TP 336 - PS 835

Emergency Power Supply
JET® Model PS-835

Part Number 501-1228-( )
Installation Manual
This manual contains installation instructions and

recommended flightline maintenance information for the
PS-835 Emergency Power Supply. This information is
supplemented and kept current by revisions, service letters
and service bulletins.
24-30-04
L-3 Communications Avionics Systems
5353 52nd Street, S.E. TP-336 (Revision J)
Grand Rapids, MI 49512-9704, USA May 11, 2011
www.as.l-3com.com
Foreword
This manual provides information intended for use by persons who, in accordance with current regulatory
requirements, are qualified to install this equipment. Installation requirements may vary, depending on the
particularities of each aircraft, and this manual is intended as a guideline for that purpose.
This manual assumes familiarity with the setup and operation of the aircraft systems that interface with
the PS-835. Standard installation practices prescribed in FAA Advisory Circular No. 43.13 must be
followed.
If further information is required, please contact:

Attn: Field Service Engineering
nd
5353 52 Street, S.E.
Grand Rapids, MI USA 49512-9704
Telephone: (800) 453-0288 or (616) 949-6600
Fax: (616) 977-6898
We welcome your comments concerning this manual. Although every effort has been made to keep it free
of errors, some may occur. When reporting a specific problem, please describe it briefly and include the
manual part number, the paragraph/figure/table number, and the page number. Send your comments to:

Attn: Technical Publications
nd
5353 52 Street, S.E.
Grand Rapids, MI USA 49512-9704
Telephone: (800) 453-0288 or (616) 949-6600
Fax: (616) 977-6898
WARNING
INFORMATION SUBJECT TO EXPORT CONTROL LAWS
This technical data is controlled under the Export Administration
Regulations (EAR) and may not be exported without proper authorization
by the U.S. Department of Commerce.
 Copyright 2007, 2009, 2010, 2011

Trademarks
JET® is a trademark of L-3 Communications Avionics Systems, Inc.
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Revision J May 11, 2011
PS-835
Installation Manual
List of Effective Pages
Dates of original and changed pages are:
Reissue ................................................................................... July 1, 1994

Revision A .......................................................................... April 30, 2002
Revision B ..................................................................... February 28, 2003
Revision C ..................................................................... February 28, 2004
Revision D ..................................................................... February 02, 2005
Revision E ............................................................................. May 12, 2006
Revision F .........................................................................August 31, 2007
Revision G ......................................................................... March 13, 2009
Revision H ..........................................................................August 9, 2010
Revision J.............................................................................. May 11, 2011
Total number of pages in this publication consists of the following:
Section Page No.

Front Matter Cover
A
i-vi
Description 1-12
Installation 101-110
Fault Isolation 201-208
Disclaimer
This Installation Manual contains information that is considered relevant only at the time of distribution
with the Avionics Systems product for which it is shipped. Information in this manual is subject to change
without notice and will not be updated after distribution.
Avionics Systems does provide a listing of all publications and directives with their current revision and
change levels to insure up-to-date information. See www.as.l-3com.com, Service Section, Technical
Publications Page for the Publications Index to get an up-to-date listing of all Avionics Systems technical
publications and directives. Contact Avionics Systems Customer Service [1-800-453-0288] to determine
availability of technical publications and directives.
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Revision J Highlights
• Add ATA number 24-30-04 to manual; that was mistakenly removed in an earlier revision.
• Page 9: In note under paragraph C; change SL-64 to SL-80.
• Page 203: Update item 1, 2, 3 and 9 in table 201 by removing specific equipment and incorporating
minimum requirements for the items.
• Page 207: Removed “digital” from voltmeter.
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Page ii TP-336
May 11, 2011 Revision J
PS-835
Installation Manual
Table of Contents
Section Page
Foreword ...................................................................................................................................................... A
List of Effective Pages ................................................................................................................................... i
Table of Contents ......................................................................................................................................... iii
Table of Contents ......................................................................................................................................... iv
List of Illustrations ........................................................................................................................................ v
List of Tables ................................................................................................................................................ v
List of Abbreviations ................................................................................................................................... vi
Description
1. General .................................................................................................................................................. 1
2. Purpose of Equipment ........................................................................................................................... 1
3. Physical Description.............................................................................................................................. 1
4. Functional Description .......................................................................................................................... 1
A. Power Input ................................................................................................................................... 1
B. Battery Heating ............................................................................................................................. 2
C. Over-Temperature Protection ........................................................................................................ 2
D. Battery Voltage Level Detection ................................................................................................... 2
5. Continued Airworthiness (Maintenance) .............................................................................................. 2
6. MOD Status........................................................................................................................................... 3
7. Environmental Test Qualifications ....................................................................................................... 5
8. Specifications ........................................................................................................................................ 7
9. Charge and Discharge Performance ...................................................................................................... 7
A. General Battery and Cell Information ........................................................................................... 7
B. Battery/Cell Out-Gassing .............................................................................................................. 8
C. Storage Time and Temperature ..................................................................................................... 9
D. Cell Current Discharge Time ...................................................................................................... 10
E. Cell Voltage Discharge Time ...................................................................................................... 11
Installation
1. General .............................................................................................................................................. 101
2. Emergency Power Supply Location .................................................................................................. 101
3. Pre-Installation Inspection and Preparation ...................................................................................... 101
4. Post Installation ................................................................................................................................. 102
5. Affiliated Equipment......................................................................................................................... 102
A. SI-100 Static Inverter ................................................................................................................ 102
B. SC-841 Static Converter............................................................................................................ 102
C. BC-815 Battery Charger............................................................................................................ 102
D. Connector Plug for AC and DC powered Indicators ................................................................ 102
E. Transformer (used with SI-100 Static Inverter) ....................................................................... 102
F. ATR Mounting Rack ................................................................................................................ 102
G. Mating Connectors .................................................................................................................... 102
6. Installation Kits ................................................................................................................................. 104
7. Interconnect Diagrams ...................................................................................................................... 105
A. Fuse and Circuit Breakers ......................................................................................................... 105
B. Retrofits ..................................................................................................................................... 105
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Table of Contents
Section Page
Testing and Fault Isolation

