ELECTRICAL POWER-STATIC INVERTER - BRIDGE ASSEMBLY R170 RELOCATION

Transcription

1 ELECTRICAL POWER-STATIC INVERTER - BRIDGE ASSEMBLY R170 RELOCATION I PLANNING INFORMATION A. Effectivity- Static Inverter Part Number , (Boeing P/N S282T004-5), Model 1C1000-1A, Mod Levels - thru H. The following serial number units require special instructions to perform this modification. If you have the following serial number units, please return them to Avionic Instruments Inc. Repair Department for upgrade at no cost. BV BV BV BV BV BV BV Static Inverter Part Number , (Boeing P/N S282T004-7), Model 1C1000-1B, Mod Levels - thru E. Static Inverter Part Number , (Boeing P/N S282T004-8), Mod Level "-" thru C. Static Inverter Part Number , (Boeing P/N S282T004-10), Model 1C1000-1C, Mod Levels - thru A up to serial number CJ with the following exceptions: 1. The following S/N s have been upgraded and delivered but were not identified as MOD B on the nameplate: CJ CJ CJ CJ CJ CJ CJ CJ CJ CJ Additionally, the following S/N s delivered prior to S/N 1750 have MOD B incorporated. CJ CJ CJ CJ CJ CJ CJ Revision 2: November 24, 2003 Page 1 of 31

2 B. Reason- Engineering Quality Analysis (EQA) conducted by Boeing Commercial Airplane Company on a model 1C1000-1C static inverter has determined that a potential condition exists in which the proximity of resistor R170 to capacitors C50 and C51 on the Bridge Control Logic Assembly may lead to damage or failure of capacitors C50 or C51. It is believed that a combination of obstructed convection cooling and localized heat dissipation from resistor R170 results in sufficient energy to damage the adjacent capacitors. The relocation of the resistor from the component side of the board to the solder side will reduce the likelihood of overheating C50 or C51. C. Description- Relocation of the resistor will require removal of inverter covers, some disassembly of the inverter, desoldering, and soldering of the resistor R170 (AI² P/N ) and installing #410 Nomex Insulation,.010 thick (2.5 x 2.5 ). Customers may return the unit to Avionic Instruments Inc. (AI²) Repair Station No. V5AR787J located at 1414 Randolph Ave, Avenel, New Jersey USA for upgrade to be performed at no charge. AI² Repair Department will notify customer of applicable re-certification and freight charges. When field upgrades are performed by operators, it is requested that they notify AI² Repair Department, within 30 days, at repair@avionicinstruments.com or FAX (732) of unit S/N and date performed within 30 days. Any units received in-house for service bulletin upgrade will be subjected to the ATP prior to the upgrade being completed. AI² will notify the airline customer of any out-of-specification condition noted during performance of the ATP. The unit would need to be repaired prior to the upgrade being initiated. D. Approval- This Service Bulletin has been reviewed by the Federal Aviation Administration (FAA) and the modifications herein comply with the Federal Aviation Regulations (FAR) and are FAA approved for installation on Boeing aircraft. E. Manpower- The estimated time required to accomplish this task is two hours. F. Material- NONE Cost and Availability G. Tooling- NONE Revision 2: November 24, 2003 Page 2 of 31

3 H. Weight and- Net weight change ±.01 lbs. Balance I. Electrical- Not Affected Load Data J. Software- Not Applicable Accomplishment Summary K. Reference- (AI 2 Internal File No ) L. Other Component Maintenance Manuals, ATA No Publications will be revised to revision 3 and ATA No will be revised Affected- to revision 6 to include this Service Bulletin. M. Additional If units have been modified in accordance with a previously issued Comments- service bulletin revision, this work shall be deemed compliant and meeting the intent of the service bulletin. Operators may maintain or apply the appropriate marking (option 1 or 2) outlined in Section II, for the appropriate model, to identify incorporation of this service bulletin. Revision 2: November 24, 2003 Page 3 of 31

