Transmittal Letter: TO: Holders of Component Maintenance Manual 25-60-03, Revision 15

RADIANT POWER CORP.
COMPONENT MAINTENANCE MANUAL

PART NUMBER RPS1-B
TRANSMITTAL LETTER
TO: HOLDERS OF COMPONENT MAINTENANCE MANUAL 25-60-03, REVISION 15
REVISION NO. 16, DATED AUGUST 2009
HIGHLIGHTS
The pages that have been added or revised are outlined below together with the highlights of the
revision.
CHAPTER/SECTION AND WAS IS NOW

PAGE NO.
Page T-1 6416 Parkland Dr. Suite B 7135 16th Street, Suite 101
Page RR-1 Added: 16 Aug 2009
Page LEP-1 T-1 Jul 2007 T-1 Aug 2009
RR-1 Jul 2007 RR-1 Aug 2009
LEP-1 Jul 2007 LEP-1 Aug 2009
Intro-1 Jul 2006 Intro-1 Aug 2009
Page Intro-1 6416 Parkland Dr. Suite B 7135 16th Street, Suite 101
Entire Document Old Logo New Logo
Highlights-1
Copyright 2004 by: Radiant Power Corp., a HEICO Company 25-60-03 Aug 2009
RADIANT POWER CORP.
PART NUMBER RPS1-B
THIS PAGE INTENTIONALLY LEFT BLANK
Highlights-2
RADIANT POWER CORP.
PART NUMBER RPS1-B
RADIANT POWER CORP.

7135 16th STREET. SUITE 101
SARASOTA, FL 34243
(FORMERLY DERLAN INC.)
Component Maintenance Manual

With
Illustrated Parts List
Battery
Power Supply
Part Number: RPS1-B
THIS MANUAL CONTAINS PROPRIETARY INFORMATION OF RADIANT POWER

CORP., AND IS TENDERED SUBJECT TO THE CONDITION THAT NO COPY OR
OTHER REPRODUTION BE MADE IN WHOLE OR IN PART, AND THAT NO OTHER
USE BE MADE OF SUCH INFORMATION WITHOUT EXPRESS WRITTEN PERMISSION
REVISION 16
OF RADIANT POWER CORP.
T-1
RADIANT POWER CORP.
PART NUMBER RPS1-B
T-2
RADIANT POWER CORP.
PART NUMBER RPS1-B
RECORD OF REVISIONS
REVISION REVISION DATE BY REVISION REVISION DATE BY

NUMBER DATE FILED NUMBER DATE FILED
1 Mar 1/87
2 Feb 12/88
3 Jan 2/90
4 Feb 1/94
5 Feb 1/97
6 Oct 15/97
7 Feb 1/00
8 Dec 18/00
9 Sep 26/02
10 Jan 2003
11 Jan 2004
12 Mar 2006
13 Jun 2006
14 Jul 2006
15 Jul 2007
16 Aug 2009
Page RR-1
RADIANT POWER CORP.
PART NUMBER RPS1-B
Page RR-2
RADIANT POWER CORP.
PART NUMBER RPS1-B
RECORD OF TEMPORARY REVISIONS
REVISION REVISION DATE BY REVISION REVISION DATE BY

NUMBER DATE FILED NUMBER DATE FILED
Page TR-1
RADIANT POWER CORP.
PART NUMBER RPS1-B
Page TR-2
RADIANT POWER CORP.
PART NUMBER RPS1-B
SERVICE BULLETIN LIST
SERVICE ISSUE DATE BY SERVICE ISSUE DATE BY

BULLETIN DATE FILED BULLETIN DATE FILED
SB-004 OCT 24/86 JAN 20/87 DERLAN
RPS1-B-33 NOV 24/86 JAN 20/87 DERLAN
Page SB-1
RADIANT POWER CORP.
PART NUMBER RPS1-B
Page SB-2
RADIANT POWER CORP.
PART NUMBER RPS1-B
LIST OF EFFECTIVE PAGES

Subject Page Date Subject Page Date
Title Page T-1 Aug 2009 Testing and Fault 101 Aug 2009
T-2 Aug 2009 Isolation 102 Aug 2009
103 Aug 2009
Record of Revisions RR-1 Aug 2009 104 Aug 2009
RR-2 Aug 2009 105 Aug 2009
106 Aug 2009
Record of Temporary TR-1 Aug 2009 107 Aug 2009
Revisions TR-2 Aug 2009 108 Aug 2009
109 Aug 2009
110 Aug 2009
Service Bulletin List SB-1 Aug 2009 111 Aug 2009
SB-2 Aug 2009 112 Aug 2009
113 Aug 2009
List of Effective Pages LEP-1 Aug 2009 114 Aug 2009
LEP-2 Aug 2009 115 Aug 2009
116 Aug 2009
Table of Contents TC-1 Aug 2009 117 Aug 2009
TC-2 Aug 2009 118 Aug 2009
119 Aug 2009
Introduction Intro-1 Aug 2009 120 Aug 2009
Intro-2 Aug 2009 121 Aug 2009
Intro-3 Aug 2009 122 Aug 2009
Intro-4 Aug 2009 123 Aug 2009
124 Aug 2009
Description and 1 Aug 2009
Operation 2 Aug 2009 Disassembly 301 Aug 2009
3 Aug 2009 302 Aug 2009
4 Aug 2009 303 Aug 2009
5 Aug 2009 304 Aug 2009
6 Aug 2009 305 Aug 2009
7 Aug 2009 306 Aug 2009
8 Aug 2009 307 Aug 2009
9 Aug 2009 308 Aug 2009
10 Aug 2009
11 Aug 2009 Cleaning 401 Aug 2009
12 Aug 2009 402 Aug 2009
13 Aug 2009
14 Aug 2009 Check 501 Aug 2009
15 Aug 2009 502 Aug 2009
16 Aug 2009 503 Aug 2009
17 Aug 2009 504 Aug 2009
18 Aug 2009
19 Aug 2009 Repair 601 Aug 2009
20 Aug 2009 602 Aug 2009
21 Aug 2009 603 Aug 2009
22 Aug 2009 604 Aug 2009
23 Aug 2009 605 Aug 2009
24 Aug 2009 606 Aug 2009
607 Aug 2009
608 Aug 2009
Page LEP-1
RADIANT POWER CORP.
PART NUMBER RPS1-B
Subject Page Date Subject Page Date
Assembly (including 701 Aug 2009

