M/A-Com P5100 Series User manual

Maintenance Manual
LBI-38551
Rev. D, May-04
MASTR®II/III
12/24V Power Supply
19A149979P1 - 120 VOLT/60 Hz
19A149979P2 - 230 VOLT/50 Hz
19A149979P3 – 220VOLT/60 Hz

M/A-COM Technical Publications would particularly appreciate feedback on any errors that might be found in
this document, and suggestions on how it could be improved. Submit you comments and suggestions to:
Wireless Systems Business Unit
M/A-COM, Inc.
Technical Publications
221 Jefferson Ridge Parkway
Lynchburg, VA 24501
fax [phone]
[email protected]
WARNING
The 19A149979P1 power supply is UL recognized and repairs to this unit require only
the use of materials listed in the parts list. After a repair, a hi-pot test should be
performed to avoid the possibility of a short discharging the input into ground and
possibly injure an operator or burn a building. This manual implies that it is possible to
open the unit, check the problem, change the components according to the
troubleshooting guide, close the unit and power on the system. After a replacement of
components a functional and hi-pot test should be performed. This does not refer to
replacing a fuse that does not require opening of the unit. If anyone other than an
authorized M/A-COM Service technician attempts to repair this unit, M/A-COM,
Inc will assume no responsibility.
CREDITS
MASTR is a registered trademark of M/A-COM, Inc.
All other brand and product names are trademarks, registered trademarks or service marks of their respective
holders. NOTE
Repairs to this equipment should be made only by an authorized service technician or facility designated by the
supplier. Any repairs, alterations or substitution of recommended parts made by the user to this equipment not
approved by the manufacturer could void the user’s authority to operate the equipment in addition to the
manufacturer’s warranty.
NOTICE!
The software contained in this device is copyrighted by M/A-COM, Inc. Unpublished rights are reserved under
the copyright laws of the United States.
This manual is published by M/A-COM, Inc. without any warranty. Improvements and changes to this manual necessitated by typographical errors,
inaccuracies of current information, or improvements to programs and/or equipment, may be made by M/A-COM, Inc. at any time and without notice. Such
changes will be incorporated into new editions of this manual. No part of this manual may be reproduced or transmitted in any form or by any means,
electronic or mechanical, including photocopying and recording, for any purpose, without the express written permission of M/A-COM, Inc.
Copyright ©1992-2004, M/A-COM, Inc. All rights reserved.
2 LBI-38551D

TABLE OF CONTENTS
TABLE OF CONTENTS
Page
1.0 SPECIFICATIONS 4
2.0 IMPORTANT SAFETY INFORMATION 5
3.0 DESCRIPTION 8
4.0 CIRCUIT ANALYSIS 9
5.0 MAINTENANCE 12
5.1 TROUBLE-SHOOTING....................................................................................................................... 12
5.2 ADJUSTMENTS................................................................................................................................... 12
5.3 INSTALLATION.................................................................................................................................. 12
5.4 FUSE REPLACEMENT ....................................................................................................................... 12
5.5 TROUBLESHOOTING PROCEDURES.............................................................................................. 15
6.0 PARTS LIST 18
6.1 12/24 VDC, 121VAC, 60 HZ POWER SUPPLY 19A149979P1.......................................................... 18
6.2 12/24 VDC, 230 VAC, 50 HZ POWER SUPPLY 19A149979P2......................................................... 22
6.3 12/24 VDC, 220 VAC, 60HZ POWER SUPPLY 19A149979P3.......................................................... 25
7.0 ASSEMBLY DIAGRAMS 28
7.1 12/24 VDC, 121VAC, 60 HZ POWER SUPPLY 19A149979P1.......................................................... 28
7.2 12/24 VDC, 230VAC, 50 HZ POWER SUPPLY 19A149979P2.......................................................... 30
7.3 12/24 VDC, 220VAC, 60 HZ POWER SUPPLY 19A149979P3.......................................................... 31
8.0 OUTLINE DIAGRAM 32
8.1 PRINTED CIRCUIT BOARD 50 HZ AND 60 HZ MODELS (19A149979P1 & P2)........................... 32
8.2 PRINTED CIRCUIT BOARD 60 HZ MODELS (19A149979P2)........................................................ 33
8.3 12/24 VDC, 220VAC, 60 HZ POWER SUPPLY 19A149979P3.......................................................... 34
9.0 SCHEMATIC DIAGRAMS 35
9.1 POWER SUPPLY 19A149979P1 (MODEL 289PS15)........................................................................... 35
9.2 POWER SUPPLY 19A149979P2 (MODEL 289PS16)........................................................................... 36
9.3 POWER SUPPLY 19A149979P3 (MODEL 289PS25)........................................................................... 37
TABLES
Table 3-1: Typical Output Voltages.........................................................................................................................8
Table 5-1: Symptoms and Procedures for 60 Hz Power Supply 19A149979P1.....................................................15
Table 5-2: Symptoms and Procedures for 50 Hz Power Supply 19A149979P2.....................................................16
Table 5-3: Symptoms and Procedures for 60 Hz Power Supply 19A149979P3.....................................................17
FIGURES
Figure 4-1: 60 Hz Power Supply (19A149979P1)..................................................................................................10
Figure 4-2: 50 Hz Power Supply (19A149979P2)..................................................................................................10
Figure 4-3: 60 Hz Power Supply (19A149979P3)..................................................................................................11
Figure 5-1: Front and Rear View 60 Hz Power Supply (19A149979P1)...............................................................13
Figure 5-2: Front and Rear View of 50 Hz Power Supply (19A149979P2)............................................................13
Figure 5-3: Front and Rear View of 60 Hz Power Supply (19A149979P3)...........................................................14
LBI-38551D 3