4 II ACCOMPLISHMENT INSTRUCTIONS CAUTION: DISCONNECT INPUT POWER PRIOR TO HANDLING OR REMOVAL OF THE COVER OF THE STATIC INVERTER TO PREVENT ELECTRICAL SHOCK. Relocation of resistor R170 requires the installer to gain access to the Bridge Control Logic PCB Assembly shown in Figures 3 and 8. When removing the resistor, visually inspect the parts in proximity to R170 including C50 (AI² P/N ) and C51 (AI² P/N ), for possible replacement. The cleaning procedure of the Component Maintenance Manual should be followed as appropriate after all work. INSTRUCTIONS FOR MODIFYING PART NUMBER (BOEING S282T004-10) STATIC INVERTER FOR SERIAL NUMBERS CJ AND UP These parts have been delivered with this modification incorporated prior to this service bulletin release. To comply with marking requirements and tracability control, verify that the mod has been performed by inspection and that label is marked with MOD B. Then to complete marking upgrade, perform steps numbered below. Note that previous MODs which are not mandatory and are not implied by this marking. INSTRUCTIONS FOR MODIFYING PART NUMBER (BOEING S282T004-10) STATIC INVERTER FOR PRE-SERIAL NUMBER CJ STATIC INVERTERS 1. Remove two (2) screws, item 10, on bottom of the rear panel, item 5 on figure Remove eight (8) screws secured with loctite threadlocker, item 60, securing the heatsink, item 55, to the bridge assembly, item 260, and the flyback assembly, item 220 on figure Carefully remove the heatsink, item 55 on figure Remove eight (8) screws secured with loctite threadlocker, item 70, securing the heatsink, item 65, to the bridge assembly, item 260, and the flyback assembly, item 220 on figure Carefully remove the heatsink, item 65 on figure Remove ten (10) screws, item 50, on the front panel, item 100 on figure Remove eight (8) screws, item 45 on figure 1. The inner four (4) screws are secured with locktite threadlocker. 8. Remove fourteen (14) screws, item 35 on figure 1. Revision 2: November 24, 2003 Page 4 of 31

5 9. Remove fourteen (14) screws, item 40 on figure Carefully remove the top cover, item 30 on figure Remove one (1) screw item 185, one (1) screw item 190, one (1) screw item 195, one (1) screw item 245, and One (1) screw item 250 on figure Remove the two (2) rear screws, item 80, securing the LPS/Bridge Logic Subassembly to the bottom panel, item 75 on figure Carefully tilt the LPS/Bridge Logic Subassembly back. 14. Cut cable tie, item 265, figure 1 to gain access to the rear of the Bridge Logic Subassembly. 15. Using figure 3, locate position of R170, item Desolder resistor R170, item 180, and remove. 17. Solder resistor R170, to solder side of board as shown in figure Verify resistor body is installed inches off PCB to ensure that adequate clearance between chassis, item 45, (figure 2), and the body of resistor R170 exists, to preclude any potential contact during aircraft operation. To provide an additional isolation in the event of contact between the body of resistor R170 and the chassis, resulting from installation exceeding 0.06 inches, it is suggested that a #410 Nomex insulator, item 150 (.010 thick X 2.5 x 2.5 ) be installed on chassis, item 45, (figure 2), directly across from the PCB where R170 is now located. The Nomex insulator should be located at the bottom left, positioned even with the middle two standoffs. The insulator should be secured with RTV adhesive or equivalent adhesive 19. Replace cable tie, item 265, figure Carefully reassemble the rear section of the inverter, rotating assembly upward. 21. Replace the two (2) rear screws, item 80, securing the LPS/Bridge Logic Subassembly to the bottom panel, item 75 on figure Replace one (1) screw item 185, one (1) screw item 190, one (1) screw item 195, one (1) screw item 245, and one (1) screw item 250 on figure Carefully install the top cover, item 30 removed in step 10. Revision 2: November 24, 2003 Page 5 of 31