Storage) 702 Aug 2009
703 Aug 2009
704 Aug 2009
705 Aug 2009
706 Aug 2009
707 Aug 2009
708 Aug 2009
709 Aug 2009
710 Aug 2009
711 Aug 2009
712 Aug 2009
713 Aug 2009
714 Aug 2009
Special Tools, Fixtures, 901 Aug 2009

and Equipment 902 Aug 2009
Illustrated Parts List 1001 Aug 2009

1002 Aug 2009
1003 Aug 2009
1004 Aug 2009
1005 Aug 2009
1006 Aug 2009
1007 Aug 2009
1008 Aug 2009
1009 Aug 2009
1010 Aug 2009
1011 Aug 2009
1012 Aug 2009
1013 Aug 2009
1014 Aug 2009
1015 Aug 2009
1016 Aug 2009
1017 Aug 2009
1018 Aug 2009
1019 Aug 2009
1020 Aug 2009
Page LEP-2
RADIANT POWER CORP.
PART NUMBER RPS1-B
TABLE OF CONTENTS
Subject Page
Description and Operation 1

Testing and Fault Isolation 101
Automatic Test Requirements Not Applicable
Disassembly 301
Cleaning 401
Check 501
Repair 601
Assembly (Including Storage) 701
Fits and Clearances Not Applicable
Special Tools, Fixtures, and Equipment 901
Illustrated Parts List 1001
LIST OF FIGURES
Figure Page
1 Battery Power Supply 3

2 General Aircraft Interface Diagram 5
3 Circuit Schematic 6
4 Aircraft-Specific Jumper and Operation Truth Table 10
101 Bench Test Setup 108
102 Fuse Location 109
103 Fuse Bending 110
104 Battery Discharge 119
105 Battery Charge 120
106 Battery Housing Analyzer 121
601 Clinch Nut Installation 606
701 Resistor R1/R2 Wiring Diagram 704
702 Battery Connection Diagram 708
IPL 1 Battery Power Supply 1008
IPL 2 Electronics Assembly 1014
IPL 3 Regulator PCB Assembly A2 1018
LIST OF TABLES
Table Page
1 Technical Properties 9
101 Test Equipment and Materials 101
102 Control Logic Test Requirements 107
103 Fault Isolation Procedures 111
301 Disassembly Materials 303
401 Cleaning Materials 401
501 Check Procedures 501
601 Repair Tools and Materials 603
602 Connect J1 Wire List 606
Page TC-1
RADIANT POWER CORP.
PART NUMBER RPS1-B
LIST OF TABLES
Figure Page
701 Assembly Tools and Materials 713

702 Storage Materials 713
703 Assembly Wire List 714
901 Special Tools, Fixtures, and Equipment 901
1001 Manufacturer Names and Addresses 1002
EQUIPMENT DESIGNATOR INDEX 1005
NUMERICAL INDEX 1006
PARTS LIST 1011
PARTS LIST 1015
PARTS LIST 1019
Page TC-2
RADIANT POWER CORP.
PART NUMBER RPS1-B
INTRODUCTION
1. Scope
This Component Maintenance Manual (CMM) contains maintenance instructions and lists
replacement parts to assist qualified repair personnel in off-aircraft maintenance of Battery
Power Supply, (BPS) part number RPS1-B. The BPS is made by Radiant Power Corp. of
Sarasota, Florida.
NOTE: This CMM covers maintenance of the RPS1-B configuration only. Contact Radiant
Power Corp. for maintenance of the earlier configurations given below:
Part Number Serial Numbers

RPS1 0001 through 0016
RPS1-A 0017 through 0052
Two electrically identical but physically different logic PCB assemblies are used in the
RPS1-B configuration depending on the serial number. Both variations are covered in
this CMM.
Part Number Serial Numbers IPL Figure-item Number
11-0041-1 0626 and subsequent 2-15

11-0041-2 0053 through 0625 2-15A
2. Product Support Services
Repair and overhaul services, replacement parts, technical documentation, and other product
support services are available from Radiant Power Corp. Please contact our Sales
Department at:
Radiant Power Corp. Telephone: (941) 739-3200

7135 16th Street. Suite 101 FAX: (941) 739-3201
Sarasota, FL. 34243
USA
3. Usage Guide
A. Refer to the Table of Contents to find the necessary maintenance procedures or other
data. This CMM is written to ATA 100, Revision 30 and AECMA Simplified English.
(1) Description and Operation describes the purpose, primary components, and
technical properties of the BPS battery pack.
(2) Testing and Fault Isolation contains bench test and fault isolation procedures.
(3) Disassembly contains procedures to disassemble the BPS battery pack for repair or
part replacement.
(4) Cleaning contains procedures to clean the BPS battery pack.
Page Intro-1
RADIANT POWER CORP.
PART NUMBER RPS1-B
(5) Check contains procedures to check parts for damage.
(6) Repair contains procedures to refinish and rework parts to serviceable condition.
(7) Assembly contains procedures to reassemble and store the BPS battery pack.
(8) Illustrated Parts List contains the information necessary to order replacement
parts. An equipment designator index, a numerical index, and exploded-view
drawings are provided to help find and identify the parts. The introduction to the IPL
gives more data.
B. The recommended tools and materials are given in each section. Equivalent items can
be used.
C. WARNINGS, CAUTIONS and NOTES
(1) WARNINGS are provided before potentially dangerous procedures, materials,

methods, and processes which must be followed precisely to avoid injury.
(2) CAUTIONS are provided before procedures, materials, methods, and processes
which must be followed precisely to avoid equipment damage.
(3) NOTES are provided after applicable procedure steps when necessary to highlight
or clarify information.
4. General Safety Precautions
The following general safety precautions must be observed during all phases of operation,
service, and repair of the battery/pack.
ELECTROSTATIC DISCHARGE All Integrated Circuits (ICs), surface mounted devices,

and many semiconductors are susceptible to Electrostatic
Discharge (ESD). Careless handling during repair can
drastically decrease the component life.
Follow the PCB handling procedures given in REPAIR to

avoid ESD damage.
GROUNDING Connect equipment and personnel to electrical ground to
minimize shock hazards. When handling PCB
assemblies, place them on a grounded workbench.
EXPLOSIVE ENVIRONMENT Do not operate the battery/ pack in the presence of
flammable gas or fumes.
LIVE CIRCUITS The battery/ pack contains high voltage electrical circuits.
Do not service the unit with the power on. To avoid injury,
always disconnect power and discharge the circuits
before maintenance.
Page Intro-2
RADIANT POWER CORP.
PART NUMBER RPS1-B
DO NOT SERVICE OR ADJUST Only qualified maintenance personnel are authorized to

