J Jack
Page Intro-3
RADIANT POWER CORP.
PART NUMBER BPAS10
kg kilogram (I kg = 2.205 lb.) PCB Printed Circuit Board

kPag kiloPascal - gage (1 kPag 0. 145 SW Switch
psig) psig pounds per square inch - gage
lb pound VDC Voltage, Direct Current
LED Light Emitting Diode R Resistor
LRU Line Replaceable Diode RF Reference
MEK Methyl-Ethyl-Ketone SB Service Bulletin
mm Millimeter SCD Source Control Drawing
mV millivolt PED Passenger Entry Door
N-m Newton-meter (torque) UUT Unit Under Test
NHA Next Higher Assembly Q Transistor
NIST National Institute of Standards W Watt
and Technology
No. Number
Page Intro-4
RADIANT POWER CORP.
PART NUMBER BPAS10
DESCRIPTION AND OPERATION
1. Purpose
A. The Emergency Door Open Power Assist System (EPAS) Battery Pack provides direct
current (DC) power to provide firing current for a bridge wire igniter in the EPAS pressure
reservoir assembly. The bridge wire actuation ruptures a valve to release pressurized
gas to assist Passenger Entry Door (PED) opening in emergency conditions. Under
normal conditions, the EPAS battery pack remains fully charged in a ready state.
B. The EPAS battery pack is a Line Replaceable Unit (LRU).
2. Primary Components
A. The primary components of the EPAS battery pack are shown in Figure 1.
B. The EPAS battery pack consists of an electronics assembly, battery pack assembly
(BPA), a battery test switch, and test Light Emitting Diode (LED), and an ARM/DISARM
safety switch actuator assembly mounted in an aluminum chassis. The electronics
assembly is made up of two Printed Circuit Board (PCB) assemblies, electrical
connector, resistors R222 and R225, transistors Q204 and Q208 with heatsink, and
safety switches SW1 and SW2. The chassis assembly provides protection from moisture
and handling damage. The interior access cover can easily be removed for maintenance
access.
C. Battery pack assembly, BPA, consists of eighteen Nickel-Cadmium batteries wrapped in

heat shrink material. The battery pack is secured in the housing with protective padding
to simplify removal and replacement. The batteries are wired in series and connected to
a receptacle.
D. All components are secured by standard attaching hardware. All wire connections are
soldered. The chassis is painted flat black with adhesive-backed labels.
E. A single 12-pin BACC63CB14 –12SN electrical connector provides the electrical

interface with the aircraft. The connector mates to a BACC63CC14-12PN receptacle. The
interface circuits and voltage levels are given in Figure 2 and Table 1.
F. The EPAS battery pack mounts against a flat surface with fasteners through the four
0.250 inch (6.35 mm) diameter, mounting holes in the chassis.
3. Functional Description
A. The EPAS battery pack provides firing current pulses to rupture a valve, which releases
pressurized gas to assist PED door opening in emergency conditions. Each firing pulse is
6.0 Amperes minimum for 50 milliseconds minimum. The EPAS battery pack has the
capacity to provide a total of 5 firing current pulses for up to 350 hours after the loss of
input power.
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RADIANT POWER CORP.
PART NUMBER BPAS10
B. The switch lever cam is attached to the shaft of an actuator, which mechanically actuates
switches SW1 and SW2 arm/disarm switch assembly. With the lever in one of the two
DISARM positions, the battery output voltage at connector J1 pins 3, 4, & 8 (+) and 2 (-)
is reduced to less than 0.1 VDC, which is insufficient to actuate the bridge wire igniter.
With the lever in the ARM position, and the unit fully charged, the battery output voltage
is typically 24.0 to 26.0 VDC.
C. The test switch and the test LED, verify: battery performance by pulsed load test current,
input voltage, fuse condition and indicate whether the battery pack is operational.
(1) With the switch lever cam in the ARM position, pins 11 & 12 shorted, the emitters of
transistors Q204 and Q208 are connected to the positive battery terminal. With 28
VDC nominal input voltage present at pins 1(+) and 2(-) of connector J1, pushing
test switch will turn on transistor Q211 for 0.25-second nominal to turn on transistors
Q204 and Q208.
(2) Transistors Q204 and Q208 provide a load path through resistor R244, which
provides a minimum reference corresponding to a battery current of approximately
5.0 Amps. Comparator U212 will then turn on transistor Q211 and LED if the battery
pack voltage is above 20.2 VDC to indicate that the battery pack is ready to provide
the required current pulses. If the battery pack current is less than 5.00 AMPS DC,
the LED will not turn on.
D. The EPAS battery pack has one charge rate, slow (trickle), which is generated by power
supply circuits on the main PCB assembly. The battery charging current is maintained
whenever 28 VDC nominal input voltage is present at pins 1(+) and 2(-) of the connector.
(1) The battery terminal voltage is monitored by voltage divider R256/ R257, and is
compared to the temperature dependent voltage reference provided by the non-
inverting input of quad comparator, U207.
E. Electromagnetic interference (EMI) filter circuits on the EMI PCB assembly limit
transients and other conducted and radiated emissions to other components in the same
circuit as the battery pack. The circuits also protect the battery pack circuits from input
power transients caused by circuit components, lightning, and other sources.
F. Fuse F101 limit the battery output at pin 3 of connector J1 to 5 Amperes, F102 and F103
limit the battery output at pins 4 & 8 of connector J1 to 10 Amperes and, F104 limit the
relay current at pin 9 of connector J1 to 0.5 Amperes
4. Operation
A. To charge the EPAS battery pack, short pins 11 & 12, continuously apply 22.0 to 29.5
VDC (28VDC nominal) voltage across pins 1(+) and 2(-) of connector J1. The battery
pack will charge automatically, and continuously to maintain the required voltage. The
charging can only occur in the “armed mode”.
B. For automatic operation of the EPAS battery pack, set the switch lever cam to the ARM
position. The battery pack will discharge as needed to assist door opening when the PED
inside handle is rotated fully to the open position.
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RADIANT POWER CORP.
PART NUMBER BPAS10
C. To prevent operation of the EPAS battery pack for maintenance or other purposes, set
the switch lever cam to the DISARM position. This will also prevent operation of test
switch, and prevent the unit from charging.
NOTE: The switch lever cam will always return to the ARM position when it is rotated
60 degrees or less. There is a detent of 1 to 4 lbs (0.5 to 1.8 kg) at the DISARM
position.
D. To test the EPAS battery pack, push test switch and verify that the LED illuminates. The
LED will activate if: the battery current is greater than 5 Amps across the test load, pins
11 & 12 are shorted together, the fuses are good, and the input voltage from the aircraft
power is greater than 20 Volts.
5. Technical Properties
Technical properties of the EPAS battery pack are given in Table 2.
6. Modification
Equipment is marked per the modifications listed in Table 3.
BPAS10-5 Primary Components

Figure 1
Page 3
RADIANT POWER CORP.
PART NUMBER BPAS10
Electrical Connector Pin Assignment

Table 1
Pin Number Pin Function Description Function Group

1 +28 Volts DC Input Power Power
2 DC Input Power Ground Power
3 Battery Output #4 (Squib) Signal
5 Door Switch Return Signal
6 Chassis Ground Power
7 Battery Output #2 (Remote Relay Coil) Signal
9 Remote Relay Coil Power Out to Interlock Switches. Signal
10 Battery Negative Return Line Signal
11 Battery Loop Output Signal
12 Battery Loop Input Signal
Pin-out for Electrical Connector (5, IPL Figure 5)

Figure 2
Page 4
RADIANT POWER CORP.
PART NUMBER BPAS10
Schematic Diagram
Figure 3 (Sheet 1 of 2)
Page 5
RADIANT POWER CORP.
PART NUMBER BPAS10
Schematic Diagram
Figure 3 (Sheet 2 of 2)
Page 6
RADIANT POWER CORP.
PART NUMBER BPAS10
Technical Properties
Table 2 (Sheet 1 of 2)
Property Specification
Description
Manufacturer Radiant Power Corp.
Nomenclature Emergency Door Open Power Assist System
(EPAS) Battery Pack
Part Number
Radiant Power Corp. BPAS10-5, BPAS10-5 MOD A
Boeing S283W203-5
Functional Properties
Number of outputs 3
Input Power
Voltage 22.0 to 29.5 VDC (28 VDC nominal)
Current 45 to 160 milliamps
Output Power
Voltage
Switch Lever Cam at ARM Position 24.0 to 26 VDC
Switch Lever Cam at DISARM Position 0.1 VDC maximum
Remote Relay Coil 10 to 12 VDC (during firing pulses)
Current 6.00 Ampere, 55-millisecond minimum pulses,

Firing Current maximum. Limited to 10 Amperes by Fuses F102,
F103; 5 Amperes by fuse F101.
Capacity 5 firing current pulses after loss of input power for 350
hours
Battery Pack Data 18 connected in series

Number of Batteries Nickel-Cadmium
Battery Type 600 milliamp-hours
Rating 24 to 26 VDC
Fully-Charged Voltage
Charge Rates and Transition Voltage 22.9 to 32.3 milliamps
Charge Current 60 minutes minimum from full discharge to have
Time to Charge adequate power to pass self-test and fire the outputs.
Insulation Resistance 100 meg-ohms minimum at 500 VDC

Electromagnetic Compatibility D200Z001, Section 3.3.2
Lightning and HIRF D200Z001, Section 12.7.3
Service Life 3 years operational after 10 years storage
Switch Lever Cam Operation
Rotation to DISARM Position Greater than 60°; safety switch lever will return
Minimum to ARM position if rotated less than 60°
Full Travel 90° ±2°

Force Required to Overcome DISARM 1 to 4 lbs (0.5 to 1.8 kg) Detent
Page 7
RADIANT POWER CORP.
PART NUMBER BPAS10
Technical Properties
Property Specification
Electrical Connector BACC63CC14-12PN
Mating Connector BACC63CB14-12SN
Dimensions and Weight
Overall Dimensions: 10.45 inches (26.54 cm)

Height 8.13 inches (20.65 cm)
Width 1.22 inches (3.10 cm)
Thickness 6.000x5.000x5.500 ±0.007 inches
Dimension Between Mounting Hole Centerlines (15.24x12.70x13.97 ±0.018 cm)
0.209 +0.010/ -0.000 inches
Diameter of Mounting Hole (4 Places) (0.531 +0.025/-0.000 cm)
Weight 3.11 lbs (1.41 kg) maximum
Unit Modification
Table 3
MOD Description
None Initial unit issued.
A Test Switch Assembly (130, IPL Figure 1) and LED/PCB Assembly (120)
connector hardware changed from items (10 & 15, IPL Figure 6) to items
(10A & 15A) and from items (20 & 25, IPL Figure 6) to items (20A &
25A). The mating headers changed from item (45, IPL Figure 9) to item
(45A). MOD A configured equipment is indicated on the ID labels.
Page 8
RADIANT POWER CORP.
PART NUMBER BPAS10
TESTING AND FAULT ISOLATION
1. General
A. This section contains the test, calibration, and fault isolation procedures given below.
Perform the tests before disassembly to identify damaged parts.
Procedures
2. Insulation Resistance Test
3. Battery Assembly BPA Tests
4. Performance (Final Assembly) Tests
5. Fault Isolation Procedures
B. The recommended test equipment and materials are given in Table 101. Equivalent
items can be used.
NOTE: Equivalent items can be used.
C. All tests must be performed at standard laboratory conditions, defined as follows:
• Ambient Temperature: 50°F to 86°F (10°C to 30°C)
• Relative Humidity: 80% maximum
• Atmospheric Pressure: 25 to 32 inHg
D. All test equipment must be calibrated to NIST (National Institute of Standards and
Technology) standards.
E. Unless otherwise specified, the primary power applied to the test unit is 28 ±0.5 VDC.
Test Equipment and Materials

Nomenclature Part or Specification Source (CAGE)* QTY
Number
Meg-ohmmeter, 100 meg-ohms Model 1864 GenRad Inc. (24655) 1
500 VDC, ±2% Full Scale
Multi-meter (Ohmmeter, Ammeter or Fluke 79 Fluke Electronics Corp. (89536) 2

Voltmeter can be used), 0 to 10 Amps
DC (±2% Full Scale), 0 to 100 VDC
(3-1/2 digits) 200 to 300 kilohms
Multi-meter (Ohmmeter, Ammeter or HP34401A Hewlett-Packard Co. (28480) 1

Voltmeter can be used), 0 to 10 Amps
DC (±2% Full Scale), 0 to 100 VDC
(3-1/2 digits) 200 to 300 kilohms
Solder Iron (Low wattage 24-40 watt) None listed Commercially available 1
*Refer to TABLE 1001in the IPL for the address
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RADIANT POWER CORP.
PART NUMBER BPAS10
Test Equipment and Materials

Part or Specification
Nomenclature Source (CAGE)* QTY
Number
Press, Hydraulic or Mechanical None listed Commercially available 1
Oscilloscope, Digital Storage, 4 DL1540CL Yokogawa (60366) 2

Channel
Power Supply, 0 to 32 VDC / 1 1711 BK Precision (08098) 2

AMP (2 Required)
Current Probe MA-2000 FW Bell (7H140) 1
Current Probe A622 Tektronix (0RR61) 1
Differential Probe Model 2593-2 Cal Test Electronics 3
Male Insulated test jack to BNC Model 76-083 Tenma (5X082) 3
Battery charging fixture RP-3300 Radiant or fabricated 1
BPAS10-5 Test fixture RT-141 Radiant or fabricated 1
Coax cables BNC to BNC 50 None listed Commercially available 2

ohm (3-6 feet long)
Banana to banana plug cords, 22 None listed Commercially available 12

GA, various colors
Alligator clip to meter jack leads None listed Fabricated 4
Hookup leads for Meg-ohmmeter None listed Commercially available 2

Alligator clip to banana plug
3.3K Resistor with black wires None listed Fabricated or purchased from OEM 1
and banana plugs
10K Resistor with red wires and None listed Fabricated or purchased from OEM 1
banana plugs
Test cable w/ alligator clip on one None listed Commercially available 1

end and banana clip on other
Tank or Shop Compressed Air None listed Commercially available 1

20 psig (138 kPa)
STC500 Test Cable STC500 Radiant or fabricated 1

* Refer to TABLE 1001in the IPL for the address
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RADIANT POWER CORP.
PART NUMBER BPAS10
2. Insulation Resistance Test
WARNING: THIS TEST APPLIES HIGH VOLTAGE, WHICH CAN CAUSE DEATH OR
SEVERE SHOCK. SET POWER SWITCHES TO OFF BEFORE CONNECTING
AND DISCONNECTING EQUIPMENT. USE CAUTION DURING TEST.
CAUTION: BATTERY PACK ASSEMBLY BPA (200, IPL FIGURE 1) MUST BE

DISCONNECTED. MAKE CERTAIN THAT THERE IS NO GROUND BETWEEN
THE CHASSIS AND THE MEG-OHMMETER
NOTE: All of the pins except for pin 6 & 12 on the STC500 test cable assembly are
shorted together and then go to a single wire with a RED banana plug at
the end.
STC500 Test Cable Assembly

Figure 101
A. Turn on the Fluke DMM (digital multi-meter meter). Set the meter into the Ohms position
and the range either to the auto-ranging position, or to the Meg Ohm range; depending
on the model of meter in use.
B. Attach the STC500 test cable assembly to the UUT Plug this RED banana plug into the
Positive input of the Fluke DMM.
C. Fasten the alligator clip to the metal of the heat-sink assembly. Insert the banana plug
into the Negative input of the Fluke DMM. Read the resistance on the meter. The reading
must be greater than 100 Meg Ohms before proceeding to step D. Any reading lower
than 100 Meg Ohms will indicate some short on the heatsink cabled assembly (170),
which must be repaired before step D.
D. Disconnect the wires from the Fluke Meter. Make certain the General Radio Meg-
ohmmeter is turned off! Connect the common wire from the STC500 test cable assembly
to the plus (+) terminal of the General Radio 1864 Meg Ohm Meter which has been set to
50 VDC. With the alligator clip still attached to the chassis, insert the other banana plug
to the negative (-) terminal. Turn on the Meg Ohm Meter.
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RADIANT POWER CORP.
PART NUMBER BPAS10
• Reading must be > 100 Meg Ohms at 50 volts DC.
E. Turn off the General Radio Meg-ohmmeter, disconnect the test leads.
3. Battery Pack Assembly BPA Test
NOTE: Use this test to verify that the battery cells in battery assembly BPA (200, IPL
Figure 1) are connected properly in series with no open or short circuits. This test
must be done before the battery assembly is installed in the chassis assembly (5).
If battery assembly BPA (200) has been discharged, it can be recharged during the
performance (final assembly) tests.
A. Use a Multimeter (Table 101) to measure the output voltage across the black (-) and the
white (+) wire leads (receptacle P2).
• The voltage should be 22.5 to 25.3 VDC (fully charged). The battery pack can be
charged during the performance (final assembly) tests.
B. Refer to ASSEMBLY to install battery pack assembly BPA (200) in the chassis assembly
(5) before doing the performance (final assembly) tests.
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RADIANT POWER CORP.
PART NUMBER BPAS10
Test Fixture Set-up

Figure 102
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RADIANT POWER CORP.
PART NUMBER BPAS10
Schematic for Test Fixture, BPAS10-5

Figure 103
Page 106
Copyright 2004 by: Radiant Power Corp., a HEICO Company 52-11-01 Jan 07/2013
RADIANT POWER CORP.
PART NUMBER BPAS10
4. Performance (Final Assembly) Tests
WARNING: THE FOLLOWING TESTS REQUIRE VOLTAGE AND CURRENT

MEASUREMENTS OF LIVE CIRCUITS. ELECTRICAL SHOCK CAN CAUSE
DEATH OR INJURY. USE CAUTION DURING THE TESTS AND FOLLOW
APPROVED ELECTRICAL SAFETY GUIDELINES.
NOTES: 1. The pulsed load test set includes battery discharge switch, SW 4 and
firing switch SW6.
2. Pins 11 and 12 in the BACC63CB12-12SN mating connector must be
jumpered.
3. PS1 and PS2 must be separate power supplies, and must never share
a common ground with relation to the test fixture. Damage to the test
fixture or the test unit could result.
A. Charge Rate Test
(1) Set the switch lever cam (160, IPL Figure 1) to one of the two DISARM positions.
• Setup to Figure 102
(2) Use a Multi-meter (Table 101) to measure the output voltage indicated by V2 DVM.
• Set the switch cam lever to ARM.