1. General .............................................................................................................................................. 201
2. Battery Testing .................................................................................................................................. 201
3. Battery/Cell Out-Gassing .................................................................................................................. 202
4. Recommended Test Equipment ........................................................................................................ 203
5. Charging Procedures ......................................................................................................................... 203
A. Constant-Voltage Charging Method ......................................................................................... 203
B. Constant-Voltage Float (trickle) Charging Method .................................................................. 204
C. BC-815 Battery Charger Method .............................................................................................. 204
D. BC-815 Battery Float (trickle) Charging Method ..................................................................... 204
6. Preflight Checks (Recommended) .................................................................................................... 205
A. Pre-Flight Check for Aircraft with Remote Test Capability ..................................................... 205
B. Pre-Flight Check for Aircraft with No Remote Test Capability ............................................... 205
7. Periodic Checks (Required 3 to 6 Months) ....................................................................................... 205
8. Capacity Testing (Required Annually) ............................................................................................. 206
A. Capacity Test ............................................................................................................................. 206
B. Preferred Discharge Test Method (Load Resistor).................................................................... 207
9. Cell Isolation Test ............................................................................................................................. 208
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List of Illustrations
Figure Pages
1: PS-835 Emergency Power Supply ........................................................................................................ 6

2: Cell Storage Time vs. Temperature ...................................................................................................... 9
3: Typical Discharge Time for Sealed Lead-Acid Cells ......................................................................... 10
4: PS-835( ) Discharge Curves................................................................................................................ 11
101: Affiliated Equipment .................................................................................................................... 103
102: Typical Installation Interconnections for PS-835A through D & G ............................................. 106
103: Typical Installation Interconnections for PS-835E and F ............................................................. 107
104: Interconnections to AC Powered Indicators ................................................................................. 108
105: Interconnections to DC Powered Indicators ................................................................................. 108
106: PS-835 Installation Drawing ......................................................................................................... 109
107: PS-835 Pin Configurations ........................................................................................................... 110
201: Locally Manufactured Power Cable ............................................................................................. 203
202: PS-835 Access Panel .................................................................................................................... 206
List of Tables
Table Pages
1: Service Bulletins and Modifications ..................................................................................................... 3

2: Environmental Qualifications ............................................................................................................... 5
3: Specifications ............................................................................................................................... 7
101: List of Installation Kits ................................................................................................................. 104
102: Installation Kit Components [504-1019-01] ................................................................................. 104
201: Test Equipment and Fixtures ........................................................................................................ 203
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List of Abbreviations
SYMBOL OR ACRONYM DEFINITION
A Ampere
AC Alternating Current
AWG American Wire Gauge
AMP Ampere
AR As Required
CH Chemical Hazard
CCA Circuit Card Assembly
CCW Counterclockwise
CW Clockwise
DC Direct Current
EPS Emergency Power Supply
Hz Hertz (frequency)
" inch
lbs pounds
in-lbs Inch-Pounds (torque)
Max maximum
MSDS Material Safety Data Sheet
PWB Printed Wiring Board
RPM revolutions per minute
UUT unit under test
Vdc Volts direct current
Vac Volts alternating current
± + (plus) or – (minus)
° Angular Degree
F° Temperature Fahrenheit
C° Temperature Celsius
Ω Ohm
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Description
1. General
This manual provides description and operation instructions for Models PS-835 A through G
Emergency Power Supplies, Part Numbers 501-1228-01 through -07 (respectively). Models C, D, E,
F, and G are current and Models A and B are considered obsolete, see Service Bulletins and
Modifications Table 1.
Model Number Part Number Cell Type

