TM 11-6130-243-35D E P A R T M E N T O F T H E A R M Y T E C H N I C A L M A N U A L

DIRECT SUPPORT, GENERAL SUPPORT AND

DEPOT MAINTENANCE MANUAL

POWER SUPPLY PP-4606/G

This copy is a reprint which includes current

pages from Change 1.

H E A D Q U A R T E R S , D E P A R T M E N T O F T H E A R M Y

6 FEBRUARY 1967

WARNING

DANGEROUS VOLTAGES EXIST IN THIS EQUIPMENT

High voltages and currents exist in this equipment. Serious injury ordeath may result from contact with the input and output connections. De-energize the equiqment before connecting or disconnecting the load to bepowered, before changing jumper connections, and before performing anymaintenance. Discharge all capacitors before performing maintenance.

DON’T TAKE CHANCES!

TM 11-6130-243-35C1

CHANGE

No. 1

HEADQUARTERSDEPARTMENT OF THE ARMYWASHINGTON DC, 3 December 1981

Direct Support, General Support, AndDepot Maintenance ManualPOWER SUPPLY PP-4606/G

(NSN 6130-00-504-0327)

TM 11-6130-243-35, 6 February 1967, is changed as follows:1. Title of the manual is changed as shown above.2. New or changed material is indicated by a vertical bar in the margin of the page.3. Remove and insert pages as indicated below:

Remove Insert

None . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A through C (FRONT OF MANUAL)

i.. . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .i/(ii blank)

1-1 and 1-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1 and 1-2

A-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . .A-1(A-2 blank)

4. File this change sheet in front of the publication for reference purposes.

By Order of the Secretary of the Army:

Official:

ROBERT M. JOYCEBrigadier General, United States Army

The Adjutant General

E. C. MEYERGeneral, United States Army

Chief of Staff

Distribution:To be distributed in accordance with DA Form 12-31, Direct Support and General Support Maintenance

requirements for All Fixed and Rotor Wing Aircraft.

TM 11-6130-243-35

S A F E T Y S T E P S T O F O L L O W I F S O M E O N E

I S T H E V I C T I M O F E L E C T R I C A L S H O C K

D O N O T T R Y T O P U L L O R G R A B T H E I N D I V I D U A L

I F P O S S I B L E , T U R N O F F T H E E L E C T R I C A L P O W E R

I F Y O U C A N N O T T U R N O F F T H E E L E C T R I C A L

P O W E R , P U L L , P U S H , O R L I F T T H E P E R S O N T O

S A F E T Y U S I N G A W O O D E N P O L E O R A R O P E O R

S O M E O T H E R I N S U L A T I N G M A T E R I A L

S E N D F O R H E L P A S S O O N A S P O S S I B L E

A F T E R T H E I N J U R E D P E R S O N I S F R E E O F

C O N T A C T W I T H T H E S O U R C E O F E L E C T R I C A L

S H O C K , M O V E T H E P E R S O N A S H O R T D I S T A N C E

A W A Y A N D I M M E D I A T E L Y S T A R T A R T I F I C I A L

RESUSCITATION

Change 1 A(B blank)

TM 11-6130-243-35

WARNINGS

DANGEROUS VOLTAGES (220 vac, and 440 vac) exist in this equipment. When equipment is operated with coversopen or removed, DO NOT touch exposed connections or components. SERIOUS INJURY OR DEATH MAYRESULT. Deenergize the equipment before connecting or disconnecting the battery to be charged, and before per-forming any maintenance. Follow all precautions listed in TB 385-4.

Avoid personal injury. Power Supply PP-4606/G weighs 375 pounds; be careful when moving. A mechanical lift isrequired.

Adequate ventilation should be provided while using TRICHLOROTRIFLUOROETHANE. Prolonged breathing ofvapors should be avoided. The solvent should not be used near heat or open flame; the products of decomposition aretoxic and irritating. Since TRICHLOROTRIFLUOROETHANE dissolves natural oils, prolonged contact with skinshould be avoided. When necessary, use gloves which the solvent cannot penetrate. If the solvent is taken internally,consult a physician immediately.