• The voltage should be between 18V (full discharge) and 25V (full charge).
• Set the switch cam lever to DISARM.
(3) Set up the battery current monitoring oscilloscope shown in Figure 102 according to
the settings below:
Channel Number 1 2
Source Bell Probe Tektronix Probe
Amplitude 500mV/div 2V/div
Position -4div 0div
Input Coupling DC DC
Probe 1:1 1:1
Trigger Mode Single Auto
Trigger Position 0div 0div
Trigger Level +0.5V ↑ +0.05V ↑
Trigger Source CH1 Internal
Timebase 20ms/div 20ms/div
(4) Set up the UUT current pulse monitoring oscilloscope shown in Figure 102 according
to the settings below:
Channel Number 1 2 3 4
UUT Output pin 3 4 8 7 (Relay)
Amplitude 2V/div 2V/div 2V/div 5V/div
Position 0div -1div -2div -4div
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RADIANT POWER CORP.
PART NUMBER BPAS10
Input Coupling DC DC DC DC
Probe 10:1 10:1 10:1 10:1
Trigger Mode Normal Normal Normal Normal
Trigger Position 0div 0div 0div 0div
Trigger Level +0.5V ↑ +0.05V ↑ +0.05V ↑ +0.05V ↑
Trigger Source External External External External
Timebase 20ms/div 20ms/div 20ms/div 20ms/div
(5) Set SW1-OFF, SW2-E, SW3-DISARM, SW4-OFF, SW5-OFF, and with the 10kOhm
resistor across J7 and J8 on the test box. Set the output voltage on power supplies
PS1and PS2 to 28V.
(6) Install the Unit Under Test (UUT) in the test setup shown in Figure 102.
• The voltage across J7 and J8, indicated by V2 DVM, should be <0.1 VDC.
• Remove the 10kOhm resistor from across J7and J8 on the test box.
(7) With the bell current probe measure the battery current through the battery
disconnect wire loop between connector J1 pins 11 (-) and 12 (+).
• The current should be < 0.1 milliamps.
(8) Set the switch lever cam (160) to the ARM position. Use the Bell Current Probe to
measure the charging current through the battery disconnect wire loop between
connector J1 pins 11 (-) and 12 (+).
• The current should be < 0.1 milliamps.

• The battery voltage at J7 (+) and J8 (-) indicated by V2 must be between
22.5 and 26.0 VDC.
• Remove the Bell current probe
(9) Set switch SW1 to ON and SW2 to I (input current) on the test box. Voltmeter V1 will
indicate the voltage developed across a 0.1 Ohm resistor, internal to the test box,
which results from the input current draw of the UUT.
• Measure the voltage indicated by voltmeter V1. The voltage reading on V1

should be between 0.009V and 0.012V to represent an input current of
between 90 and 120 milliamps (indicating the battery assembly (200) is
charging).
• This value is for a charged battery pack. A discharged battery pack will
charge at a higher value, typically around 120-135 milliamps.
• The voltage indicated by V2 must be between 24-26 VDC.
• If the voltage indicated by V2 is below 24VDC allow the UUT to charge until
the battery meets this specification.
(10) Decrease the power to zero by moving SW1 to “OFF”. Set SW2 to “E”. Do not
remove the UUT from the test setup.
B. Switch Lever Cam Test
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RADIANT POWER CORP.
PART NUMBER BPAS10
(1) With the UUT installed in the test setup shown in Figure 102, set the PS1 and PS2
power supply (Figure 102) to 28.0 +/- .2 VDC and apply power by setting SW1 to the
ON position.
(2) Set the switch lever cam (160) to one of the two DISARM positions. Measure the
battery output voltage on voltmeter V2 (Figure 102).
• Place the 10kOhm resistor across J7and J8 on the test box.

• The voltage must be less than 0.1 VDC.
(3) Press the test switch (130) for a few seconds once and release.
• Test LED L1 must not illuminate.
(4) Set the switch lever cam (160) to the opposite DISARM position. Measure the
battery output voltage indicated by voltmeter V2 (Figure 102).
• The voltage must be less than 0.1 VDC.
• Test LED L1 must not illuminate.

• Remove the 10kOhm resistor from across J7and J8 on the test box.
(6) Set the switch lever cam (160) to the ARM position. Measure the battery output
voltage indicated by voltmeter V2 (Figure 102).
• The voltage must be between 24 and 26 VDC.
C. Test Switch and LED Test
(1) Set the switch lever cam (160) to the ARM position.
• Tektronix current probe is to be set at 100 mV per Amp.
• Test LED L1 must illuminate bright enough to show a visible light spot six
inches from the UUT (200 foot-candles minimum) for about 10 seconds.
• Tektronix current probe scope trace should be approximately 1.8V to 2V to
represent 18A to 20A.
D. Firing Circuit Test
(1) With the UUT in the test setup as shown in Figure 102. Set the PS1 and PS2 power
supplies (Figure 102) to 28.0 VDC and apply power. PS1 is switched to the UUT
through SW1 & PS2 is switched to the test fixture internal relay through SW5.
(2) Connect and adjust the oscilloscope as described below, and follow measurement
ranges for the channels given below.
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RADIANT POWER CORP.
PART NUMBER BPAS10
(3) With the switch lever cam (160) to the ARM position.
• Move SW5 to the ON position, SW1 to the OFF position, and SW3 to the
ARM position.
(4) Push switch SW6 on the test box.
• J1 connector pins 3, 4, and 8 (corresponding to oscilloscope channels 1, 2
and 3 respectively) must indicate voltage greater than 6V (equivalent to 6.00
Amperes) during the 50-millisecond load pulse.
• Relay output must indicate voltage greater than 10V, but not more than 13V,
during the 50-millisecond load pulse.
• Tektronix current probe scope trace should be approximately 2V.
(5) Disarm the UUT.
(6) Remove the UUT from the test setup.
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RADIANT POWER CORP.
PART NUMBER BPAS10
5. Fault Isolation Procedures
Fault isolation procedures are given in Table 102
NOTE: Radiant Power Corp. recommends that the entire Heat Sink Cabled Assembly (170,
IPL Figure 1) be repaired by technicians familiar with the layout and function of the
card. All PCB repairs must be completed to the guidelines stated in this CMM,
Radiant Power Corp. does not warranty repairs that have been made by third party
repair stations.
The two primary PCB assemblies (1, IPL Figure 9 and 1, IPL Figure 8) in the unit are
assembled together as one piece with various components permanently staked. The
replacement of permanently staked components is considered to be beyond
economical repair. If the fault isolation has determined that a permanently staked
component has failed, the repair station is to replace the entire PCB assembly. All
replaceable components on the assemblies, as well as related hardware are listed in
the IPL section.
Improper application of adhesives, protective padding, and vibration absorbing

material can result in the failure of the BPAS10-5 unit to withstand shock and
vibration. Take special care when reassembling portions of the unit to be sure that all
components are reinstalled as stated in the ASSEMBLY section.
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RADIANT POWER CORP.
PART NUMBER BPAS10
Troubleshooting
Trouble Possible Cause Corrective Action

Self Test Failed No input power. Verify power to the unit.
Low battery voltage. Apply 28VDC to Pins 1 & 2 with
Pins 11 & 12 shorted and unit in the
ARM position.
Open fuse. Verify continuity of fuses. Replace
fuses F101 (140, IPL Figure 2),
F102 (135), F103 (135), or F104
(130) if necessary.
Possible components failures: Replace R101 (25, IPL Figure 8),
R101 (25, IPL Figure 8), R102-R105 (5), R102-R105 (5), R106 (40, IPL
R106 (40, IPL Figure 2), R219 (10, IPL Figure 2), R219 (10, IPL Figure 9),
Figure 9), R220 (70), R221 (95), R222 (160), R220 (70), R221 (95), R222 (160),
R223 (50), R224 (95), R225 (160), R226 R223 (50), R224 (95), R225 (160),
(50), R229 (175), R230 (170), R231 (50), R226 (50), R229 (175), R230 (170),
R232 (160), R233 (155), R237 (50), R238 R231 (50), R232 (160), R233 (155),
(70), R243 (50), R244 (115), R245 (110), R237 (50), R238 (70), R243 (50),
R246 (50), R247 (120), R248 (100), R249 R244 (115), R245 (110), R246 (50),
(50), R251 (50), R252 (130), R253 (135), R247 (120), R248 (100), R249 (50),
R254 (130), R255 (125), R256 (130), R257 R251 (50), R252 (130), R253 (135),
(140), D108-D111 (20, IPL Figure 8), C106- R254 (130), R255 (125), R256
C109, C224-C226, C232, Q203, Q204 (145, (130), R257 (140), D108-D111 (20,
IPL Figure 9), Q208 (145), Q209-Q211 (15), IPL Figure 8), Q204 (145, IPL
Q213-Q214 (15), U203, U207 (150), U208 Figure 9), Q208 (145), Q209-Q211
(165), U209 (30), U210 (180), U212 (35), (15), Q213-Q214 (15), U203, U207
U213-U217 (25), L101 (5, IPL Figure 3). (150), U208 (165), U209 (30), U210
(180), U212 (35), U213-U217 (25),
or L101 (5, IPL Figure 3). Otherwise
replace heatsink cabled assembly
(170, IPL Figure 1).
Open D215 self test LED. Repair/replace LED/ PCB assembly
(120).
Open or shorted test switch. Repair/replace test switch assembly
(130).
Open SW1 or SW2. Verify continuity, wiring, and
adjustment of the switches. Replace
arm/ disarm switch assembly (140).
Page 112
RADIANT POWER CORP.
PART NUMBER BPAS10
Troubleshooting

Self test cycle to Possible components failures: Replace D205 (185), D207-D214
fast/slow or C224, C225, D205 (185, IPL Figure 9), (185), D217 (65), D221 (5), D222
intermittent D207-D214 (185), D217 (65), D221 (5), (185), D223-D226 (20), Q211-Q215
D222 (185), D223-D226 (20), Q211-Q215 (15), U208 (165), U209 (30), U210
(15), U208 (165), U209 (30), U210 (180), (180), U212 (35), U213-U217 (25),
U212 (35), U213-U217 (25), R224 (95), R224 (95), R227 (105), R228 (65,
R227 (105), R228 (65, IPL Figure 2), R229 IPL Figure 2), R229 (175, IPL
(175, IPL Figure 9), R230 (170), R234 (70), Figure 9), R230 (170), R234 (70),
R235-R236 (95), R245 (110). R235-R236 (95), or R245 (110).
Otherwise replace heatsink cabled
assembly (170, IPL Figure 1).
Excessive input Possible components failures: Replace R101 (25), L101 (5, IPL
current R101 (25, IPL Figure 8), C101-C105, C201, Figure 3), D102 (35, IPL Figure 8),
C215-C222, C228-C231, C233, L101 (5, IPL or D103 (40). Otherwise replace
Figure 3), D102 (35, IPL Figure 8), D103 heatsink cabled assembly (170, IPL
(40), VR101. Figure 1).
Battery current to Possible components failures: Replace D201 (90), D217 (65),
high/low C202, C203, D201 (90, IPL Figure 9), D217 R201 (85), R202 (40), R203 (75),
(65), R201 (85), R202 (40), R203 (75), R241 R241 (60), or U201 (80). Otherwise
(60), L201, U201 (80). replace heatsink cabled assembly
No output pin 3, 4, Low battery voltage. Apply 28VDC to Pins 1 & 2 with
8, and 9 Pins 11 & 12 shorted and unit in the
ARM position.
Open fuse F104 (130, IPL Figure 2). Verify continuity of fuses. Replace
fuse F104 (130).
arm/ disarm switch assembly (140,
IPL Figure 1).
Possible components failures: Replace R102 (5), R107 (30), or
R102 (5, IPL Figure 8), R107 (30), D111 D111 (20). Otherwise replace
(20), D112, C109. heatsink cabled assembly (170, IPL
Figure 1).
Page 113
RADIANT POWER CORP.
PART NUMBER BPAS10
Troubleshooting

No Output at Pin 3 Open fuse F101 (140, IPL Figure 2). Verify continuity of fuses.
Replace fuse F101 (140).
Possible components failures: R105 (5, IPL Replace R105 (5), R106 (40,
Figure 8), R106 (40, IPL Figure 2), D108 (20, IPL Figure 2), or D108 (20, IPL
IPL Figure 8), C106. Figure 8). Otherwise replace
heatsink cabled assembly (170,
IPL Figure 1).
Possible components failures: R104 (5, IPL Replace R104 (5) or D109 (20).
Figure 8), D109 (20), C107. Otherwise replace heatsink
cabled assembly (170, IPL
Figure 1).
Possible components failures: R103 (5, IPL Replace R103 (5) or D110 (20).
Figure 8), D110 (20), C108. Otherwise replace heatsink
Figure 1).
No Output at Pin 9. Open fuse F104 (130, IPL Figure 2). Verify continuity of fuses.
Relay will not close Replace fuse F104 (130).
Possible components failures: R102 (5, IPL Replace R102 (5), R106 (40,
Figure 8), R106 (40, IPL Figure 2), R107 (30, IPL Figure 2), R107 (30, IPL
IPL Figure 8), D111 (20), D112, C109. Figure 8), or D111 (20).
Otherwise replace heatsink
Figure 1).
Page 114
RADIANT POWER CORP.
PART NUMBER BPAS10
Fault Isolation Procedures


INSULATION
RESISTANCE TEST
The insulation resistance is Cut or cracked insulation behind the Check the insulation on the heat
not as specified. transistors mounted to the heat sink. sink. Replace insulation (10 or 35,
IPL Figure 3) if necessary.
Cut or cracked wire insulation; open Check the wire circuits, solder the
or short circuit or solder connection; connections, check pin and socket
solder flux path to ground. contacts for damage; verify wire
routing per Table 602. Refer to
REPAIR to replace damaged pin and
socket contacts.
Excessive moisture inside the Dry the unit thoroughly with

chassis assembly (5, IPL compressed shop air; examine the
Figure 1). unit carefully for corrosion or other
moisture damage.
BATTERY PACK ASSEMBLY

BPA TESTS
The battery assembly (200) Battery assembly BPA (200) has Recharge battery assembly BPA
voltage is not as specified. been discharged. (200) when specified in the
performance tests.
The battery assembly (200) There is an open or short circuit in Replace battery assembly BPA
resistance is not as specified. the battery assembly (200); (200).
damaged battery cell or circuit.
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RADIANT POWER CORP.
PART NUMBER BPAS10

CHARGE RATE TEST
The battery voltage is not as Damaged arm/ disarm switch Check the function of each switch and
specified (para. 4.A, Step (2/3 assembly (140). examine the arm/ disarm switch
& 5)). assembly (140) for damage; refer to
Table 602 for wire connections.
The battery voltage is not as Battery pack assembly BPA (200) Recharge the battery assembly (200)
specified (para. 4.A, Step has been discharged or has a when specified later in the test; replace
(6)). damaged battery cell or circuit. battery assembly BPA (200) if it cannot
be fully charged or will not hold the
charge.
Damaged or incorrectly wired Check the function of each switch and

switch SW1 or SW2; damaged arm/ examine the arm/ disarm switch
disarm switch assembly (140). assembly (140) for damage; refer to
The output voltage is not as Damaged arm/ disarm switch Refer to CHECK to examine each
specified (para. 4.A, Step assembly (140). component of the arm/ disarm switch
(7)). assembly (140) for damage; replace
the damaged component.
Damaged circuit components on Replace heatsink cabled assembly

heatsink cabled assembly (170). (170).
SAFETY SWITCH TEST
The voltage is not as Damaged or incorrectly wired Check the function of each switch and
specified (para. 4.B Steps switch SW1 or SW2; damaged arm/ examine the arm/ disarm switch
(2,4&6)). disarm switch assembly (140). assembly (140) for damage; refer to

heatsink cabled assembly (170). (170).
Damaged pin contact (10 or 15, IPL Refer to REPAIR to replace the
Figure 5) in electrical connector (5). damaged pin contact (10 or 15).
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RADIANT POWER CORP.
PART NUMBER BPAS10

Damaged or incorrectly wired test Check the function of test switch

switch assembly (130, IPL Figure 1). Assembly (130); refer to
ASSEMBLY, Table 702 for wire
connections. Replace test switch
assembly (130) if necessary.
Test LED L1 illuminated when Damaged or incorrectly wired LED/ Refer to CHECK to examine LED/
switch SW1 on the test set PCB assembly (120). PCB assembly (120) for damage;
was pushed (para. 4.B Steps refer to, Table 602 for wire
(3&5)). connections. Replace LED/ PCB
assembly (120) if necessary.
Test LED L1 did not illuminate Damaged circuit components on Replace heatsink cabled assembly
when test switch heatsink cabled assembly (170). (170).
S1 on the UUT was pushed
(para. 4.C, Step (2)).
Test LED L1 is not as bright as Damaged LED/ PCB assembly Replace LED/ PCB assembly (120).
specified (para. 4.C, Step (2)). (120).
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RADIANT POWER CORP.
PART NUMBER BPAS10

Trouble Probable Cause Corrective Action
FIRING CIRCUIT TEST
The channel 1 (battery The voltage is less than 10.2 VDC, Check battery with a voltmeter.
output #4) voltage is not as F101 (140, IPL Figure 2) blown. Check F101 (140) with an
specified (para. 4.D, Step ohmmeter, replace if open.
(11)).
D108 (20, IPL Figure 8) open. Check D108 (20) with an
ohmmeter, replace if open.

heatsink cabled assembly (170, (170).
IPL Figure 1).
The channel 2 (battery The voltage is less than 10.2 VDC, Check battery with a voltmeter.
output #1) voltage is not as F102 (135, IPL Figure 2) blown. Check F102 (135) with an
(11)).