A 501-1228-01 2.5Ah
B 501-1228-02 5.0Ah
C 501-1228-03 2.5Ah
D 501-1228-04 5.0Ah
E 501-1228-05 2.5Ah
F 501-1228-06 5.0Ah
G 501-1228-07 5.0Ah
2. Purpose of Equipment
The Model PS-835 Emergency Power Supply is designed as a 24 Vdc (nominal) emergency power
source for prolonging the operation of a connected standby attitude indicator when the aircraft main
power buss has de-energized. The aircraft main power buss provides trickle charging to the PS-835
while the aircraft performs normally.
The output of the PS-835 can be subsequently converted using either Avionics Systems Model SI-
100( ) Static Inverter or the SC-841 Static Converter to provide power for standby indicators of
different power requirements.
The SI-100 provides outputs of 115 Vac or 5 Vac, 400Hz either at single or three phase alternating
current. The SC-841 provides direct current outputs of 2.0 to 6.5 Vdc (user adjustable).
3. Physical Description
The PS-835 Emergency Power Supply is fully enclosed unit, designed to easily mount onto an
existing avionics shelf or the optional ATR mounting rack (Avionics Systems part number 572-
1424-01). The face of the unit provides individual cell monitor LED's, voltage output monitor
LED's, battery Heater Operation Monitor LED's, and a battery test switch to assist in assessing the
condition of the unit and cells.
4. Functional Description
A. Power Input
Aircraft 28 Vdc is connected to the emergency power buss through pin 10 of connector J1. The
input is diode isolated from the internal batteries and circuits to prevent battery discharge in the
event of a short circuit, or battery draw caused by low input from the aircraft main DC buss,
such as at engine start.
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B. Battery Heating
Battery heating is provided by an etched foil Heating Resistor mounted onto the unit chassis.
With 28 Vdc applied to the unit and the temperature is 19°C (66°F) the green HEATER ON
LED (Figure 1, Item 4) will come on showing that the heater is operating. The red LED will
come on if the temperature exceeds 55°C.
The heating element, also, functions as a test load during the time the power supply is being
tested aboard the aircraft. The HEATER ON LED (Figure 1, Item 3) will come on when the
TEST SWITCH (Figure 1, Item 4) on the front panel is pressed.
C. Over-Temperature Protection
When the temperature of the power supply exceeds +55°C, the temperature sensor imbedded
within the unit will cause the OVER 55°C LED (Figure 1, Item 3) to go on. The heating control
circuitry would then cease the heating-resistor's operation. The heating circuit will remain
inoperable until the temperature of sensor drops low enough to again permit heater operation.
D. Battery Voltage Level Detection
There are four OUTPUT VOLTAGE MONITOR LED's on the front panel of the supply (Figure
1, Item 2). These indicate the state-of-charge of the stored power. The LED's go on when the
TEST SWITCH is pressed or when the supply is being charged.
The power supply is considered greater than 50% charged when the 24V LED momentarily
illuminates when the TEST SWITCH is pressed, and fully discharged when the 20V LED is
goes out.
5. Continued Airworthiness (Maintenance)
The Model PS-835 Emergency Power Supply requires regular checks and testing to ensure that the
unit will provide standby electrical power under emergency conditions experienced by the aircraft in
which it is installed.
Use the instructions provided in this Installation Manual, or the corresponding Maintenance Manual
(TP-329) to perform Preflight Checks, Periodic Checks, and Annual Capacity Testing procedures to
monitor the operational capability of the unit.
Follow the associated guidance provided in those procedures that will direct service and maintenance
actions that will restore the unit to full and correct operation.
This unit has unlimited service life, where service life is defined as that point in time when repair is
no longer economical. No scheduled overhaul requirement exists for this unit.
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6. MOD Status
The PS-835 Emergency Power Supply is a proven design that has experienced numerous
improvements. This manual offers information concerning the various levels of modification at
which a unit may exist in the field.
The table below lists all Service Bulletins that pertain to the PS-835 Emergency Power Supply up to
the date of this publication.
Modification Kits and

Model and Part
Service Bulletin MOD # Purpose part required for
Number
Modification
SB501-1228-1( ) A-501-1228-01 1 Wiring modification to
B-501-1228-02 prevent connector J2 arcing
during extreme vibrations.
SB501-1228-2( ) A-501-1228-01 2 Replace Thermal Resistor to MOD Kit 504-1637-01
B-501-1228-02 reduce shorting possibility.
SB501-1228-3( ) B-501-1228-02 3 Add insulation plate to prevent MOD Kit 504-1638-01
shorting possibility between
cell BT12 and chassis.
SB501-1228-4( ) A-501-1228-01 3 Modify wiring to prevent MOD Kit 504-1642-01
B-501-1228-02 4 CCA damage because loss of
grounding isolation between
battery and chassis.
SB501-1228-5( ) A-501-1228-01 4 Additional instructions to (Pervious MOD 3 and 4
B-501-1228-02 5 insure previous MOD's 3 and instructions failed to
4 are properly applied. instruct soldering wire
back onto lug)
SB501-1228-6( ) A-501-1228-01 5 Replace and reposition MOD Kit 504-1648-01
B-501-1228-02 6 resistors A2R1 and A2R7 on
Battery Monitor CCA.
SB501-1228-7( ) A-501-1228-01 6 Modify wiring to provide self-
B-501-1228-02 7 testing capability for fuse
C-501-1228-03 1 failure.
D-501-1228-04 1
SB501-1228-8( ) A-501-1228-01 Modifies Models A and B into MOD Kit 504-1745-01
B-501-1228-02 Models C and D to meet DO- Re-identifies CCA A2
160A voltage spike test. from 542-1634-01 to
542-1495-01
SB501-1228-9( ) A-501-1228-01 7 Replace Battery Monitor CCA Replace CCA A2 part
B-501-1228-02 8 to improve Heater Circuit number 542-1495-01
C-501-1228-03 2 performance. with CCA A2 part
D-501-1228-04 2 number 542-1521-01.
SB501-1228-10( ) A-501-1228-01 Modify wiring to circumvent MOD Kit 504-1746-01
B-501-1228-02 fuse for emergency operation. (All previous MOD's to
C-501-1228-03 Re-identifies Models C and D A, B, C, and D must first
D-501-1228-04 into Models E and F. have been performed)
Table 1: Service Bulletins and Modifications
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Modification Kits and

Model and Part
Service Bulletin MOD # Purpose part required for
Number
Modification
SB501-1228-11( ) A-501-1228-01 8 Prevent possible shorting MOD Kit 504-1811-01
C-501-1228-03 3 between cells and chassis.
E-501-1228-05 1
SB501-1228-12( ) A-501-1228-01 9 Prevent possible shorting MOD Kit 504-1839-01
B-501-1228-02 9 between cells and chassis.
C-501-1228-03 4
D-501-1228-04 3
E-501-1228-05 2
F-501-1228-06 1
SB501-1228-13( ) A-501-1228-01 10 Modify wiring to prevent
B-501-1228-02 10 improper charging.
C-501-1228-03 5
D-501-1228-04 4
E-501-1228-05 3
F-501-1228-06 2
SB501-1228-14( ) D-501-1228-04 5 Prevent shorting of cell leads
Serial No's by correcting wire routing and
8647 and improved soldering of cell
higher. terminals.
SB501-1228-15() A-501-1228-01 11 To add warning instructions Warning Label (p/n
B-501-1228-02 11 for proper care and 535-1873-01)
C-501-1228-03 6 maintenance of battery pack to
D-501-1228-04 6 prevent voiding warranty.
E-501-1228-05 4
F-501-1228-06 3
Table 1: Service Bulletins and Modifications (Cont.)
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7. Environmental Test Qualifications
The following tests have been conducted to satisfy DO-160A test conditions.
Name of Test Qualified to DO-160A elements:

Low Temperature Section 4.0 Cat. A2F2
Humidity Section 6.0 Cat. B
Vibration Section 8.0 Cat. J
Explosion Section 9.0 Cat. E
Voltage Spikes Section 17 Cat. A for Models C, D, E, F, and G
Temperature Variation Section 5.0 Cat. B
Magnetic Effect Section 15
Audio Frequency Conducted Section 18 Cat. A
Susceptibility
Electromagnetic Compatibility Section 19 Cat. A
Section 20 Cat. A
Section 21 Cat. A
Table 2: Environmental Qualifications
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Figure 1: PS-835 Emergency Power Supply
1 Individual Cell Monitor LED's

2 Output Voltage Monitor LED's
3 Battery Heater Operation Monitor LED's
4 Test Switch
5 Individual Cell Dip Switches
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8. Specifications
Part Number 501-1228-01, -02, -03, -04, -05, -06, -07

Certification: FAA-PMA (for 501-1228-03, -04, -06, -07)
RTCA Compliance: Environmental: DO-160A
Size: Length: 14.110 max.
Height: 7.774 max.
Width: 2.400 max.
Weight: Model A, C, E - 8 lbs. [3.65Kg]
Model B, D, F, G - 13 lbs. [6.0Kg]
Power Requirements: Input: 28 to 30 Vdc, 15 Amp max.
Output: 24 Vdc nominal, 10 Amp max. steady state
Model A, C, E - 2.5 Amp Hour
Model B, D, F, G - 5.0 Amp Hour
See Figure 3 Current Discharge Times
and Figure 4 Voltage Discharge Curves
Operating Altitude Sea level to 55,000 ft. at 25°C
Operating Temperature: -55°C to +70°C
Storage Temperature: -55°C to +85°C
Connector Type: Model A, B, C, D, G: DPXB-13-33S-0001 (Avionics Systems P/N
S24140-01)
Model E, F: DPXB-13-33S-0019 (Avionics Systems P/N S24140-02)
Service Life: The EPS has unlimited service life.
Table 3: Specifications
9. Charge and Discharge Performance
A. General Battery and Cell Information
The cells are constructed with thin pure lead plates. The overall chemistry is typical of the
traditional lead-acid battery. A unique aspect of the sealed lead-acid cell is that the majority of
the oxygen generated within the cell during an overcharge condition is recombined within the
cell. The quality of the lead grids used in construction minimizes the evolution of hydrogen
when overcharging occurs.
Each cell has a self-resealing release valve designed to operate in the 50-60 psi range. In
normal use, the battery internal cell pressure never exceeds 20 psi. This means that in normal
conditions the cell can be operated in a perfect vacuum and still have a sufficient safety margin,
so that venting will not occur.
NOTE
Batteries and Cells should not be left in a discharged state under any circumstances.
Cells should not be left connected to a load when in a discharged state or their ability to accept a
charge will be impaired. The cell may develop shorts or chemical action will create water that
will freeze at low temperatures and destroy the cell.
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B. Battery/Cell Out-Gassing
CAUTION
Some of the types of gasses that may vent from a cell are toxic and
should not be contained in a closed, non-vented area.
CAUTION
Cell/battery corrosion is evidence of the loss of seal, likely caused by out
gassing. Cells must be replaced when corrosion is apparent.
All lead-acid cells and batteries produce gasses during charging. The amount and type of gas
produced depends on state of charge, rate of charge, chemical composition of the electrolyte,
and general condition of the battery. Normally, gasses produced are recombined within the
cells to form oxides and water. Venting occurs when excessive charge rates are placed on the
battery or because of a defective cell (s) which subjects the remaining good cells to excessive
charge rates. Venting may also result from battery abuse or neglect.
If the odor of rotten eggs becomes apparent in the cockpit, pull the aircraft Emergency Power
Supply circuit breaker. The rotten egg odor is evidence that the lead-acid cells vent due to
prolonged high rate overcharging. Although the possibility of toxic levels is extremely remote,
the precaution of pulling the circuit breaker will prevent increased discomfort from the odor.
Venting is an indication that the Power Supply in not controlling the charging process. If
venting occurs the factory recommends that the Power Supply be removed from the
aircraft, tested according to the procedures listed in this manual, and to replace the
defective cell(s).
NOTE
With proper maintenance and periodic testing, the likelihood of any
battery developing undetected problems is very remote.
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C. Storage Time and Temperature
NOTE
Avionics Systems Service Letter SL-80( ) contains additional information
on Lead-acid Battery out-gassing and Service Letter SL-80( ) contains
additional information for Charging Emergency Power Supplies.
If a ready condition is required of a power supply being stored, recharge batteries every 4 months
for 1 hour at 28 to 30Vdc input. Do not store where temperature may exceed 85°F (29°C).
Low storage temperatures on fully charged cells lessen the rate of self-discharge, thus
increasing shelf life. There is no danger of damage to cells since they will not freeze even at
temperatures of -75° F. On the other hand, high storage temperatures will accelerate self-
discharge of the cells and storage under such conditions is not recommended. Refer to Figure 2.
Figure 2: Cell Storage Time vs. Temperature
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D. Cell Current Discharge Time
The rate of energy being withdrawn from a cell affects the amount of energy that can be
obtained over time. For example, at low current rates the energy in a cell lasts longer than at
high current rates. The actual hours of service (Amp-hours, or Ah) from fully charged "D" or
"X" cells can be determined from Figure 3 below.
Figure 3: Typical Discharge Time for Sealed Lead-acid Cells
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E. Cell Voltage Discharge Time
Figure 4 displays typical discharge curves at room temperature. At -55°C an internal heater
blanket maintains the cells at no lower than 0°C for the "X'' type cells and 20°C for the "S" type
cells. A typical discharge rate with the cells at 0°C reduces the capacity by approximately 15%.
Figure 4: PS-835( ) Discharge Curves
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Installation
1. General
The installation information provided is for “typical” install situations, not including information for
specific aircraft. Additional information may be obtained from the original aircraft manufacturer.
2. Emergency Power Supply Location
The following steps provide general requirements for locating the Emergency Power Supply in an
aircraft.
A. The Emergency Power Supply provides limited direct-current power and 115Vac (when in
combination with Static Inverter Model SI-100) to the aircraft emergency bus equipment in case
of primary power failure. Therefore, the supply should be located in the general area of aircraft
AC and DC busses.
B. Ensure that space requirements for the supply match space available for the installation being
considered.
1) The Emergency Power Supply should be accessible for inspection, maintenance, or