SPECIFICATIONS
1.0 SPECIFICATIONS1
OUTPUT VOLTAGE
Transmit and Receive Simultaneously 26.0 VDC ±1.0 VDC @ 15 Amps (F801A)
13.0VDC ±0.5VDC @ 3Amps (J801)
Receive only Less than 16VDC @ 3 Amps (J801)
INPUT VOLTAGE 121 VAC ±20% (60 Hz version)
230 VAC ±15% (50 Hz version)
220VAC ±15% (60 Hz version)
INPUT FREQUENCY 60 Hz ± 2 Hz (60 Hz version)
50 Hz ± 2 Hz (50 Hz version)
NOTE: For every + 1.0% change in the input frequency, the output voltage will not vary
more than + 1.6% from the output voltage measured at the nominal input line frequency.
INPUT LINE SURGE PROTECTION 150 V rated MOV (60 Hz version)
275 V rated MOV (50 Hz version)
DUTY CYCLE (For 0-18 Amp Output) 100% (Continuous Duty)
OUTPUT VOLTAGE RIPPLE Less than 100 mVp-p @ 25°C
Less than 200 mVp-p @ -30°C
OUTPUT TRANSIENT RESPONSE
Overshoot Not to exceed 30 Volts (F801A)
Undershoot Not less than 22 Volts (F801A)
EFFICIENCY 70% @ rated TX/RX load current and nominal
line
voltage
FUSE CAPABILITY
Input 10 Amp (60 Hz version)
(2) 5 Amp (50 Hz version)
Output 5 Amp (Low Current Port)
20 Amp High Current Port)
DIMENSIONS (HxWxD) 5.25" x 19" x 10.35"
WEIGHT 45 lbs.
OPERATING ENVIRONMENT -30°C To + 60°C
1These specifications are intended primarily for the use of the service personnel.
LBI-38551D 4