Change 1 C

*TM 11-6130-243-35

T E C H N I C A L M A N U A L HEADQUARTERSDEPARTMENT OF THE ARMY

No. 11-6130-243-35 WASHINGTON , DC, 6 February 1967

DIRECT SUPPORT, GENERAL SUPPORT, AND DEPOTMAINTENANCE MANUAL

POWER SUPPLY PP-4606/G(NSN 6130-00-504-0327)

ParagraphCHAPTER 1. FUNCTIONING OF EQUIPMENT

Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1lndex of Technical Publications.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2Block diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3Input power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 Output circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5Monitor circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

2. TROUBLESHOOTINGGeneral instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Organization of troubleshooting procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Test equipment required. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3Localizing troubles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4Additional troubleshooting data... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5Capacitor test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6General parts replacement techniques. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7Replacement of diode rectifiers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8 Adjustment of variable resistors R1 and R2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

3. GENERAL SUPPORT TESTING PROCEDURESGeneral . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Test equipment, tools, and materials. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Physical tests and inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Power output, regulation, and ripple tests at 220-volt input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Insulation resistance test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Output power test at 440-volt input. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Test data summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4. DEPOT OVERHAUL STANDARDSApplicability of depot overhaul standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Test facilities required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Power output, regulation, ripple, and efficiency test at 220-volt input. . . . . . . . . . . . . . . . . .Insulation resistance test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Output power test at 440-volt input.. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-13-23 - 33 - 43 - 53 - 63 - 7

4 - 14 - 24 - 34 - 44 - 5

APPENDIX References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Page

1-11-11-11-21-21-4

2-12-12-12-12-32-62-72-12-1

3-13-13-33-53-63-9

3-10

4-14-14-14-24-2A-1

Change 1 i/(ii blank)

TM 11-6130-243-35

CHAPTER 1FUNCTIONING OF EQUIPMENT

1 - 1 . S c o p e

a. This manual contains direct support, general sup-port, and depot maintenance instructions for PowerSupply PP-4606/G (power supply). It includes instruc-tions appropriate for troubleshooting, testing, andrepairing the equipment. It also lists tools, materials,and test equipment required for maintenance, Func-tional analysis of the equipment is covered in thischapter.

b. The complete technical manual for this equip-ment includes TM11-6130-243-12.

c. You can help improve this manual. If you findany mistakes or if you know of a way to improve theprocedures, please let us know. Mail your letter or DAForm 2028 (Recommended Changes to Publications andBlank Forms) direct to Commander, US ArmyCommunications-Electronics Command, ATTN:DRSEL-ME-MQ, Fort Monmouth, NJ 07703. In eithercase, a reply will be furnished direct to you.

NOTEFor applicable forms and records, seeparagraph 1-3, TM11-6130-243-12.

1-2. Index of Technical PublicationsRefer to the latest issue of DA Pam 310-4 to determinewhether there are new editions, changes, modificationwork orders (MWO’S) or additional publications per-taining to the equipment.

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

Three-phase, wye-connected primary input power is ap-

plied to the input circuit consisting of circuit breakerswitch CB1, the tap board, VOLTAGE ADJUST switchS2, indicator lamp DS1, and power transformer T1. Thetap board connects the input powerlines to the primarywindings of power transformer T1. Jumpers are con-nected between various terminals on the tap board topermit operation of the power supply from either 220-or 440-volt alternating current (at) power mains. Withcircuit breaker switch CB1 set to POWER ON, inputpower is applied through the jumpers on the tap boardand VOLTAGE ADJUST switch S2 to the primarywindings of stepdown power transformer T1 and in-dicator light DS1. The input circuit to transformer Tl iswye-connected, the output circuit from the transformeris delta-connected. VOLTAGE ADJUST switch S2 con-trols application of input power to specific taps of theprimary windings of transformer T1. The ac outputvoltages from the secondary windings of thetransformer is converted to a pulsating direct current(dc) voltage by full-wave rectifiers CR1 through CR6and filtered by the network consisting of capacitors C1through C8 and inductor L1. Resistors R1 and R2 com-prise a load network across the rectifiers. The powersupply current and voltage are monitored by DIRECTCURRENT AMPERES meter M1 and DIRECT CUR-RENT VOLTS meter M2. Resistor R3 is the ammetershunt resistor. Resistor R4 is the meter movement seriesresistor used to establish the deflection sensitivity of theammeter. AMMETER switch S1 (spring-loaded to theOFF position) connects the ammeter to the output cir-cuit when depressed to the READ position.