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

A. Check unit for physical damage that may have occurred during shipping and handling.
B. Press TEST SWITCH (Figure 201, Item 4) into TEST position for 5 seconds. The PS-835
indicates that it is adequately charged when the VOLTAGE LEVEL 24Vdc LED (Figure 201,
Item 2, at least, illuminates momentarily, AND the 20Vdc LED (Figure 201, Item 6) remains lit
during the test.
NOTE
Ensure Test Switch is returned to normal position and all LED's are extinguished.
1) If the unit reveals that it is at a fully charged state, proceed with installation into aircraft.
2) If the unit is not fully charged, perform charging procedures as directed in Testing and
Fault Isolation section, step 2. Charging Procedures.
C. At completion of charging period, again perform step B.
1) If the unit reveals that it is at a fully charged state, proceed with installation into aircraft.
2) If the unit is not fully charged, return the unit to the factory or service center for repair.
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4. Post Installation
Perform either the Preflight or the Periodic Check, see Testing and Fault Isolation section,
immediately after installation of the PS-835 Emergency Power Supply.
5. Affiliated Equipment
A. SI-100 Static Inverter
The SI-100 Static Inverter provides for alteration of the PS-835 output for use of equipment that
requires alternating current (AC).
The Model SI-100A Static Inverter (Avionics Systems part number 501-1240-01) has 3Ø,
400Hz, 115Vac, 25VA output capability.
The Model SI-100B Static Inverter (Avionics Systems part number 501-1240-02) has 1Ø,
400Hz 115Vac, 75VA output capability, or 1Ø, 400Hz, 5Vac, 5VA output capability.
B. SC-841 Static Converter
The SC-841 Static Converter (Avionics Systems part number 501-1318-01) provides for direct
current conversion for 2 to 6.5 Vdc, 25 Watt output capability. See Avionics Systems
Installation Instructions TP-351 for additional information.
C. BC-815 Battery Charger
The BC-815 Battery Charger (Avionics Systems part number 501-1321-01) provides the
capability to charge the PS-835 Emergency Power Supply when not mounted on aircraft. See
Avionics Systems Installation Instructions TP-350 for additional information.
D. Connector Plug for AC and DC powered Indicators [Figure 101, Item 1]
MS3126E10-16S for AC power Indicators, Avionics Systems part number 563-1013-04 for DC
powered Indicators.
E. Transformer (used with SI-100 Static Inverter) [Figure 101, Item 2]
For aircraft applications that require 26Vac output. (Avionics Systems part number 556-2006-01)
F. ATR Mounting Rack [Figure 101, Item 3]
ATR Mounting Rack (Avionics Systems part number S53001-01) for use with PS-835 in
aircraft applications.
G. Mating Connectors
Avionics Systems part numbers S24140-02 for PS-835 E and F, S24140-01 for PS-835 A
through D & G. (See Figure 106 and Figure 107)
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ITEM 1
ITEM 2
Figure 101: Affiliated Equipment
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Installation Manual
6. Installation Kits
Kit Part Number PS-835 Model Including Inverter or Converter Connecting to Indicator units:
504-1019-01 A-D, G SI-100( ) AI-804 or AI-904 AC powered
504-1019-02 A-D, G SI-100( ) or SC-841 AI-804 or AI-904 DC powered
504-1019-05 E-F SI-100( ) or SC-841 AI-804 or AI-904 AC powered
504-1019-06 E-F SI-100( ) or SC-841 AI-804 or AI-904 DC powered
504-1035-01 A-D, G - - GH-3000 and GH-3100 ESIS
Table 101: List of Installation Kits
Kit Component Description Qty.