IPL Figure 1).
The channel 3(battery output The voltage is less than 10.2 VDC, Check battery with a voltmeter.
#3) voltage is not as F103 (135, IPL Figure 2) blown. Check F103 (135) with an
(11)).
. D110 (20, IPL Figure 8) open. Check D110 (20) with an

IPL Figure 1).
The channel 4 voltage is not The voltage is less than 10.2 VDC, Check battery with a voltmeter.
as specified (para. 4.D, Step F104 (130, IPL Figure 2) blown. Check F104 (130) with an
(11)). ohmmeter, replace if open.


IPL Figure 1).
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RADIANT POWER CORP.
PART NUMBER BPAS10
DISASSEMBLY
1. General
A. This section contains disassembly instructions in the same sequence as the IPL. Before
disassembly, refer to TESTING AND FAULT ISOLATION or CHECK to identify the
damaged components. Disassemble the EPAS battery pack only as far as necessary to
remove the damaged or worn parts.
NOTE: As the arm/ disarm switch assembly (140, IPL, Figure 1) is specifically calibrated at
the manufacture, radiant power recommends that the entire arm/ disarm switch
assembly (140) be repaired, aligned and calibrated by technicians familiar with the
layout and function of that assembly.
B. Note the methods of insulation (shrink sleeving, etc.) and routing of electrical wire leads
for assembly reference. Unsolder the wire leads from the terminals or pads and tag all
wires to aid assembly.
C. Refer to IPL Figure 1 for an exploded-view illustration of the EPAS battery pack.
2. Special Tools and Equipment
All repair work must be done at an Electrostatic Discharge (ESD) safe workbench. Refer to
paragraph 3, below, for general ESD handling instructions and workbench requirements. Refer
to the individual sections for special tools and devices. Refer to table for the listing of special
tools and equipment to be used for the disassembly/ repair/ assembly of BPAS10-5.
Page 301
RADIANT POWER CORP.
PART NUMBER BPAS10
3. Handling Instructions and Electronics Devices
The EPAS battery pack contains electronic components that can be damaged by ESD and
rough handling. The general handling precautions and instructions given below will help
minimize or eliminate possible damage.
WARNING: THE EPAS BATTERY PACK CONTAINS HIGH VOLTAGE CIRCUITS, WHICH
CAN CAUSE DEATH OR SEVERE SHOCK. FOLLOW THE SAFETY
PRECAUTIONS GIVEN IN THE INTRODUCTION TO THIS CMM TO PREVENT
INJURY.
CAUTION: THE PCB ASSEMBLIES CONTAIN ESD SENSITIVE DEVICES. HANDLE THE
PCB ASSEMBLIES IN ACCORDANCE WITH STATIC CONTROL
PROCEDURES TO PREVENT COMPONENT DAMAGE.
THE EPAS BATTERY PACK CONTAINS SENSITIVE ELECTRONIC

COMPONENTS THAT CAN BE DAMAGED BY ROUGH HANDLING AND
EXPOSURE TO HIGH HUMIDITY, WATER OR OTHER LIQUIDS, CIGARETTE
SMOKE, AND OTHER CONTAMINATION. STORE THE EPAS BATTERY PACK
IN AN ENVIRONMENT SUITABLE FOR ELECTRONIC COMPONENTS AND
HANDLE THE UNIT WITH CARE TO PREVENT DAMAGE.
A. Do not touch the EPAS battery pack if liquid or grease is spilled on or in the EPAS
battery pack, until power is removed. Immediately disconnect power and wipe off the
contaminant.
B. Do not use or store the EPAS battery pack in a high humidity environment or in direct
sunlight. High humidity can short or corrode electronic components.
C. All integrated circuits (ICs), and many other semiconductors are susceptible to ESD.
Careless handling during repair can ruin components or drastically decrease component
life.
D. When handling ESD sensitive devices, work at an ESD safe area. The ESD area should
include:
(1) A grounded conductive sheet covering the workbench area.
(2) A grounded wrist strap in contact with skin.
(3) If the chair or the floor is nonconducting, the chair must have a ground strap.
(4) ESD safe tools and equipment. Use plastic instead of metal tools where possible to
prevent short circuits
E. Store the PCB assemblies in protective antistatic shipping bags until ready for use. Do
not store the PCB assemblies in any non-antistatic shipping materials or containers.
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PART NUMBER BPAS10
F. Once removed from the bags, PCB assemblies must be handled in accordance with
static control procedures. The preferred method is to handle PCB assemblies with clean
lint-free cloths or rubber gloves only on the edge of the board. If gloves or cloths are not
available, wash your hands to remove oils and handle the boards only on the edges; do
not touch the conductive patterns or components.
G. Do not stack PCB assemblies. Stacking can damage surface mounted components.
H. The workstation must be clean. To prevent contamination of PCB assemblies, there must
be no smoking, eating, or drinking in the work area.
4. Main Component and Disassembly Instructions
NOTE: Refer to repair for instructions to replace the adhesive-backed labels (220, 225, &
230, IPL Figure 1 and 10 & 15, IPL Figure 4).
CAUTION: DISASSEMBLING THE UNIT MUST BE COMPLETED TO THE GUIDELINES

STATED IN THIS CMM.THE PCB ASSEMBLIES CONTAIN SENSITIVE
ELECTRONIC COMPONENTS THAT CAN BE DAMAGED BY ESD AND ROUGH
HANDLING. HANDLE THE PCB ASSEMBLIES WITH CARE TO PREVENT
DAMAGE.
DO NOT OVERHEAT ELECTRONIC COMPONENTS WHEN UNSOLDERING

WIRE LEADS. USE A HEAT SINK AND LOW WATTAGE SOLDER IRON TO
PREVENT DAMAGE. USE A SOLDER SUCKER AND/OR SOLDER WICK TO
REMOVE EXCESS SOLDER. THE BPAS10-5 UNIT PCBS ARE MULTILAYERED
BOARDS WHICH ARE VERY DIFFICULT TO DESOLDER.
A. Top Cover Removal:
(1) Remove the six side cover screws (215, IPL Figure 1) and the two top cover screws
(210).
(2) Remove the top cover (205) from the chassis assembly (5). Refer to REPAIR to
replace the adhesive-backed interior marking label (220), cover label (225), and
disarm label (230).
B. Battery Assembly Removal:
CAUTION: DISCONNECT THE BATTERY PACK WIRE LEADS BEFORE REMOVING

THE BATTERY ASSEMBLY (200) FROM THE CHASSIS ASSEMBLY (5).
PULLING THE WIRE LEADS CAN DAMAGE THE CONNECTORS AND
OTHER COMPONENTS.
(1) Disconnect battery assembly BPA (200) receptacle from connector on the heatsink
cabled assembly (170).
(2) Clip the two natural tiedown straps (240) securing the battery assembly (200) wires,
test switch assembly (130) wires, and the LED/ PCB assembly (120) wires to the
heatsink assembly cable.
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PART NUMBER BPAS10
(3) Remove battery pack assembly BPA (200) from its position in the chassis assembly
(5). Further disassembly of battery assembly BPA (200) is not approved.
C. LED/ PCB Assembly Removal:
(1) Clip the natural tiedown strap (240) securing the test switch assembly (130) wires to
the LED/ PCB assembly (120) PCB.
(2) Unplug wire housing P4 from connector J4 on the main PCB in the heatsink cabled
assembly (170)
(3) Remove two screws (125) holding LED/ PCB assembly (120) onto chassis assembly
(5).
D. Test Switch Assembly Removal:
(1) Verify that the natural tiedown strap (240) is clipped from the LED/ PCB assembly
(120) holding the test switch assembly (130) wires.
(2) Unplug wire housing P3 from connector J3 on the main PCB in the heatsink cabled
assembly (170).
(3) Remove two screws (135) holding test switch assembly (130) onto chassis assembly
(5).
E. Switch Lever Cam Removal:
NOTE: Removal of the switch lever cam (160) from the arm/ disarm switch assembly
(140) is not recommended to be done by the end user, due to the fact that an
arbor press with a special fixture and tool are required to remove the spring pin
(165). Also, great care must be taken not to damage the switch lever cam (160)
or cam shaft while inserting or extracting the spring pin (165). Damage resulting
from improper disassembly is not covered under warranty.
(1) Remove the spring pin (165) with roll pin extraction tool 3389 (Table 701).
(2) Slide the switch lever cam (160) from the cam shaft of the arm /disarm switch
assembly (140).
F. Arm/ Disarm Switch Assembly Removal:
CAUTION: THE ARM/DISARM SWITCH ASSEMBLY (140) IS CAREFULLY ALIGNED

FOR PROPER OPERATION. DO NOT LOOSEN THE FOUR SCREWS ON
THE SWITCH PLATE OR REALIGNMENT WILL BE REQUIRED. HANDLE
THEM WITH CARE TO PREVENT DAMAGE.
(1) Remove the switch lever cam (160) as instructed in Section E above.
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RADIANT POWER CORP.
PART NUMBER BPAS10
(2) Remove the four switch bracket mounting screws (150) and the two shaft bearing
screws (145) attaching the arm/ disarm switch assembly (140) to the chassis
assembly (5). Carefully remove the arm/ disarm switch assembly (140) from the
chassis assembly (5).
(3) Any further disassembly will require recalibration of the actuation switches (25, IPL
Figure 10) when reassembled. Refer to REPAIR Paragraph 10 for switch
adjustment.
(4) Remove hardware (30, 35 & 40) to remove switches (25).
(5) Remove hardware (15 & 20) to remove switch plate (10).
(6) Remove screws (50) to remove shaft bearing (45).
(7) Slide cam shaft (65) from the shaft bearing (45) and cam housing (55).
G. Connector Assembly Removal:
(1) Remove the four connector mounting screws (15, IPL Figure 1) to disconnect the
connector assembly (10) from the mounting spacer (20, IPL Figure 4) and chassis
assembly (5, IPL Figure 1).
(2) Refer to the REPAIR section to replace damaged pin contacts in the electrical
connector J1 (5, IPL Figure 5). If the connector shell or internal seal is damaged
discard the connector shell (5) and contacts (10, 15).
(3) To replace the damaged pin housing (5) or pin contacts (10, 15), remove the pin
contacts (10, 15) from the pin housing.
H. Heatsink Cabled Assembly Removal:
CAUTION: THE HEATSINK CABLED ASSEMBLY (170, IPL FIGURE 1) CONTAINS

SENSITIVE ELECTRONIC COMPONENTS THAT CAN BE DAMAGED BY
ESD AND ROUGH HANDLING. HANDLE THEM WITH CARE TO PREVENT
DAMAGE.
(1) Tag, unsolder and/or cut (near the micro switches in the arm/ disarm switch
assembly (140)) the four wire leads from the main PCB assembly in the heatsink
NOTE: If the wires are too short the heat sink cabled assembly (170) must be
replaced.
(2) Remove the five heatsink mounting screws (175), battery retainer screw (190),
retainer assembly (185), and battery retainer (195).
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RADIANT POWER CORP.
PART NUMBER BPAS10
(3) Remove the inductor mounting screw (90), and attaching hardware (60, 65, 67, 70,
75, 80, 85) which holds the locking clamtie (55) and the inductor (5, IPL Figure 3) to
the EMI PCB assembly (1, IPL Figure 8) and the chassis assembly (5, IPL Figure 1).
(4) Remove the foam pad spacers (40, 45, 50) from the chassis assembly (5).
(5) Remove the heatsink cabled assembly (170) from the chassis assembly (5).
I. Switch Protector Removal:
(1) Remove switch protector (95) and battery retainer (100) from chassis assembly (5)
by removing the two screws (105) and nuts (110).
5. Disassembly of Sub-Assemblies
A. Chassis Assembly:
(1) Refer to REPAIR to replace chassis label (10, IPL Figure 4) and disarm label (15).
(2) Detach mounting spacer (20) from chassis (5) by removing four screws (25).
(3) Remove paper insulator (30, IPL Figure 1) and PCB insulator (35) from chassis
assembly (5).
(4) Peel off double-coated cloth tape (25) from chassis assembly (5).
B. Heatsink Cabled Assembly:
CAUTION: THE HEATSINK CABLED ASSEMBLY (170) CONTAINS SENSITIVE

ELECTRONIC COMPONENTS THAT CAN BE DAMAGED BY ESD AND
ROUGH HANDLING. HANDLE THEM WITH CARE TO PREVENT
DAMAGE.
(1) Remove fuses F101 (140, IPL Figure 2), F102-F103 (135), and F104 (130) from EMI
PCB assembly (1, IPL Figure 8).
(2) Remove hex standoffs (90, IPL Figure 2) from heatsink PCB assembly (5) by
detaching the two standoff mounting screws (95). Remove the locking clamties (100)
from the hex standoffs (90) by detaching the two clamtie mounting screws (115), two
spring lock washers (110), and two flat washers (105).
(3) Remove the two resistor mounting screws (75) and nuts (70) from heatsink PCB
assembly (5) and use isopropyl alcohol (Table 401) to dissolve thermal compound
(125) underneath resistor R228 (65).
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RADIANT POWER CORP.
PART NUMBER BPAS10
(4) Remove the two resistor mounting screws (50) and nuts (45) from heatsink PCB
assembly (5) and use isopropyl alcohol (Table 401) to dissolve thermal compound
(125) underneath resistor R106 (40).
(5) Detach solder lug (10) from heatsink PCB assembly (5) by removing its screw (15)
and nut (20).
C. Heatsink PCB Assembly:
CAUTION: THE HEATSINK PCB ASSEMBLY (5) CONTAINS SENSITIVE

ELECTRONIC COMPONENTS THAT CAN BE DAMAGED BY ESD AND
ROUGH HANDLING. HANDLE THEM WITH CARE TO PREVENT
DAMAGE.
(1) Remove the four transistor mounting screws (40, IPL Figure 3), three shoulder
washers (45), the belleville washer (50), and four hex nuts (55) to remove the
insulator (35) from the heatsink.
(2) Remove the two transistor mounting screws (20), two washers (15), two Belleville
washers (30), and two hex nuts (25) to remove the other insulator (10) and spacer
(12) from the heatsink.
D. Test Switch Assembly:
(1) Unscrew mini-switch (25, IPL Figure 6) from spacer (20).
E. LED/PCB Assembly:
(1) Remove hardware (5 & 15, IPL Figure 7) from PCB (30).
Page 307
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PART NUMBER BPAS10
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RADIANT POWER CORP.
PART NUMBER BPAS10
CLEANING
1. Cleaning Materials
The recommended cleaning materials are given in Table 401.
NOTE: EQUIVALENT ITEMS CAN BE USED.
2. Cleaning Instructions
WARNING: THE CLEANING SOLVENTS ARE VERY FLAMMABLE AND CAN IRRITATE
YOUR EYES AND NOSE. BE CAREFUL AND USE SOLVENTS IN WELL-
VENTILATED AREAS ONLY. KEEP FLAMMABLE SOLVENTS AWAY FROM
OPEN FLAMES. FLUSH IRRITATED EYES WITH WATER.
CAUTION: THE HEATSINK CABLED ASSEMBLY (170, IPL FIGURE 1) (INCLUDES THE
MAIN AND EMI PCB BOARDS) CONTAINS SENSITIVE ELECTRONIC
COMPONENTS THAT CAN BE DAMAGED BY ESD AND ROUGH HANDLING.
HANDLE THE HEATSINK CABLED ASSEMBLY (170) WITH CARE TO
PREVENT DAMAGE.
DO NOT GET THE ELECTRONIC AND ELECTRICAL COMPONENTS TOO

WET. EXCESS MOISTURE CAN DAMAGE THE COMPONENTS.
A. Use clean cotton swabs and isopropyl alcohol (Table 401) to clean the circuit board and
electrical/electronic components. Wipe the components dry with clean, lint-free cloths.
Cleaning Materials
Table 401
Nomenclature Source
Number
Alcohol, Isopropyl Federal Specification Commercially Available

TT-I-735
Brush, Stiff-Bristle, Federal Specification Commercially Available

Nonmetallic H-B-1490
Cloth, Lint-Free Military Specification Commercially Available

MIL-C-85043
Goggles, Safety None Listed Commercially Available
Swab, Cotton None Listed Commercially Available
Tank Compressed Air, None Listed Commercially Available

20 psig (140 kPag)
Page 401
RADIANT POWER CORP.
PART NUMBER BPAS10
WARNING: WEAR SAFETY GOGGLES OR GLASSES WHEN YOU USE COMPRESSED