6 24. Replace the eight (8) screws, item 40 on figure 1. The inner four (4) screws should be secured with locktite threadlocker or equivalent. 25. Replace the fourteen (14) screws, item 35 on figure Replace the fourteen (14) screws, item 45 on figure Replace the ten (10) screws, item 50, on the front panel, item 100 on figure Carefully replace the heatsink, item 65 on figure Replace the eight (8) screws secured with loctite threadlocker, item 70, securing the heatsink, item 65, to the bridge assembly, item 260, and the flyback assembly, item 220 on figure Carefully replace the heatsink, item 55 on figure Replace the eight (8) screws secured with loctite threadlocker, item 60, securing the heatsink, item 55, to the bridge assembly, item 260, and the flyback assembly, item 220 on figure Carefully replace the rear panel, item 5 on figure Replace the two (2) screws, item 10, securing the rear panel, item 5 on figure Identification of the Static Inverter following modification: There are two options for marking the inverter following incorporation of this modification. Marking Option No. 1 (Modified Stamp) Use a "B" metal stamp to identify the Part Number (Boeing S282T004-10) Static Inverter MOD LEVEL by stamping an "B" in the silver area next to the existing letter for S282T static inverters. (See figure 11). Note that previous MODs which are not mandatory and are not implied by this marking. Marking Option No. 2 (Part Number Change) 1- Verify that the new nameplate has the Part Number (Boeing SCD No. S282T004-20). The serial number and date of Mfg must be transferred to the new nameplate. Note that previous MODs which are not mandatory and are not implied by this marking. Revision 2: November 24, 2003 Page 6 of 31

7 2.- Using the flat-head screwdriver, or equivalent, carefully pry the old nameplate from the front panel at location of rivets. 3.- Using pliers, or equivalent, carefully grasp rivet head and pull the rivet out. Repeat for second rivet. 4.- Discard used rivets and old nameplate. 5.- Position new nameplate on front panel as shown in figure 1, item 90 and carefully secure with new rivets, item 95 by tapping rivets lightly with hammer. 35. Perform function testing defined in Addendum 1 to verify inverter performance. 36. Return inverter to stock or installation upon successful completion of functional test. 37. Should the inverter fail the functional test, test and troubleshoot unit or return to Avionic Instruments Inc. for repair. Revision 2: November 24, 2003 Page 7 of 31

8 INSTRUCTIONS FOR MODIFYING PART NUMBERS (BOEING S282T004-8) AND (BOEING S282T004-7) STATIC INVERTERS NOTE: It is recommended that static inverters configured as part number (Boeing S282T004-7) should be upgraded to Part Number (Boeing SCD S282T004-8) (Ref: Service Bulletin Number ) before performing this upgrade. 1. Remove four (4) screws, item 55 and 55A securing front top cover, item 50, on figure Remove eight (8) screws from the front and side panels securing front top cover; two (2) of item 10A and six (6) of item 60 on figure Carefully pry off front top cover, item 50 on figure Remove four (4) screws, item 70 securing rear top cover, and item 65, on figure Remove six (6) screws from the rear and side panels securing rear top cover; two (2) of item 205 and four (4) of item 75 on figure Carefully pry off rear top cover, item 65 on figure Remove seven (7) screws, item 105 securing rear bottom cover, item 95, on figure Remove six (6) screws from the rear and side panels securing rear bottom cover; four (4) of item 100 secured with loctite threadlocker, and two (2) of item 45 on figure Carefully pry off rear bottom cover, item 95 on figure Remove three (3) screws from wire connections; one (1) item 30, one (1) item 30A and one (1) item 155 on figure Remove two (2) screws from wire connections; item 115 and item 135 on figure Cut cable tie, item 200, securing wires on figure Using figure 5, locate the 12 forward screws secured with loctite threadlocker, item 15, and remove side plate items 20 and 10; rear plate stays attached to side plates. 14. Carefully release wires and lay Bridge Control Board Assembly flat. 15. Using figure 3, locate position of resistor R170, item 180. Revision 2: November 24, 2003 Page 8 of 31