S53001-01 ATR Rack 1
MS3126E10-6S Connector 1
S24140-01 Connector, Electrical Rectangular Single Insert 13 1
Table 102: Installation Kit Components [504-1019-01]

563-1013-04 Connector, Electrical Circular 1

MS3126E10-6S Connector 1
S24140-02 Connector, Electrical 1

563-1013-04 Connector, Electrical Circular 1
S24140-02 Connector, Electrical 1

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PS-835
Installation Manual
7. Interconnect Diagrams
A. Fuse and Circuit Breakers
The PS-835 Emergency Power Supply contains internal fuses and circuit breakers to protect the
supply against shorting conditions. Additional fuses or breakers may be required to protect
aircraft wiring, as determined by the specific loads. The required current-rating of any
additional current protection is dependent on the load applied to the unit's connector J1 Pin 11.
All circuits connecting to the output Pin 11 should use current/load appropriate sized wire.
Refer to the Typical Installation Interconnect Diagrams (Figure 102 or Figure 103) for
additional information. See Specifications Table 3 for PS-835 current output information.
B. Retrofits
The older PS-823 Emergency Power Supply can be replaced by the PS-835. The PS-823, when
providing 115 Vac output, can be replaced with the PS-835/SI-100 combination to provide
115Vac output, also.
In cases where the previous PS-823 provided 26 Vdc output, add the Transformer (Figure 101,
Item 2 Avionics Systems part number 556-2006-01) to the PS-835/SI-100 combination. See
Figure 101, Item 3 for suggested Transformer location. Tap either phase A or C output leg
when using a SI-100A, 3 -phase Static Inverter.
Test-switch circuitry of the previous PS-823 setup must be altered as indicated below.
PS-823 (/T) Test PS-835 () Test

Comparison Switch Switch
2 EXT 28 Vdc
28 Vdc
2
Test Test
Lamp Lamp
6 6
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PS-835
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Figure 102: Typical Installation Interconnections for PS-835A through D & G
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PS-835
Installation Manual
Figure 103: Typical Installation Interconnections for PS-835E and F
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PS-835
Installation Manual
*If an existing installation is being converted from a PS-823 to a PS-835

and a Transformer is required, remove wire from power supply mating
connector pin 4 and connect to transformer yellow lead.
Figure 104: Interconnections to AC Powered Indicators
Figure 105: Interconnections to DC Powered Indicators
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PS-835
Installation Manual
Figure 106: PS-835 Installation Drawing
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PS-835
Installation Manual
Pin Configuration for Models A, B, C, D, and G

Pin Configuration for Models E and F
Figure 107: PS-835 Pin Configurations
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PS-835
Installation Manual
Testing and Fault Isolation

1. General
This section of the manual provides battery testing, preflight checks, periodic checks, annual
capacity test, and cell isolation test procedures to insure the satisfactory performance of the PS-835
Emergency Power Supply.
NOTE
Read these procedures thoroughly before proceeding with any testing.
2. Battery Testing
NOTE
Test functions should be performed only with the main buss not providing
power to the unit (OFF of disconnected).
Toggling the unit TEST SWITCH (Figure 202, Item 4) on the power supply front panel bypasses the
thermostatic heat control system. That, in-turn, applies the battery voltage to the internal battery
heater. While in the TEST mode, the batteries are placed under an approximate 7.5Ω load. The
voltage level detection system analyzes the battery voltage level and causes the appropriate
OUTPUT VOLTAGE MONITOR LED's (Figure 202, Item 2) to illuminate.
NOTE
NOTE
If the unit TEST SWITCH or Remote Test Switch is depressed at a
battery ambient temperature of 55°C or greater, the unit internal heater
will not turn ON to provide a test load for the unit battery. This is not an
ideal condition for battery state of charge tests and should not be
considered valid.
If the remote test is being performed, the Remote Battery-Voltage Level Lamp momentarily
illuminates, provided the internally loaded battery voltage level is greater than 24Vdc.
NOTE
After testing, it is possible that the lamp will not illuminate again until
the batteries are recharged.
The INDIVIDUAL CELL MONITOR LED's (Figure 202, Item 1) function as GO/NO GO indicators
for each of the PS-835 lead acid cells. In case of low output capacity, these LED's will indicate
which cell or cells have failed. Any variation of brightness does not indicate cell condition.
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TP-336 Test and Fault Isolation Page 201
PS-835
Installation Manual
3. Battery/Cell Out-Gassing
CAUTION
Some of the types of gasses that may vent from a cell are toxic and
should not be contained in a closed, non-vented area.
CAUTION
Cell/battery corrosion is EVIDENCE of the loss of seal, likely caused by
out gassing. Cells must be replaced when corrosion is APPARENT.
All lead-acid cells and batteries produce gasses during charging. The amount and type of gas
produced depends on state of charge, rate of charge, chemical composition of the electrolyte, and
general condition of the battery. Normally, gasses produced are recombined within the cells to form
oxides and water.
Venting occurs when excessive charge rates are placed on the battery or because of a defective
cell(s), which will subject the remaining good cells to excessive charge rates. Venting may also
result from battery abuse or neglect.
If the odor of rotten eggs becomes apparent in the cockpit, pull the aircraft Emergency Power
Supply circuit breaker. The rotten egg odor is evidence that the lead-acid cells vent due to
prolonged high rate overcharging. Although the possibility of toxic levels is extremely remote, the
precaution of pulling the circuit breaker will prevent increased discomfort from the odor.
Venting is an indication that the Power Supply in not controlling the charging process. If venting
occurs, the factory recommends that the Power Supply be removed from the aircraft, and
tested to identify and replace defective cell(s).
NOTE
With proper maintenance and periodic testing, the likelihood of any
battery developing undetected problems is very remote.
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PS-835
Installation Manual
4. Recommended Test Equipment
Table 201 provides a list of recommended test equipment needed to accomplish the test listed in this
manual.
NOTE
Equivalent substitutes may be used for listed items.
Item Description Manufacturer - Model / Part No.