IMPORTANT SAFETY INFORMATION
2.0 IMPORTANT SAFETY INFORMATION
The following conventions are used throughout this manual to alert the user to general
safety precautions that must be observed during all phases of operation, service, and
repair of this product. Failure to comply with these precautions for with specific warnings
elsewhere in this manual violates safety standards of design, manufacture, and intended
use of the product. M/A-COM Inc. assumes no liability for the customer’s failure to
comply with these standards
WARNING
The WARNING symbol calls attention to a procedure, practice, or the like, which, if
not correctly performed or adhered to, could result in personal injury. Do not proceed
beyond a WARNING symbol until the conditions identified are fully understood or
met.
CAUTION
The CAUTION symbol calls attention to an operating procedure, practice, or the like,
which, if not performed correctly or adhered to, could result in damage to the
equipment or severely degrade the equipment performance.
NOTE
The NOTE symbol calls attention to supplemental information, which may improve
system performance or clarify a process or procedure.
The ESD symbol calls attention to procedures, practices, or the like, which could
expose equipment to the effects of Electro-Static Discharge. Proper precautions must
be taken to prevent ESD when handling circuit modules.
1. SAVE THIS MANUAL - It contains important safety and operating instructions.
2. Before using the product, please follow and adhere to all warnings, safety and
operating instructions located on the product and in the manual.
3. DO NOT expose product to rain, snow or other type of moisture.
4. Care should be taken so objects do not fall or liquids do not spill into the product.
5. DO NOT expose product to extreme temperatures.
6. DO NOT use auxiliary equipment not recommended or sold by the manufacturer. To
do so may result in a risk of fire, electric shock or injury to persons.
7. To reduce risk of damage to electrical cord, pull by plug rather than cord when
disconnecting unit.
8. Make sure the cord is located so it will not be stepped on, tripped over or otherwise
LBI-38551D 5

IMPORTANT SAFETY INFORMATION
subjected to damage or stress.
9. An extension cord should not be used unless absolutely necessary. Use of an
improper extension cord could result in a risk of fire and electric shock. If an
extension cord must be used, make sure:
a. That pins on the plug of the extension cord are the same number, size and
shape as those of the plug on the power supply.
b. That the extension cord is properly wired in good condition.
c. That the wire size is large enough for AC ampere rating of unit.
10. DO NOT operate unit with a damaged cord or plug. Replace the damaged cord
immediately.
11. DO NOT operate this product in an explosive atmosphere unless it has been
specifically certified for such operation.
12. To reduce risk of electric shock, unplug unit from outlet before attempting any
maintenance or cleaning.
13. DO NOT operate this product with covers or panels removed.This unit does not
contain any user serviceable components.
14. Use only fuses of the correct type, voltage rating and current rating as specified in the
parts list. Failure to do so can result in fire hazard.
15. GROUNDING AND AC POWER CORD CONNECTION - To reduce risk of
electrical shock use only a properly grounded outlet. The unit is equipped with an
electric cord having an equipment - grounding conductor and a grounding plug. Be
sure the outlet is properly installed and grounded in accordance with all local codes
and ordinances.
16. DANGER - Never alter the AC cord or plug. Plug into an outlet properly wired by a
qualified electrician. Improper connection or loss of ground connection can result in
risk of an electrical shock.
17. The Model 19A149978P2 is for use on a circuit having a nominal rating of 230 VAC
and is factory equipped with a specific electric cord to permit connection to an
acceptable electric circuit. A plug meeting local electrical codes must be supplied by
the customer. Make sure the unit is connected to an outlet having the same
configuration as the plug. No adapter should be used with this unit.
NOTE
A ferroresonant power supply is designed to work specifically at a given frequency.
The 60 and 50 Hz supplies should be used at their nominal frequency ±2 Hz.
6LBI-38551D

IMPORTANT SAFETY INFORMATION
WARNING
The 19A149979P1 power supply is UL recognized and repairs to this unit require only
the use of materials listed in the parts list. After a repair, a hi-pot test should be
performed to avoid the possibility of a short discharging the input into ground and
possibly injure an operator or burn a building. This manual implies that it is possible to
open the unit, check the problem, change the components according to the
troubleshooting guide, close the unit and power on the system. After a replacement of
components a functional and hi-pot test should be performed. This does not refer to
replacing a fuse that does not require opening of the unit. If anyone other than an
authorized M/A-COM Service technician attempts to repair this unit, M/A-COM,
Inc will assume no responsibility.
LBI-38551D 7