Change1 1-1

TM 11-6130-243-35

T M 6 1 3 0 - 2 4 3 - 3 5 - 1

1-4. Input Power(fig. 4-4).

a. The power supply is designed to operate

Figure 1-1. Power Supply PP-4606/G block diagram.

from either 220- or 440-volt, 60-cycle, 3-phasepower mains. To provide for correct connec-tion of the power mains to the primary wind-ings of input power transformer T1, a tapboard is provided on the rear of the powersupply. Wire links are connected betweenspecific terminals on the tap board, depend-ing upon the voltage of the power mains fromwhich the power supply is to be operated. Fig-ures 1-2 and 1-3 are simplified schematic dia-grams that show how the primary windingsare wye-connected to the power mains. Referto the complete schematic diagram (fig. 4-4)while studying the two simplified schematicdiagrams. For simplicity, VOLTAGE AD-JUST switch S2 is not shown on the simplifiedschematic diagrams; however, assume that itis at the fully clockwise position (HIGH) forthe discussions in b and c below.

b. When the power supply is arranged tooperate with 220-volt input power, wire linksare connected between specific terminals onthe tap board as shown by the short heavylines in figure 1-2. The six primary windingsof input transformer T1 are thus parallel-con-nected into a wye configuration which corre-sponds to the wye configuration of the inputpower mains. When circuit breaker switchCB1 is at POWER ON, input power is routedfrom the 220-volt terminals of the circuitbreaker through the wire links on the tapboard and the VOLTAGE ADJUST switch

1-2

(not shown on fig. 1-2) to each parallel-con-nected pair of primary windings in each leg ofthe wye. VOLTAGE ADJUST switch S2 con-trols the voltage in the secondary windings oftransformer T1 by controlling the number ofturns energized in the primary windings. (En-ergized turns decrease and secondary windingvoltages increase as switch S2 is turned clock-wise.)

c. When the power supply is arranged tooperate with 440-volt input power, wire linksare connected between a different group ofspecific terminals on the tap board as shownby the short heavy lines in figure 1-3. Thesix primary windings of input transformer T1are now series-connected into a wye configu-ration. When circuit breaker switch CB1 is atPOWER ON, input power is routed from the440-volt terminals of the circuit breakerthrough the wire links on the terminal boardand the VOLTAGE ADJUST switch (notshown on fig. 1-3) to each series-connectedpair of primary windings in each leg of thewye.

1-5. Output Circuit(fig. 4-4)

a. The output circuit includes the three sec-ondary windings of power transformer T1,diode rectifiers CR1 through CR6, surge-sup-pressor capacitors C3 through C8, bleeder re-sistors R1 and R2, choke L1, and filter capaci-tors C1 and C2. The secondary windings of thepower transformer are connected in a delta

TM6130-243-35-2

TM6130-243-35-3

TM 11-6130-243-35

Figure 1-2. Connections to power transformer primary windings for220-volt input, simplified schematic diagram.

Figure 1-3. Connections to power transformer primary windings for440-volt input, simplified schematic diagram.