AIR. POINT THE AIR STREAM AWAY FROM YOURSELF AND OTHER
PEOPLE.
B. Clean all other components in a sonic bath or use lint-free cloths and the solvent (Table
401). Use a nonmetallic, stiff-bristle brush if necessary to scrub the parts. Dry the parts
with clean, lint-free cloths or clean shop air at less than 20 psig (140 kPag) pressure.
C. Store the non-electronic components in clean plastic bags or on clean, lint-free cloths
until they are needed for CHECK and ASSEMBLY. Store heatsink cabled assembly (170)
as specified in DISASSEMBLY.
Page 402
RADIANT POWER CORP.
PART NUMBER BPAS10
CHECK
Component check procedures are given in Table 501. Use a bright light, and a 5x power or greater
magnifier to aid visual examinations of hard to see parts.
Checking Procedures
Method of
Component Check For Corrective Action
Inspection
Threaded Parts Visual Crossed or stripped threads; Replace damaged

loose attaching hardware. components.
Solder Connections Visual Loose or broken solder Refer to ASSEMBLY to

connections; cracked or repair solder connections
deteriorated wire insulation; during final assembly
burns or other signs of open or
short circuits.
Electrical Wire Leads Visual Cracked or cut insulation; cut Refer to ASSEMBLY to
wire strands; check all wires for replace damaged wire
continuity; verify that all wires are leads during final
properly routed and bundled. assembly.
Interior Marking Label Visual Unreadable; cut edges; loose Refer to REPAIR to
(220) adhesive bond to the top access replace the interior
cover (205). marking label (220).
Battery Assembly BPA Visual Cracked or cut insulation; cut Refer to REPAIR to
(200) wire strands; wire leads pulled replace battery assembly
from the battery pack; cracked BPA (200).
receptacle housing or damaged
terminals; leakage from a
cracked or corroded cell.
Functional Use a voltmeter or Multimeter to Replace battery assembly

verify the voltage at receptacle BPA (200) if it cannot be
P2; the voltage across the white charged to the specified
(+) and black (-) wire leads must voltage.
be 22.5 VDC or greater after the
battery pack has charged for 5
minutes at approximately 100
mA.
Page 501
RADIANT POWER CORP.
PART NUMBER BPAS10
Checking Procedures
Method of
Inspection
Switch Lever Cam (160) Visual Worn or chipped black paint; Refer to REPAIR to paint
dents; deformation. the switch lever cam (160),
or replace the switch lever
cam (160).
Arm/ Disarm Switch Visual Deformed or permanently set Replace spring (60, IPL
Assembly (140) spring; the ends of the spring Figure 10).
must be square within ±1°; the
spring must roll smoothly on a flat
surface.
Visual Crossed or stripped threads on Replace cam follower

the cam follower screw; stripped screw (70).
slot in the head of the pin;
deformation.
Visual Crossed or stripped threads in Replace affected part.

the cam shaft; anodized finish
scratched or worn to base metal;
deformation.
LED/ PCB Visual Cracked or burned LED; Replace LED (35, IPL
Assembly (120) discolored, cracked, chipped, or Figure 7) or PCB (30) as
warped PCB laminate; damaged needed.
circuit traces.
Test Switch Assembly (130) Visual Damaged switch mechanism; Replace switch (25, IPL
crossed or stripped threads on Figure 6) or mounting
the switch body or jam nut. spacer (20) as needed.
Heatsink Cabled Assembly Visual Bent or damaged pin contacts Refer to REPAIR to
(170) (10 or 15, IPL Figure 5) in replace damaged pin
electrical connector (5); sheared contacts (10 or 15) or wire
or deformed tri-lock tabs; leads, or replace the
damaged shell or corroded seal. damaged electrical
connector (5).
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RADIANT POWER CORP.
PART NUMBER BPAS10
Checking Procedures
Method of
Inspection
Visual Crossed or stripped threads in Replace the cam housing

the cam housing; bent switch (55, IPL Figure 10) or switch
bracket. bracket (5).
Visual Cracked or burned resistors Replace the damaged

resistor(s) (40 or 65, IPL
Figure 2) or replace the
heatsink cabled assembly
Visual Loose or damaged nuts (20, 45, Replace damaged nuts (20,
or 70, IPL Figure 2; 25 or 55, IPL 45, or 70, IPL Figure 2; 25 or
Figure 3); crossed or stripped 55, IPL Figure 3) or replace
threads in the nuts; bent heat the heatsink cabled
sink chassis. assembly (170, IPL Figure
1).
Visual Loose electronic components or Replace the damaged

damaged circuit traces on main heatsink cabled assembly
PCB assembly (1, IPL Figure 9); (170, IPL Figure 1).
discolored, cracked, or chipped
printed circuit board; damaged
pins or sockets in board
mounting connector.
Top Cover (205, IPL Visual Scratched or chipped paint; Refer to REPAIR to touchup
Figure 1) unreadable DISARM label (230), the paint and reapply the
interior marking label (220), or DISARM label (230), interior
cover label (225); there must be marking label (220), or cover
no paint on the threads in the label (225), or replace the
nutplate. top cover (205); clean the
paint from the threads in the
nutplate.
Visual Dents or cracks; pay special Replace the top cover (205).
attention to the areas around the
mounting holes.
Page 503
RADIANT POWER CORP.
PART NUMBER BPAS10
Checking Procedures
Method of
Inspection
Chassis Assembly (5) Visual Damaged standoff; standoff loose Replace the chassis
or out of alignment with the assembly (5).
cover.
Visual Unreadable DISARM label (15, Refer to REPAIR to

IPL Figure 4); cut or chipped replace the DISARM label
edges; loose adhesive bond to (15).
the chassis.
Visual Scratched or chipped paint. Refer to REPAIR to touch-

up the paint.
Page 504
RADIANT POWER CORP.
PART NUMBER BPAS10
REPAIR
1. General
A. Use the appropriate procedures given below to repair damaged parts. Refer to
ASSEMBLY to replace damaged wire leads and repair solder connections during final
assembly of the EPAS battery pack
Repair Actions
2. Tools and Materials

3. Handling Instructions for Electronic Devices
4. Repair Minor Thread Damage
5. Replace Adhesive-Backed Labels
6. Replace Pin Contacts in Connector J1
7. Replace Battery Assembly BPA Receptacles P2 and P3
8. Touchup Paint and Reapply Labels
9. Repair Anodized Finishes
10. Adjust ARM/DISARM Switch Assembly
11. Electrical Wire Replacement
CAUTION: THE HEATSINK CABLED ASSEMBLY (170, IPL FIGURE 1) CONTAINS

SENSITIVE ELECTRONIC COMPONENTS THAT CAN BE DAMAGED BY ESD
AND ROUGH HANDLING. HANDLE THE HEATSINK CABLED ASSEMBLY (170)
WITH CARE TO PREVENT DAMAGE.
B. The heatsink cabled assembly (170) contains fragile electronic components and circuits.
The handling precautions and instructions given below will minimize or eliminate possible
damage.
(1) All integrated circuits (ICs) and many other semiconductors are susceptible to ESD
(electrostatic discharge). Careless handling during repair can drastically decrease
the component life.
C. The recommended tools and materials are given in Table 601.
2. Tools and Materials
A. The recommended tools and materials are given in Table 601.
NOTE: EQUIVALENT ITEMS CAN BE USED.
Page 601
RADIANT POWER CORP.
PART NUMBER BPAS10
B. All work must be done at an electrostatic discharge (ESD) safe workbench. Refer to
REPAIR for general ESD handling instructions and workbench requirements. No other
special tools or equipment are required.
3. Handling Instructions for Electronic Devices
The EPAS battery pack contains electronic components that can be damaged by ESD and
rough handling. The general handling precautions and instructions given below will help
minimize or eliminate possible damage.
WARNING: THE EPAS BATTERY PACK CONTAINS HIGH VOLTAGE CIRCUITS, WHICH
CAN CAUSE DEATH OR SEVERE SHOCK. FOLLOW THE SAFETY
PRECAUTIONS GIVEN IN THE INTRODUCTION TO THIS CMM TO PREVENT
INJURY.
CAUTION: THE PCB ASSEMBLIES CONTAIN ESD SENSITIVE DEVICES. HANDLE THE
PCB ASSEMBLIES IN ACCORDANCE WITH STATIC CONTROL
PROCEDURES. THIS WILL PREVENT COMPONENT DAMAGE.

COMPONENTS THAT CAN BE DAMAGED BY ROUGH HANDLING, AND
EXPOSURE TO: HIGH HUMIDITY, WATER OR OTHER LIQUIDS, CIGARETTE
SMOKE, AND OTHER CONTAMINATION. USE THE EPAS BATTERY PACK IN
AN ENVIRONMENT SUITABLE FOR ELECTRONIC COMPONENTS AND
A. If liquid or grease is spilled on or in the EPAS battery pack, immediately remove power
and wipe off the liquid or grease. Do not touch the EPAS battery pack until power has
been removed.
B. Do not use or store the EPAS battery pack in a high humidity environment or in direct
sunlight. High humidity can short or corrode electronic components.
C. All integrated circuits (ICs), and many other semiconductors are susceptible to ESD.
Careless handling during repair can drastically decrease the component life.
D. When handling ESD sensitive devices, work at an ESD safe workbench. The workbench
should include:
(1) A grounded conductive sheet covering the bench work area.
(2) A grounded wrist strap in contact with skin.
(3) If the chair or the floor is nonconducting, the chair must have a ground strap.
(4) ESD safe tools and equipment. Use plastic instead of metal tools where possible to
prevent short circuits
E. Store the PCB assemblies in protective antistatic shipping bags until ready for use. Do
not store the PCB assemblies in conventional plastic snow, Styrofoam, or plastic trays.
Page 602
RADIANT POWER CORP.
PART NUMBER BPAS10
F. Once removed from the bags, PCB assemblies must be handled in accordance with
static control procedures. The preferred method is to handle PCB assemblies with clean
lint-free' cloths or rubber gloves only on the edge of the board. If gloves or cloths are not
available, wash your hands to remove oils and handle the boards only on the edges; do
not touch the conductive patterns or components.
G. Do not stack PCB assemblies. Stacking can damage surface mounted components.
H. The workstation must be clean. To prevent contamination of PCB assemblies, there must
be no smoking, eating, or drinking in the work area.
Page 603
RADIANT POWER CORP.
PART NUMBER BPAS10
Repair Tools and Materials

Table 601
Nomenclature Source (CAGE)*
Number
Abrasive Cloth, Aluminum Federal Specification P-C-451 Commercially Available
Oxide
Adhesive, Epoxy RF912 E. V. Roberts & Assoc. Inc.

(03355)
Alodine, Brush None Listed Commercially Available
Test switch (P4) / LED (P3)

Receptacles
Socket (2 Required) 50212-8100 TTI (8N187)
Socket Housing 51065-0200 TTI (8N187)
Ink, Epoxy (White) 50-100R Dexter Corp. (12405)
Insertion Tool, (for 16AWG) M81969/17-04 or MS24256A16 Commercially Available

Electrical Pin Contact (for 20AWG) M81969/17-03 or MS24256A20
Extraction Tool, (for 16AWG) M18969/19-01 or MS24256R16 Commercially Available

Electrical Pin Contact (for 20AWG) M18969/19-06 or MS24256R20
Pin Contact, Electrical Military Specification Commercially Available

Connector MIL-C-26636
Press, Hydraulic or None listed Commercially Available

Mechanical
Paint, Primer Boeing Material Specification The Boeing Co. (81205)

BMS 10-11, Type I (BAC 5736)
Paint, Topcoat, Color BAC701 Boeing Material Specification The Boeing Co. (81205)
(Black) BMS 10-83, Type III (BAC 5755)
Solder, Resin Core, Federal Specification Commercially Available

Composition Sn63 QQ-S-571
Solder Iron, Low Wattage (24 None listed Commercially Available

to 40 Watt)
Wire, Electrical, 18/20 AWG BMS13-48C or Commercially Available

(select size and color per MIL-W-22759/32 or 34
Table 602) (Raychem 55AO111)
Roll Pin Extraction Tool 3389 Radiant Power Corp.
Roll Pin Insertion Tool 3388 Radiant Power Corp
Charging Cable RP-3300 Radiant Power Corp

*Refer to Table 1001 in the IPL for the address
Page 604
RADIANT POWER CORP.
PART NUMBER BPAS10
4. Repair Minor Thread Damage
Repair damaged threads with an appropriate die or tap if less than 50 percent of one thread is
damaged. Replace non-repairable parts.
5. Replace Adhesive-Backed Labels
A. Peel or scrape the damaged label (220, 225, or 230, IPL Figure 1; 10 or 15, IPL Figure 4)
from the chassis assembly (5, IPL Figure 1) or top cover (205). Use a plastic tool to avoid
damage to the anodized finish.
B. Refer to CLEANING to clean the chassis assembly (5) or top cover (205).
C. Apply new label (220, 225, or 230, IPL Figure 1; 10 or 15, IPL Figure 4).
D. Install the label (220, 225, or 230, IPL Figure 1; 10 or 15, IPL Figure 4) in the same
location on the chassis assembly (5, IPL Figure 1) or top cover (205). Press the label
from the center out to remove any air bubbles.
6. Replace Pin Contacts in Electrical Connector J1
A. Use the insertion/extraction tool (Table 601) to remove damaged pin contacts (10 or 15,
IPL Figure 5) from electrical connector (5).
B. Use the insertion/extraction tool to insert the pin contacts (10 or 15) into the appropriate
electrical connector (5) sockets.
C. Fill all empty sockets with dummy pin contacts (Table 601).
7. Repair Battery Assembly BPA
NOTE: The battery pack comes preconditioned, with the proper length leads and connector.
Repair of battery pack assembly, BPA, (200, IPL Figure 1) is limited to replacement
of the battery pack itself. No other field repair is authorized or approved by Radiant
Power Corp.
8. Touchup Paint and Reapply Labels
NOTE: This procedure gives general instructions for skilled personnel. Refer to Boeing
Specification D6T10840-1 if necessary for more information.
Page 605
RADIANT POWER CORP.
PART NUMBER BPAS10
WARNING: PAINT AND PRIMER ARE VERY FLAMMABLE AND CAN DAMAGE YOUR
EYES AND NOSE. USE THE MATERIALS ONLY IN WELL VENTILATED
AREAS AWAY FROM OPEN FLAMES. WEAR RUBBER GLOVES AND
GOGGLES TO PROTECT YOUR HANDS AND EYES.
A. Use aluminum oxide abrasive cloth (Table 601) to smooth and polish the chipped area.
B. Refer to CLEANING to clean the repair area.
C. Mask all threads and undamaged labels.
D. Apply one coat primer paint (Table 601) to all bare metal and damaged areas. Do not get
primer on the threads.
E. After the primer dries, apply two coats topcoat paint (Table 601). The finish must be
smooth with no drips or runs. Do not get paint on the threads and labels.
9. Repair Anodized Finishes
WARNING: ALODINE IS VERY FLAMMABLE AND CAN DAMAGE YOUR EYES AND
NOSE. USE ALODINE ONLY IN WELL VENTILATED AREAS AWAY FROM
OPEN FLAMES. WEAR RUBBER GLOVES, AN APRON, AND GOGGLES FOR
SAFETY.
A. Repair damaged anodized finishes with No. 120 brush Alodine (Table 601) as specified
below.
NOTE: This procedure gives general instructions for skilled technicians. Refer to
Technical Process Bulletin No. 1161, available from the Henkel Corp.
(CAGE 84063), for complete instructions.
B. Clean the component to remove grease, oil, and corrosion.
C. Apply undiluted Alodine liberally to the aluminum surface. Apply as many coats as
needed. Allow approximately one minute reaction time between the applications.
NOTE: The alodine will dry faster when the alodine and the part are at room
temperature (approximately 65°F to 75°F). One to five minutes is normally
required for the coat to dry. The alodine can be applied with an acid-resistant
brush, swab, synthetic sponge, or portable spray equipment.
D. Remove any excess Alodine with clean water and lint-free cloths.
E. Use lint-free cloths or compressed air at less than 20 psig (138 kPag) to dry the part. Pay
close attention to the seams, joints, and crevices.
Page 606
RADIANT POWER CORP.
PART NUMBER BPAS10
10. Adjust Arm/Disarm Switch Assembly
This section describes the adjustments and measurements to insure that both micro switches
mounted in the arm/ disarm switch assembly (140, IPL Figure 1) will actuate in either direction
of the switch lever cam (160) of the BPAS10-5 within the middle 1/3 of rotation (Figure 601).
Figure 601
A. Install the Unit Under Test (UUT) in the test setup shown in Figure 102.
B. Set SW1-OFF, SW2-E, SW3-DISARM, SW4-OFF, SW5-OFF, and the 10k ohm resistor
across J7and J8 on the test box.
C. Rotate the pointer clockwise. (Initially battery voltage shall be present > 22 VDC on V2 of
test setup) until it drops to < 0.1 volt. The lever shall fall between the lines on the front
dial when it drops to < 0.1 volt. Continue rotating in the clockwise direction until the
disarm detent is engaged. Battery voltage shall continue to be < 0.1 volt.
D. Pull the cam shaft axially (using the pointer) until the cam follower screw clears the point
of the cam track and rotate counterclockwise until battery voltage is present > 22 VDC.
Note that the pointer is between the marks on the dial face.
NOTE: If the switches fail to actuate within the 35° to 75° lines on the dial face when
rotating in either direction, loosen the switch mounting screws (Figure 602) and
adjust the actuating point. Repeat steps C & D after adjustment as many times
as required to bring the actuating point within the lines on the dial face. Tighten
and relock the switch mounting screws after adjustment.
Page 607
RADIANT POWER CORP.
PART NUMBER BPAS10
E. Repeat steps C and D but start rotation from the center position in the counterclockwise
direction for step C and clockwise for step D. The same criteria shall apply.
Figure 602
Arm/Disarm Switch Assembly (140, IPL Figure 1)
11. Electrical Wire Replacement
NOTE: This procedure provides general instructions to select and solder new wire leads
during assembly. Refer to MIL-STD-454, Requirement 5 for soldering instructions.
A. Trim new wire leads as needed to the length given in Table 602. Select the wire color
and gage to match.
NOTE: All wire lengths to be ±1/16 inch (±1,6 mm). Pre-strip all wire ends to 1/8 inch
(3,2 mm).
B. Solder the wire leads to the applicable terminals given in Table 602 with the solder given
in Table 701. Duplicate the original wire routing as closely as possible.
NOTE: Refer to DESCRIPTION AND OPERATION, Figure 3, for wire routing.
Page 608
RADIANT POWER CORP.
PART NUMBER BPAS10
Assembly Wire List

