Emergency Power Supply: Installation Manual

Emergency Power Supply
JET® Model PS-835

Part Number 501-1228-( )
Installation Manual
L-3 Communications Avionics Systems

5353 52nd Street, S.E. TP-336 (Revision E)
Grand Rapids, MI 49512-9704, USA May 12, 2006
www.as.l-3com.com
Foreword
This manual provides information intended for use by persons who, in accordance with current regulatory
requirements, are qualified to install this equipment. Installation requirements may vary, depending on
the particularities of each aircraft, and this manual is intended as a guideline for that purpose. If further
information is required, please contact:

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

Attn: Technical Publications
5353 52nd Street, S.E.
Grand Rapids, MI USA 49512-9704
Telephone: (800) 453-0288 or (616) 949-6600
Fax: (616) 977-6898
WARNING
INFORMATION SUBJECT TO EXPORT CONTROL LAWS
This technical data is controlled under the Export Administration Regulations
and may not be exported to a foreign person, either in the United States or
abroad without the proper authorization of the U.S. Department of Commerce.
This document must be marked in compliance with L-3 Avionics Systems
Policy WI 0321S17 prior to distribution to foreign persons.
© Copyright 2004, 2005, 2006

(Formally Goodrich Avionics Systems, Inc.)
JET® is a registered trademark of L-3 Avionics Systems, Inc.
TP-336 Front Section - Page A

Revision E May12, 2006
L-3 Avionics Systems
Installation Manual
JET® Model PS-835
List of Effective Pages
Dates of original and changed pages are:
Reissue ................................................................................... July 1, 1994

Revision A ..........................................................................April 30, 2002
Revision B .....................................................................February 28, 2003
Revision C .....................................................................February 28, 2004
Revision D .....................................................................February 02, 2005
Revision E.............................................................................May 12, 2006
Total number of pages in this publication consists of the following:
Section Page No.

Front Matter Cover
A
i-vi
Description 1-12
Installation 101-110
Fault Isolation 201-206
Disclaimer
This Installation and Operation Manual contains information that is considered relevant only at the time
of distribution with the Avionics Systems product for which it is shipped. Information in this manual is
subject to change without notice and will not be updated after distribution.
Avionics Systems does provide a listing of all publications and directives with their current revision and
change levels to insure up-to-date information. See www.as.l-3com.com, Service Section, Technical
Publications Page for the Publications Index to get an up-to-date listing of all Avionics Systems technical
publications and directives. Contact Avionics Systems Customer Service [1-800-453-0288] to determine
availability of technical publications and directives.
TP-336 Front Section - Page i

Installation Manual
JET® Model PS-835
Revision Highlights
Revision D
Revision corrects figure and table call outs in test and fault section. Adds installation kit component (pg.
104) list and add call outs to text for items in figure 101.
Revision E
Corrected pg. 107, figure 103 (J2 pin 8 was pin 3 and on SI-100 module added P2 pin 8). Updated figure
2, 3, and 4 with better versions. Updated battery testing procedures pg. 202 and 203 per recent changes to
SL-80R. Added export control statement to front section. Removed operation from title of manual located
on top of each page.
TP-336 Front Section - Page ii

Installation Manual
JET® Model PS-835
Table of Contents
Section Page
Title Page ............................................................................................................................................... cover
Introduction.................................................................................................................................................. A
List of Effective Pages ................................................................................................................................... i
Table of Contents.........................................................................................................................................iii
List of Illustrations and Tables .................................................................................................................... iv
List of Symbols and Abbreviations............................................................................................................... v
Description
1. General.................................................................................................................................................. 1
2. Purpose of Equipment........................................................................................................................... 1
3. Physical Description ............................................................................................................................. 1
4. Functional Description.......................................................................................................................... 1
5. Continued Airworthiness (Maintenance).............................................................................................. 2
6 MOD Status .......................................................................................................................................... 3
7. Environment Qualifications.................................................................................................................. 5
8. Specifications........................................................................................................................................ 7
9. Charge and Discharge Performance...................................................................................................... 7
Installation
1. General.............................................................................................................................................. 101
2. Location Considerations ................................................................................................................... 101
3. Pre-Installation Inspection and Preparation ...................................................................................... 101
4. Post Installation ................................................................................................................................ 102
5. Affiliated Equipment ........................................................................................................................ 102
6. Installation Kits................................................................................................................................. 104
7. Interconnect Diagrams ...................................................................................................................... 105
Testing and Fault Isolation
1. General.............................................................................................................................................. 201
2. Charging Procedures......................................................................................................................... 202
3. Preflight Checks................................................................................................................................ 202
4. Periodic Checks ................................................................................................................................ 203
5. Capacity Checks ............................................................................................................................... 204
6. Cell Isolation Test............................................................................................................................. 205
TP-336 Front Section - Page iii

Installation Manual
JET® Model PS-835
List of Illustrations
Figure Pages
Figure 1: PS-835 Emergency Power Supply ................................................................................................ 6