1-3

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configuration as shown in the simplified sche-matic diagram (A, fig. 1-4). Each secondarywinding applies an ac voltage to a bridge rec-tifier circuit consisting of four of the sixdiodes CR1 through CR6. The middle sec-ondary winding of transformer T1 (fig. 4-3) isassociated with the bridge rectifier consistingof diodes CR2, CR3, CR5, and CR6 as shownin the simplified schematic diagram (B, fig.1-4). Similarly, the top secondary winding oftransformer T1 is associated with diodes CR1,CR2, CR4, and CR5 while the bottom wind-ing is associated with diodes CR1, CR3, CR4,and CR6. The simplified schematic diagram(fig. 1-4) shows only those diodes associatedwith the middle winding.

b. When the half-cycle of the ac voltage oc-curs, making secondary winding terminal 9positive with respect to terminal 10 (B, fig.1-4), diodes CR3 and CR5 become forward-biased and diodes CR2 and CR6 become re-verse-biased. Electrons flow from terminal 10through diode CR3, resistors R1 and R2 diodeCR5, terminal 9, and to terminal 10. The cur-rent pulse thus produced causes a dc voltageof the polarity indicated on figure 1-4 to ap-pear across resistors R1 and R2. During theother half-cycle, diodes CR2 and CR6 becomeforward-biased and diodes CR3 and CR5 be-come reverse-biased. Electrons flow from ter-minal 9 through diode CR2, resistors R1 andR2, diode CR6, terminal 10, and to terminal 9.This current pulse also causes a dc voltageof the same polarity to appear across resistorsR1 and R2.

c. The dc voltage pulses appearing acrossresistors R1 and R2 are applied to the choke-input filter consisting of inductor L1 and ca-pacitors C1 and C2. The filter networksmoothes the ripple and assists in power sup-ply regulation. AS a result, the output volt-age approaches the average value of voltageproduced by the bridge rectifiers. Bleeder re-sistors R1 and R2 also provide a dischargepath for capacitors C1 and C2.

Figure 1-4. Power supply output circuit, simplifiedschematic diagram.

1-6. Monitor Circuit(fig. 4-4)

DIRECT CURRENT VOLTS meter M2 isconnected across the output of the power sup-ply and monitors the output voltage. DIRECTCURRENT AMPERES meter M1 monitorsoutput current whenever spring-loaded AM-METER switch S1 is set to the READ (de-pressed) position. With switch S1 de-pressed, load current flowing through low-re-sistance shunt resistor R3 produces a smallvoltage drop which is proportional to the cur-rent. Although the scale of DIRECT CUR-RENT AMPERES meter M1 is marked to in-dicate amperes, the meter is actually a milli-voltmeter which measures the voltage acrossshunt R3. Resistor R4 is a calibrating resistorfor meter M1. When AMMETER switch S1 isreleased to the OFF position, the switchcreates a short circuit across R3, R4, and M1.

1-4

TM 11-6130-243-35

CHAPTER 2

TROUBLESHOOTING

Warning: When servicing the power supply, be extremely careful of the high voltages.

2-1. General Instructions

Troubleshooting at the direct support,general support, and depot maintenance cate-gories includes all the techniques outlined fororganizational maintenance and any special oradditional techniques required to isolate a de-fective part. Paragraph 2-4d provides thetroubleshooting chart to be used by the re-pairman.

2-2. Organization of TroubleshootingProcedures

a. General. The first step in servicing a de-fective power supply is to localize the fault,which means tracing the fault to defective cir-cuit responsible for the abnormal indication.The second step is to isolate the fault, whichmeans locating the defective part or parts.Some defective parts, such as burned resis-tors and shorted transformers, can often belocated by sight, smell, and hearing. Most de-fective parts, however, must be isolated bychecking voltages and resistance.

b. L.ocalization and Isolation. The first stepin tracing trouble is to locate the circuit orpart at

(1)

(2)

fault by the following methods:Visual inspection. The purpose ofvisual inspection is to locate faultswithout testing or measuring cir-cuits. All meter indications or othervisual signs should be observed andan attempt made to localize the faultto a particular part.Operational test. Operational testsfrequently indicate the general loca-tion of trouble. In many instances,the test will help in determining the

(3)

(4)

exact nature of the fault. The op-erator’s daily preventive maintenanceservices inspection chart (TM11-6130-243-12) contains a good oper-ational test.