9 16. Desolder resistor R170, item 180, and remove. 17. Remove 13 screws, item 35 on figure 5; holding Bridge Control Board, item 30 on figure 5 to the chassis item 45 on figure Solder resistor R170, to solder side of board as shown in figure Verify resistor body is installed inches off PCB to ensure that adequate clearance between chassis, item 45, (figure 5), and the body of resistor R170 exists, to preclude any potential contact during aircraft operation. To provide an additional isolation in the event of contact between the body of resistor R170 and the chassis, resulting from installation exceeding 0.06 inches, it is suggested that a #410 Nomex insulator, item 150 (.010 thick X 2.5 x 2.5 ) be installed on chassis, item 45, (figure 5), directly across from the PCB where R170 is now located. The Nomex insulator should be located at the bottom left, positioned even with the middle two standoffs. The insulator should be secured with RTV adhesive or equivalent adhesive. 20. Reinstall Bridge Control Board, item 30 on figure 5 to the chassis, item 45 on figure Using figure 5, locate side plates, items 10 and 20, install items 10 and 20 using twelve (12) screws secured with loctite threadlocker, item 15, six (6) on each side plate. 22. Replace two (2) screws from wire connections; item 115 and item 135 on figure Replace three (3) screws from wire connections; one (1) item 30, one (1) item 30A and one (1) item 155 on figure Carefully replace rear bottom cover, item 95, on figure Replace six (6) screws from the rear and side panels securing rear bottom cover; four (4) of item 100 secured with loctite threadlocker or equivalent and two (2) of item 45 on figure Replace seven (7) screws, item 105, securing rear bottom cover, item 95, on figure Carefully replace rear top cover, item 65 on figure Replace six (6) screws from the rear and side panels securing rear top cover; two (2) of item 205 and four (4) of item 75, on figure Replace four (4) screws, item 70, securing rear top cover, item 65, on figure Carefully replace front top cover, item 50 on figure 4 and replace eight (8) screws from the front and side panels securing front top cover; two of item 10A and six of item 60 on figure 4. Revision 2: November 24, 2003 Page 9 of 31

10 31. Replace four (4) screws, item 55 and 55A securing front top cover, item 50, on figure Identification of the Static Inverter following modification: There are two options for marking the inverter following incorporation of this modification. Marking Option No. 1 (Modified Stamp) Use the "D" metal stamp to re-identify the MOD LEVEL by stamping a "D" in the silver area next to the existing letter for S282T004-8 static inverters or use the "F" metal stamp to re-identify the MOD LEVEL by stamping an "F" in the silver area next to the existing letter for S282T004-7 static inverters. (See figure 12). Note that previous MODs which are not mandatory and are not implied by this marking. Marking Option No. 2 (Part Number Change) 1- Verify that the new nameplate has the Part Number (Boeing SCD No. S282T004-17) for (Boeing SCD No. S282T004-7) and Part Number (Boeing SCD No. S282T004-18) for (Boeing SCD No. S282T004-8). The serial number and date of Mfg must be transferred to the new nameplate. Note that previous MODs which are not mandatory and are not implied by this marking. 2.- Using the flat-head screwdriver, or equivalent, carefully pry the old nameplate from the front panel at location of rivets. 3.- Using pliers, or equivalent, carefully grasp rivet head and pull the rivet out. Repeat for second rivet. 4.- Discard used rivets and old nameplate. 5.- Position new nameplate on front panel, item 5 as shown in figure 4 and carefully secure with new rivets by tapping rivets lightly with hammer. 33. Perform tests defined in Addendum 1 to verify inverter performance. 34. Return inverter to stock or installation upon successful completion of tests. 35. Should the inverter fail the test, test and troubleshoot unit or return to Avionic Instruments Inc. for repair. Revision 2: November 24, 2003 Page 10 of 31

11 INSTRUCTIONS FOR MODIFYING PART NUMBER (BOEING S282T004-5) STATIC INVERTER NOTE : The following serial number units require special instructions to perform this modification. If you have the following serial number units, please return them to Avionic Instruments Inc. Repair Department for upgrade at no cost. Serial Numbers BV000105, BV000106, BV000107, BV000108, BV000111, BV000112, and BV Remove four (4) screws, item 40 and 40A securing top cover, item 35, on figure Remove eight (8) screws from the front and side panels securing top cover, two (2) of item 10A and six of item 40 on figure Carefully pry off top front panel, item 35 on figure Remove two (2) screws item 30 on top edge of rear panel item 25 on figure Remove four (4) screws item 60 securing top rear panel item 50 on sides on figure Remove four (4) screws item 55 securing top rear panel item 50 on top on figure Remove top rear panel item 50 on figure Remove two (2) screws item 30 on bottom edge of rear panel item 25 on figure Remove four (4) screws item 85 on figure 6 securing bottom rear panel item 80 on sides and seven (7) screws item 90 securing bottom rear panel item 80 on bottom. 10. Remove bottom rear panel item 80 on figure Using figure 7, locate the twelve (12) screws, items 15 and 25 secured with Loctite thread locker or equivalent, securing side plates items 10 and 20 (side plates will remain attached to rear plate). 12. Remove six (6) screws item 15 and remove the side plate heatsink item 10 on figure Remove six (6) screws item 25 and remove the side plate heatsink item 20 on figure Locate six (6) screws in figure 6 (items 22, 22A, 110, 110A, 115, and 126) and remove them. Cut wire tie at item 110 on figure 6. Fold the Bridge Control Board Assembly down flat on workbench cutting any wires preventing the assembly from lying flat. Revision 2: November 24, 2003 Page 11 of 31