Figure 2: Cell Storage Time vs. Temperature............................................................................................... 9
Figure 3: Typical Discharge Time for Sealed Lead-acid Cells................................................................... 10
Figure 4: PS-835( ) Discharge Curves ........................................................................................................ 11
Figure 101: Affiliated Equipment ............................................................................................................. 103
Figure 102: Typical Installation Interconnections for PS-835A through D.............................................. 106
Figure 103: Typical Installation Interconnections for PS-835E and F ..................................................... 107
Figure 104: Interconnections to AC Powered Indicators.......................................................................... 108
Figure 105: Interconnections to DC Powered Indicators.......................................................................... 108
Figure 106: PS-835 Installation Drawing ................................................................................................. 109
Figure 107: PS-835 Pin Configurations.................................................................................................... 110
Figure 201: PS-835 Access Panel ............................................................................................................. 204
List of Tables
Table Pages
Table 1: Service Bulletins and Modifications............................................................................................... 3

Table 2: Environmental Qualifications ......................................................................................................... 5
Table 3: Specifications.................................................................................................................................. 7
Table 101: List of Installation Kits ........................................................................................................... 104
Table 102: Installation Kit Components [504-1019-01]........................................................................... 104
Table 201: Test Equipment and Fixtures .................................................................................................. 202
TP-336 Front Section - Page iv

Installation Manual
JET® Model PS-835
List of Abbreviations
A Ampere
AC Alternating Current
awg American Wire Gauge
AMP Ampere
AR As Required
CH Chemical Hazard
CCA Circuit Card Assembly
CCW Counterclockwise
CW Clockwise
DC Direct Current
Hz Hertz (frequency)
″ inch
lbs pounds
in-lbs Inch-Pounds (torque)
Max maximum
MSDS Material Safety Data Sheet
PWB Printed Wiring Board
RPM revolutions per minute
UUT unit under test
Vdc Volts direct current
Vac Volts alternating current
± + (plus) or – (minus)
° Angular Degree
F° Temperature Fahrenheit
C° Temperature Celsius
Ω Ohm
TP-336 Front Section - Page v

Installation Manual
JET® Model PS-835
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TP-336 Front Section - Page vi

L-3 Avionics Systems, Inc.
Installation Manual
JET® Model PS-835
Description
1. General
This manual provides description and operation instructions for Models PS-835 A through F
Emergency Power Supplies, Part Numbers 501-1228-01 through -06 (respectively). Models C, D, E,
and F are current and Models A and B are considered obsolete, see Service Bulletins and
Modifications Table 1. Models A, C, and E use 2.5Ah cells and Models B, D, and F use 5.0Ah cells.
Model Number Part Number

A 501-1228-01
B 501-1228-02
C 501-1228-03
D 501-1228-04
E 501-1228-05
F 501-1228-06
2. Purpose of Equipment
The Model PS-835 Emergency Power Supply is designed as a 24 Vdc (nominal) emergency power
source for prolonging the operation of a connected standby attitude indicator when the aircraft main
power buss has de-energized. The aircraft main power buss provides trickle charging to the PS-835
while the aircraft performs normally.
The output of the PS-835 can be subsequently converted using either Avionics Systems Model SI-
100( ) Static Inverter or the SC-841 Static Converter to provide power for standby indicators of
different power requirements.
The SI-100 provides outputs of 115 Vac or 5 Vac, 400Hz either at single or three phase alternating
current. The SC-841 provides direct current outputs of 2.0 to 6.5 Vdc (user adjustable).
3. Physical Description
The PS-835 Emergency Power Supply is fully enclosed unit, designed to easily mount onto an
existing avionics shelf or the optional ATR mounting rack (Avionics Systems part number 572-
1424-01). The face of the unit provides individual cell monitor LED's, voltage output monitor
LED's, battery Heater Operation Monitor LED's, and a battery test switch to assist in assessing the
condition of the unit and cells.
4. Functional Description
A. Power Input
Aircraft 28 Vdc is connected to the emergency power buss through pin 10 of connector J1. The
input is diode isolated from the internal batteries and circuits to prevent battery discharge in the
event of a short circuit, or battery draw caused by low input from the aircraft main DC buss,
such as at engine start.
TP-336 Description - Page 1