ALONE replace or adjust internal components of the battery/ pack.
Maintenance personnel must be familiar with high voltage
equipment safety guidelines. Another person capable of
providing first aid and resuscitation must be present.
DO NOT SUBSTITUTE PARTS Do not alter or add to the mechanical or electrical design
OR MODIFY EQUIPMENT of the battery/ pack. Design changes and additions can
alter safety characteristics and create a hazard. Any
design alterations or additions will void the warranty. Do
not install substitute parts or do any unauthorized
modifications to the equipment.
SHOCK To prevent electrical discharge, do not expose the
equipment to rain or high humidity.
Visually check for pinched, out of place, or frayed wiring

during maintenance. Components and/or wiring that
appear to have overheated or are otherwise damaged
should be replaced with components that meet the
original specifications.
Do a safety check of the entire unit before returning the

equipment for operation.
5. Verification Dates
Procedure Date
Testing/Fault Isolation Jan 15/87
Disassembly Jan 15/87
Assembly Jan 15/87
6. Revision Service
Revised pages will be issued when necessary to correct errors or to add new configurations.
The revised part of the page will be identified by a change bar or capital R in the left margin.
Page Intro-3
RADIANT POWER CORP.
PART NUMBER RPS1-B
7. Abbreviations and Unit Symbols
Abbreviations and unit symbols used in this manual are defined below. All weights and
measurements are given first in English standard units followed by the metric equivalent in
parentheses.
Assy Assembly kPag kiloPascal - gage

ATA Air Transport Association (1 kPag 0. 145 psig)
AWG American Wire Gage lb. pound
BPS Battery Power Supply LRU Line Replaceable Unit
C degree Celsius M Mega
C Capacitor MEK Methyl-Ethyl-Ketone
CAGE Commercial And Government mm Millimeter
Entity N-m Newton-meter (torque)
cm centimeter NHA Next Higher Assembly
CMM Component Maintenance NIST National Institute of Standards
Manual and Technology
D Diode No. Number
DC Direct Current PCB Printed Circuit Board
EFF Effectivity P/N Part Number
ESD Electrostatic Discharge psig pounds per square inch - gage
F Farad Q Transistor
F Fuse R Resistor
F degree Fahrenheit RF Reference
GND Ground SB Service Bulletin
Fig. Figure SCD Source Control Drawing
Hz Hertz SIT Select In Test
IC Integrated Circuit SPST Single Pole, Single Throw
IPL Illustrated Parts List SW Switch
J Jack UUT Unit Under Test
K Kilo V Vendor
kg kilogram (1 kg = 2.205 lb.) VDC Voltage, Direct Current
W Watt
Page Intro-4
RADIANT POWER CORP.
PART NUMBER RPS1-B
DESCRIPTION AND OPERATION
1. Purpose
The Battery Power Supply (BPS) provides direct current (DC) power to operate the escape
track lights.
2. Primary Components
A. The primary components of the BPS are shown in Figure 1.
B. The BPS consists of a battery holder assembly and an electronics assembly mounted on
an aluminum chassis. The battery holder assembly and the electronics assembly are
separate, fully contained modules that can be independently removed for repair or
replacement.
C. The battery holder assembly consists of six nickel-cadmium batteries mounted in a

lightweight, durable plastic case. The batteries are wired in series and connected to red
and black pin sockets J2-1 and J2-2. The pin sockets connect directly to pin contacts
J3-1 and J3-2 on regulator PCB assembly A2 when the battery holder assembly is
installed in the chassis against the electronics assembly. The battery holder assembly
can easily be removed by disengaging two 1/4-turn fasteners and sliding the assembly
out of the chassis away from the electronics assembly.
D. The electronics assembly is made up of logic PCB assembly A1, regulator PCB
assembly A2, connector J1, resistors R1 and R2, TEST switch SW1, and transistors Q1
and Q2. A cover assembly provides protection from moisture and handling damage. All
electronic components including the solder connections are conformal coated. The cover
can easily be removed for maintenance access. The electronics assembly can also be
removed from the chassis by removing the mounting screws and sliding the assembly out
of the chassis away from the battery holder assembly.
E. All components except the battery holder assembly are secured by standard attaching
hardware. All wire connections are soldered or crimp. The chassis cover assembly and
other exposed aluminum components have a chemical film finish for protection from
corrosion.
F. A single 24-pin BACC45FN16-24P or 48-10-R16-24P (Amphenol) electrical connector

provides the electrical interface with the aircraft. The connector mates to a
BACC45FN16-24S receptacle. The interface circuits are described in Figures 2 through 4
and Table 2.
G. The BPS is a Line Replaceable Unit (LRU). It mounts against a flat surface with fasteners
through the four 0.192/0.203 inch (4.88/5.16 mm) diameter mounting holes in the
chassis. It can be removed and replaced on the aircraft in less than 1 minute without the
use of special tools.
Page 1
RADIANT POWER CORP.
PART NUMBER RPS1-B
3. Differences Between Configurations
This CMM covers maintenance of the RPS1-B configuration only. Contact Radiant Power
Corp. for maintenance of the earlier configurations given below:

Two electrically identical but physically different logic PCB assemblies are used in the
RPS1 –B configuration depending on the serial number. Logic variations are covered in this
CMM.