DESCRIPTION
3.0 DESCRIPTION
The M/A-COM MASTR® II/III Base Station 12/24 Volt Power Supply provides up to
429 watts to power a MASTR II/III 800 or 900 MHz base station receiver, system
circuitry, and transmitter. The nominal 12 volt output is actually 13.0 VDC and provides
a maximum of 3 amperes to power the receiver and system circuitry. The nominal 24 volt
output is actually 26.0 VDC and provides a maximum of 15 amperes to power the
transmitter power amplifier.
The 60 Hz Model (19A149979P1) operates from a nominal 121 VAC, 60 Hz source. If a
208/220/240VAC, 60 Hz source is used, an external step-down transformer (similar to
19C307148P1) must be used with the ’979P1 supply. The 50 Hz model (19A149979P2)
provides the same output as the ’979P1 supply, but operates from a nominal 230 VAC,
50 Hz source. The output voltage will change a maximum of +1.6% for each +1.0%
change in the input line frequency. The 60 Hz model (19A149979P3) provides the same
output as the 979P1&P2 supplies, but operates from a nominal 220 VAC, 60 Hz source.
NOTE
A ferroresonant power supply is designed to work specifically at a given frequency.
The 60 Hz and 50 Hz supplies should be used at their nominal frequency ± 2 Hz.
The power supply step-down ferroresonant transformer provides excellent line voltage
regulation. For the rated input line voltage range ( ±20% for P1, ± 15% for P2), the
output voltage will not vary more than 2%. A ferroresonant power supply provides
inherently excellent line voltage surge protection, and fewer parts for high reliability. No
active semiconductor devices are used, which could reduce reliability.
The output voltages will vary depending on the load currents that the supply is being
asked to source. As the load current rises, the output voltage will drop. Typical output
voltages for various load currents are shown in Table 3-1.
Table 3-1: Typical Output Voltages
LOAD CURRENT CONDITIONS 12 V OUTPUT 24 V OUTPUT
TX AND RX SIMULTANEOUSLY (15 + 3 AMPS) ~13.0 VDC ~26.0 VDC
RX ONLY (0 + 3 AMPS) <15.8 VDC <29.0 VDC
NO LOAD (0 + 0 AMPS) <16.3 VDC <30.0 VDC
The operation and servicing of the power supply are completely accessible from the
front. The ON/OFF switch and all fuses are located on the front panel. The low profile
slot type fuse holders contain the primary fuse(s) F1 (F1 and F4 for P2), the high current
output fuse F2, and the low current output fuse F3. The primary fuse(s) protect the input
wiring to the ferroresonant transformer (one 10 amp fuse for P1, two 5 amp fuses for P2).
The output fuses F2 (20 amps) and F3 (5 amps) provide external overload protection.
The 60 Hz supply provides a courtesy dual AC receptacle. The primary line current fuse
(F1) also provides overcurrent protection for the dual receptacle. The 60 Hz supply draws
5 amps under nominal conditions and 7 amps under all conditions. Thus, the dual
courtesy receptacles are rated for 3 amps.
8 LBI-38551D