12 15. Remove thirteen (13) screws, item 35 on figure 7 holding the Bridge Control board, item 30 on figure 7 to the chassis, item 45 on figure Using figure 8, locate position of resistor R170, item Desolder resistor R170, item 180, and remove. 18. Solder resistor R170, to solder side of board as shown in figure Verify resistor body is installed inches off PCB to ensure that adequate clearance between chassis, item 45, (figure 7), and the body of resistor R170 exists, to preclude any potential contact during aircraft operation. To provide an additional isolation in the event of contact between the body of resistor R170 and the chassis, resulting from installation exceeding 0.06 inches, it is suggested that a #410 Nomex insulator, item 150 (.010 thick X 2.5 x 2.5 ) be installed on chassis, item 45, (figure 7), directly across from the PCB where R170 is now located. The Nomex insulator should be located at the bottom left, positioned even with the middle two standoffs. The insulator should be secured with RTV adhesive or equivalent adhesive. 20. Reassemble Bridge Control Assembly reversing steps 14 and 15. Replace any wires cut in disassembly. 21. Using figure 7, locate side plate item 20. Install item 20 using the six (6) screws secured with locktite threadlocker or equivalent. 22. Using figure 7, locate side plate item 10. Install item 10 using the six (6) screws secured with locktite threadlocker or equivalent. 23. Position bottom rear panel item 80). 24. Install four (4) screws item 85 on figure 6 securing bottom rear panel item 80 on sides and seven (7) screws item 90 securing bottom rear panel item 80 on bottom. 25. Install two (2) screws item 30 on figure 6 on bottom edge of rear panel item Position top rear panel item 50 on figure Install four (4) screws item 55 on figure 6 securing top rear panel item 50 on top. 28. Install four (4) screws item 60 on figure 6 securing top rear panel item 50 on sides. 29. Install two (2) screws item 30 on figure 6 on top edge of rear panel item Carefully position top front panel, item 35 on figure 6. Revision 2: November 24, 2003 Page 12 of 31

13 31. Install eight (8) screws from the front and side panels securing top cover, two (2) of item 10A and six (6) of item 40 on figure Install four (4) screws, items 40 and 40A securing top cover, item 35, on figure Identification of the Static Inverter following modification: There are two options for marking the inverter following incorporation of this modification. Marking Option No. 1 (Modified Stamp) Use the "I" metal stamp to identify the MOD LEVEL by stamping an "I" in the silver area next to the existing letter for S282T004-5 static inverters. (See figure 13). Note that previous MODs which are not mandatory and are not implied by this marking. Marking Option No. 2 (Part Number Change) 1- Verify that the new nameplate has the Part Number (Boeing SCD No. S282T004-15). The serial number and date of Mfg must be transferred to the new nameplate. Note that previous MODs which are not mandatory and are not implied by this marking. 2.- Using the flat-head screwdriver, or equivalent, carefully pry the old nameplate from the front panel at location of rivets. 3.- Using pliers, or equivalent, carefully grasp rivet head and pull the rivet out. Repeat for second rivet. 4.- Discard used rivets and old nameplate. 5.- Position new nameplate on front panel, item 5 as shown in figure 6 and carefully secure with new rivets by tapping rivets lightly with hammer. 34. Perform tests defined in Addendum 1 to verify inverter performance. 35. Return inverter to stock or installation upon successful completion of tests. 36. Should the inverter fail the tests, test and troubleshoot unit or return to Avionic Instruments Inc. for repair. Revision 2: November 24, 2003 Page 13 of 31