Revision E May 12, 2006
Installation Manual
JET® Model PS-835
B. Battery Heating
Battery heating is provided by an etched foil Heating Resistor mounted onto the unit chassis.
With 28 Vdc applied to the unit and the temperature is 19°C (66°F) the green HEATER ON
LED (Figure 1, Item 4) will come on showing that the heater is operating. The red LED will
come on if the temperature exceeds 55°C.
The heating element, also, functions as a test load during the time the power supply is being
tested aboard the aircraft. The HEATER ON LED (Figure 1, Item 3) will come on when the
TEST SWITCH (Figure 1, Item 4) on the front panel is pressed.
C. Over-Temperature Protection
When the temperature of the power supply exceeds +55°C, the temperature sensor imbedded
within the unit will cause the OVER 55°C LED (Figure 1, Item 3) to go on. The heating control
circuitry would then cease the heating-resistor's operation. The heating circuit will remain
inoperable until the temperature of sensor drops low enough to again permit heater operation.
D. Battery Voltage Level Detection
There are four OUTPUT VOLTAGE MONITOR LED's on the front panel of the supply (Figure
1, Item 2). These indicate the state-of-charge of the stored power. The LED's go on when the
TEST SWITCH is pressed or when the supply is being charged.
The power supply is considered greater than 50% charged when the 24V LED momentarily
illuminates when the TEST SWITCH is pressed, and fully discharged when the 20V LED is
goes out.
5. Continued Airworthiness (Maintenance)
The Model PS-835 Emergency Power Supply requires regular checks and testing to ensure that the
unit will provide standby electrical power under emergency conditions experienced by the aircraft in
which it is installed.
Use the instructions provided in this Installation Manual, or the corresponding Maintenance Manual
(TP-329) to perform Preflight Checks, Periodic Checks, and Annual Capacity Testing procedures to
monitor the operational capability of the unit.
Follow the associated guidance provided in those procedures that will direct service and maintenance
actions that will restore the unit to full and correct operation.
This unit has unlimited service life, where service life is defined as that point in time when repair is
no longer economical. No scheduled overhaul requirement exists for this unit.

Installation Manual
JET® Model PS-835
6. MOD Status
The PS-835 Emergency Power Supply is a proven design that has experienced numerous
improvements. This manual offers information concerning the various levels of modification at
which a unit may exist in the field.
The table below lists all Service Bulletins that pertain to the PS-835 Emergency Power Supply up to
the date of this publication.
Modification Kits and

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

Installation Manual
JET® Model PS-835
Modification Kits and

Model and Part
Service Bulletin MOD # Purpose part required for
Number
Modification
SB501-1228-11( ) A-501-1228-01 8 Prevent possible shorting MOD Kit 504-1811-01
C-501-1228-03 3 between cells and chassis.
E-501-1228-05 1
SB501-1228-12( ) A-501-1228-01 9 Prevent possible shorting MOD Kit 504-1839-01
B-501-1228-02 9 between cells and chassis.
C-501-1228-03 4
D-501-1228-04 3
E-501-1228-05 2
F-501-1228-06 1
SB501-1228-13( ) A-501-1228-01 10 Modify wiring to prevent
B-501-1228-02 10 improper charging.
C-501-1228-03 5
D-501-1228-04 4
E-501-1228-05 3
F-501-1228-06 2
SB501-1228-14( ) D-501-1228-04 5 Prevent shorting of cell leads
Serial No.s by correcting wire routing and
8647 and improved soldering of cell
higher. terminals.
Table 1: Service Bulletins and Modifications (Cont.)

Installation Manual
JET® Model PS-835
7. Environmental Test Qualifications
The following tests have been conducted to satisfy DO-160A test conditions.
Name of Test Qualified to DO-160A elements:

Low Temperature Section 4.0 Cat. A2F2
Humidity Section 6.0 Cat. B
Vibration Section 8.0 Cat. J
Explosion Section 9.0 Cat. E
Voltage Spikes Section 17 Cat. A for Models C, D, E and F
Temperature Variation Section 5.0 Cat. B
Magnetic Effect Section 15
Audio Frequency Conducted Section 18 Cat. A
Susceptibility
Electromagnetic Compatibility Section 19 Cat. A
Section 20 Cat. A
Section 21 Cat. A
Table 2: Environmental Qualifications

Installation Manual
JET® Model PS-835
Figure 1: PS-835 Emergency Power Supply
1 Individual Cell Monitor LED's

2 Output Voltage Monitor LED's
3 Battery Heater Operation Monitor LED's
4 Test Switch
5 Individual Cell Dip Switches

Installation Manual
JET® Model PS-835
8. Specifications
Weight Model A, C, E - 8 lbs. [3.65Kg]

Model B, D, F - 13 lbs.[6.0Kg]
Electrical
Input 28 to 30 Vdc.
15 Amp max
Output 24 Vdc nominal, 10 Amp max. steady state

Model A, C, E - 2.5 Amp Hour
Model B, D, F - 5.0 Amp Hour See Figure 3 Current Discharge Times
and Figure 4 Voltage Discharge Curves
Dimensions See Figure 106 and 107 PS-835( ) Installation Drawing
Operating -55°C to 70°C

Temperature
Range
Altitude Sea level to 55,000 ft. at 25°C
Mating Model A, B, C, D- DPXB-13-33S-0001 (Avionics Systems PN S24140-01)