11-0041-1 0626 and subsequent 2-15
11-0041-2 0053 through 0625 2-15A
4. Functional Description (Figures 2 and 3)
A. The BPS provides DC power to operate the escape track lights. It charges and maintains
the battery holder assembly and outputs 5.7 to 6.7 VDC at connector J1, pins 9, 10 and
11, depending on the presence or absence of 28 VDC at connector J1, pin 2, the jumper
configuration of the mating connector, and the status of pins 3, 4, 8, 12, 17, 18 and 24
(open, ground, or +28 VDC).
B. When 22 to 32 VDC from the aircraft electrical system is present at connector J1, pin 2,
transistor Q1 and charging circuits on regulator PCB assembly A2 provide 300 to 375
milliamperes constant charging current to the six-cell battery pack.
C. Pushing TEST switch SW1 mounted on the BPS will turn on the escape track lights. The
test switch is provided to confirm circuit continuity, the condition of the escape track
lights, and function of the BPS. It does not assure adequate battery capacity in an
emergency.
D. The logic circuits on logic PCB assembly A1 include a low battery cutoff circuit and a
slow turn-on feature. The low battery cutoff circuit senses battery voltage and
automatically turns the BPS off when the voltage drops to 4.8 VDC minimum (5.4 VDC
nominal). This avoids deep discharging of the batteries, a condition that can result in cell
reversal and permanent battery damage.
E. The slow turn-on circuit made up of resistor/capacitor combinations at the input of

comparator U1 ramp-up the turn-on signal from the logic circuits to the regulator circuits.
This limits the lamp inrush current to prolong the life of the escape track lights.
F. The regulator circuits on regulator PCB assembly A2 maintain the output voltage across
the escape track lights to between 5.7 and 6.7 VDC at a load of 7.0 Amperes. This is
accomplished by comparing the output voltage sensed at the collector of transistor Q2 to
the 2.5 VDC turn-on signal from the logic circuits. The resultant error signal is then
amplified and used to drive regulator output transistor Q3. Excessive current through
drive transistor Q3 will cause transistor Q6 to conduct, decreasing the reference voltage
and the excessive current.
Page 2
RADIANT POWER CORP.
PART NUMBER RPS1-B
G. The batteries are high temperature, matched D-size nickel-cadmium cells with higher
voltage electrolyte and lower internal resistance than normally available. Each cell is
rated 1.25 VDC at 149°F (65°C) and 4 ampere-hours (minimum) when discharged at the
one hour or C rate. The cells are connected in series by solder tabs, forming a 7.5 VDC
(nominal) battery. The battery pack provides sufficient power to sustain, through the
control circuits, a 7 Ampere lamp load at 5.7 to 6.7 VDC for a minimum of 10 minutes.
Under worst case conditions, the BPS has enough battery capacity to meet the
requirements of FAR 25.812 .Paragraph (i) [emergency illuminate system].
H. Fuses F1 through F3 limit the output voltage at pins 9 through 11 of connector

J1 to 5 Amperes.
5. Operation
A. To charge the BPS, continuously apply 22 to 32 VDC (28 VDC nominal) voltage across
pins 2(+) and 1(-) and jumper pin 5 to pin 6 of connector J1. A fully discharged battery
pack will charge from 0% of full capacity to 100% in less than 16 hours at 77°F (25°C).
NOTE: Figure 2 gives a general aircraft interface diagram for the BPS. Refer to Figure 4 for
aircraft-specific jumper configuration data and operation truth tables.
Battery Power Supply

Figure 1
Page 3
RADIANT POWER CORP.
PART NUMBER RPS1-B
B. Set the pilot/attendant aircraft switches to the proper positions for the aircraft type to
discharge the BPS. The BPS will output 5.7 to 6.7 VDC at connector J1, pins 9, 10 and
11, depending on the presence or absence of 28 VDC at connector J1, pin 2, the jumper
configuration of the mating connector, and the status of pins 3, 4, 8, 12, 17, 18 and 24
(open, ground, or +28 VDC). Refer to Figure 4.
C. Push TEST switch SW1 on the BPS to turn on the escape track lights. A successful test
will indicate that the BPS is functioning properly and is connected correctly in the circuit,
and the escape track lights are functioning properly. The test will also show that the BPS
is charged sufficiently to turn on the lights, but it will not show adequate battery capacity
for the 10 minutes duration requirements of FAR 25.812.
6. Technical Properties
Technical properties of the BPS are given in Table 1.
7. Truth Tables and Jumper Connections
Refer to Figure 4 for aircraft-specific jumper configuration data and operation truth tables.
Figure 2 gives a general aircraft interface diagram.
Page 4
RADIANT POWER CORP.
PART NUMBER RPS1-B
General Aircraft Interface Diagram

Figure 2
Page 5
RADIANT POWER CORP.
PART NUMBER RPS1-B
Circuit Schematic
Figure 3 (Sheet 1 of 3)
Page 6
RADIANT POWER CORP.
PART NUMBER RPS1-B
Circuit Schematic
Page 7
RADIANT POWER CORP.
PART NUMBER RPS1-B
Circuit Schematic
Page 8
RADIANT POWER CORP.
PART NUMBER RPS1-B
Technical Properties
Table 1
Property Specification
Description
Manufacturer Radiant Power Corp.
Nomenclature Battery Power Supply (BPS)
Part Number
Radiant Power Corp. RPS1-B
Functional Properties
Input Power 22.0 to 29.5 VDC (28 VDC nominal)
Output Power
Voltage
Escape Track Lights 5.7 to 6.7 VDC for 15 minutes
Full Charge Battery Voltage 7.5 VDC nominal
Low Battery Cutoff Voltage 4.8 VDC minimum (5.4 VDC nominal)
Current
Output Limited to 5 Amperes by Fuses F1, F2 and F3(40 or
40A)
Charging 300 to 375 milliamperes at 22 to 32 VDC input
voltage
Charging Time Charge from 0% of full capacity to 100% in less than 16
hours at 77°F (25°C)
Battery Pack Data
Number of Batteries 6 connected in series
Battery Type Nickel-Cadmium
Rating 4 ampere-hours
Fully-Charged Voltage 1.25 VDC at 149°F (65°C)
Insulation Resistance 100 megohms minimum at 500 VDC
Removal and Replacement Time 1 minutes maximum with no special tools
Electrical Connector BACC45FT16-24P or 48-10-R16-24P
(Amphenol)
Mating Connector BACC45FT16-24S
Dimensions and Weight
Overall Dimensions
Height 2.0 inches (5.1 cm) maximum
Width
Overall 3.5 inches (8.9 cm) maximum
Between Mounting Hole Centerlines 2.700 ±0.010 inches (6.858 ±0.025 cm)
2.600 ±0.010 inches (6.604 ±0.025 cm)
Length
Overall 11.0 inches (27.9 cm) maximum
Between Mounting Hole Centerlines 10.100 ±0.010 inches (25.654 ±0.025 cm)
10.020 ±0.010 inches (25.451 ±0.025 cm)
Diameter of Mounting Holes (4 Places) 0. 1975 ±0.0055 inch (5.0165 ±0.1397mm)
Weight
Battery Holder Assembly 2.3 lbs (1.0 kg) maximum
Battery Charger Assembly 1.0 lbs (0.5 kg) maximum
3.3 lbs (1.5 kg) maximum
Page 9
RADIANT POWER CORP.
PART NUMBER RPS1-B
BOEING 727/737
AIRCRAFT
INTERCONNECT
CHART
BPS Connector Aircraft Connector Pin for Jumper