CIRCUIT ANALYSIS
4.0 CIRCUIT ANALYSIS
In the 60 Hz power supply (19A149979P1), the ON/OFF switch (S1) provides line
voltage to the power supply through the primary line fuse F1. Line current flows through
F1 to the courtesy receptacle prior to S1. This allows line voltage to always be available
at the receptacles. Current then flows through the primary of stepdown transformer (T1)
via the 200°C thermal fuse. The thermal fuse would only open in the unlikely event that
an internal short would develop in the transformer. The varistor (VR1- 150 V rating)
provides addition input line voltage suppression.
In the 50 Hz power supply (19A149979P2) and the 60 Hz power supply (19A149979P3),
the ON/OFF switch (S1) is a DPST type switching both primary AC lines. In addition,
both input lines have 5 amp fuses (F1 and F4). The varistor (VR1-275 V rating) provides
additional input line voltage suppression. When power is applied, current flows through
the primary of step-down transformer (T1) via the 200°C thermal fuse. As in the 60 Hz,
19A149979P1 model, the thermal fuse would only open if the transformer develops an
internal short.
The step-down transformer (T1) is a ferroresonant type, which has inherently good input
line voltage regulation. This eliminates the need for additional high current regulators.
Capacitor C9 serves as a resonating capacitor across the secondary taps of the
transformer.
The transformer steps the input voltage down to approximately 28 VAC across two
secondary windings. Each winding drives two separate full wave bridge rectifiers
consisting of D1A, D1B through D4A and D4B. The rectifiers are dual diode packages
and are mounted on heat sink HS 1. During the first half of the period diodes D1B, D2A,
D3B, and D4A are conducting and delivering current, which is summed at the input to
the high current filter. During the second half of the period diodes D1A, D2B, D3A, and
D4B are conducting and also delivering current, which is summed at the input to the high
current filter. The high current filter consists of capacitors C1-C4, and C7, inductor L1,
and resistor R1. It is designed to reduce the output ripple to less than 100 mV p-p for any
current load up to 15 amps. It also keeps transient responses greater than 22 volts and less
than 30 volts. Resistor R1 is a 30-ohm, 50 watt resistor that serves two functions. One, it
acts as a bleeder resistor to discharge the capacitors when the supply is turned off. Two, it
provides a minimum current load to prevent the output voltage from ever rising above 30
volts under any load condition. The high current filter sources up to 15 amps through the
20 amp fuse F2 to the high current output port F801A on the rear wall of the chassis.
F801A-1 and F801A-2 are A + and A-, respectively, and connect to the transmitter power
amplifier. The two secondary windings are also center tapped to produce a step-down
voltage of around 14 VAC, which is also fed to the two full wave bridge rectifiers.
During the first half of the period, diodes D2A and D4A provide a conduction path for
current going to both the high current filter and the low current filter. During the second
half of the period, diodes D1A and D3A provide the conduction path for current going to
the high current filter and the low current filter. The low current filter consists of C5, C6,
L2, and R2. It is designed to reduce the output ripple to less than 100 mV p-p for any
current load up to 3 amps. It also keeps transient responses greater than 11 volts and less
than 18 volts. Resistor R2 is a 100-ohm, 10 watt resistor that serves two functions. One, it
acts as a bleeder resistor to discharge the capacitors when the supply is turned off. Two, it
provides a minimum current load to prevent the output voltage from ever rising above 18
volts under any load condition. The low current filter sources up to 3 amps through the 5
amp fuse F3 to the low current output port J801 on the rear wall of the chassis. J801-1, 2,
LBI-38551D 9

CIRCUIT ANALYSIS
3 and J801-4,5,6 are A+ and A-, respectively, and connect to the receiver and system
circuitry.
The power supply is rated for a nominal 26.0 VDC for a 15 amp load out of F801A and
for a nominal 13.0 VDC for a 3 amp load out of J801 (receiving and transmitting
simultaneously). When receiving only (a 3 amp load out of J801) the output voltage is
less than 15.8 VDC at J801 and less than 29.0 VDC at F801A.
Figure 4-1: 60 Hz Power Supply (19A149979P1)
Figure 4-2: 50 Hz Power Supply (19A149979P2)
10 LBI-38551D

CIRCUIT ANALYSIS
Figure 4-3: 60 Hz Power Supply (19A149979P3)
LBI-38551D 11

MAINTENANCE
5.0 MAINTENANCE
For disassembly, remove 8 screws and lift off top cover. Disassembly is required before
working on the power supply. When replacing any component be certain to use an
identical component. Thermal joint compound is required between diodes D1, D2, D3,
and D4 and the heat sink.
WARNING
To avoid electrical shock, disconnect power supply from the AC input power source
before removing or replacing any component or assembly.
5.1 TROUBLE-SHOOTING
The troubleshooting procedure in Table 1 may be helpful in isolating a defective
component or assembly in a malfunctioning power supply. When a component or
assembly is identified as defective, replace the defective component with an identical
component. Be sure to check associated circuitry for any other damaged components
before applying power to the unit.
5.2 ADJUSTMENTS
This power supply has no adjustments or controls other than the ON/OFF switch.
5.3 INSTALLATION
The power supply is normally installed in an EIA 19-inch wide rack of a MII/III base
station cabinet. It can also be installed in a 19-inch wide stand alone open rack.
NOTE
Insure that ventilation holes in the unit are not obstructed when the unit is mounted or
in operation.
5.4 FUSE REPLACEMENT
To replace a defective fuse, perform the following procedure:
1. Place ON/OFF switch to the OFF position.
2. For fuses F1 (F1 & F4 on 19A149979P2), F2, or F3; remove cap from fuse holder
and replace fuse with a fuse of the same type and rating.
WARNING
1. To avoid possible electric shock, DO NOT operate this power supply with the
fuse cover removed.
2. No one should be permitted to handle any portion of the equipment that is
supplied with high voltage, or to connect any external apparatus to the units while
the units are supplied with power. KEEP AWAY FROM LIVE CIRCUITS.
12 LBI-38551D