Connectors Model E, F- DPXB-13-33S-0019 (Avionics Systems PN S24140-02)
Table 3: Specifications
9. Charge and Discharge Performance
A. General Battery and Cell Information
The cells are constructed with thin pure lead plates. The overall chemistry is typical of the
traditional lead-acid battery. A unique aspect of the sealed lead-acid cell is that the majority of
the oxygen generated within the cell during an overcharge condition is recombined within the
cell. The quality of the lead grids used in construction minimize the evolution of hydrogen
when overcharging occurs.
Each cell has a self-resealing release valve designed to operate in the 50-60 psi range. In
normal use, the battery internal cell pressure never exceeds 20 psi. This means that in normal
conditions the cell can be operated in a perfect vacuum and still have a sufficient safety margin,
so that venting will not occur.
NOTE: Batteries and Cells should not be left in a discharged state under any
circumstances.
Cells should not be left connected to a load when in a discharged state or their ability to accept a
charge will be impaired. The cell may develop shorts or chemical action will create water that
will freeze at low temperatures and destroy the cell.

Installation Manual
JET® Model PS-835
B. Battery/Cell Out-Gassing
CAUTION: SOME OF THE TYPES OF GASSES THAT MAY VENT FROM A CELL ARE TOXIC AND
SHOULD NOT BE CONTAINED IN A CLOSED, NON-VENTED AREA.
CAUTION: CELL/BATTERY CORROSION IS EVIDENCE OF THE LOSS OF SEAL, LIKELY CAUSED BY

OUT GASSING. CELLS MUST BE REPLACED WHEN CORROSION IS APPARENT.
All lead-acid cells and batteries produce gasses during charging. The amount and type of gas
produced depends on state of charge, rate of charge, chemical composition of the electrolyte,
and general condition of the battery. Normally, gasses produced are recombined within the
cells to form oxides and water. Venting occurs when excessive charge rates are placed on the
battery or because of a defective cell (s) which subjects the remaining good cells to excessive
charge rates. Venting may also result from battery abuse or neglect.
If the odor of rotten eggs becomes apparent in the cockpit, pull the aircraft Emergency Power
Supply circuit breaker. The rotten egg odor is evidence that the lead-acid cells vent due to
prolonged high rate overcharging. Although the possibility of toxic levels is extremely remote,
the precaution of pulling the circuit breaker will prevent increased discomfort from the odor.
Venting is an indication that the Power Supply in not controlling the charging process. If
venting occurs the factory recommends that the Power Supply be remove from the aircraft,
tested according to the procedures listed in this manual, and to replace the defective
cell(s).
NOTE: With proper maintenance and periodic testing, the likelihood of any battery
developing undetected problems is very remote.

Installation Manual
JET® Model PS-835
C. Storage Time and Temperature
NOTE: Avionics Systems Service Letter SL-64( ) contains additional information on

Lead-acid Battery out-gassing and Service Letter SL-80( ) contains additional
information for Charging Emergency Power Supplies.
If a ready condition is required of a power supply being stored, recharge batteries every 4 months
for 1 hour at 28 to 30Vdc input. Do not store where temperature may exceed 85°F (29°C).
Low storage temperatures on fully charged cells lessen the rate of self-discharge, thus
increasing shelf life. There is no danger of damage to cells since they will not freeze even at
temperatures of -75° F. On the other hand, high storage temperatures will accelerate self-
discharge of the cells and storage under such conditions is not recommended. Refer to Figure 2.
Figure 2: Cell Storage Time vs. Temperature

Installation Manual
JET® Model PS-835
D. Cell Current Discharge Time
The rate of energy being withdrawn from a cell affects the amount of energy that can be
obtained over time. For example, at low current rates the energy in a cell lasts longer than at
high current rates. The actual hours of service (Amp-hours, or Ah) from fully charged "D" or
"X" cells can be determined from Figure 3 below.
Figure 3: Typical Discharge Time for Sealed Lead-acid Cells

Installation Manual
JET® Model PS-835
E. Cell Voltage Discharge Time
Figure 4 displays typical discharge curves at room temperature. At -55°C an internal heater
blanket maintains the cells at no lower than 0°C for the "X'' type cells and 20°C for the "S" type
cells. A typical discharge rate with the cells at 0°C reduces the capacity by approximately 15%.
Figure 4: PS-835( ) Discharge Curves

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JET® Model PS-835
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Installation Manual
JET® Model PS-835
Installation
1. General
The installation information provided is for “typical” install situations, not including information for
specific aircraft. Additional information may be obtained from the original aircraft manufacturer.
2. Emergency Power Supply Location
The following steps provide general requirements for locating the Emergency Power Supply in an
aircraft.
A. The Emergency Power Supply provides limited direct-current power and 115Vac (when in
combination with Static Inverter Model SI-100) to the aircraft emergency bus equipment in case
of primary power failure. Therefore, the supply should be located in the general area of aircraft
AC and DC busses.
B. Ensure that space requirements for the supply match space available for the installation being
considered.
1) The Emergency Power Supply should be accessible for inspection, maintenance, or