Table 602
Wire Color Wire Size Length From Component To Component

Inches Cm
Green 22 2.25 5.72 GND1 Heatsink

White 16 3.75 9.53 R228 A2-EXT228 (SQ pad)
White 16 4.75 12.07 R228 A2-EXT228 (RND pad)
Black 16 6.00 15.24 R106 A1-R106 (RND pad)
Black 16 4.50 11.43 R106 A1-R106 (SQ pad)
Bus 18 0.500 1.27 SW2-1 (SQ pad) SW2-2 (RND pad)
White 14 11.75 29.85 SW1 (NO) SW1-2 (RND pad)
Red 14 11.50 29.21 SW1 (NO) SW1-1 (SQ pad)
Black 14 11.75 29.85 SW2 (NO) J5-2
Red 14 5.00 12.70 P2-2 J5-1
Black 14 16.75 42.55 P2-1 SW2 (NO)
Red 14 6.00 15.24 Battery (+) P2-2
Black 14 6.00 15.24 Battery (-) P2-1
Red 24 7.25 18.42 P3-1 Test SW-(NO)
Red 24 7.25 18.42 P3-2 Test SW-(NO)
Green 24 8.00 20.32 P4-2 E9
Orange 24 8.00 20.32 P4-1 E10 (CATH)
Page 609
Copyright 2004 by: Radiant Power Corp., a HEICO Company 52-11-01 Mar 11/2013
RADIANT POWER CORP.
PART NUMBER BPAS10
Page 610
RADIANT POWER CORP.
PART NUMBER BPAS10
REPAIR-1 (MAINTENANCE)
1. Battery Maintenance for Continued Airworthiness
BPAS10-5 requires proper battery maintenance and conditioning to ensure the longest life and
best performance possible. The battery pack must be charged for 24 hours twice a month to
insure that the LRU is fully charged and is in a ready to fly state. To charge the LRU, apply
28VDC to the red banana plug (pin 1) with the return at the black banana plug
(pin 2) of the charging cable (RP-3300). With the LRU disarmed, connect the LRU to the cable
then arm the LRU. NOTE: charging will not start until the LRU is armed. An LRU can be left
on continuous standby charge (Note this will reduce LRU battery life). It should be noted that
during storage the minimum battery voltage should never be allowed to fall below 18 volts to
ensure maximum performance and longevity.
Charging Cable RP-3300

Figure 601R
2. Battery Conditioning after Long Term Storage
For batteries that are subjected to Long Term Storage without maintenance, a conditioning
procedure is required prior to using the battery pack. This conditioning procedure subjects the
battery pack subassembly to five (5) charge / discharge cycles. Below is a summary of the
procedure for completing this task.
CAUTION: BEFORE CHARGING OR DISCHARGING THE BATTERY PACK, THE

CONNECTOR’S POLARITY MUST BE VERIFIED. FAILURE TO DO THIS MAY
DESTROY THE BATTERY OR THE TEST EQUIPMENT ATTACHED TO IT.
WARNING: IT IS IMPERATIVE THAT THE BATTERY VOLTAGE BE MONITORED CLOSELY

DURING DISCHARGE. IF THE VOLTAGE OF THE BATTERY PACK DROPS
BELOW 16.2 VOLTS THE PACK WILL BE RUINED! ONE EXTRA MINUTE OF
DISCHARGE CAN RUIN A PACK AND IT WILL HAVE TO BE SCRAPPED.
Repair-1
Page 601R
Copyright 2004 by: Radiant Power Corp., a HEICO Company Dec 01/2014
52-11-01
RADIANT POWER CORP.
PART NUMBER BPAS10
Use a digital meter and connect the positive lead of the meter to the battery pack connector pin
with the red wire. Connect the negative lead of the meter to the connector pin with the black
wire. Note that a charged battery should measure between 22 to 27 volts open circuit and be
positive polarity.
If the Battery Pack voltage is less than 20V, proceed to the Charging Procedure.
A. Discharge Procedure
WARNING: IT IS IMPERATIVE THAT THE BATTERY VOLTAGE BE MONITORED

CLOSELY DURING DISCHARGE. IF THE VOLTAGE OF THE BATTERY
PACK DROPS BELOW 16.2 VOLTS THE PACK WILL BE RUINED! ONE
EXTRA MINUTE OF DISCHARGE
(1) Connect the battery pack as shown in Figure 602R.
(2) Monitor the discharge voltage and terminate the discharge once the battery pack
voltage reaches 18.0 VDC.
Discharging Setup
Figure 602R
Repair-1
Page 602R
52-11-01
RADIANT POWER CORP.
PART NUMBER BPAS10
B. Charge Procedure
(1) Connect the battery pack as shown in Figure 603R. The AC Power Timer Switch is
optional. Without this, manual on/off control is required. Note that the Power Supply
must have an adjustable current limit control.
(2) Ensure that the polarity of the diode is correct before connecting the battery pack or
damage to the power supply may occur. With the battery pack disconnected, turn the
power supply switch “On”, turn the current limit knob all the way down, and the voltage
limit knob up to 30 volts. Now connect the battery pack.
(3) While monitoring the current meter, turn up the current limit knob on the power supply
until the current reads 180 mA ± 5 mA. Charge for 4 hours.
(4) At the end of the 180 mA charge, turn the current limit knob all the way back down.
Monitor the current meter and turn up the current limit knob on the power supply until
the current reads 60 mA ± 5 mA. Charge for 4 hours.
(5) At the end of the 60mA charge, turn off the Power Supply.
(6) Repeat the discharge/charge procedure four more times according to the following
parameters:
a. Cycle 2:
Discharge Battery to 18 volts.
Charge Battery at 180 mA for 4 hours.
b. Cycle 3:
c. Cycle 4:
d. Cycle 5:
NOTE: NOTE THAT THE FINAL CYCLE HAS A 60 mA CHARGE LASTING FOR 8
HOURS.
Repair-1
Page 603R
52-11-01
RADIANT POWER CORP.
PART NUMBER BPAS10
Charging Setup
Figure 603R
Repair-1
Page 604R
52-11-01
RADIANT POWER CORP.
PART NUMBER BPAS10
ASSEMBLY (INCLUDING STORAGE)
1. General
A. This section contains reassembly, packaging, and storage instructions. The procedures
are arranged in the reverse sequence of DISASSEMBLY. Skip procedures and/or
procedure steps as applicable if the EPAS battery pack is already partially assembled.
NOTE: Refer to repair for instructions to replace the adhesive-backed labels (220, 225,
& 225, IPL Figure 1 and 10 & 15, IPL Figure 4).
B. Refer to IPL Figure 1 for an exploded-view illustration of the EPAS battery pack. Refer to
Table 602 for wire routing.
2. Tool and Materials
A. The recommended tools and materials are given in Table 701.
B. All work must be done at an electrostatic discharge (ESD) safe work bench. Refer to
REPAIR for general ESD handling instructions and work bench requirements. No other
special tools or equipment are required.
Page 701
RADIANT POWER CORP.
PART NUMBER BPAS10
Assembly Tools and Materials

Table 701
Nomenclature Source (CAGE)
Number
Alcohol, Isopropyl Federal Specification TT-I-735 Commercially Available
Solder, Resin Core, Composition Federal Specification QQ-S-571 Commercially Available

Sn63
Solder Iron, Low Wattage (24 to None Listed Commercially Available

40 Watt)
Thermal Compound 00Z1245 Newark Electronics (02929)

(125, IPL Figure 2) (Wakefield No. 120-2)
Thread Lock Compound Military Specification MIL-S-22473 Loctite Corp. (05972)

(235, IPL Figure 1; 120, IPL (Loctite No. 242)
Figure 2; 35, IPL Figure 6; 15,
IPL Figure 7; 80, IPL Figure 10)
Wire, Electrical, 18/20 AWG BMS13-48C or MIL-W-22759/32 or 34 Commercially Available

(select size and color per Table (Raychem 5SA0111)
702)
Press, Hydraulic or Mechanical None Listed Commercially Available

To press new roll pin in the
safety switch lever.
Roll Pin Insertion Tool 3388 Radiant Power Corp.
Roll Pin Extraction Tool 3389 Radiant Power Corp.
Uralene No. 5774 (two-part 999996183 Vantico (99384)

epoxy)
Adhesive (35, IPL Figure 2) Permabond 101 Contact East (5P301)
Lubricant, Moly Anti-seize (75, 1279K33 McMaster Carr (MCMAS)

IPL Figure 10)
*Refer to Table 1001 in the IPL for the address.

3. Chassis Assembly Instructions
A. Refer to REPAIR to apply chassis label (10, IPL Figure 4) and disarm label (15).
B. Attach mounting spacer (20) to chassis (5) with the four mounting spacer screws (25).
4. Connector Assembly Instructions
A. Insert double connector pins (10 & 15, IPL Figure 5) into the electrical connector (5) as
shown in IPL Figure 5.
Page 702
RADIANT POWER CORP.
PART NUMBER BPAS10
5. Heatsink PCB Assembly Instructions
A. Inductor (5, IPL Figure 3) is soldered onto EMI PCB assembly (1, IPL Figure 8).
B. Secure transistors on main PCB assembly (1, IPL Figure 9) by placing insulator (10, IPL
Figure 3) and spacer (12) between the transistors and the heatsink and fastening them
with two mounting screws (20), two washers (15), two belleville washers (30), and hex
nuts (25) as shown in IPL Figure 3. Place the other insulator (35) between the transistors
and the heatsink on the opposite side and attach with the four mounting screws (40),
three shoulder washers (45), a belleville washer (50), and four nuts (55) as shown in IPL
Figure 3.
6. Heatsink Cabled Assembly Instructions
CAUTION: DO NOT OVERHEAT ELECTRONIC COMPONENTS WHEN SOLDERING WIRE

LEADS. USE A HEAT SINK AND LOW WATTAGE SOLDER IRON TO PREVENT
DAMAGE. USE A SOLDER SUCKER AND/OR SOLDER WICK TO REMOVE
EXCESS SOLDER.
THE HEATSINK CABLED ASSEMBLY (170, IPL FIGURE 1) AND ARM/DISARM

SWITCH ASSEMBLY (140) CONTAIN SENSITIVE ELECTRONIC
COMPONENTS THAT CAN BE DAMAGED BY ESD AND ROUGH HANDLING.
HANDLE THEM WITH CARE TO PREVENT DAMAGE.
NOTE: This procedure contains information for wire routing. Duplicate the original wire
routing, as indicated in the disassembly section. Take care to properly follow
insulation, and soldering methods as closely as possible.
A. Strip, crimp, and solder wire (25, IPL Figure 2) onto terminal solder lug (10).
B. Attach terminal solder lug (10) to heatsink PCB assembly (5) with screw (15) and nut
(20).
C. Use Permabond 101 adhesive (Table 701) to attach caterpillar grommet (30) onto
heatsink PCB assembly (5).
D. Solder wires (55) onto resistor R106 (40) and solder wires (80) onto resistor R228 (65) as
shown in IPL Figure 2, Details B and C respectively.
E. Apply thermal compound (Table 701) to resistor R106 (40) before attaching it onto
heatsink PCB assembly (5) with two mounting screws (50) and nuts (45).
F. Apply thermal compound (Table 701) to resistor R228 (65) before attaching it onto
heatsink PCB assembly (5) with two mounting screws (75) and nuts (70).
G. Attach hex standoffs (90) to heatsink PCB assembly (5) with two mounting screws (115)
lightly coated with loctite locking compound (Table 701). Attach locking clamties (100) to
Page 703
RADIANT POWER CORP.
PART NUMBER BPAS10
the hex standoffs (90) with two springlock washers (110), two flat washers (105), and the
two mounting screws (95) lightly coated with loctite locking compound (Table 701), as
shown in IPL Figure 2.
H. Insert fuses F101 (140), F102-F103 (135), and F104 (130) into EMI PCB assembly (1,
IPL Figure 8).
7. Top Assembly Instructions
A. Chassis assembly:
(1) Attach paper insulator (30, IPL Figure 1) to chassis assembly (5) as shown in IPL
Figure 1 with double coated cloth tape (25).
(2) Attach PCB insulator (35) to chassis assembly (5) as shown in IPL Figure 1 with
double coated cloth tape (25).
(3) Attach foam silicone (115) to both inside flanges of battery retainer (100) as shown
in IPL Figure 1. Attach battery retainer (100) and switch protector (95) to chassis
assembly (5) with two mounting screws (105) and nuts (110).
B. Heatsink cabled assembly/ connector assembly:
(1) Attach foam silicone (180) to heatsink cabled assembly (170) as shown in IPL
Figure 1.
(2) Carefully place the heatsink cabled assembly (170) into the chassis assembly (5).
(3) Insert the connector assembly (10) into the heatsink cabled assembly (170).
(4) Install the four mounting screws (15) to fasten the connector assembly (10) to the
chassis assembly (5).
(5) Place static dissipative cap (20) on connector assembly (10) if EPAS Battery Pack is
being stored.
(6) Install the foam pad spacers (40, 45, & 50) between the chassis assembly (5) and
the heatsink cabled assembly (170).
(7) Install the inductor mounting screw (90) and attaching hardware (60, 65, 67, 70, 75,
80, 85), to hold the locking clamtie to the inductor (5, IPL Figure 3), the EMI PCB
assembly (1 IPL Figure 8), and the chassis assembly (5).
(8) Install the five heatsink screws (175) to the heatsink cabled assembly (170). Install
battery retainer screw (190) through the heatsink cabled assembly (170) attaching
the retainer assembly (185) and the battery retainer (195).
(9) Solder (Table 701) and two-part epoxy (Table 701) the wire leads to switches SW1 &
SW2 on the arm/ disarm switch assembly as shown in Figure 701.
Page 704
RADIANT POWER CORP.
PART NUMBER BPAS10
C. Arm/Disarm Switch Assembly:
(1) Insert cam follower screw (70, IPL Figure 10) into cam shaft (65) using loctite locking
compund (Table 701) until no threads are shown. Tighten to 12 in-lbs.
(2) Slide the cam shaft (65) through the spring (60) into the shaft bearing (45) and cam
housing (55).
(3) Mount the shaft bearing (45) to the switch bracket assembly (5) with two screws (50).
Torque screws to 7-9 in-lbs.
(4) Mount the switch plate (10) to the switch bracket assembly (5) with hardware (15 &
20). Torque screws to 7-9 in-lbs.
(5) Mount the switches (25) to the switch plate (10) with hardware (30, 35 & 40). Torque
screws to 7-9 in-lbs.
(6) Adhere gray foam silicone (155) to arm/ disarm switch assembly (140) as shown in
IPL Figure 1.
(7) Carefully place the arm/ disarm switch assembly (140) into the chassis assembly (5).
(8) Insert the two shaft bearing screws (145) through the chassis assembly (5) into the
(9) Lightly coat four screws (150) with loctite locking compound (Table 701) and insert
into the arm/ disarm switch assembly (140) through the chassis assembly (5).
(10) Verify that the heatsink cabled assembly (170) and the arm/disarm switch assembly
(140) are installed properly in the chassis assembly (5).
(11) Calibrate the position of the actuation switches (25) to ensure proper operation.
Refer to REPAIR Paragraph 10 for switch adjustment.
(12) Apply a generous amount of anti-seize lubricant (Table 701) from where the cam
shaft (65) enters the cam housing (55) and along the “V” groove. Also apply to the
part of the cam shaft (65) inside the shaft bearing (45). Rotate the cam shaft (65) a
few times and remove the excess lubricant.
D. Switch Lever Cam Assembly:
(1) Slide switch lever cam (160) onto the cam shaft of the arm/ disarm switch assembly
(140).
(2) Insert spring pin (165) into switch lever cam (160) with roll pin insertion tool (Table
701).
Page 705
RADIANT POWER CORP.
PART NUMBER BPAS10
E. Test Switch Assembly:
(1) Mount switch (25, IPL Figure 6) to mounting spacer (20) using loctite locking
compund (Table 701).
(2) Fasten two tie wraps (5) to test switch assembly wires as illustarted in IPL Figure 6.
(3) Insert test switch assembly (130, IPL Figure 1) into chassis assembly (5) and attach
with two mounting screws (135) lightly coated with loctite locking compund (Table
701).
(4) Plug test switch wire housing P3 into connector J3 on the main PCB in the heatsink
F. LED/ PCB Assembly:
(1) Solder LED (35, IPL Figure 7) so that it is .09-.10 above the PCB (30).
(2) Attach hex standoffs (5) to LED PCB with two screws (10) lightly coated with loctite
locking compound (Table 701). Torque screws to 7-9 in-lbs.
(3) Insert LED/ PCB assembly (120, IPL Figure 1) into chassis assembly (5) and attach
with two screws (125) lightly coated with loctite locking compound (Table 701).
(4) Plug LED/ PCB wire housing P4 into connector J4 on the main PCB in the heatsink
(5) Replace the natural tiedown strap (240) securing the test switch assembly (130)
wires to the LED/ PCB assembly (120) PCB as shown in Figure 702.
G. Battery Replacement:
NOTE: This procedure provides general instructions to install the battery assembly
(200) during assembly.
(1) Position battery assembly (200) into chassis assembly (5) as shown in IPL Figure 1.
(2) Plug male connector, from heatsink cabled assembly (170) into female connector,
from battery assembly (200).
(3) Replace the two natural tiedown straps (240) securing the battery assembly (200)
wires, test switch assembly (130) wires, and LED/ PCB assembly (120) wires to the
heatsink assembly cable as shown in Figure 702.
(4) Verify proper placement of the insulative padding (115, 155, & 180) and securness
of the battery assembly (200).
H. Top Cover Replacement:
(1) Refer to REPAIR and IPL Figure 1 to replace the interior marking label (220), cover
label (225), and the disarm label (230).
Page 706
RADIANT POWER CORP.
PART NUMBER BPAS10
(2) Place the top cover (205) onto the chassis assembly (5).
(3) Secure the top cover (205) with the six side screws (215) and two top screws (210).
8. Final Evaluation
A. Visually examine all solder connections, wire leads, and wire routing. Refer to Table 501
in CHECK and Figure 3 in DESCRIPTION AND OPERATION.
B. Refer to TESTING AND FAULT ISOLATION and do the insulation resistance and battery
pack assembly (200) tests.
C. Refer to TESTING AND FAULT ISOLATION and do the performance (final assembly)
tests.
9. Packaging Instructions
Protect the EPAS battery pack from humidity and shock by packaging the unit when it is not in
use or for transport. Repack the EPAS battery pack in the original shipping container when
possible.
CAUTION: THE PCB ASSEMBLIES CONTAIN ESD SENSITIVE DEVICES. REFER TO