14 III MATERIAL INFORMATION The following commercially available items will be required to complete installation. Description If using marking Option No. 1 (Modified Stamp), Nameplates are Not Required 3/32" Metal Stamps, Letter I, D, F, "X", "B" Qty 1 (as applicable) If using marking Option No. 2 (Part Number Change), Metal Stamps are Not Required *Nameplate for P/N (S282T004-15) *Nameplate for P/N (S282T004-17) *Nameplate for P/N (S282T004-18) *Nameplate for P/N (S282T004-20) Rivet, Stud, Grooved 2 Required for BOTH Options No. 1, and No. 2 Loctite Thread locker #242 Thread-Locking Compound (or equivalent) #410 Nomex Insulation, Thick x 2.5 x 2.5 RTV Adhesive (or equivalent) Solder Sn60/40 A/R 1 A/R A/R * NOTE: Only one (1) nameplate of the listed is required depending on unit being modified. Nameplates may be obtained from Avionic Instruments Inc. by contacting Repair Department by Telephone (732) , FAX (732) or repair@avionicinstruments.com. Please provide the information from the existing nameplate including (1) Serial Number, (2) Mod Level, (3) Code/Date of MFG, and (4) YR/MONTH, if possible. Facilities performing modification with capability of imprinting on a metal nameplate may request the blank nameplates. Revision 2: November 24, 2003 Page 14 of 31

15 FIGURE 1 FINAL ASSEMBLY MODEL 1C1000-1C (S282T004-10) STATIC INVERTER Revision 2: November 24, 2003 Page 15 of 31

16 150 FIGURE 2 EXPLODED VIEW OF BRIDGE ASSEMBLY OF S282T Revision 2: November 24, 2003 Page 16 of 31

17 FIGURE 3 BRIDGE CONTROL LOGIC PCB ASSEMBLY (S282T004-7, S282T004-8 AND S282T004-10) STATIC INVERTER Revision 2: November 24, 2003 Page 17 of 31

18 FIGURE 4 FINAL ASSEMBLY MODEL 1C1000-1B (S282T004-7 AND S282T004-8) STATIC INVERTER Revision 2: November 24, 2003 Page 18 of 31

19 150 FIGURE 5 EXPLODED VIEW OF BRIDGE ASSEMBLY OF S282T004-7 AND S282T004-8 Revision 2: November 24, 2003 Page 19 of 31

20 FIGURE 6 FINAL ASSEMBLY MODEL 1C1000-1A (S282T004-5) STATIC INVERTER Revision 2: November 24, 2003 Page 20 of 31

21 150 FIGURE 7 EXPLODED VIEW OF BRIDGE ASSEMBLY OF S282T004-5 Revision 2: November 24, 2003 Page 21 of 31

22 FIGURE 8 BRIDGE CONTROL LOGIC PCB ASSEMBLY (S282T004-5) STATIC INVERTER Revision 2: November 24, 2003 Page 22 of 31

23 FIGURE 9 BRIDGE CONTROL LOGIC PCB ASSEMBLY (S282T004-7, S282T004-8 AND S282T004-10) PLACEMENT OF R170 Revision 2: November 24, 2003 Page 23 of 31

24 FIGURE 10 BRIDGE CONTROL LOGIC PCB ASSEMBLY (S282T004-5) PLACEMENT OF R170 Revision 2: November 24, 2003 Page 24 of 31

25 FIGURE 11 NAMEPLATE MARKING INFORMATION FOR MODEL 1C1000-1C (S282T004-10) STATIC INVERTER FIGURE 12 NAMEPLATE MARKING INFORMATION FOR (S282T004-7 AND S282T004-8) STATIC INVERTER Revision 2: November 24, 2003 Page 25 of 31