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

A. Check unit for physical damage that may have occurred during shipping and handling.
B. Press TEST SWITCH (Figure 201, Item 4) into TEST position for 5 seconds. The PS-835
indicates that it is adequately charged when the VOLTAGE LEVEL 24Vdc LED (Figure 201,
Item 2, at least, illuminates momentarily, AND the 20Vdc LED (Figure 201, Item 6) remains lit
during the test.
1) If the unit reveals that it is at a fully charged state, proceed with installation into aircraft.
2) If the unit is not fully charged, perform charging procedures as directed in Testing and
Fault Isolation section, step 2. Charging Procedures.
C. At completion of charging period, again perform step B.
1) If the unit reveals that it is at a fully charged state, proceed with installation into aircraft.
2) If the unit is not fully charged, return the unit to the factory or service center for repair.
TP-336 Installation - Page 101

Installation Manual
JET® Model PS-835
4. Post Installation
Perform either the Preflight or the Periodic Check, see Testing and Fault Isolation section,
immediately after installation of the PS-835 Emergency Power Supply.
5. Affiliated Equipment
A. SI-100 Static Inverter
The SI-100 Static Inverter provides for alteration of the PS-835 output for use of equipment that
requires alternating current (AC).
The Model SI-100A Static Inverter (Avionics Systems part number 501-1240-01) has 3Ø,
400Hz, 115Vac, 25VA output capability.
The Model SI-100B Static Inverter (Avionics Systems part number 501-1240-02) has 1Ø,
400Hz 115Vac, 75VA output capability, or 1Ø, 400Hz, 5Vac, 5VA output capability.
B. SC-841 Static Converter
The SC-841 Static Converter (Avionics Systems part number 501-1318-01) provides for direct
current conversion for 2 to 6.5 Vdc, 25 Watt output capability. See Avionics Systems
Installation Instructions TP-351 for additional information.
C. BC-815 Battery Charger
The BC-815 Battery Charger (Avionics Systems part number 501-1321-01) provides the
capability to charge the PS-835 Emergency Power Supply when not mounted on aircraft. See
Avionics Systems Installation Instructions TP-350 for additional information.
D. Connector Plug for AC and DC powered Indicators[Figure 101, Item 1]
MS3126E10-16S for AC power Indicators, Avionics Systems part number 563-1013-04 for DC
powered Indicators.
E. Transformer (used with SI-100 Static Inverter) [Figure 101, Item 2]
For aircraft applications that require 26Vac output. (Avionics Systems part number 556-2006-01)
F. ATR Mounting Rack [Figure 101, Item 3]
ATR Mounting Rack (Avionics Systems part number S53001-01) for use with PS-835 in
aircraft applications.
G. Mating Connectors
Avionics Systems part numbers S24140-02 for PS-835 E and F, S24140-01 for PS-835 A
through D. (See Figure 106 and Figure 107)

Installation Manual
JET® Model PS-835
ITEM 1
ITEM 2
Figure 101: Affiliated Equipment

Installation Manual
JET® Model PS-835
6. Installation Kits
Kit Part Number PS-835 Model Including Inverter or Converter Connecting to Indicator units:
504-1019-01 A-D SI-100( ) AI-804 or AI-904 AC powered
504-1019-02 A-D SI-100( ) or SC-841 AI-804 or AI-904 DC powered
504-1019-05 E-F SI-100( ) or SC-841 AI-804 or AI-904 AC powered
504-1019-06 E-F SI-100( ) or SC-841 AI-804 or AI-904 DC powered
504-1035-01 A-D - - GH-3000 and GH-3100 ESIS
Table 101: List of Installation Kits
Kit Component Description Qty.

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

563-1013-04 Connector, Electrical Circular 1

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

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


Installation Manual
JET® Model PS-835
7. Interconnect Diagrams
A. Fuse and Circuit Breakers
The PS-835 Emergency Power Supply contains internal fuses and circuit breakers to protect the
supply against shorting conditions. Additional fuses or breakers may be required to protect
aircraft wiring, as determined by the specific loads. The required current-rating of any
additional current protection is dependent on the load applied to the units connector J1 Pin 11.
All circuits connecting to the output Pin 11 should use current/load appropriate sized wire.
Refer to the Typical Installation Interconnect Diagrams (Figure 102 or Figure 103) for
additional information. See Specifications Table 3 for PS-835 current output information.
B. Retrofits
The older PS-823 Emergency Power Supply can be replaced by the PS-835. The PS-823, when
providing 115 Vac output, can be replaced with the PS-835/SI-100 combination to provide
115Vac output, also.
In cases where the previous PS-823 provided 26 Vdc output, add the Transformer (Figure 101,
Item 2 Avionics Systems part number 556-2006-01) to the PS-835/SI-100 combination. See
Figure 101, Item 3 for suggested Transformer location. Tap either phase A or C output leg
when using a SI-100A, 3 -phase Static Inverter.
Test-switch circuitry of the previous PS-823 setup must be altered as indicated below.
PS-823 (/T) Test PS-835 () Test