Troubleshooting chart. The trou-bleshooting chart (para 2-4d) listssymptoms of common troubles andgives corrective measures (or refer-ences). Such a chart cannot includeall trouble symptoms that may oc-cur; therefore, the repairman shoulduse this chart as a guide in analyzingsymptoms that may not be listed.

Resistor and capacitor color codediagrams. Color code diagrams forresistors and capacitors (figs. 4-2and 4-3) provide pertinent resist-ance, voltage rating, and toleranceinformation.

2-3. Test Equipment Required

The following chart lists test equipmentrequired for troubleshooting Power SupplyPP-4606/G and the associated technical man-uals.

Test equipment Technical manual

Multimeter TS-352B/U --- TM 11-5527Analyzer ZM-3A/U ------ TM 11-5043-12

2-4. Localizing Troubles

c. General. The troubleshooting chart (dbelow) outlines procedures for localizingtroubles and for isolating troubles within

2-1

TM 11-6130-243-35

the various circuits of the power supply. Re-fer to figures 2-1 through 2-4 for parts loca-tion. Refer to the schematic diagram (fig. 4-4) to identify circuit components. Voltageand resistance measurements are given inparagraph 2-5. Depending on the nature ofthe operational symptoms, one or more of thelocalizing procedures will be necessary. Whentrouble has been localized to a particular cir-cuit, use voltage and resistance measurementsto isolate the trouble to a particular part.

b. Use of Chart. When an abnormal symp-tom is observed in the equipment, look for adescription of the symptom in the Symptomcolumn and perform the corrective measure inthe Corrective measures column.

c. Conditions to Test. All checks outlinedin the troubleshooting chart are to be con-ducted with the power supply connected to a220- or 440-volt power source, with the tapboard wired for use. The output cables shouldbe connected to a load.

d. Troubleshooting Chart.

2-2

TM6130-243-35-6

TM 11-6130-243-35

Figure 2-1. Power supply, rear oblique view of right sidewith right side panels removed.

2-5. Additional Troubleshooting Data

a. Voltage Outputs of Power TransformerT1. The voltage output data of power trans-former T1 is provided as an aid to trouble-shooting. The transformer has three second-ary windings, designated by terminals 9 and10 for each secondary winding. Each second-ary winding voltage for both 220- and 440-volt ac input and for each setting of theVOLTAGE ADJUST switch is listed below:

2-3

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Figure 2-2. Power supply, rear view with rear panels removed.

2-4

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Figure 2-3. Power supply, front view with bottom front panel removed.

b. Dc Resistance of Transformers and power supply and when the circuit breakerCoils. The dc resistance data ((3) below) is switch is at POWER ON. Place the circuitprovided as an aid to troubleshooting. When breaker switch to off (down) andusing the data, observe the following: the input power cord.

Caution: Do not measure resistance of the (1) Before making resistancewindings when input power is applied to the ments of the windings,

disconnect

measure-determine

2-5

TM6130-243-35-9

TM 11-6130-243-35

Figure 2-4. Power supply, heat sink assembly removed from unit.

that faulty operation is probablycaused by a faulty transformer orcoil. To do this, follow the trouble-shooting procedures in paragraph 2-4d.

(2) Do not use the resistance measure-ments as the sole basis for discard-ing a transformer or coil as defective.Resistances may vary from one trans-former or coil to another because ofbroad winding tolerances duringmanufacture. The values given inthe chart ((3) below) are typicalaverage values for all groups oftransformer windings and coils.

(3) Dc resistances of transformers andcoils are as follows:

2-6 Capacitor Test

Filter capacitors C1 and C2 are rated at10,000 microfarads (µf), 50 volts dc; capaci-tors C3 through C8 are rated at 2 µf, 100volts dc. Test each capacitor (figs. 2-3 and2-4 with Analyzer ZM-3A/U. Refer to the

2-6

schematic diagram (fig. 4-4) for connectionof the capacitors.