MAINTENANCE
FRONT VIEW
REAR VIEW
Figure 5-1: Front and Rear View 60 Hz Power Supply (19A149979P1)
FRONT VIEW
REAR VIEW
Figure 5-2: Front and Rear View of 50 Hz Power Supply (19A149979P2)
LBI-38551D 13

MAINTENANCE
FRONT VIEW
REAR VIEW
F4 F1
F2 F3
S1
J802 F801A
W801
J801
Figure 5-3: Front and Rear View of 60 Hz Power Supply (19A149979P3)
14 LBI-38551D

MAINTENANCE
5.5 TROUBLESHOOTING PROCEDURES
Table 5-1: Symptoms and Procedures for 60 Hz Power Supply 19A149979P1
SYMPTOM PROCEDURE
No output voltage at J801
Check the following:
1. Open F1, F3 or S1.
2. AC voltage on W801.
3. Open D1, D2, D3, or D4.
No output voltage at F801A
Check the following:
4. Open F1, F2 or S1.
5. AC voltage on W801.
6. Open D1, D2, D3, or D4.
Low output voltage on F801A.
0 < Vo < 25.0 VDC
Check the following:
7. If one of the dual diodes on D1, D2, D3, or D4
is shorted.
NOTE: All four diode packages contain two
diodes each.
8. Line frequency < 60 Hz.
9. Load current greater than 15.0 amps.
Low output voltage on J801.
0 < Vo < 12.5 VDC
Check the following:
10. If one of the dual diodes on D1, D2, D3, or D4
is shorted.
NOTE: All four diode packages contain two
diodes each.
11. Line frequency < 60 Hz.
12. Load current greater than 3.0 amps.
High output voltage on F801A
(>30.0 VDC) or J801 (>16.3 VDC).
Check the following:
13. R1 not connected between pos. 1 and 2 on
F801A.
14. R2 not connected between pos. 1 and 4 on
J801.
15. Line frequency >60 Hz.
LBI-38551D 15

MAINTENANCE
Table 5-2: Symptoms and Procedures for 50 Hz Power Supply 19A149979P2
SYMPTOM PROCEDURE
No output voltage at J801
Check the following:
1. Open F1, F3, F4 or S1.
2. AC voltage on W801.
3. Open D1, D2, D3, or D4
NOTE: Diodes also referred to as CR1-CR4.
No output voltage at F801A
Check the following:
1. Open F1, F2 or S1.
2. AC voltage on W801.
3. Open diode D1, D2, D3, or D4.
Low output voltage on F801A.
0 < Vo < 25.0 VDC
Check the following:
1. If one of the dual diodes on D1, D2, D3, or
D4 is shorted.
NOTE: All four diode packages contain two
diodes each.
2. Line frequency < 60 Hz.
3. Load current greater than 15.0 amps.
Low output voltage on J801.
0 < Vo < 12.5 VDC
Check the following:
1. If one of the dual diodes on D1, D2, D3, or
D4 is shorted.
NOTE: All four diode packages contain two
diodes each.
2. Line frequency < 60 Hz.
3. Load current greater than 3.0 amps.
High output voltage on F801A
(>30.0 VDC) or J801 (>16.3 VDC).
Check the following:
1. R1 not connected between pos. 1 and 2 on
F801A.
2. R2 not connected between pos. 1 and 4 on
J801.
3. Line frequency >60 Hz.
No output voltage at F801A
Check the following:
1. Open F1, F2, F4 or S1.
2. AC voltage on W801.
3. Open D1, D2, D3, or D4.
Low output voltage on F801A.
0 < Vo < 25.0 VDC
Check the following:
1. If one of the dual diodes on D1, D2, D3, or
D4 is shorted.
NOTE: All four diode packages contain two
diodes each.
2. Line frequency < 50 Hz.
3. Load current greater than 15.0 amps.
16 LBI-38551D