Comparison Switch Switch
2 EXT 28 Vdc
28 Vdc
2
Test Test
Lamp Lamp
6 6

Installation Manual
JET® Model PS-835
(* or Micro-semi P/N UES702)
Figure 102: Typical Installation Interconnections for PS-835A through D

Installation Manual
JET® Model PS-835
Figure 103: Typical Installation Interconnections for PS-835E and F

Installation Manual
JET® Model PS-835
*If an existing installation is being converted from a PS-823 to a PS-835

and a Transformer is required, remove wire from power supply mating
connector pin 4 and connect to transformer yellow lead.
Figure 104: Interconnections to AC Powered Indicators
Figure 105: Interconnections to DC Powered Indicators

Installation Manual
JET® Model PS-835
Figure 106: PS-835 Installation Drawing

Installation Manual
JET® Model PS-835
Pin Configuration for Models A, B, C, and D

Pin Configuration for Models E and F
Figure 107: PS-835 Pin Configurations

Installation Manual
JET® Model PS-835
Testing and Fault Isolation
1. General
This section of the manual provides preflight checks, periodic checks, annual capacity test, and cell
isolation test procedures to insure the satisfactory performance of the PS-835 Emergency Power
Supply.
NOTE: Read these procedures thoroughly before proceeding with any testing.
A. Battery Testing
NOTE: Test functions should be performed only with the main buss not providing power
to the unit (OFF of disconnected).
Toggling the unit TEST SWITCH (Figure 201, Item 4) on the power supply front panel
bypasses the thermostatic heat control system. That, in-turn, applies the battery voltage to the
internal battery heater. While in the TEST mode, the batteries are placed under an approximate
7.5Ω load. The voltage level detection system will then analyze the battery voltage level and
will cause the appropriate OUTPUT VOLTAGE MONITOR LED's (Figure 201, Item 2) to
illuminate.
NOTE: If the unit TEST SWITCH or Remote Test Switch is depressed at a battery
ambient temperature of 55°C or greater, the unit internal heater will not turn ON
to provide a test load for the unit battery. This is not an ideal condition for
battery state of charge tests and should not be considered valid.
If the remote test is being performed, the Remote Battery-Voltage Level Lamp will
momentarily illuminate, provided the internally loaded battery voltage level is greater than
24Vdc.
NOTE: After testing, it is possible that the lamp will not illuminate again until the
batteries are recharged.
B. The INDIVIDUAL CELL MONITOR LED's (Figure 201, Item 1) function as GO/NO GO
indicators for each of the PS-835 lead acid cells. In case of low output capacity, these LED's
will indicate which cell or cells have failed. Any variation of brightness does not indicate cell
condition.
C. Battery/Cell Out-Gassing
CAUTION: SOME OF THE TYPES OF GASSES THAT MAY VENT FROM A CELL ARE TOXIC AND
SHOULD NOT BE CONTAINED IN A CLOSED, NON-VENTED AREA.
CAUTION: CELL/BATTERY CORROSION IS EVIDENCE OF THE LOSS OF SEAL, LIKELY CAUSED BY

OUT GASSING. CELLS MUST BE REPLACED WHEN CORROSION IS APPARENT.
All lead-acid cells and batteries produce gasses during charging. The amount and type of gas
produced depends on state of charge, rate of charge, chemical composition of the electrolyte,
and general condition of the battery. Normally, gasses produced are recombined within the
cells to form oxides and water.
TP-336 Test and Fault Isolation - Page 201
Installation Manual
JET® Model PS-835
Venting occurs when excessive charge rates are placed on the battery or because of a defective
cell(s), which will subject the remaining good cells to excessive charge rates. Venting may also
result from battery abuse or neglect.
If the odor of rotten eggs becomes apparent in the cockpit, pull the aircraft Emergency Power
Supply circuit breaker. The rotten egg odor is evidence that the lead-acid cells vent due to
prolonged high rate overcharging. Although the possibility of toxic levels is extremely remote,
the precaution of pulling the circuit breaker will prevent increased discomfort from the odor.
Venting is an indication that the Power Supply in not controlling the charging process. If
venting occurs, the factory recommends that the Power Supply be removed from the
aircraft, and tested to identify and replace defective cell(s).
NOTE: With proper maintenance and periodic testing, the likelihood of any battery
developing undetected problems is very remote.
D. Recommended Test Equipment
Table 201 provides a list of recommended test equipment needed to accomplish the test listed in
this manual.
Item Description Characteristics/Vendor

1 DC Power Supply 0-30 Vdc 20amp capacity
Hewlett Packard Model 6291*
2 Digital Voltmeter (DVM) Fluke Model 8050A*
3 Load Resistor 7Ω ±1% 150 watt or greater *
(WireMasters, Inc. 136 Alpha Drive, Franklin,
TN 37064. Cage Code: 0FVD7)*
4 Stopwatch Meyland Corp. Model 202A*
*or equivalents
Table 201: Test Equipment and Fixtures