Pin (J1-) Emergency Packs Wires
1 Pin 1 (28 VDC Return) Pin 1 to Pins 12,17 and 18
2 Pin 2 (+28 VDC Essential Pin 5 to Pin 6

Buss)
3 Pin 3 Pin 13 to Pin 21
7 Aircraft Ground Pin 15 to Pin 16
9 Output (Load) Pin 19 to Pin 23
10 Output (Load)
11 Output (Load)
OPERATION
TRUTH TABLE
Pin J1-2 Voltage Pin J1-3 Pin J1-4 Lights Pilot Switch Attendant Switch
(Input Power) Status Status Status Position Position
+28 VDC OPEN +28 VDC OFF OFF NORMAL
0 VDC OPEN +28 VDC OFF OFF NORMAL
+28 VDC +28 VDC OPEN OFF ARMED NORMAL
0 VDC +28 VDC OPEN ON ARMED NORMAL
0 VDC +28 VDC OPEN ON ON NORMAL
0 VDC +28 VDC +28 VDC ON OFF ON
Aircraft-Specific Jumper and Operation Truth Table

Page 10
RADIANT POWER CORP.
PART NUMBER RPS1-B
INTERCONNECT
CHART

1 Pin 5 (28 VDC Return) Pin 1 to Pins 18

Buss)
10 Output (Load)
11 Output (Load)
OPERATION
TRUTH TABLE
Pin J1-2 Voltage Pin J1-3 Pin J1-4 Lights

(Input Power) Status Status Status
0 VDC GROUND GROUND OFF
+28 VDC GROUND GROUND OFF
0 VDC OPEN GROUND ON
+28 VDC OPEN GROUND ON
0 VDC GROUND OPEN ON
+28 VDC GROUND OPEN OFF
0 VDC OPEN OPEN ON
+28 VDC OPEN OPEN OFF

Page 11
RADIANT POWER CORP.
PART NUMBER RPS1-B
BAC 111
AIRCRAFT
INTERCONNECT
CHART

1 Pin 5 (28 VDC Return) Pin 1 to Pins 12, 17 and 18

Buss)
9 Output (Load)
10 Output (Load)
11 Output (Load)
OPERATION
TRUTH TABLE
OPEN OPEN +28 VDC OFF OFF NORMAL
OPEN +28 VDC OPEN ON OFF ON
OPEN +28 VDC OPEN ON ARMED NORMAL
OPEN +28 VDC OPEN ON ARMED ON
+28 VDC +28 VDC OPEN OFF ARMED NORMAL
OPEN 0 VDC OPEN ON ARMED ON
OPEN +28 VDC OPEN ON ON NORMAL
OPEN +28 VDC OPEN ON ON ON
OPEN +28 VDC OPEN ON ON NORMAL
OPEN +28 VDC OPEN ON ON ON
+28 VDC* OPEN +28 VDC OFF OFF NORMAL
OPEN +28 VDC OPEN ON OFF ON
* IN THIS CONDITION, REMOVE VOLTAGE FROM PIN 2 THEN PIN 4. THE

LIGHTS SHOULD REMAIN EXTINGUISHED (PARKED AIRCRAFT).

Page 12
RADIANT POWER CORP.
PART NUMBER RPS1-B
YS-11A
AIRCRAFT
INTERCONNECT
CHART

1 Pin 5 (28 VDC Return) Pin 1 to Pins 17 and 18
9 Output (Load)
10 Output (Load)
11 Output (Load)
24 Pins 2 and 3
OPERATION
TRUTH TABLE
Pin J1-4 Pin J1-24 Lights Pilot Switch Attendant Switch

Status Status Status Position Position
+28 VDC 0 VDC OFF OFF OFF
0 VDC +28 VDC OFF ARMED ON
0 VDC 0 VDC ON ARMED ON
0 VDC 0 VDC OFF OFF OFF

Page 13
RADIANT POWER CORP.
PART NUMBER RPS1-B
DC-8
AIRCRAFT
INTERCONNECT
CHART

2 Pin 8 (+28 VDC Essential Buss) Pin 2 to Pin 4
11 Output (Load)
24 Pins 10
OPERATION
TRUTH TABLE
Pin J1-2 Voltage Pin J1-3 Pin J1-24 Lights Aircraft Switch
(Input Power) Status Status Status Position
+28 VDC 0 VDC 0 VDC OFF OFF
0 VDC +28 VDC +28 VDC OFF ARMED
0 VDC +28 VDC 0 VDC ON ON
0 VDC 0 VDC 0 VDC OFF OFF (PARKED AIRCRAFT)

Page 14
RADIANT POWER CORP.
PART NUMBER RPS1-B
DC-9
AIRCRAFT
INTERCONNECT
CHART

2 Pin 4 (+28 VDC Essential Buss) Pin 5 to Pin 6
9 Output (Load)
10 Output (Load)
11 Output (Load)
24 Pins 7
OPERATION
TRUTH TABLE
Condition* (Input Power) Status Status Status Position
1 +28 VDC +28 VDC OPEN OFF OFF
2 OPEN OPEN +28 VDC OFF ARMED
3 OPEN OPEN OPEN ON ARMED
4 OPEN OPEN OPEN ON ON
* TO PARK THE AIRCRAFT, GO TO CONDITION 1 AND OPEN VOLTAGE

ON PIN 2 BEFORE PIN 4. THE LIGHTS WILL REMAIN OFF.