MAINTENANCE
SYMPTOM PROCEDURE
Low output voltage on J801.
0 < Vo < 12.5 VDC
Check the following:
1. If one of the dual diodes on D1, D2, D3, or
D4 is shorted.
NOTE: All four diode packages contain two
diodes each.
2. Line frequency < 50 Hz.
3. Load current greater than 3.0 amps.
High output voltage on F801A
(>30.0 VDC) or J801 (>16.3 VDC).
Check the following:
1. R1 not connected between pos. 1 and 2 on
F801A.
2. R2 not connected between pos. 1 and 4 on
J801.
3. Line frequency >50 Hz.
Table 5-3: Symptoms and Procedures for 60 Hz Power Supply 19A149979P3
SYMPTOM PROCEDURE
No output voltage at J801
Check the following:
1. Open F1, F3 or S1.
2. AC voltage on W801.
3. Open CR1, CR2, CR3, or CR4.
No output voltage at F801A
Check the following:
1. Open F1, F2 or S1.
2. AC voltage on W801.
3. Open CR1, CR2, CR3, or CR4.
Low output voltage on F801A.
0 < Vo < 25.0 VDC
Check the following:
1. If one of the dual diodes on CR1, CR2, CR3,
or CR4 is shorted.
NOTE: All four diode packages contain two
diodes each.
2. Line frequency < 60 Hz.
3. Load current greater than 15.0 amps.
Low output voltage on J801.
0 < Vo < 12.5 VDC
Check the following:
1. If one of the dual diodes on CR1, CR2, CR3,
or CR4 is shorted.
NOTE: All four diode packages contain two
diodes each.
2. Line frequency < 60 Hz.
3. Load current greater than 3.0 amps.
High output voltage on F801A
(>30.0 VDC) or J801 (>16.3 VDC).
Check the following:
1. R1 not connected between pos. 1 and 2 on
F801A.
2. R2 not connected between pos. 1 and 4 on
J801.
3. Line frequency >60 Hz.
LBI-38551D 17

PARTS LIST
6.0 PARTS LIST2
6.1 12/24 VDC, 121VAC, 60 Hz POWER SUPPLY 19A149979P1
SYMBOL PART NUMBER DESCRIPTION
- - - - CAPACITOR - - - -
C9
(Item #8) M29/17032400 Polypropylene: 8 µF, 660VAC, similar to Ronken P61A24805H05.
- - - - CONNECTOR - - - -
J801 M29/40027400 Connector: 9 position; sim to Molex
03-09-1091.
- - - - RESISTOR - - - -
R1
(Item #5) M29/16012302 Wirewound Resistor: 30 ohms, 50 w; similar to IRC PW-50E-30OHMS-5% (with bracket).
- - - - TRANSFORMER - - - -
T1
(Item #4) M29/289CV3 Ferro-Resonant Transformer.
- - - - WIRE HARNESS - - - -
W1 From E1 on PCB to rear terminal of fuse holder
F1.
W2 Ground lead on J1 to chassis ground stud.
W3 White lead on J1 to TB7 on PCB.
W4
and
W5
Part of front panel 9H910463001.
W6 From E3 on PCB to piggy back terminal of W5
on bottom of switch S1.
W7 250074313 From top terminal on switch S1 to terminal 4 of
transformer T1.
W8 From E4 on PCB to terminal 1 of transformer
T1.
W9 250074315 From terminal 2 of transformer T1 to terminal 3
of T1.
W10 From E5 to E6 on PCB.
W11 From E9 on PCB to inside terminal of resistor
R1.
W12 From E10 on PCB to outside terminal of R1.
W13 From E12 on PCB to end terminal of fuse
holder F3.
2COMPONENTS ADDED, DELETED OR CHANGED BY PRODUCTION CHANGES.
18 LBI-38551D