2-7. General Parts ReplacementTechniques

All power supply parts, except diode recti-fiers, can be reached and replaced easilywithout special procedures. The six dioderectifiers must be replaced in accordance withthe specialized procedure given in paragraph2-8. Refer to figures 2-1 through 2-4 for thelocation of all parts. Connect replaced itemsaccording to the schematic diagram (fig. 4-4).

2-8. Replacement of Diode Rectifiers

a. The following chart lists the tools re-quired to replace the diode rectifier in thepower supply.

b. The six diode rectifiers are mounted on aheat sink assembly (fig. 2-4). When a diodeis removed, the replacement diode must be ofthe same type and mounted with the same ori-entation as the removed part. Diodes CR1,CR2, and CR3 are type 1N4587; diodesCR4, CR5, and CR6 are type 1N4587R.

c. Replace any diode rectifier as follows:(1)

(2)

(3)

(4)

Before proceeding, make sure that thecircuit breaker switch is in the off(down) position and that the inputpower cable is disconnected from thepower mains.Remove the hardware that secures thediode pigtail and capacitor pigtail tothe bus bar on the heat sink. Do notdiscard hardware.Make note of the diode type; diode1N4587 is color-coded white anddiode 1N4587R is color-coded violet.Remove a defective diode by re-moving the nut and lockwasher thatsecure the diode to the bus bar.

(5)

(6)

TM 11-6130-243-35

Apply a coating of Dow CorningHeat Sink Compound No. 340 tothe mating flat surfaces on the heatsink only and replace the diode withone of the same type. Install themounting hardware and torque to 30inch-pounds; use the crowfootwrench and torsion wrench.Secure the pigtail lug of the diodeand the pigtail of the capacitor tothe bus bar on the heat sink; usethe hardware previously removed.

2-9. Adjustment of Variable ResistorsR1 and R2

a. With no load connected to the powersupply and VOLTAGE ADJUST switch S2set to NOM. set the circuit breaker switchto POWER ON.

b. Check to see that DIRECT CURRENTVOLTS meter indicates 28.5 volts. If the in-dication is not 28.5 volts, set the circuit break-er switch to off and perform the proceduresin c through h below.

Warning: Do not touch the interior com-ponents of the power supply unless the circuitbreaker switch is set to the off (down) posi-tion.

c. Remove the top left side panel of thepower supply to gain access to resistors R1and R2.

d. Loosen the sliding contacts on resistorsR1 and R2.

e. Reposition the sliding contacts slightly.

f. Set the circuit breaker switch to POWERON and check to see whether DIRECT CUR-RENT VOLTS meter M2 indicates 28.5 volts.

g. Repeat the procedures in e and f aboveuntil DIRECT CURRENT VOLTS meter in-dicates 28.5 volts; always turn the power sup-ply off before adjusting resistor sliding con-tacts.

h. Set the circuit breaker switch to the offposition. Tighten the sliding contacts on re-sistors R1 and R2; replace top left panel ofthe power supply.

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TM 11-6130-243-35

CHAPTER 3

GENERAL SUPPORT TESTING PROCEDURES

3-1. General

a. Testing procedures are prepared for useby field maintenance shops and service organi-zations responsible for general support main-tenance of electronic equipment to determinethe acceptability of repaired equipment. Theseprocedures set forth specific requirements thatrepaired equipment must meet before it is re-turned to the using organization. These pro-cedures may also be used as a guide for test-ing equipment that has been repaired at directsupport, if the proper tools and test equip-ments are available. A summary of the per-formance standards is given in paragraph 3-7.

b. Comply with the instructions precedingeach chart before proceeding to the chart. Per-

a. Test Equipment.

form each step in sequence. Do not vary thesequence. For each step, perform all theactions required in the control settingscolumns; then perform each specific test pro-cedure and verify it against its performancestandard.