Page 15
RADIANT POWER CORP.
PART NUMBER RPS1-B
DC-10
AIRCRAFT
INTERCONNECT
CHART

1 Pin T (28 VDC Return) Pin 1 to Pins 12 and 17
2 Pin K (+28 VDC Essential Buss) Pin 3 to Pin 16
3 Pin U Pin 5 to Pin 6
4 Pin V Pin 19 to Pin 21
7 Pin G (Aircraft Ground) Pin 22 to Pin 23
9 Output (Load)
10 Output (Load)
11 Output (Load)
18 Pin E
OPERATION
TRUTH TABLE
Pin J1-2 Pin J1-3 Pin J1-4 Pin J1-18 Lights Pilot Switch
Step Voltage Status Position Remarks
Status Status Status
1 +28 VDC OPEN +28 VDC GROUND OFF OFF
2* 0 VDC OPEN +28 VDC GROUND OFF OFF
3 0 VDC OPEN OPEN GROUND OFF OFF Parked Aircraft
4 +28 VDC +28 VDC OPEN GROUND OFF ARMED
5 0 VDC +28 VDC OPEN GROUND ON ARMED Power Failure
6 0 VDC OPEN OPEN GROUND ON ARMED Cabin Switch
7 OPEN ON ON ON
* TO PARK THE AIRCRAFT, DO STEP 2 THEN STEP 3.

Page 16
RADIANT POWER CORP.
PART NUMBER RPS1-B
A-300
AIRCRAFT
INTERCONNECT
CHART

1 Pin E (28 VDC Return) Pin 1 to Pin 18
2 Pin B (+28 VDC Essential Buss) Pin 5 to Pin 6
4 Pin D Pin 14 to Pins 20 and 23
10 Output (Load)
11 Output (Load)
OPERATION
TRUTH TABLE
Pin J1-2 Voltage Pin J1-4 Lights Aircraft Switch

(Input Power) Status Status Position
0 VDC GROUND OFF OFF
+28 VDC GROUND OFF OFF
+28 VDC OPEN OFF ARMED
0 VDC OPEN ON ARMED
0 VDC OPEN ON ON

Page 17
RADIANT POWER CORP.
PART NUMBER RPS1-B
A-310
AIRCRAFT
INTERCONNECT
CHART

1 Ground (DC Return) Pin 5 to Pin 6
2 Pin V Pin 13 to Pins 14 and 23
3 Pin B Pin 15 to Pin 16
4 Pin A Pin 18 to Pin 20
9 Output (Load)
10 Output (Load)
11 Output (Load)
-(N/C) Pin D
OPERATION
TRUTH TABLE
+28 VDC OPEN OPEN OFF OFF OFF
+28 VDC OPEN GROUND ON OFF ON
+28 VDC GROUND OPEN OFF ARMED OFF

GROUND
0 VDC GROUND OPEN ON ARMED OFF
+28 VDC GROUND ON ON OFF

Page 18
RADIANT POWER CORP.
PART NUMBER RPS1-B
BAe-146
AIRCRAFT
INTERCONNECT
CHART

1 28 VDC Return Pin 1 to Pins 12 and 17
2 Pin C (+28 VDC Essential Buss) Pin 2 to Pin 4
11 Output (Load)
24 Pin B
OPERATION
TRUTH TABLE
Pin J1-2 Voltage Pin J1-3 Pin J1-24 Lights Attendant Switch
0 VDC 0 VDC 0 VDC OFF AIRCRAFT OFF LATCHED
0 VDC 0 VDC +28 VDC OFF ARMED
0 VDC 0 VDC 0 VDC ON ARMED
0 VDC +28 VDC +28 VDC ON ON

Page 19
RADIANT POWER CORP.
PART NUMBER RPS1-B
F-27J
AIRCRAFT
INTERCONNECT
CHART

7 Aircraft Ground Pin 5 and 6
11 Output (Load)
24 Pins 2 and 3
OPERATION
TRUTH TABLE
Pin J1-4 Pin J1-24 Lights Aircraft Switch

Status Status Status Position
+28 VDC OPEN OFF DISARM
OPEN OPEN OFF DISARM (PARKED AIRCRAFT)
OPEN +28 VDC OFF ARMED
OPEN OPEN ON ARMED
OPEN OPEN ON ON

Page 20
RADIANT POWER CORP.
PART NUMBER RPS1-B
F-28
AIRCRAFT
INTERCONNECT
CHART

1 Pin B Pin 1 to Pins 17 and 18
2 Pin J Pin 5 and 6
4 Pin K Pin 19 to Pin 23
7 Aircraft Ground
9 Output (Load)
10 Output (Load)
11 Output (Load)
24 Pin A
OPERATION
TRUTH TABLE
+28 VDC +28 VDC OPEN OFF OFF
0 VDC 0 VDC OPEN OFF OFF (PARKED AIRCRAFT)
+28 VDC OPEN +28 VDC OFF ARMED
0 VDC OPEN 0 VDC ON ARMED
0 VDC OPEN 0 VDC ON ON

Page 21
RADIANT POWER CORP.
PART NUMBER RPS1-B
FH-227
AIRCRAFT
INTERCONNECT
CHART

4 Pin 2 Pin 2 and 4
7 Aircraft Ground Pin 5 and 6
11 Output (Load)
24 Pin 7
OPERATION
TRUTH TABLE
Pin J1-4 Voltage Pin J1-24 Lights Aircraft Switch

(Input Power) Status Status Position
+28 VDC OPEN OFF OFF
OPEN OPEN OFF OFF (PARKED AIRCRAFT)
OPEN +28 VDC OFF ARMED
OPEN OPEN ON ARMED
OPEN OPEN ON ON