2. Charging Procedures
A. Constant-Voltage Charging Method
Locally manufacture a power cable using 16AWG wire and the appropriate mating connector.
Include a Diode (15 Adc (min), 50.0 PIV or greater) to prevent battery discharge in case of loss
of power from the power source.
MODEL MATES WITH CONNECTOR

PS-835A to D DPXB-13-33S-0001
PS-835E and F DPXB-13-33S-0019
Using the external power supply (Table 201, Item 1), apply 29.0 ± 0.5 Vdc (10A maximum
current limited) to J1 connector pins 11 (+) and 7 (-) and charge the unit for 16 hours. The
batteries should reach 80% capacity within 1 hour and full charge at 16 hours.
J1 pin 11 +
PS-835 (16AWG conductors)
Power Supply Power Supply
J1 pin 7 (ground)
_

Installation Manual
JET® Model PS-835
B. Constant-Voltage Float (trickle) Charging Method
Use the locally manufactured power cable, including the appropriate mating connector and
diode, to connect a regulated/constant voltage source (28.5 ± 0.5 Vdc) to the PS-835. This
method will provide a long-term constant voltage to maintain the fully charged condition of the
PS-835 unit when not in service, without any other maintenance action.
NOTE: The trickle charge method can be maintained indefinitely without damage to the
charging batteries.
C. BC-815 Battery Charger Method
Install the BC-815 Battery Charger (Avionics Systems part number 501-1321-01) into the PS-
835 Emergency Power Supply and charge for no-less-than 23 hours. Charge time depends upon
the batteries state-of-charge. Charging for 23 hours will essentially guarantee a full charge.
The BC-815 provides a constant charging current of either 0.5 A or 0.25 A, selectable by a
switch on the face of the unit. The AMBER LED illuminates when power is applied by placing
the ON / OFF switch to ON. When the unit being charged is within 90.0% of full charge, the
GREEN LED illuminates indicating that the BC-815 has automatically switched to the trickle
charge mode. The charger/battery combination may be operated in this mode indefinitely
without damage to the BC-815 or to the batteries being charged.
D. BC-815 Battery Float (trickle) Charging Method
Install the BC-815 Battery Charger (Avionics Systems part number 501-1321-01) into the PS-
835 Emergency Power Supply. This method will provide a long-term constant voltage to
maintain the fully charged condition of the PS-835 unit when not in service, without any other
maintenance action.
NOTE: The trickle charge method can be maintained indefinitely without damage to the
charging batteries.
3. Preflight Checks (Recommended)
NOTE: This check will indicate an accurate condition of the unit only upon the intial attempt.
Repeated checks will not reveal accuratly because stored energy is used each time the
TEST SWITCH is depressed.
A. Pre-Flight Check for Aircraft With Remote Test Capability
With no power applied to the PS-835 Emergency Power Supply, press and hold for 5 seconds
the cockpit remote TEST SWITCH in the TEST position. The remote test lamp must, at least,
momentarily illuminate to indicate that the Power Supply is adequately charged. If no
illumination of the remote test lamp is apparent for the period that switch is held, the
Emergency Power Supply is incapable of providing power in an emergency.
B. Pre-Flight Check for Aircraft With NO Remote Test Capability
Access the Emergency Power Supply. Perform the check as listed in paragraph 4, Periodic
Checks.

Installation Manual
JET® Model PS-835
4. Periodic Checks (Required 3 to 6 Months)
With no power applied to the PS-835 Emergency Power Supply, press TEST SWITCH (Figure 201,
Item 4) (or remote cockpit test switch) into TEST position for 5 seconds. The PS-835 indicates that
it is adequately charged when the VOLTAGE LEVEL 24Vdc LED (Figure 201, Item 2) (or remote
test indicator), at least, illuminates momentarily, AND the 20Vdc LED (Figure 201, Item 6) remains
lit during the test.
If the VOLTAGE LEVEL 24Vdc LED does not, at least, momentarily illuminate while the 20Vdc
LED is illuminated, the Emergency Power Supply is incapable of providing power in an emergency.
Proceed to Cell Isolation Test, Step 6.
1
2
6
3
Figure 201: PS-835 Access Panel