3-2. Test Equipment, Tools, and Materials

All test equipment, tools, and materials re-quired to perform the testing proceduresgiven in this chapter are listed in a, b, and c,below and are authorized under TA 11-17,Signal Field Maintenance Shops; and TA11-100(11-17), Allowances of Signal CorpsExpendable Supplies for Signal Field Mainte-nance Shops, (Continental United States).

b. Tools. All the tools required are in-cluded in Tool Kit, Electronic Equipment TK-100/G and Tool Kit, Electronic EquipmentTK-105/G.

c. Materials.

3-1

3-3. Physical Tests and Inspections

a. Test Equipment and Materials. None re-quired.

b. Test Connections and Conditions. No

TM 11-6130-243-35

connections are necessary. Remove power sup-ply left and right side panels.

c. Procedure.

3-3

TM6130-243-35-10

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Figure 3-1. Connection diagram for power output, regulation, and rippletests at 220-volt input.

3-4

3-4.

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11-6130-243-35

3-5

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3-5. Insulation Resistance Test

a. Test Equipment. The only test equip-ment required is Ohmmeter ZM-21A/U.

b. Test Connections and Conditions. Thistest is performed with the PP-4606/G discon-nected from the ac power source. This testchecks the insulation resistance of the primarywindings of power transformer T1. The testis written for the PP-4606/G strapped for220-volt ac operation.

c. Procedure.

(2) Connect the line lead of the ZM-21A/U to any terminal 1 of the tapboard on the rear of the PP-4606/G.

(3) Operate the ZM-21A/U and ob-serve the indication on the ZM-21A/U meter. The PP-4606/U meetsthe performance standard if the ZM-21A/U meter reading is greaterthan 10 megohms.

(1) Connect the ground lead of theZM-21A/U to the frame of the PP- (4) Disconnect the ZM-21A/U from the4606/G. PP-4606/G.

3 - 6

Figure 3-2.

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6130-243-35-11

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3-8

3-6.

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3-9

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3-7. Test Data Summary

a. Input.(1) Voltage ----------220 or 440 volts.(2) Frequency ----------60 cps.(3) Phase -------------- Three, wye-connected.(4) Current (each leg 18 amperes maximum for

at full load) 220-volt input or 9 am-peres for 440-volt input.

b. Output.

(1) Voltage (VOLT- 28.5 volts dc + 2.5.AGE ADJUSTswitch S2 set toNOM)

(2) Current (maxi- 200 amperes + 15.mum)

(3) Ripple voltage 5 percent maximum.(4) Regulation 9 percent maximum.

c. Formulas Used.

Where:E is dc output voltage measured under no-load

NLconditions.

E is dc output voltage measured under full-loadL

conditions.E is the measured ripple voltage.

RMSE is the measured dc output voltage.

DC

3-10

TM 11-6130-243-35

CHAPTER 4

DEPOT OVERHAUL STANDARDS

4-1. Applicability of Depot Overhaul b. Technical Publication. The technical pub-Standards lication applicable to the equipment to be

The tests outlined in this chapter are de- tested is TM11-6130-243-12.

signed to measure the performance capabil- C. Modification Work Orders. Perform allity of a repaired equipment. Equipment that modification work orders applicable to thisis to be returned to stock should meet the equipment before making the tests specified.standards given in these tests. DA Pam 310-4 lists all available MWO’s.

a. Repair Standards. Applicable proce-dures of the depots performing these tests 4-2. Test Facilities Requiredand the general standards for repaired elec-tronics equipment given in TB SIG 355-1, TB

The following items are required for de-

SIG 355-2, and TB SIG 355-3 form a part ofpot testing.

the test requirements. a. Test Equipment.

b. Materials.