26 FIGURE 13 NAMEPLATE MARKING INFORMATION FOR (S282T004-5) STATIC INVERTER Revision 2: November 24, 2003 Page 26 of 31

27 1. GENERAL ADDENDUM 1 FUNCTIONAL TEST REQUIREMENTS This section contains instructions for testing the part number , , , , , , and Static Inverters. Acceptance testing will be successfully performed according to the procedure outlined in this section before reintroducing the inverter into service. The purpose of this test is to verify that the static inverter meets all critical parameters and operates within the specified limits. 2. TEST EQUIPMENT A. Required Test Equipment Table 1 specifies the test equipment that is required for this test procedure. Alternate test equipment may be substituted provided its accuracy and performance are suitable for obtaining data consistent with the requirements of this procedure. 3. TEST SET-UP WARNING: DISCONNECT ALL POWER FROM THE STATIC INVERTER BEFORE MAKING CONNECTIONS OR PERFORMING ASSEMBLY OR DISASSEMBLY OPERATIONS. A. Test Setup (See Figure 14) (1) Connect dc power supply, dc ammeter (with shunt, if required), and dc voltmeter to input of unit-under-test (UUT) -- TB1 on front panel. (Large diameter stud is positive (+); small diameter stud is negative (-). (2) Connect ac ammeter, ac voltmeter, and no load to pins 1 and 3 of J1 on the front panel of the inverter. NOTE: For regulation, power and efficiency measurements to be valid the AC voltage measurement must be made at P1/J1 and the DC voltage measurement must be made directly at TB1. Revision 2: November 24, 2003 Page 27 of 31

28 The equipment listed below is required to perform acceptance testing. The equipment listed is only intended as a guide to the application of such equipment. Alternate equipment may be substituted provided that, their accuracy and performance meet the requirements of the test. Actual test equipment used may vary depending on availability at test locations. TABLE 1: TEST EQUIPMENT EQUIPMENT MFG MODEL RATING DC Power Supply Sorenson DCR40-125A 0-40 V, A DC Voltmeter Weston V ±2% DC Ammeter Weston A ±0.5% Shunt, if required AC True RMS Voltmeter Weston V ±2% AC Ammeter Weston A ±2% SPST Switch Any Any 0.5A min. 1000W Linear Load Any Any 1000W, 1.0 pf Revision 2: November 24, 2003 Page 28 of 31

29 ADJUSTABLE REGULATED DC POWER SUPPLY 0-40 V A + - A (TB+) +DC (TB-) -DC UNIT UNDER TEST J1-4 J1-2 J1-1 J1-3 A LOAD BANK LINEAR LOAD 1.0 pf NO LOAD & FULL RATED LOAD V S1 V REMOTE ON/OFF NOTES: 1) AC ammeter may require external shunt or current transformer or may be self contained. 2) DC ammeter may require external shunt or be self contained. FIGURE 14 ELECTRICAL TEST CONNECTIONS Revision 2: November 24, 2003 Page 29 of 31

30 4. TEST PROCEDURE This procedure establishes the operating conditions for the unit. Perform steps of test procedure in listed order. Figure 15 specifies limits for each measured value. Testing must be stopped if any reading is out of tolerance and should be continued only after all faults have been corrected. (1) No-Load Test (a) Verify that there is No Load connected to the output of the inverter at pins of J1-1 and J1-3. (b) Adjust input dc power supply to 24-2/+4 Vdc. (c) Measure and record input current, output voltage. Record measured values and compare to limits in Figure 15. (2) Full-Load Test (a) Connect a 1000 W, nominal linear load to J1-1 and J1-3 of inverter. (b) Adjust input dc power supply to 24-2/+4 Vdc. (c) Measure and record input current and voltage, and output current and voltage. Record measured values and compare to limits in Figure 15. (d) Calculate the efficiency at 1000 W load and at input voltages of 22 V or greater using the following equation: η = Watts V in * I out in *100 The calculated efficiency at full-rated load must be at least 82% at input voltages of 22 V or greater. Revision 2: November 24, 2003 Page 30 of 31

31 (3) Remote On/Off Test (a) Adjust dc power supply to 24-2/+4Vdc. (b) Close remote on/off switch for 5 seconds. This grounds Pin J1-4. (c) The inverter output should be zero. (d) Open remote on/off switch. Verify that output returns to normal limits. (e) Turn off dc power supply and disconnect load. 5. TEST LIMITS, MEASURED VALUES Check all readings against values specified in Figure 15. Repairs are required if input current, output voltage, or efficiency is not within tolerance. Input Output Voltage (Vdc) Current (Adc) Voltage (Vrms) Current (A) Nominal Load (W) (1) (1) (2) 1000 NOTES: (1) Worst case input current limit for 22 V input, 1000 W load. (2) Nominal output current, load dependent W current equal to output voltage divided by load resistance (typically 13.2 ohms at 1000 W). FIGURE 15 LIMITS FOR MEASURED VALUES Revision 2: November 24, 2003 Page 31 of 31