1 Power Supply Regulated Commercial Power Supply
Minimum Requirements: Maintain 29.5 VDC
± 0.5 at 10 amps 300 watts or greater.
2 Voltmeter Commercially Available.
Minimum Requirements: 0 to 35 Vdc 0.1%
accuracy
3 Stopwatch Commercially Available.
Minimum Requirements: Able to provide
minutes and seconds indications.
4 Load Resistor WireMasters, Inc.
7Ω ±1% 150 watt (minimum), Ceramic 136 Alpha Drive,
wire wrap Franklin, TN 37064. Cage Code: 0FVD7
Tel: 800-635-5342
(Part Number WM910053 …300 watt version)
5 Isolation Diode WireMasters, Inc.
15 Amp, 50 Volt PIV (Part Number WM1N3208)
6 Mating Connector for PS-835 A to D, & G P/N: DPXB-13-33S-0001
7 Mating Connector for PS-835 E and F P/N: DPXB-13-33S-0019
8 Wire, 16 AWG Local Manufacturer
9 BC-815 Battery Charger (Optional - used in Avionics Systems Part No. 501-1321-01
place of DC power supply)
Table 201: List of Equipment and Hardware
5. Charging Procedures
A. Constant-Voltage Charging Method
Locally manufacture a power cable using 16AWG wire and the appropriate mating connector.
Include a Diode (15 ADC (min), 50.0 PIV or greater) to prevent battery discharge in case of
loss of power from the power source. See Figure 201.
Using the external power supply (Table 201, Item 1), apply 29.0 ± 0.5 Vdc (10A maximum
current limited) to J1 connector pins 11 (+) and 7 (-) and charge the unit for 16 hours. The
batteries should reach 80% capacity within 1 hour and full charge at 16 hours.
Figure 201: Locally Manufactured Power Cable
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PS-835
Installation Manual
B. Constant-Voltage Float (trickle) Charging Method
Use the locally manufactured power cable, including the appropriate mating connector and
diode, to connect a regulated/constant voltage source (28.5 ± 0.5 Vdc) to the PS-835. This
method will provide a long-term constant voltage to maintain the fully charged condition of the
PS-835 unit when not in service, without any other maintenance action.
NOTE
The trickle charge method can be maintained indefinitely without damage to
the charging batteries.
C. BC-815 Battery Charger Method
Install the BC-815 Battery Charger (Avionics Systems part number 501-1321-01) into the PS-
835 Emergency Power Supply and charge for no-less-than 23 hours. Charge time depends upon
the batteries state-of-charge. Charging for 23 hours will essentially guarantee a full charge.
The BC-815 provides a constant charging current of either 0.5 A or 0.25 A, selectable by a
switch on the face of the unit. The AMBER LED illuminates when power is applied by placing
the ON / OFF switch to ON. When the unit being charged is within 90.0% of full charge, the
GREEN LED illuminates indicating that the BC-815 has automatically switched to the trickle
charge mode. The charger/battery combination may be operated in this mode indefinitely
without damage to the BC-815 or to the batteries being charged.
D. BC-815 Battery Float (trickle) Charging Method
Install the BC-815 Battery Charger (Avionics Systems part number 501-1321-01) into the PS-
835 Emergency Power Supply. This method will provide a long-term constant voltage to
maintain the fully charged condition of the PS-835 unit when not in service, without any other
maintenance action.
NOTE
The trickle charge method can be maintained indefinitely without
damage to the charging batteries.
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PS-835
Installation Manual
6. Preflight Checks (Recommended)
NOTE
This check indicates an accurate condition of the unit only upon the
initial attempt. Repeated checks will not reveal accurately because
stored energy is used each time the TEST SWITCH is depressed.
A. Pre-Flight Check for Aircraft with Remote Test Capability
CAUTION
Do not leave the emergency power supply switch in the on/armed
position after aircraft shutdown. Battery discharge will cause irreversible
damage to cells.
With no power applied to the PS-835 Emergency Power Supply, press and hold for 5 seconds
the cockpit remote TEST SWITCH in the TEST position. The remote test lamp must, at least,
momentarily illuminate to indicate that the Power Supply is adequately charged. If no
illumination of the remote test lamp is apparent for the period that switch is held, the
Emergency Power Supply is incapable of providing power in an emergency.
• If the Test Indicator does not illuminate follow the Capacity Testing procedures on page 206.
B. Pre-Flight Check for Aircraft with NO Remote Test Capability
Access the Emergency Power Supply. Perform the check as listed in paragraph 7, Periodic
Checks.
7. Periodic Checks (Required 3 to 6 Months)
With no power applied to the PS-835 Emergency Power Supply, press TEST SWITCH (Figure 202,
Item 4) (or remote cockpit test switch) into TEST position for 5 seconds. The PS-835 indicates that
it is adequately charged when the VOLTAGE LEVEL 24Vdc LED (Figure 202, Item 2) (or remote
test indicator), at least, illuminates momentarily, AND the 20Vdc LED (Figure 202, Item 6) remains
lit during the test.
NOTE
Ensure Test Switch is placed to normal position and all LED's are extinguished.
If the VOLTAGE LEVEL 24Vdc LED does not, at least, momentarily illuminate while the 20Vdc
LED is illuminated, the Emergency Power Supply is incapable of providing power in an emergency.
Proceed to Cell Isolation Test, paragraph 9.
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PS-835
Installation Manual
1
2
6
3
Figure 202: PS-835 Access Panel
8. Capacity Testing (Required Annually)
NOTE
The PS-835 Emergency Power Supply must have completed a full charge
prior to any discharge testing.
A. Capacity Test
1) Press and hold TEST SWITCH (Figure 202, Item 4) and observe the OUTPUT VOLTAGE
MONITOR LED's (Figure 202, Item 2).
NOTE
2) If the 24VDC OUTPUT VOLTAGE MONITOR LED comes on, proceed with either
Discharge Test procedures.
3) If OUTPUT VOLTAGE MONITOR LED's do not come on, check Fuse A1F1 (Figure 106)
and replace if blown. Perform step 9. Cell Isolation Test if fuse is not blown.
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PS-835
Installation Manual
B. Preferred Discharge Test Method (Load Resistor)
1) Prepare for test by first constructing an X-Y graft similar to the one at Figure 4. If
possible, use pre-printed graft paper to create a record of the discharge period along the X-
axis and voltage readings along the Y-axis.
2) Position all INDIVIDUAL CELL DIP SWITCHES (Figure 202, Item 5) to the ON
position.
a. If the INDIVIDUAL CELL MONITOR LED DS12 (DS1 for models E and F) is the
only LED not illuminated, proceed to step 6. Cell Isolation Test.
3) Connect Voltmeter (Figure 202, Item 2) leads to J1 connector pins 11 (+) and 7 (-).
4) Connect the Load Resistor (Figure 202, Item 4) across J1 connector pins 11 (+) and 7 (-)
and start timing the discharge period with the stopwatch (Figure 202, Item 3) now.
5) Monitor and plot voltage values at 10-minute intervals.
6) At 48.0 minutes (Model’s B, D, F and G) and 20.0 minutes (Model’s A, C and E), note
voltage on Voltmeter. This voltage must be greater than 20.0 Vdc.
a. All INDIVIDUAL CELL MONITOR LED’s (Figure 202, Item 1) must remain on.
b. Any LED that does go OFF will represent a defective individual cell, which must be
replaced.
7) Remove the Load Resistor from J1 connector pins 11 (+) and 7 (-).
8) Position all INDIVIDUAL CELL DIP SWITCHES (Figure 202, Item 5) to the OFF
position.
9) Compare the voltage vs. time plot created during this test to that of curve identified as
typical for the External Load test method on the chart in Figure 4.
10) If the plot reveals a discharge curve that meets or exceeds the MINIMUM ACCEPTABLE
DISCHARGE CURVE, the unit is considered satisfactory.
11) If unit discharge plot is satisfactory and no other failures were revealed, perform either of
the Charging Procedures listed in Step 2 within 2 hours of completion of the discharge test.
Return the unit into service or storage as required.
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PS-835
Installation Manual
9. Cell Isolation Test
NOTE
No power should be applied to PS-835 Emergency Power Supply during test.
A. Press and hold TEST SWITCH (Figure 202, Item 4). If no OUTPUT VOLTAGE MONITOR
LED's come on:
NOTE
1) Position all INDIVIDUAL CELL DIP SWITCHES (Figure 202, Item 4) to the ON
position.
2) Press and hold TEST SWITCH (Figure 202, Item 4) and observe the INDIVIDUAL CELL
MONITOR LED's (Figure 202, Item 1).
a. If all INDIVIDUAL CELL MONITOR LED’s come on except DS12, the unit is
damaged and requires repair at an authorized repair station.
b. If all INDIVIDUAL CELL MONITOR LED’s are on, there exists a low-battery
voltage condition. Perform the Charging Procedures of Step 2.
24-30-04