Page 22
RADIANT POWER CORP.
PART NUMBER RPS1-B
L-1011
AIRCRAFT
INTERCONNECT
CHART

1 Pin 9 and 11 Pin 1 to Pins 16 and 21
2 +28 VDC Pin 5 and 6
10 Output (Load)
11 Output (Load)
18 Pin 7

Page 23
RADIANT POWER CORP.
PART NUMBER RPS1-B
EMB 135BJ / 145 FAMILY
AIRCRAFT
INTERCONNECT
CHART

1 28 VDC Return Pin 1 to Pins 12 and 17
2 Pin C (+28 VDC Essential Buss) Pin 2 to Pin 4
11 Output (Load)
24 Pin B
OPERATION
TRUTH TABLE
Pin J1-2 Voltage Pin J1-3 Pin J1-24 Lights Attendant Switch
0 VDC 0 VDC 0 VDC OFF AIRCRAFT OFF LATCHED
0 VDC 0 VDC +28 VDC OFF ARMED
0 VDC 0 VDC 0 VDC ON ARMED
0 VDC +28 VDC +28 VDC ON ON

Page 24
RADIANT POWER CORP.
PART NUMBER RPS1-B
TESTING AND FAULT ISOLATION
1. General
A. This section contains bench test and fault isolation procedures (starting this page),
recommended battery maintenance procedures (page 114) and optional on-aircraft fault
testing (page 121).
B. Perform the tests in the order given before disassembly to identify damaged parts.
Perform the tests after assembly to select the Select In Test (SIT) components and to
verify performance.
C. The recommended test equipment and materials are given in Table 101.
NOTE: Equivalent items can be used.
D. All tests must be performed at standard laboratory conditions, defined as follows:
Ambient Temperature: 70o 5o F

Relative Humidity: 35% to 65%
Atmospheric Pressure: 25 to 32 in Hg
E. All test equipment must be calibrated to NIST (National Institute of Standards and
Technology) standards.
F. Unless otherwise specified, the primary power applied to the test unit is 28 ±0.5 VDC.
Test Equipment and Materials

Table 101
Part or Specification
Nomenclature Source (CAGE)*
Number
Connector, Electrical BACC45FN16-24S The Boeing Co. (81205)
or 48-16R16-24S Amphenol Corp. (77820)
Diode, Light Emitting Mfg P/N SSILXH9GD-150 Chicago Miniature Lamp Inc. (71744)
Lamp, Incandescent (7 Required) No. 82 General Electric Co. (0EE74)
Megohmmeter, 100 megohms, Model 1644-9701 Quadtech Inc. (0PK96)
500 VDC, ±2% Full Scale
Multimeter (Ohmmeter, Ammeter or Model 77 John Fluke Mfg. Co., Inc. (89536)
Voltmeter can be used), 0 to 10 Amps
DC (±2% Full Scale), 0 to 100 VDC
(3-1/2 digits) 200 to 300 kilohms
Power Supply, Model Agilent (89536)
0 to 8 VDC (E1) 6631
0 to 32 VDC (E2) E3641A
Switch, Momentary Contact, SPST (S1) --- Commercially Available
Switch, Toggle SPST (S4 through S7) --- Commercially Available
Switch, Toggle SPST (on, off, on) --- Commercially Available
Switch, Toggle DPDT (S11) --- Commercially Available
RPS1-B Battery Housing Analyzer Kit 550-13057-00 Radiant Power Corp. (1MXA1)
*Refer to Table 1001 in the IPL for the address.
Page 101
RADIANT POWER CORP.
PART NUMBER RPS1-B
2. Test Procedures
A. Insulation Resistance Test
WARNING: THIS TEST APPLIES HIGH VOLTAGE WHICH CAN CAUSE DEATH OR
SEVERE SHOCK. SET POWER SWITCHES TO OFF BEFORE
CONNECTING AND DISCONNECTING EQUIPMENT USE CAUTION
DURING TEST.
CAUTION: THE BATTERY HOLDER ASSEMBLY MUST BE REMOVED FROM THE

UUT BEFORE THIS TEST. THIS TEST CAN DAMAGE THE BATTERY
CELLS.
(1) Remove the battery holder assembly (5, IPL Figure 1), as follows:
(a) Turn the 1/4-turn fastener (25) counterclockwise approximately 90° to the stop.
The fasteners should retract from the force of the retraction springs (30).
CAUTION: DO NOT LIFT THE BATTERY HOLDER ASSEMBLY BEFORE

SLIDING IT AWAY FROM THE ELECTRONICS ASSEMBLY. DOING
SO CAN DAMAGE THE PIN CONTACTS ON PCB ASSEMBLY A2.
(b) Carefully slide the battery holder assembly (5) out away from the electronics
assembly (120 or 120A) to disconnect pin contacts J3-1 and J3-2 on regulator
PCB assembly A2 from pin sockets J2-1 and J2-2 (60 and 65). Remove the
battery holder assembly.
(2) Connect a megohmmeter (Table 101) between connector J1, pin 1, and the chassis
assembly (130).
(3) Apply 500 ±10 VDC. Hold the voltage for 30 seconds or until the resistance reading
stabilizes, and measure the insulation resistance.
(4) The insulation resistance must be 100 meg-ohms minimum.
(5) Repeat the test between all connector J1 pins, except for pin J1-7, and the chassis.
(6) Decrease the voltage to zero.
B. Control Logic Test
CAUTION: THE BATTERY HOLDER ASSEMBLY MUST BE REMOVED FROM THE

UUT BEFORE THIS TEST. THIS TEST CAN DAMAGE THE BATTERY
CELLS.
(1) Remove the battery holder assembly (5, IPL Figure 1), as follows:
(a) Turn the 1/4-turn fastener (25) counterclockwise approximately 90°0 to the
stop. The fasteners should retract from the force of the retraction springs (30).
Page 102
RADIANT POWER CORP.
PART NUMBER RPS1-B