REPAIR FOR ESD SAFE HANDLING PROCEDURES. THE EPAS BATTERY
PACK CONTAINS SENSITIVE ELECTRONIC COMPONENTS THAT CAN BE
DAMAGED BY ROUGH HANDLING AND EXPOSURE TO HIGH HUMIDITY,
WATER OR OTHER LIQUIDS, CIGARETTE SMOKE, AND OTHER
CONTAMINATION. USE THE EPAS BATTERY PACK IN AN ENVIRONMENT
SUITABLE FOR ELECTRONIC COMPONENTS AND HANDLE THE UNIT WITH
CARE TO PREVENT DAMAGE.
A. Refer to REPAIR for ESD safe handling procedures.
B. If loose components must be shipped, pack the PCB assemblies in antistatic shipping
bags. Pack all other components in clean plastic bags. The materials given below are
unacceptable and prohibited from use in any packaging where they could come into
direct contact with the PCB assemblies.
(1) Untreated styrofoam, polyform or polystyrene sheets, black inserts, and foam filler
pieces (for example, foam peanuts).
(2) Untreated plastic boxes.
(3) Static-generating plastic wrap, bags, or bubble pack.
(4) Pink poly foam and bubble wrap that is not certified Amine-free.
(5) Untreated connector plastic dust covers.
C. If the original shipping containers are not available, pack the EPAS battery pack, as
follows:
Page 707
RADIANT POWER CORP.
PART NUMBER BPAS10
(1) Write the maintenance data and dates on a tag. Attach the tag to the unit.
(2) Install a static dissapative cap (20, IPL Figure 1) on connector J1.
(3) Overwrap the battery pack in nylon film or bubble wrap to cushion the unit and
prevent damage to the battery pack.
(4) Pack the battery pack in a corrugated paper box. Fill all voids with cellulose wadding
or brown Kraft paper.
(5) Add a sufficient amount of desiccant and seal the box with unit.
(6) Write the EPAS battery pack nomenclature, part number, and maintenance/ test
dates on the box.
Packaging and Storage Materials

Table 702
Description Number
Source (CAGE)
Bag, Polyethylene Military Specification Commercially Available

MIL-B-117
Box, Corrugated Paper Federal Specification Commercially Available

PPP-B-636
Cover, Protective None Listed Protective Closures Inc.

(99017)
Tape, Packing Federal Specification Commercially Available

JAN-P-127
Tag, Identification None Listed Commercially Available

10. Storage Instructions
CAUTION: THE PCB ASSEMBLIES CONTAIN ESD SENSITIVE DEVICES. REFER TO

REPAIR FOR ESD SAFE HANDLING PROCEDURES.

COMPONENTS THAT CAN BE DAMAGED BY ROUGH HANDLING AND
EXPOSURE TO HIGH HUMIDITY, WATER OR OTHER LIQUIDS, CIGARETTE
SMOKE, AND OTHER CONTAMINATION. USE THE EPAS BATTERY PACK IN
AN ENVIRONMENT SUITABLE FOR ELECTRONIC COMPONENTS AND
A. Refer to REPAIR for ESD safe handling procedures.
B. Refer to ASSEMBLY, paragraph 9 to package the EPAS battery pack for storage.
Page 708
RADIANT POWER CORP.
PART NUMBER BPAS10
(1) Store the EPAS battery pack in an area suitable for electronic equipment. The
storage area must have adequate ventilation with low humidity, dust, and protection
from direct sunlight and high heat.
(2) For battery storage relating to electrical parameters refer to the MAINTENANCE
section.
Arm/ Disarm Switch Assembly Wire Leads

Figure 701
Page 709
RADIANT POWER CORP.
PART NUMBER BPAS10
Tiedown Strap Placement

Figure 702
Page 710
RADIANT POWER CORP.
PART NUMBER BPAS10
SPECIAL TOOLS, FIXTURES AND EQUIPMENT
The recommended special tools, fixtures, and test equipment are given in Table 901. A
schematic diagram for the pulsed load test set is given in Figure 103.

Special Tools, Fixtures and Equipment
Table 901
Nomenclature Part Number Source (CAGE)* Use

Bright Light None Listed Commercially Available To assist in the inspection
of parts.
Megohmmeter, 100 1864 GenRad Inc. (24655) To measure the insulation

megohms, 500 VDC, ±2% resistance of the EPAS
Full Scale battery pack circuits.
Multimeter (Ohmmeter, Model 79 Fluke Electronics Corp. (89536) To measure voltage,

Ammeter or Voltmeter can be current, and resistance for
used), 0 to 10 Amps DC (±2% bench tests.
Full Scale), 0 to 100 VDC
(31/2 digits); 200 to 300
kilohms
Oscilloscope, Digital Storage, DL1540CL Yokogawa (60366) To measure and display

Two Channel the load pulse voltage and
current.
Power Supply, 0 to 32 VDC None Listed Commercially Available DC power source for
(2 Required) bench tests.
Solder Iron, Low Wattage (24 None Listed Commercially Available To solder wire connections
to 40 Waft) to the circuit board pads.
Tank or Shop Compressed None Listed Commercially Available To clean and dry EPAS
Air, 20 psig (140 kPag) battery pack components.
BPAS10-5 Test fixture RT-141 Local Manufacturer or Radiant Test set for the shop
Power Corp (Figure 103) bench tests.
Thread Chaser None Listed Commercially Available To repair damaged

threads.
Roll Pin Insertion Tool 3388 Radiant Power Corp. To insert the spring pin into
the switch lever cam.
Roll Pin Extraction Tool 3389 Radiant Power Corp. To remove the spring pin
from the switch lever cam.
Page 901
RADIANT POWER CORP.
PART NUMBER BPAS10
Page 902
RADIANT POWER CORP.
PART NUMBER BPAS10
ILLUSTRATED PARTS LIST
1. Introduction
A. Purpose
(1) The IPL illustrates and lists authorized replacement parts for the BPAS10-5.
B. Guide to Use the IPL
(1) If the part number is not known:
(a) Find the part in the exploded-view illustrations.
(b) Refer to the parts list and find the item number in the FIG. ITEM column.
(2) If the part number is known:
(a) Refer to the parts list, numerical index, or reference designator index and find
the part in the PART NUMBER column.
(b) Refer to the exploded-view illustration to identify the attaching hardware and
related assembly parts.
2. Reference Designator Index
A. This index contains all reference designators for electronic parts that are replaceable.
The designators are arranged in alphanumeric sequence along with the corresponding
part number, parts list figure and item number.
3. Numerical Index
A. This index is an aid to find the parts in the IPL by part number. It contains all part
numbers that are replaceable including all top assemblies. They are arranged
alphanumerically with the corresponding parts list figure(s), item number(s), and quantity
required for each.
4. Detail Parts List
A. The Detail Parts List in each figure is arranged in general sequence of assembly. The
parts are illustrated in exploded-view illustrations and listed in the related parts list.
B. FIGURE/ ITEM Column
(1) The first number at the top of each FIG. ITEM column is the figure number for the
illustration to which it refers. The number opposite each part number is the item
number given to the part in the illustration.
(2) A dash (-) will prefix item numbers of parts not illustrated.
Page 1001
RADIANT POWER CORP.
PART NUMBER BPAS10
(3) Alpha-variants A through Z (except I and O) are given to item numbers when
necessary to identify added parts, alternative parts, and service bulletin modified
parts.
C. PART NUMBER Column
(1) This column contains the replaceable components’ part numbers. The part number
was modified if it contained blank spaces, special characters (excluding dashes), or
was more than 15 characters in length. Dashes are permitted only between numeric
characters. If the part number needed modification, it was modified per ATA
iSpec2200 and the actual part number is referenced in the NOMENCLATURE
Column.
D. NOMENCLATURE Column
(1) This column lists what a component is, how it relates to the top assembly, who
makes it, gives supplier specification numbers (if any), attaching parts, service
bulletin modification information, the actual part number (if applicable) and any
miscellaneous information required to fully define the use of the part.
(2) Assembly Order Indenture System:
(a) The indenture system used in the parts list shows the relationship of one part
to another. For a given item, the number of indentures depicts the relationship
of the item to the associated next higher assembly as follows:
End Item or Major Assembly

• Detail Parts for End Item or Major Assembly
ATTACHING PARTS
• Attaching Parts for Detail Parts
----****----
• Subassembly
ATTACHING PARTS
• • Attaching Parts for Subassembly
•• ----****----
• • Detail Parts for Subassembly
(3) Assemblies, subassemblies and detail parts subject to modification, deletion,
addition or replacement by an issued service bulletin are annotated to indicate both
pre- and post-service bulletin configurations. The term (PRE-SB XXXX) in the
NOMENCLATURE column designates the original configuration, and the term
(POST SB XXXX) identifies assemblies and parts after the modification has been
completed. The new item number will be an alpha-variant of the original part.
(4) The terms defined below are used when applicable to show the interchangeability of
parts.
Page 1002
RADIANT POWER CORP.
PART NUMBER BPAS10
Term Abbreviation Definition
Superseded By SUPSD BY The part is replaced by and is not

interchangeable with the item
numberdesignated in the notation
Supersedes SUPSDS The part replaces and is not
interchangeable with the item number
designated in the notation.
Replaced By REPLCD BY The part is replaced by and is
interchangeable with the item number
designated in the notation.
Replaces REPLCS The part replaces and is interchangeable
with the item number disignated in the
notion.
E. EFF CODE Column
(1) This column contains effectivity codes (letters A through Z except I or O) to show the
alternative models or configurations of the end item to which the parts apply.
Subassemblies and detail parts will carry the effectivity code for all next higher
assemblies on which they are used, except that if a subassembly or detail part is
used on all listed top assemblies, the EFF CODE column will be blank.
(2) In the event that more than 24 effectivity codes are required, an alpha variable
appended to the figure number (e.g. Figs. 1A, 1B, and 1C) will be used.
(3) The effectivity codes are unique to the figure number they are used on.
F. UNITS PER ASSY Column
(1) This column reflects the quantity of a specific item number used on one next higher
assembly or subassembly. For bulk items, the notation AR (As Required) is entered.
Top assemblies bear the notation RF (Reference).
G. Commonly Used abbreviations
BH Button Head
FH Flat Head
L Long
NHA Next Higher Assembly
PH Pan Head
SH Socket Head
SS Stainless Steel
THK Thick
W Wide
Page 1003
RADIANT POWER CORP.
PART NUMBER BPAS10
5. Vendor Names and Addresses
A. The Vendor Codes for the companies that make the parts, materials, or compounds
referenced in this CMM are given in Table 1001. The codes are of the format VXXXXX.
The XXXX is the CAGE code for each company. No code is given in the parts list when
the part is made by Radiant Power Corp.
Page 1004
RADIANT POWER CORP.
PART NUMBER BPAS10
Vendor Names and Addresses

CAGE Name and Address CAGE Name and Address

1L0V9 A & A Engineering 8R639 Century Fasteners Corp.
164 Aero Camino 5040 Tampa W. Blvd.
Goleta, CA 93117 Tampa, FL 33643
057Q7 ACI Electronics 5P301 Contact East

345 Paseo Tesoro 335 Willow St.
Walnut, CA 91789 North Andover, MA 01845-5995
*
ADCPROA Adcraft Prod. Co. Inc. 12405 Dexter Corp.
1230 S. Sherman St. 15051 E. Don Julian Rd.
Anaheim, CA 92805 La Puente, CA 91746
5X895 Aeroflite Components Inc. 03355 E.V. Roberts & Assoc. Inc.
261 Gemini 8500 Steller Dr.
Brea, CA 92621 Culver City, CA 90232
1E559 Air Electro, Inc. 7H140 FW Bell

P.O. Box 2231 6120 Hanging Moss Rd.
Chatsworth, CA 91313 Orlando, FL 32807
0TBK5 Allied Electronics Inc. 24655 GenRad, Inc.

9500 Koger Blvd. 7 Technology Park Drive
Suite 105 Westford, MA 01886-0033
St. Petersburg, FL 33702
6M193 Arrow/ Zeus Electronics 28480 Hewlett-Packard Co.

55 Skyline Drive 3000 Minuteman Rd.
Lake Mary, FL 32746 Andover, MA 01810-1032
00779 Tyco Electronics Corp. 0CMZ7 House of Batteries

M/S 38-77 16512 Burke Lane
2800 Fulling Mill Rd. Huntington Beach, CA 92647
Middletown, PA 17057
0EU87 Avnet 30687 Jacon Aircraft Supply Co.

5516 Rio Vista Drive 9539 Vassar Avenue
Clearwater, FL 34620 Chatsworth, CA 91311
08098 BK Precision 89536 Fluke Electronics Corp.

1031 Segovia Circle 6920 Seaway Blvd.
Placentia, CA 92870-7137 Everett, WA 98206
81205 The Boeing Co. 05972 Loctite Corp.

20415 72nd Ave. S. Bldg 18-230 4 1001 Trout Brook Crossing
P.O. Box 3999 Rocky Hills, CT 06067
Seattle, WA 98124-2499
N/A Cal Test Electronics MCMAS* McMaster Carr

1031 Segovia Circle, 6100 Fulton Industrial Blvd.
Placentia, CA, 92870-7137 Atlanta, GA 30336-2852
Page 1005
RADIANT POWER CORP.
PART NUMBER BPAS10
Vendor Names and Addresses

CAGE Name and Address CAGE Name and Address
05ZP2 MetalPro Industries, Inc. 0RR61 Tektronix

28064 Ave. Stanford P.O. Box 500
Unit H MS 50-216
Santa Clarita, CA 91355 Beaverton, OR 97077
02929 Newark Electronics 5X082 Tenma Test Equipment

5601 Mariner St. 650 Congress Park Dr.
Tampa, FL 33609 Centerville, OH 45459
66827 Pacific Transformer Corp. 8N187 TTI, Inc.

5399 E. Hunter Ave. 5772 S. Semoran Blvd.
Anaheim, CA 92807 Bldg. E Suite 5774
Orlando, FL 32822
PREMR* Premier Fabricating & Stamping, 99384 Vantico

LLC 5121 San Fernando Rd. W.
232 Dunbar Ct. Los Angeles, CA 90039-1011
Oldsmar, FL 34677
28523 Powell Electronics Inc. 7R617 Weico Wire & Cable

1890 N. University Dr., Ste 115 161 Rodeo Dr.
Coral Springs, FL 33071 Edgewood, NY 11717
99017 Protective Closures Inc. 92218 The Wakefield Corp.

P.O. Box 98174 29 Foundry St.
Chicago, IL 60693 Wakefield, MA 01880-3206
1MXA1 Radiant Power Corp. 60366 Yokogawa Corp.