TP 336 - PS 835

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Emergency Power Supply

JET® Model PS-835

This manual contains installation instructions and

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L-3 Communications Avionics Systems

L-3 Communications Avionics Systems

 Copyright 2007, 2009, 2010, 2011

List of Effective Pages

Dates of original and changed pages are:

Reissue ................................................................................... July 1, 1994

Total number of pages in this publication consists of the following:

Section Page No.

Testing and Fault Isolation

1: PS-835 Emergency Power Supply ........................................................................................................ 6

1: Service Bulletins and Modifications ..................................................................................................... 3

Model Number Part Number Cell Type

D. Battery Voltage Level Detection

5. Continued Airworthiness (Maintenance)

Modification Kits and

Table 1: Service Bulletins and Modifications

Modification Kits and

Table 1: Service Bulletins and Modifications (Cont.)

7. Environmental Test Qualifications

Name of Test Qualified to DO-160A elements:

Table 2: Environmental Qualifications

Figure 1: PS-835 Emergency Power Supply

1 Individual Cell Monitor LED's

Part Number 501-1228-01, -02, -03, -04, -05, -06, -07

9. Charge and Discharge Performance

A. General Battery and Cell Information

C. Storage Time and Temperature

Figure 2: Cell Storage Time vs. Temperature

D. Cell Current Discharge Time

Figure 3: Typical Discharge Time for Sealed Lead-acid Cells

E. Cell Voltage Discharge Time

Figure 4: PS-835( ) Discharge Curves

This page intentionally left blank.

1) The Emergency Power Supply should be accessible for inspection, maintenance, or

D. The cable should not run adjacent to heaters or engine exhausts.

3. Pre-Installation Inspection and Preparation

C. At completion of charging period, again perform step B.

A. SI-100 Static Inverter

B. SC-841 Static Converter

C. BC-815 Battery Charger

D. Connector Plug for AC and DC powered Indicators [Figure 101, Item 1]

E. Transformer (used with SI-100 Static Inverter) [Figure 101, Item 2]

F. ATR Mounting Rack [Figure 101, Item 3]

Figure 101: Affiliated Equipment

Table 101: List of Installation Kits

Kit Component Description Qty.

Table 102: Installation Kit Components [504-1019-01]

Kit Component Description Qty.

Table 103: Installation Kit Components [504-1019-02]

Kit Component Description Qty.

Table 104: Installation Kit Components [504-1019-05]

Kit Component Description Qty.

Table 105: Installation Kit Components [504-1019-06]

Kit Component Description Qty.

Table 106: Installation Kit Components [504-1035-01]

A. Fuse and Circuit Breakers

PS-823 (/T) Test PS-835 () Test

Figure 102: Typical Installation Interconnections for PS-835A through D & G

Figure 103: Typical Installation Interconnections for PS-835E and F