Installation Manual
JET® Model PS-835
5. Capacity Testing (Required Annually)
NOTE: The PS-835 Emergency Power Supply must have completed a full charge prior to any
discharge testing.
A. Press and hold TEST SWITCH (Figure 201, Item 4) and observe the OUTPUT VOLTAGE
MONITOR LED's (Figure 201, Item 2).
1) If the 24VDC OUTPUT VOLTAGE MONITOR LED comes on, proceed with either
Discharge Test procedures.
2) If OUTPUT VOLTAGE MONITOR LED's do not come on, check Fuse A1F1 (Figure 106)
and replace if blown. Perform step 6. Cell Isolation Test if fuse is not blown.
B. Preferred Discharge Test Method (Load Resistor)
1) Prepare for test by first constructing an X-Y graft similar to the one at Figure 4. If
possible, use pre-printed graft paper to create a record of the discharge period along the X-
axis and voltage readings along the Y-axis.
2) Position all INDIVIDUAL CELL DIP SWITCHES (Figure 201, Item 5) to the ON
position.
a. If the INDIVIDUAL CELL MONITOR LED DS12 (DS1 for models E and F) is the
only LED not illuminated, proceed to step 6. Cell Isolation Test.
3) Connect Digital Voltmeter (Table 201, Item 2) leads to J1 connector pins 11 (+) and 7 (-).
4) Connect the Load Resistor (Table 201, Item 3) across J1 connector pins 11 (+) and 7 (-)
and start timing the discharge period with the stopwatch(Table 201, Item 4) now.
5) Monitor and plot voltage values at 10-minute intervals.
6) At 48.0 minutes (Model’s B, D and F) and 20.0 minutes (Model’s A, C and E), note voltage
on Digital Voltmeter. This voltage must be greater than 20.0 Vdc.
a. All INDIVIDUAL CELL MONITOR LED’s (Figure 201, Item 1) must remain on.
b. Any LED that does go OFF will represent a defective individual cell, which must be
replaced.
7) Remove the Load Resistor from J1 connector pins 11 (+) and 7 (-).
8) Position all INDIVIDUAL CELL DIP SWITCHES (Figure 201, Item 5) to the OFF
position.
9) Compare the voltage vs. time plot created during this test to that of curve identified as
typical for the External Load test method on the chart in Figure 4.

Installation Manual
JET® Model PS-835
10) If the plot reveals a discharge curve that meets or exceeds the MINIMUM ACCEPTABLE
DISCHARGE CURVE, the unit is considered satisfactory.
11) If unit discharge plot is satisfactory and no other failures were revealed, perform either of
the Charging Procedures listed in Step 2 within 2 hours of completion of the discharge test.
Return the unit into service or storage as required.
6. Cell Isolation Test
NOTE: No power should be applied to PS-835 Emergency Power Supply during test.
A. Press and hold TEST SWITCH (Figure 201, Item 4). If no OUTPUT VOLTAGE MONITOR
LED's come on:
1) Position all INDIVIDUAL CELL DIP SWITCHES (Figure 201, Item 4) to the ON
position.
2) Press and hold TEST SWITCH (Figure 201, Item 4) and observe the INDIVIDUAL CELL
MONITOR LED's (Figure 201, Item 1).
a. If all INDIVIDUAL CELL MONITOR LED’s come on except DS12, the unit is
damaged and requires repair at an authorized repair station.
b. If all INDIVIDUAL CELL MONITOR LED’s are on, there exist a low-battery voltage
condition. Perform the Charging Procedures of Step 2.


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Emergency Power Supply

JET® Model PS-835

L-3 Communications Avionics Systems

L-3 Communications Avionics Systems

L-3 Communications Avionics Systems

© Copyright 2004, 2005, 2006

TP-336 Front Section - Page A

List of Effective Pages

Dates of original and changed pages are:

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

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

Section Page No.

TP-336 Front Section - Page i

TP-336 Front Section - Page ii

Testing and Fault Isolation

TP-336 Front Section - Page iii

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

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

TP-336 Front Section - Page iv

TP-336 Front Section - Page v

This page intentionally left blank.

TP-336 Front Section - Page vi

Model Number Part Number

TP-336 Description - Page 1

D. Battery Voltage Level Detection

5. Continued Airworthiness (Maintenance)

TP-336 Description - Page 2

Modification Kits and

TP-336 Description - Page 3

Modification Kits and

Table 1: Service Bulletins and Modifications (Cont.)

TP-336 Description - Page 4

7. Environmental Test Qualifications

Name of Test Qualified to DO-160A elements:

Table 2: Environmental Qualifications

TP-336 Description - Page 5

Figure 1: PS-835 Emergency Power Supply

1 Individual Cell Monitor LED's

TP-336 Description - Page 6

Weight Model A, C, E - 8 lbs. [3.65Kg]

Output 24 Vdc nominal, 10 Amp max. steady state

Dimensions See Figure 106 and 107 PS-835( ) Installation Drawing

Operating -55°C to 70°C

Altitude Sea level to 55,000 ft. at 25°C

Mating Model A, B, C, D- DPXB-13-33S-0001 (Avionics Systems PN S24140-01)

9. Charge and Discharge Performance

A. General Battery and Cell Information

TP-336 Description - Page 7

CAUTION: CELL/BATTERY CORROSION IS EVIDENCE OF THE LOSS OF SEAL, LIKELY CAUSED BY

TP-336 Description - Page 8

C. Storage Time and Temperature

NOTE: Avionics Systems Service Letter SL-64( ) contains additional information on

Figure 2: Cell Storage Time vs. Temperature

TP-336 Description - Page 9

D. Cell Current Discharge Time

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

TP-336 Description - Page 10

E. Cell Voltage Discharge Time

Figure 4: PS-835( ) Discharge Curves