7135 16th Street., Suite 101 2 Dart Rd.
Sarasota, FL 34243 Newnan, GA 30265-1018
3A934 Sager Electronics

105 Research Rd.
Hingman, MA 02043
*Internal vendor code, CAGE code pending
Page 1006
RADIANT POWER CORP.
PART NUMBER BPAS10
REFERENCE DESIGNATOR INDEX
DESIGNATOR PART NUMBER FIGURE ITEM

D101 JANTX1N5552 8 20
D102 1N6287A 8 35
D103 1N6285A 8 40
D108 JANTX1N5552 8 20
D109 JANTX1N5552 8 20
D110 JANTX1N5552 8 20
D111 JANTX1N5552 8 20
D113 02F5300 8 10
37N495 8 15
D201 MBR745 9 90
D204 JANTX1N3957 9 65
D205 JANTX1N4148-1 9 185
D207 JANTX1N4148-1 9 185
D208 JANTX1N4148-1 9 185
D209 JANTX1N4148-1 9 185
D210 JANTX1N4148-1 9 185
D211 JANTX1N4148-1 9 185
D212 JANTX1N4148-1 9 185
D213 JANTX1N4148-1 9 185
D214 JANTX1N4148-1 9 185
D217 JANTX1N3957 9 65
D221 JANTX1N754A-1 9 5
D222 JANTX1N4148-1 9 185
D223 JANTX1N972B-1 9 20
D224 JANTX1N972B-1 9 20
D225 JANTX1N972B-1 9 20
D226 JANTX1N972B-1 9 20
F101 267005 2 140
FM08A125V5AT 2 140A
F102 267010 2 135
FM08A125V10AT 2 135A
F103 267010 2 135
FM08A125V10AT 2 135A
F104 267.500 2 130
FM08A125V1/2AT 2 130A
J3 10-32-1023 9 45
53253-0270 9 45A
J4 10-32-1023 9 45
53253-0270 9 45A
L101 3352 3 5
Q204 RFG60P06E 9 145
IXTQ52P10P 9 145A
Q208 RFG60P06E 9 145
IXTQ52P10P 9 145A
Q209 JANTX2N2222A 9 15
Q210 JANTX2N2222A 9 15
Q211 JANTX2N2222A 9 15
Q212 JANTX2N2222A 9 15
Q213 JANTX2N2222A 9 15
Q214 JANTX2N2222A 9 15
Q215 JANTX2N2222A 9 15
Page 1007
RADIANT POWER CORP.
PART NUMBER BPAS10

R101 RWR89S2R61FR 8 25
R102 RLR07C2201GR 8 5
R103 RLR07C2201GR 8 5
R104 RLR07C2201GR 8 5
R105 RLR07C2201GR 8 5
R106 RER65F1R21R 2 40
R107 RWR89S20R0FR 8 30
R201 RLR07C59R0GR 9 85
R202 RLR07C2201GR 9 40
R203 RNC55H5902BR 9 75
R219 RLR07C1401GR 9 10
R220 RLR07C1001GR 9 70
R221 RLR07C1003GR 9 95
R222 RLR07C2202GR 9 160
R223 RLR07C1002GR 9 50
R224 RLR07C1003GR 9 95
R225 RLR07C2202GR 9 160
R226 RLR07C1002GR 9 50
R227 RLR07C4702GR 9 105
R228 RER65FR845R 2 65
R229 RNC55H8981BS 9 175
R230 RNC55H4991BS 9 170
R231 RLR07C1002GR 9 50
R232 RLR07C2202GR 9 160
R233 RLR07C1402GR 9 155
R234 RLR07C1001GR 9 70
R235 RLR07C1003GR 9 95
R236 RLR07C1003GR 9 95
R237 RLR07C1002GR 9 50
R238 RLR07C1001GR 9 70
R239 RLR07C1003GR 9 95
R240 RLR07C1002GR 9 50
R241 MP850-168 9 60
R243 RLR07C1002GR 9 50
R244 RLR07C47R0GR 9 115
R245 RLR07C3303GR 9 110
R246 RLR07C1002GR 9 50
R247 RLR07C1501GR 9 120
R248 RLR07C3302GR 9 100
R249 RLR07C1002GR 9 50
R250 RLR07C1001GR 9 70
R251 RLR07C1002GR 9 50
R252 RNC55H4992BR 9 130
R253 RNC55H6042BS 9 135
R254 RNC55H4992BR 9 130
R255 RNC55H1003BS 9 125
R256 RNC55H4992BR 9 130
R257 RNC55H2673BS 9 140
R258 RLR07C2201GR 9 40
U201 LM2577T-ADJ 9 80
Page 1008
RADIANT POWER CORP.
PART NUMBER BPAS10

U206 L7812CV 9 55
L7812CV-DG 9 55A
U207 5962-7700801CA 9 150
U208 5962-8982402PA 9 165
U209 JM38510/05651BEA 9 30
U210 JM38510/10901BPA 9 180
U212 JM38510/05151BCA 9 35
U213 JANTX4N49 9 25
U214 JANTX4N49 9 25
U215 JANTX4N49 9 25
U216 JANTX4N49 9 25
U217 JANTX4N49 9 25
Page 1009
RADIANT POWER CORP.
PART NUMBER BPAS10
NUMERICAL INDEX
AIRLINE TTL
PART NUMBER FIGURE ITEM
STOCK NO. REQ
02F5300 8 10 1
06-5-652 2 35 AR
08-70-0073 6 10 2
7 20 2
10-01-4024 6 15 1
7 25 1
10-32-1023 9 45 2
1125-4-N 1 60 1
120-2 2 125 AR
1279K33 10 75 AR
1N6285A 8 40 1
1N6287A 8 35 1
2055-440-SS 7 5 2
2217-3 1 95 1
2225 7 30 1
242 1 235 AR
2 120 AR
6 35 AR
7 15 AR
10 80 AR
267.500 2 130 1
267005 2 140 1
267010 2 135 2
3302-3 1 205 1
3304-1 2 5 1
3305-1 4 5 1
3306-1 1 5 1
3307-1 1 225 1
3307-3 4 10 1
3307-5 1 230 1
4 15 1
3309-1 1 10 1
3310-1 5 15 9
3310-3 5 10 3
3311-1 1 220 1
3319-1 1 140 1
3322-1 4 20 1
3325-1 6 20 1
3327-1 1 130 1
3331-1 1 195 1
3331-3 1 100 1
3331-5 1 185 1
3333-1 1 120 1
3334-1 1 170 1
3337-1 3 35 1
3337-3 3 10 1
3342 1 35 1
3343-1 1 160 1
3344-1 1 40 2
Page 1010
RADIANT POWER CORP.
PART NUMBER BPAS10
NUMERICAL INDEX
AIRLINE TTL
STOCK NO. REQ
3347 1 200 1
3352 3 5 1
3354 10 10 1
3365 10 5 1
3368 10 40 4
3373 10 65 1
3374 10 45 1
3376 10 55 1
3377 1 45 2
3378-1 1 50 2
3379-1 1 30 1
3386 10 70 1
3398 3 12 1
37N495 8 15 1
50212-8100 6 10A 2
7 20A 2
51065-0200 6 15A 1
7 25A 1
53253-0270 9 45A 2
5607-150 3 45 3
5804-188-1 3 30 2
3 50 1
5962-7700801CA 9 150 1
5962-8982402PA 9 165 1
65-201000 10 25 2
76125A17 1 25 2.50’
90130A027 1 75 2
91145A145 1 67 1
91145A148 1 65 1
92196A106 4 25 4
92196A112 10 30 4
92446A119 1 90 1
92949A146 1 150 4
93493A234 1 70 2
96F7217 2 30 1
999996398 2 80 7.50”
999996399 2 55 9.75”
999996470 1 115 AR
1 155 AR
1 180 AR
999996552 2 60
2 85
A18-6 2 10 1
AND190HRP 7 35 1
BACC63CC14-12PN 5 5 1
FM08A125V5AT 2 140A 1
FM08A125V10AT 2 135A 2
FM08A125V1/2AT 2 130A 1
IXTQ52P10P 9 145A 2
JANTX1N3957 9 65 2
JANTX1N4148-1 9 185 10
Page 1011
RADIANT POWER CORP.
PART NUMBER BPAS10
NUMERICAL INDEX
AIRLINE TTL
STOCK NO. REQ
JANTX1N5552 8 20 5
JANTX1N754A-1 9 5 1
JANTX1N972B-1 9 20 4
JANTX2N2222A 9 15 7
JANTX4N49 9 25 5
JM38510/05151BCA 9 35 1
JM38510/05651BEA 9 30 1
JM38510/10901BPA 9 180 1
L7812CV 9 55 1
LM2577T-ADJ 9 80 1
M16878/1BFE5 2 25 2.25”
M22759/32-24-2 6 30 AR
M22759/32-24-3 7 40 AR
M22759/32-24-5 7 45 AR
MBR745 9 90 1
M38527/1-036D 9 17 7
MP850-168 9 60 1
MS15795-803 3 15 2
10 20 4
10 35 4
MS16997-9 1 15 4
MS24693-C28 1 105 2
10 50 2
MS24693-C3 1 145 2
MS24693-C6 1 190 1
MS3367-4-9 1 240 3
MS35338-135 2 110 2
MS51957-13 1 125 2
1 135 2
7 10 2
MS51957-14 1 215 6
2 15 1
10 15 4
MS51957-15 3 40 4
2 115 2
MS51957-17 3 20 2
MS51959-5 2 75 2
2 50 2
MS90376-14RF 1 20 1
NAS1291C02M 2 70 2
2 45 2
NAS1291C04M 2 20 1
3 25 2
3 55 4
NAS1291C06M 1 110 2
NAS561C6-14 1 165 1
NAS620C4 1 80 1
NAS620C4L 2 105 2
NAS679C04M 1 85 1
P7-526221 6 25 1
Page 1012
RADIANT POWER CORP.
PART NUMBER BPAS10
NUMERICAL INDEX
AIRLINE TTL
STOCK NO. REQ
PLCIM-S4-C 1 55 1
2 100 2
RER65F1R21R 2 40 1
RER65FR845R 2 65 1
RFG60P06E 9 145 2
RLR07C1001GR 9 70 4
RLR07C1002GR 9 50 9
RLR07C1003GR 9 95 5
RLR07C1401GR 9 10 1
RLR07C1402GR 9 155 1
RLR07C1501GR 9 120 1
RLR07C2201GR 8 5 4
9 40 2
RLR07C2202GR 9 160 3
RLR07C3302GR 9 100 1
RLR07C3303GR 9 110 1
RLR07C4702GR 9 105 1
RLR07C47R0GR 9 115 1
RLR07C59R0GR 9 85 1
RNC55H1003BS 9 125 1
RNC55H2673BS 9 140 1
RNC55H4991BS 9 170 1
RNC55H4992BR 9 130 3
RNC55H5902BR 9 75 1
RNC55H6042BS 9 135 1
RNC55H8981BS 9 175 1
RWR89S20R0FR 8 30 1
RWR89S2R61FR 8 25 1
SS-3806-440-0 2 90 2
TY23M 6 5 2
Y-27 10 60 1
Page 1013
RADIANT POWER CORP.
PART NUMBER BPAS10
Page 1014
RADIANT POWER CORP.
PART NUMBER BPAS10
Emergency Door Power Assist System Battery Pack

IPL Figure 1 (Sheet 1 of 2)
Page 1015
RADIANT POWER CORP.
PART NUMBER BPAS10
Emergency Door Power Assist System Battery Pack

Page 1016
RADIANT POWER CORP.
PART NUMBER BPAS10
Emergency Door Power Assist System Battery Pack, IPL Figure 1

PARTS LIST
UNITS
FIGURE PART AIRLINE EFF
NOMENCLATURE PER
ITEM NUMBER STOCK NO CODE
1234567 ASSY
1-
-1 BPAS10-5 PACK, BATTERY, EMERGENCY RF
DOOR POWER ASSIST SYSTEM
(BOEING SCD S283W203-5)
5 3306-1  ASSY, CHASSIS 1
(SEE IPL FIG. 4 FOR DETAILS)
10 3309-1  ASSY, CONNECTOR 1
ATTACHING PARTS
15 MS16997-9  SCREW, SH (4-40x0.25L) 4
----****----
20 MS90376-14RF   CAP, STATIC DISSAPATIVE 1
-25 76125A17  TAPE, DOUBLE COATED CLOTH 1
(2.50” LONG) (V8R639)
30 3379-1  INSULATOR, PAPER 1
35 3342  INSULATOR, PCB 1
40 3344-1  SPACER, HEATSINK/ CHASSIS 2
45 3377  SPACER, FOAM PAD 2
50 3378-1  SPACER, FOAM PAD 2
55 PLCIMS4C  CLAMTIE, LOCKING (PLCIMS4C IS 1
REF CODE FOR PLCIM-S4-C) (V8R639)
ATTACHING PARTS
60 1125-4N  SPACER, ¼ ROUND NYLON (1125-4N 1
IS REF CODE FOR 1125-4-N) (V8R639)
65 91145A148  WASHER, SHOULDER, NYLON 1
(V8R639)
67 91145A145  WASHER, SHOULDER, NYLON 1
(V8R639)
70 93493A234  WASHER, FLAT, FIBERGLASS (ID .250 2
OD .500) (V8R639)
75 90130A027  WASHER, FLAT, RUBBER (ID .230 OD 2
.500) (V8R639)
80 NAS620C4  WASHER, FLAT (#4) 1
85 NAS679C04M  NUT, SELF-LOCKING 1
90 92446A119  SCREW, PH (4-40x1.5L) (V8R639) 1
----****----
95 2217-3  PROTECTOR, SWITCH (V1L0V9) 1
100 3331-3  RETAINER, BATTERY (V1L0V9) 1
ATTACHING PARTS
105 MS24693C28  SCREW, FH, SS (MS24693C28 IS REF 2
CODE FOR MS24693-C28)
(6-32 UNC-2Ax0.50L)
110 NAS1291C06M  NUT, HEX, SELFLOCKING (0.138- 2
32UNJC-3B)
----****----
115 999996470   SILICONE, FOAM, GRAY (.093x.50W) AR
(V7R617)
Dashed (-) items not illustrated
Page 1017
RADIANT POWER CORP.
PART NUMBER BPAS10

PARTS LIST
UNITS
NOMENCLATURE PER
1234567 ASSY
1-
120 3333-1  ASSY, LED/ PCB 1
ATTACHING PARTS
125 MS51957-13  SCREW, PH, SS (4-40x0.25L) 2
----****----
130 3327-1  ASSY, TEST SWITCH 1
ATTACHING PARTS
135 MS51957-13  SCREW, PAN HEAD, SS (4-40x0.25L) 2
----****----
140 3319-1  ASSY, ARM/ DISARM SWITCH (SEE 1
IPL FIG. 10 FOR DETAILS)
ATTACHING PARTS
145 MS24693C3  SCREW, FH (MS24693C3 IS REF 2
(4-40x0.312L)
150 92949A146  SCREW, BH, SS (6-32x0.375L) 4
(V8R639)
----****----
(V7R617)
160 3343-1  CAM, SWITCH LEVER (V1L0V9) 1
165 NAS561C6-14   PIN, SPRING 1
170 3334-1  ASSY, CABLED, HEATSINK 1
ATTACHING PARTS
(4-40x0.312L)
----****----
(V7R617)
185 3331-5   ASSY, RETAINER 1
ATTACHING PARTS
190 MS24693C6   SCREW, FH, SS (MS24693C6 IS REF 1
(4-40x0.50L)
----****----
195 3331-1    RETAINER, BATTERY (V1L0V9) 1
200 3347  ASSY, BATTERY (V0CMZ7) 1
205 3302-3  COVER, TOP (V05ZP2) 1
ATTACHING PARTS
(4-40x0.312L)
Page 1018
RADIANT POWER CORP.
PART NUMBER BPAS10

PARTS LIST
UNITS
NOMENCLATURE PER
1234567 ASSY
1-
215 MS51957-14  SCREW, PH (4-40 UNC-2Ax0.312L) 6
----****----
220 3311-1   LABEL, INTERIOR MARKING 1
(VADCPROA)
225 3307-1   LABEL, COVER (VADCPROA) 1
230 3307-5   LABEL, DISARM (VADCPROA) 1
-235 242  COMPOUND, LOCKING, LOCTITE AR
(V5P301)
-240 MS3367-4-9  STRAP, TIEDOWN, NATURAL (1/16-5/8 3
BUN. DIA.)
Page 1019
RADIANT POWER CORP.
PART NUMBER BPAS10
Page 1020
RADIANT POWER CORP.
PART NUMBER BPAS10
Heatsink Cabled Assembly

Page 1021
RADIANT POWER CORP.
PART NUMBER BPAS10
Heatsink Cabled Assembly

Page 1022
RADIANT POWER CORP.
PART NUMBER BPAS10

PARTS LIST
UNITS
NOMENCLATURE PER
1234567 ASSY
2-
-1 3334-1 ASSY, CABLED, HEATSINK RF
(SEE IPL FIG. 1, ITEM 170 FOR NHA)
5 3304-1  ASSY, PCB, HEATSINK 1
10 A18-6  LUG, TERMINAL SOLDER (V8R639) 1
ATTACHING PARTS
15 MS51957-14  SCREW, PH (4-40 UNC-2Ax0.312L) 1
20 NAS1291C04M  NUT SELFLOCKING (4-40) 1
----****----
25 M16878-1BFE5   WIRE, 22GA, GREEN (2.25” LONG) 1
(M16878-1BFE5 IS REF CODE FOR
M16878/1BFE5)
30 96F7217  GROMMET, CATERPILLAR (V8R639) 1
-35 06-5-652  PERMABOND #101 (V5P301) AR
40 RER65F1R21R  RESISTOR, 1.21 10W 1% (R106) 1
(V6M193)
ATTACHING PARTS
45 NAS1291C02M  NUT, HEX, SELFLOCKING (086-56 2
UNS)
50 MS51959-5  SCREW, FH (2-56x0.375L) 2
----****----
55 999996399   WIRE, 16GA, BLACK (9.75” LONG) 1
(V7R617)
60 999996552  DELETED
65 RER65FR845R  RESISTOR, 0.845 10W 1% (R228) 1
(V6M193)
ATTACHING PARTS
70 NAS1291C02M  NUT, HEX, SELFLOCKING (086-56 2
UNS)
75 MS51959-5  SCREW, FH (2-56x0.375L) 2
----****----
80 999996398   WIRE, 16GA, WHITE (7.50” LONG) 1
(V7R617)
85 999996552  DELETED
90 SS3806-440-0  STANDOFF, HEX (SS3806-440-0 IS 2
REF CODE FOR SS-3806-440-0)
(4-40x0.50L) (V8R639)
ATTACHING PARTS
(4-40x0.312L)
----****----
Page 1023
RADIANT POWER CORP.
PART NUMBER BPAS10

PARTS LIST
AIRLINE UNITS
FIGURE PART EFF
STOCK NOMENCLATURE PER
ITEM NUMBER CODE
NO 1234567 ASSY
2-
100 PLCIMS4C   CLAMTIE, LOCKING (PLCIMS4C IS 2
REF CODE FOR PLCIM-S4-C) (V8R639)
ATTACHING PARTS
105 NAS620C4L   WASHER, FLAT (#4, .016 THK) 2
110 MS35338-135   WASHER, SPRINGLOCK (#4) 2
115 MS51957-15   SCREW, PH (4-40UNC2Ax0.375L) 2
----****----
(V5P301)
-125 120-2  COMPOUND, THERMAL (V02929) AR
130 267500  FUSE, 0.5A (267.500 IS REF CODE 1
FOR 267.500) (F104) (V3A934)
-130A FM08A125V12AT  FUSE, 0.5A (FM08A125V12AT IS REF 1
CODE FOR FM08A125V1/2AT) (F104)
(ALT)
135 267010  FUSE, 10A (F102, F103) (V3A934) 2
-135A FM08A125V10AT  FUSE, 10A (F102, F103) (ALT) 2
140 267005  FUSE, 5A (F101) (V3A934) 1
-140A FM08A125V5AT  FUSE, 5A (F101) (ALT) 1
Page 1024
RADIANT POWER CORP.
PART NUMBER BPAS10
Page 1025
RADIANT POWER CORP.
PART NUMBER BPAS10
Heatsink PCB Assembly