PARTS LIST
SYMBOL PART NUMBER DESCRIPTION
W14 From terminal 1 of connector F801A to side
terminal of fuse holder F2.
W15 From terminal 2 of F801A to TB8 on PCB.
W16 Red lead from J801 to side terminal of fuse
holder F3.
W17 Black Lead from J801 to E13 on PCB.
W18 From E8 on PCB to end terminal of fuse holder
F2.
W801 M29/11022301 Power Cord.
- - - - MISCELLANEOUS - - - -
Item #3 070698702 Case
Item #7 M29/05065600 Bracket for capacitor C9.
Item #9 M29/22043200 Nylon Standoff: Quantity 7; Used to separate
PCB from case.
Item #10 M29/11022000 Strain relief, black similar to Heyco 1200. To
secure W801 to case.
Item #11 11022301 Power Cord.
Item #12 72067900 Terminal boot.
Item #13 31024000 Insulator (Not shown – goes on C1 thru C4 and
C6 and C7.
Item #14 M29/07062201 Top Cover.
Item #15 M29/22041501 Hex nut: No. 6-32 x .250, quantity 10; used to
secure PCB.
Item #16 11024500 Ty-Wraps
Item #17 22046400 Screw: 3.5 mm.
M29/22043800 Machine screw, TORX head: 3.5m x 1/2;
Quantity 8; similar to Camcar/Textron Inc.
Secures cover.
Item #18 M29/22041503 Nut: No. 10-32, quantity 4; used to secure
terminal lugs to PCB.
Item #19 M29/22041502 Hex nut: No. 8-32, quantity 4; secures C9, R1,
and ground wire to case.
Item #20 22008207 Nut: #8-32.
Item #21 M29/22041504 Nut: 1/4-20 x 7/16, quantity 4; secures T1 to
case.
Item #23 M29/22044600 Machine screw, hex head; No. 8-32 x 5/8"
secures C9 to case.
Item #24 40028400 Plug: Housing (Blank).
Item #25 35002900 Pad: 3” x 6” x 3/16”.
Item #26 43019000 High temperature RTV.
LBI-38551D 19

PARTS LIST
SYMBOL PART NUMBER DESCRIPTION
Item #27 220496205 Washer: #10
Item #28 22049500 Screw: #10-32 x 3/8”, Tork.
Item #29 22010305 Washer: #6 internal tooth LW.
Item #30 22009003 Screw: #6-32 x 0.312.
Item #31 43017000 Cement RTV 6700
Item #32 51092475-000 Label
Item #2 M29/07063000
(Old Number) FRONT PANEL
9H910463001
Assembly includes the following:
83070684000 Front Panel (Blank).
821090172PE
(M29/09014200) Fuse Holder, screwdriver slot design: similar to Bussman "HTB-96I". (Used with F1 and F2).
821090215PE
(M29/09014200) Fuse Holder. (Used with F3).
F1 821157200PE
(M29/09013901) Fuse: 10 Amp: sim to AGC10, 6.3x32 F. (Old number M29/09013901).
F2 821090214PE
(M29/09013903) Normal Blow Fuse: 20 amps, 32V; similar to Bussman AGC-20.
F3 821097100PE
(M29/09016300) Slow Blow Fuse: 5 amps, 250V; similar to Bussman MDL-5.
J1 81525013000 AC Receptacle. power, 3 wire grounding, 15
amps at 125V. (Previously RE1 and RE2
M29/40027800).
81622043800 Screw: 3.5 x 10mm PHTXTT.
81622010305 Washer. Split lock washer #6, zinc. Secures J1
81622044500 Nut: to M3.5 6MMAF HEX ZN. Secures J1.
W4 81525007430 Black wire from AC receptacle piggy backed
with black wire W5 at side terminal of fuse
holder F1.
W5 81525007430 Black wire from switch S1 to side terminal of
fuse holder F1..
F801A
(Item #6) 81525013100 Connector: 4 position; sim to AMP 641685-2 (Old number M29/40028600)
S1 82191100000
(M29/20003300) Switch: SPST, 16 amps, 125V switch; similar to Carling RA911VB-B-0-V.
20 LBI-38551D