4-3. Power Output, Regulation, Ripple,and Efficiency Test at 220-Volt Input

a. With 220-volt, 3-phase, 60-cps inputpower, connect the equipment as shown in fig-ure 4-1.

b. With no load connected to the powersupply, set the PP-4606/G VOLTAGE AD-

JUST switch to NOM and the circuit breakerswitch to POWER ON. The TS-352B/Ushould indicate 28.5 volts + 2.5. If necessary,set the VOLTAGE ADJUST switch to LOWor HIGH to obtain 28.5 volts + 2.5 on the TS-352B/U. The DIRECT CURRENT VOLTSmeter on the PP-4606/G should indicate with-in ±5 percent of the reading on the TS-352B/U.

c. Set the circuit breaker switch on the PP-4606/G to off.

d. Connect the load (three each, 0.41-ohm,3,400-watt resistors connected in parallel for atotal resistance of 0.1366 ohm). Connect theTV-100 to measure the output current. Setthe circuit breaker switch on the PP-4606/G

4-1

TM 11-6130-243-35

to POWER ON. The TS-352B/U should in-dicate within 9 percent of the reading obtainedin b above. The TV-100 should indicate 200amperes ±15. Depress the AMMETERswitch on the PP-4606/G. Indication on theDIRECT CURRENT AMPERES metershould be within ±5 percent of the currentreading obtained on the TV-100.

e. The ME-30(*)/U should indicate lessthan 1.3 volts.

f. Both wattmeters (TS-430/U) should in-dicate less than 7,400 watts total.

g. Set the circuit breaker switch on the PP-4606/G to OFF and disconnect the equip-ment.

4-4. Insulation Resistance Test

The depot overhaul standards insulationresistance test procedures are the same asthose for general support (para 3-5). Equip-ment that meets the performance standardsstated in paragraph 3-5 will furnish satisfac-tory insulation resistance equivalent to thatof new equipment.

4-5. Output Power Test at 440-Volt Input

The depot overhaul standards output powertest procedures at 440-volt input are the sameas those for general support (para 3-6).Equipment that meets the performancestandards stated in paragraph 3-6 will fur-nish satisfactory output power at 440-volt in-put equivalent to that of new equipment.

4-2

TM6130-243-35-12

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Figure 4-1. Connection diagram for power output, regulation, ripple,and efficiency at 220-volt input.

4-3

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Figure 4-2. Color code markings for MIL STD resistors.

4-4

Figure 4-4.

TM6130-243-35-5

I

Figure 4-3.

TM 11-6130-243-35

APPENDIX

REFERENCES

DA Pam 310-4TB SIG 355-1TB SIG 355-2TB SIG 355-3TB 385-4TM11-487H-l/lTM11-2050TM11-5043-12

TM11-6130-243-12TM11-6625-320-12

TM11-6625-366-15

lndex of Technical Publications.Depot Inspection Standard for Repaired Signal Equipment.Depot Inspection Standard for Refinishing Repaired Signal Equipment.Depot Inspection Standard for Moisture and Fungus Resistant Treatment.Safety Precautions for Maintenance of Electrical/EIectronic Equipment.Military Standardization Handbook: Electronic Test Equipment.Test Set I-48B and Ohmmeter ZM-21A/U.Operator’s and Organizational Maintenance Manual For Analyzers, ZM-3/U

and ZM-3A/U.Organizational Maintenance Manual: Power Supply PP-4606/G.Operator’s and Organizational Maintenance Manual: Voltmeter, Meter

ME-30A/U and Voltmeters, Electronic ME-30B/U, ME-30C/U, andME-30E/U.

Operator’s, Organizational, Direct Support, General Support, and DepotMaintenance Manual: Multimeter TS-352B/U.

Change 1 A-1/(A-2 Blank)

TM 11-6130-243-35

By Order of the Secretary of the Army:

Official:

KENNETH G. WICKHAM,Major General, United States Army,

TM 11-6130-243-35

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

The Adjutant General.

Distribution:

To be distributed in accordance with DA Form 12-36, unclassified requirements for Direct and GeneralSupport maintenance literature for all Rotor Wing Accounts (2) plus USASESCS (60).

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