IPL Figure 3
Page 1026
RADIANT POWER CORP.
PART NUMBER BPAS10

PARTS LIST
UNITS
NOMENCLATURE PER
1234567 ASSY
3-
-1 3304-1 ASSEMBLY, PCB, HEATSINK RF
5 3352  INDUCTOR, 150uH, 0.5A (V66827) 1
10 3337-3  INSULATOR 1
12 3398  SPACER 1
ATTACHING PARTS
15 MS15795-803  WASHER 2
20 MS51957-17  SCREW, PH (4-40x0.50L) 2
25 NAS1291C04M  NUT, SELFLOCKING (4-40) 2
30 5804-188-1  WASHER, BELLEVILLE (V8R639) 2
----****----
35 3337-1  INSULATOR 1
ATTACHING PARTS
40 MS51957-15  SCREW, PH (4-40UNC2Ax0.375L) 4
45 5607-150  WASHER, SHOULDER, NYLON 3
(V8R639)
50 5804-188-1  WASHER, BELLEVILLE (V8R639) 1
55 NAS1291C04M  NUT, SELFLOCKING (4-40) 4
----****----
60 NONPROC1  ASSY, A1 PCB (SEE FIG 8 FOR BKDN) 1
(NONPROCURABLE)
65 NONPROC2  ASSY, A2 PCB (SEE FIG 9 FOR BKDN) 1
(NONPROCURABLE)
Page 1027
RADIANT POWER CORP.
PART NUMBER BPAS10
Chassis Assembly
IPL Figure 4
PARTS LIST
UNITS
NOMENCLATURE PER
1234567 ASSY
4-
-1 3306-1 ASSY, CHASSIS RF
5 3305-1  FABRICATION, CHASSIS (V05ZP2) 1
10 3307-3  LABEL, CHASSIS (VADCPROA) 1
15 3307-5  LABEL, DISARM (VADCPROA) 1
20 3322-1  SPACER, MOUNTING (V1L0V9) 1
ATTACHING PARTS
25 92196A106  SCREW, SH (4-40x0.25L) (V8R639) 4
----****----
Page 1028
RADIANT POWER CORP.
PART NUMBER BPAS10
Connector Assembly
IPL Figure 5

PARTS LIST
UNITS
NOMENCLATURE PER
ITEM NUMBER STOCKNO CODE
1234567 ASSY
5-
-1 3309-1 ASSEMBLY, CONNECTOR RF
5 BACC63CC1412PN  CONNECTOR, FLANGE MOUNT, 1
ELECTRICAL, 12 PIN
(BACC63CC1412PN IS REF CODE
FOR BACC63CC14-12PN) (V5X895)
10 3310-3   PIN, CONNECTOR, DOUBLE 3
ENDED (V1E559)
15 3310-1   PIN, CONNECTOR, DOUBLE 9
ENDED (V1E559)
Page 1029
RADIANT POWER CORP.
PART NUMBER BPAS10
Test Switch Assembly

IPL Figure 6

PARTS LIST
UNITS
NOMENCLATURE PER
1234567 ASSY
6-
-1 3327-1 ASSEMBLY, TEST SWITCH RF
5 TY23M  WRAP, TIE (V8R639) 2
10 08-70-0073  TERMINAL, FEMALE CRIMP 2
(V8N187) (PRE SB 52-01 FOR SN 0001
THRU 2183) (SUPSD BY ITEM 10A)
-10A 50212-8100  TERMINAL, FEMALE CRIMP 2
(V8N187) (POST SB 52-01)
(SUPSDS ITEM 10)
15 10-01-4024  TERMINAL, CRIMP HOUSING 1
(V8N187) (PRE SB 52-01 FOR SN 0001
-15A 51065-0200  TERMINAL, CRIMP HOUSING 1
(V8N187) (POST SB 52-01)
(SUPSDS ITEM 15)
20 3325-1  SPACER, TEST SWITCH MOUNTING 1
(V1L0V9)
25 P7-526221  MINI-SWITCH (SW1) (V3A934) 1
30 M22759-32-24-2  WIRE, 24GA, RED (7.25” LONG) AR
(M22759-32-24-2 IS REF CODE FOR
M22759/32-24-2)
(V5P301)
Page 1030
RADIANT POWER CORP.
PART NUMBER BPAS10
LED/PCB Assembly
IPL Figure 7
PARTS LIST
UNITS
NOMENCLATURE PER
1234567 ASSY
7-
-1 3333-1 ASSEMBLY, LED/ PCB RF
5 2055-440SS  STANDOFF, HEX, SS (2055-440SS IS 2
REF CODE FOR 2055-440-SS)
(4-40x0.375L) (V8R639)
ATTACHING PARTS
10 MS51957-13  SCREW, PH, PHILLIPS, SS (4-40 x 2
0.25L)
----****----
(V5P301)
20 08-70-0073  TERMINAL, FEMALE CRIMP 2
(V8N187) (PRE SB 52-01 FOR SN 0001
-20A 50212-8100  TERMINAL, FEMALE CRIMP 2
(V8N187) (POST SB 52-01)
(SUPSDS ITEM 20)
25 10-01-4024  TERMINAL, CRIMP HOUSING 1
(V8N187) (PRE SB 52-01 FOR SN 0001
-25A 51065-0200  TERMINAL, CRIMP HOUSING 1
(V8N187) (POST SB 52-01)
(SUPSDS ITEM 25)
30 2225  PCB (1MXA1)
35 AND190HRP  LED, RED (V0TBK5)
40 M22759-32-24-3  WIRE, 24GA, ORANGE (8.0” LONG) AR
M22759/32-24-3)
45 M22759-32-24-5  WIRE, 24GA, GREEN (8.0” LONG) AR
M22759/32-24-5)
Page 1031
RADIANT POWER CORP.
PART NUMBER BPAS10
A1 PCB Assembly
IPL Figure 8

PARTS LIST
UNITS
NOMENCLATURE PER
1234567 ASSY
8-
-1 NONPROC1 ASSY, A1 PCB RF
(RF IPL FIG. 3 FOR NHA)
(NONPROCURABLE)
5 RLR07C2201GR  RESISTOR, 2.2K 1/4W 2% (RI02) 4
(V6M193)
10 02F5300  WIRE, 18GA (D113) (V02929) 1
15 37N495  SLEEVING (D113) (V02929) 1
20 JANTX1N5552  DIODE (D101, D108-D111) (V057Q7) 5
25 RWR89S2R61FR  RESISTOR, 2.61 3W 1% (RI01) 1
(V8N187)
30 RWR89S20R0FR  RESISTOR, 20 3W 1% (RI07) 1
(V0EU87)
35 1N6287A  DIODE, ZENER (DI02) (V057Q7) 1
40 1N6285A  DIODE, ZENER (DI03) (V057Q7) 1
Page 1032
RADIANT POWER CORP.
PART NUMBER BPAS10
A2 PCB Assembly
Page 1033
RADIANT POWER CORP.
PART NUMBER BPAS10
A2 PCB Assembly
Page 1034
RADIANT POWER CORP.
PART NUMBER BPAS10

PARTS LIST
UNITS
NOMENCLATURE PER
1234567 ASSY
9-
-1 NONPROC2 ASSY, A2 PCB RF
(NONPROCURABLE)
5 JANTX1N754A1  DIODE, ZENER (D221) (JANTX1N754A1 1
IS REF CODE FOR JANTX1N754A-1)
(V057Q7)
10 RLR07C1401GR  RESISTOR, 1.4K (R219) (V8N187) 1
15 JANTX2N2222A  TRANSISTOR, NPN (Q209-Q215) 7
(V057Q7)
17 M38527-1-036D  INSULATOR, THERMALLOY (M38527-1- 7
036D IS REF CODE FOR M38527/1-036D)
20 JANTX1N972B1  DIODE, ZENER 30V 100MW 4
(D223-D226)
(JANTX1N972B1 IS REF CODE FOR
JANTX1N972B-1) (V6M193)
25 JANTX4N49  ISOLATOR, OPTO (U213-U217) 5
(V057Q7)
30 JM3851005151BCA  COUNTER, JOHNSON (U209) 1
(JM3851005151BCA IS REF CODE FOR
JM38510/05151BCA) (V0EU87)
35 JM3851005651BEA  FLOP, FLIP, DUAL D (U212) 1
(JM3851005651BEA IS REF CODE FOR
JM38510/05651BEA) (V0EU87)
40 RLR07C2201GR  RESISTOR, 2.2K 1/4W 2% (R202, R258) 2
(V6M193)
45 10-32-1023  HEADER, PIN LOCK (J3, J4) (V30687) 2
(PRE SB 52-01 FOR SN 0001 THRU 2183)
(SUPSD BY ITEM 45A)
-45A 53253-0270  HEADER, PIN LOCK (J3, J4) (V30687) 2
(POST SB 52-01) (SUPSDS ITEM 45)
50 RLR07C1002GR  RESISTOR, 10K 1/4W 2% (R223, R226, 9
R231, R237, R240, R243, R246, R249,
R251) (V6M193)
55 L7812CV  REGULATOR, VOLTAGE, 12V (U206) 1
(V0EU87) (SUPSD BY ITEM 55A)
-55A L7812CVDG  REGULATOR, VOLTAGE, 12V (U206) 1
(L7812CVDG IS REF CODE FOR L78
12CV-DG) (V0EU87) (SUPSDS ITEM 55)
60 MP850-168  RESISTOR, 168 1% (R241) (V0TBK5) 1
65 JANTX1N3957  DIODE (D204, D217) (V057Q7) 2
70 RLR07C1001GR  RESISTOR, 1K 1/4W 2% (R220, R234, 4
R238, R250) (V6M193)
75 RNC55H5902BR  RESISTOR, 59K (R203) (V8N187) 1
Page 1035
RADIANT POWER CORP.
PART NUMBER BPAS10

PARTS LIST
UNITS
NOMENCLATURE PER
1234567 ASSY
9-
80 LM2577TADJ  REGULATOR, BOOST (LM2577TADJ 1
IS REF CODE FOR LM2577T-ADJ)
(U201) (V0EU87)
85 RLR07C59R0GR  RESISTOR, 59 1/4W 2% (R201) 1
(V8N187)
90 MBR745  RECTIFIER, SCHOTTKY, 7.5A 0.45V 1
(D201) (V6M193)
95 RLR07C1003GR  RESISTOR, 100K 1/4W 2% (R221, 5
R224, R235, R236, R239) (V6M193)
100 RLR07C3302GR  RESISTOR, 33K 1/4W 2% (R248) 1
(V6M193)
(V6M193)
(V6M193)
115 RLR07C47R0GR  RESISTOR, 47 1/4W 3% (R244) 1
(V8N187)
120 RLR07C1501GR  RESISTOR, 1.5K 1/4W 2% (R247) 1
(V6M193)
125 RNC55H1003BS  RESISTOR, 100K 1/8W 0.1% (R255) 1
(V8N187)
130 RNC55H4992BR  RESISTOR, 49.9K 1/8W 0.1% (R252, 3
R254, R256) (V8N187)
135 RNC55H6042BS  RESISTOR, 60.4K 1/8W 0.1% (R253) 1
(V8N187)
140 RNC55H2673BS  RESISTOR, 267K 1/8W 0.1% (R257) 1
(V8N187)
145 RFG60P06E  TRANSISTOR, MOSFET (P-CH 60V, 2
60A) (Q204, Q208) (V6M193) (SUPSD
BY ITEM 145A)
-145A IXTQ52P10P • TRANSISTOR, MOSFET (P-CH 60V, 2
60A) (Q204, Q208) (V6M193) (SPSDS
ITEM 145)
150 5962-7700801CA  COMPARATOR, QUAD (U207) 1
(V0EU87)
155 RLR07C1402GR  RESISTOR, 1.4K (R233) (V8N187) 1
160 RLR07C2202GR  RESISTOR, 22K 1/4W 2% (R222, 3
R225, R232) (V6M193)
165 5962-8982402PA  REFERENCE, VOLTAGE (U208) 1
(V0EU87)
(V8N187)
(V8N187)
Page 1036
RADIANT POWER CORP.
PART NUMBER BPAS10

PARTS LIST
UNITS
NOMENCLATURE PER
1234567 ASSY
9-
180 JM3851010901BPA  TIMER (JM3851010901BPA IS REF 1
CODE FOR JM38510/10901BPA)
(U210) (V0EU87)
185 JANTX1N4148-1  DIODE, SIGNAL (D205, D207-D214, 10
D222) (V057Q7)
Page 1037
RADIANT POWER CORP.
PART NUMBER BPAS10
Arm/ Disarm Switch Assembly

IPL Figure 10
Page 1038
RADIANT POWER CORP.
PART NUMBER BPAS10

PARTS LIST
UNITS
NOMENCLATURE PER
1234567 ASSY
10-
-1 3319-1 ASSY, ARM/ DISARM SWITCH RF
5 3365  ASSY, SWITCH BRACKET (VPREMR) 1
10 3354  ASSY, SWITCH PLATE (VPREMR) 1
ATTACHING PARTS
15 MS51957-14  SCREW, PH, SS (4-40x0.312L) 4
20 MS15795-803  WASHER, FLAT (#4) 4
----****----
25 65-201000  MICRO SWITCH (SW1,SW2) (V28523) 2
ATTACHING PARTS
30 92196A112  SCREW, SH CAP, SS (4-40x0.625L) 4
(VMCMAS)
35 MS15795-803  WASHER, FLAT (#4) 4
40 3368  WASHER, FLAT (#4, .062 THK) 4
(V8R639)
----****----
45 3374  BEARING, SHAFT (V1L0V9) 1
ATTACHING PARTS
50 MS24693-C28  SCREW, FH (MS24693C28 IS REF 2
(6-32x0.50L)
----****----
55 3376  HOUSING, CAM (V1L0V9) 1
60 Y-27  SPRING (V8R639) 1
65 3373  SHAFT, CAM, SS (V1L0V9) 1
70 3386  SCREW, CAM FOLLOWER (V1L0V9) 1
-75 1279K33  LUBRICANT, MOLY LUBE ANTISEIZE AR
(VMCMAS)
-80 242 • COMPOUND, LOCKING, LOCTITE AR
(V5P301)
Page 1039
RADIANT POWER CORP.
PART NUMBER BPAS10
Page 1040

CMM 52-11-01 1mxa1 15417738

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RADIANT POWER CORP.

COMPONENT MAINTENANCE MANUAL

HOLDERS OF COMPONENT MAINTENANCE MANUAL 52-11-01, REVISION 8

REVISION NO. 9, DATED DEC 01/2014

Chapter/Section and Page No. Description of Change

Record of Revisions: RR-1 ADDED Revision 9

Service Bulletin List: SB-1 ADDED SB 52-01 & SB 52-02

Description and Operation

Testing and Fault Isolation

Chapter/Section and Page No. Description of Change

RADIANT POWER CORP.

Component Maintenance Manual

Standby Instrument Battery

Part Number: BPAS10-5

THIS MANUAL CONTAINS PROPRIETARY INFORMATION OF RADIANT POWER

INFORMATION SUBJECT TO EXPORT CONTROL LAWS

THIS PAGE INTENTIONALLY LEFT BLANK

REVISION REVISION DATE BY REVISION REVISION DATE BY

THIS PAGE INTENTIONALLY LEFT BLANK

RECORD OF TEMPORARY REVISIONS

REVISION REVISION DATE BY REVISION REVISION DATE BY

THIS PAGE INTENTIONALLY LEFT BLANK

SERVICE BULLETIN LIST

SERVICE DATE DATE BY SERVICE DATE DATE BY

THIS PAGE INTENTIONALLY LEFT BLANK

LIST OF EFFECTIVE PAGES

Subject Page Date Subject Page Date

Title Page T-1 Dec 01/14 Disassembly 301 Jan 07/13

Subject Page Date Subject Page Date

Illustrated Parts List 1005 Jun 27/12

Description and Operation 1

1 BPAS10-5 Primary Components 3

1 Electrical Connector Pin Assignment 4

LIST OF TABLES (CONT)

401 Cleaning Materials 401

Configuration Serial Numbers

2. Product Support Services

(4) Maintenance contains information on proper storage and electrical conditioning of

(5) Cleaning contains procedures to clean the EPAS battery pack.

(6) Check contains procedures to check parts for damage.

C. WARNINGS, CAUTIONS and NOTES

(1) WARNINGS are provided before potentially dangerous procedures, materials,

4. General Safety Precautions

ELECTROSTATIC DISCHARGE All Integrated Circuits (ICs), surface mounted devices,

Follow the PCB handling procedures given in REPAIR

GROUNDING Connect equipment and personnel to electrical ground

MODIFY EQUIPMENT additions can alter safety characteristics and create a

SHOCK To prevent electrical discharge, do not expose the

Visually check for pinched, out of place, or frayed

Do a safety check of the entire unit before returning

Disassembly Dec 21/96

Assembly Dec 21/96

7. Abbreviations and Unit Symbols

AC Alternating Current EFF Effectivity

kg kilogram (I kg = 2.205 lb.) PCB Printed Circuit Board

DESCRIPTION AND OPERATION

B. The EPAS battery pack is a Line Replaceable Unit (LRU).

C. Battery pack assembly, BPA, consists of eighteen Nickel-Cadmium batteries wrapped in

E. A single 12-pin BACC63CB14 –12SN electrical connector provides the electrical

Technical properties of the EPAS battery pack are given in Table 2.

Equipment is marked per the modifications listed in Table 3.

BPAS10-5 Primary Components

Electrical Connector Pin Assignment