SLIDING IT AWAY FROM THE ELECTRONICS ASSEMBLY DOING
(2) Install the Unit Under Test (UUT) in the test setup (Figure 101). Connect power
supply E1 to pin sockets J2-1 (+) and J2-2 (-) (60 and 65, IPL Figure 1). All switches
must be open.
NOTE: Connector J1, Pin 8 is connected through an LED (Table 101) to show the
presence of VCC (reference) for all tests. Any time the LED is not
energized is a test failure.
CAUTION: DO NOT APPLY MORE THAN 12.0 VDC AT PIN SOCKETS J2-1 AND J2-
2. HIGH VOLTAGE CAN DAMAGE THE UUT
(3) Turn on power supply E1. Set the voltage to 8.0 VDC.
NOTE: A momentary drop in the DC power supply voltage when the lamp load is
initially applied can cause the UUT to go into low battery cutoff. Preloading
the power supply will prevent the cutoff. The amount of preload will vary
depending on the DC power supply used.
(4) Close switch S1.
(5) Cycle switches S2 through S7 and S11 to perform tests 1 through 14 in Table 102.
Adjust power supplies E1 and E2 as specified. Measure the output voltage at test
points A(+) and C(-) (Figure 101).
• The output voltage must be as specified in Table 102.
C. TEST Switch Test
(1) Install the UUT in the test setup (Figure 101). Connect power supply E1 at pin
sockets J2-1(+) and J2-2(-) (60 and 65, IPL Figure 1).
NOTE: The battery holder assembly must be removed from the UUT
(2) Turn on power supply E2 and set it to 28 ±1 VDC. Close switch S1.
(3) Open switches S2, S3, S4, S5 and S7. Close switch S6 (ground). Switch S11 to the
“A” position.
(4) Push TEST switch SW1 on the side of the UUT.
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RADIANT POWER CORP.
PART NUMBER RPS1-B
• The test lamps must turn on.
(5) Release TEST switch SW1.
• The test lamps must turn off.
(6) Remove power from E1 and E2.
D. Low Battery Cut-Off Test
(1) Install the UUT in the test setup (Figure 101). Connect power supply E1 at pin
sockets J2-1 (+) and J2-2 (-) (60 and 65, IPL Figure 1).
(2) Open S1 through S7 switches.
• All test lamps must be off.
(4) Turn on power supply E1 and set it to 7.5 ±0.1 VDC.
• All test lamps must turn on.
(5) Slowly decrease the voltage at power supply E1 until the test lamps turn off.
Measure the voltage.
• The voltage must be greater than 4.8 VDC.
E. Charging Test
(1) Install the UUT in the test setup (Figure 101).
(2) Disconnect power supply E1 at pin sockets J2-1(+) and J2-2(-) (60 and 65, IPL
Figure 1).
(3) Install the battery holder assembly (5), as follows:
NOTE: The batteries must be fully charged.
(a) Insert the battery holder assembly (5) into the chassis assembly (130).
(b) Press the battery holder assembly (5) against the chassis and carefully slide it
inward to insert pin contacts J3-1 and J3-2 on regulator PCB assembly A2 into
pin sockets J2-1 and J2-2 (60 and 65).
CAUTION: DO NOT TURN THE 1/4-TURN FASTENERS PAST THE DETENT
(c) Turn the 1/4-turn fastener (25) clockwise approximately 90°, to the stop. An
audible click will be heard when the stop is reached. The fasteners should
compress the retraction springs (30).
Page 104
RADIANT POWER CORP.
PART NUMBER RPS1-B
(5) Turn on power supply E2 and set it to 22 VDC. Close switch S1.
(6) Measure the current at test point I1 (Figure 101).
(7) The charging current must be between 300 and 375 milliamperes.
(8) Set power supply E2 to 32 VDC. Measure the current at test point I1.
(9) The charging current must be between 300 and 375 milliamperes.
F. Battery Discharge Test
(1) Install the UUT in the test setup (Figure 101).
(2) Disconnect power supply E1 at pin sockets J2-1 (+) and J2-2 (-) (60 and 65, IPL
Figure 1).
(3) Install the battery holder assembly (5), as follows:
NOTE: The batteries must be fully charged.
(a) Insert the battery holder assembly (5) into the chassis assembly (130).
(b) Press the battery holder assembly (5) against the chassis and carefully slide it
inward-to insert pin contacts J3-1 and J3-2 on regulator PCB assembly A2 into
pin sockets J2-1 and J2-2 (60 and 65).
CAUTION: DO NOT TURN THE 1/4-TURN FASTENERS PAST THE DETENT
(c) Turn the 1/4-turn fastener (25) clockwise approximately 90° to the stop. An
audible click will be heard when the stop is reached. The fasteners should
compress the retraction springs (30).
(6) Open switches S1 and S6. Measure the output voltage across test points A(+) and
C(-).
(a) • All test lamps must turn on and stay on for 15 minutes minimum.
(b) • The output voltage must be between 5.7 and 6.7 VDC for 15 minutes.
(c) • After 15 minutes, the lamps must stay on until the low battery cut-off voltage
(which must exceed 4.8 VDC).
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RADIANT POWER CORP.
PART NUMBER RPS1-B
(8) If there was insufficient battery capacity or a low open circuit voltage, the battery
assembly should be cycled as follows and then retested. If the test fails again, all six
batteries should be replaced in accordance with disassembly and assembly
instructions.
(a) Close switches S2, S3 and S6
(b) Turn on power supply E2 and set it to 22 VDC. Close switch S1. Measure the
current at test point I1.
(c) • The charging current must be between 300 and 375 milliamperes.
(d) Charge the UUT at 350 milliamperes for 16 to 24 hours.
(e) Open switch S1.
(f) Discharge the battery assembly into a 7 Ampere load until it reaches the cutoff
voltage.
(g) Repeat this cycle.
(9) Disconnect and remove the UUT
(10) Refer to ASSEMBLY for final assembly instructions.
Page 106
RADIANT POWER CORP.
PART NUMBER RPS1-B
Control Logic Test Requirements

Table 102
Power Switch Positions Load Output Voltage

T Supply Lamp Across Load
e E2 Voltage S2 S3 S4 S5 S6 S7 S11
s S1 (J1-2) (J1-3) (J1-4) (J1-12) (J1-17) (J1-18) (J1-24)
t
1 0 or 28vdc Open Open Open Open Open Open A ON 5.7 to 6.7vdc
2 0 or 28vdc Open Open Open Open GND Open A OFF 0vdc
3 0 or 28vdc GND Open Open Open GND Open A ON 5.7 to 6.7vdc
4 28vdc Open GND Open Open GND Open A OFF 0vdc
5 28vdc GND GND Open Open GND Open A OFF 0vdc
6 0vdc GND GND Open Open GND Open A ON 5.7 to 6.7vdc
7 0 or 28vdc Open Open Open Open GND 28vdc A ON 5.7 to 6.7vdc
8 28vdc Open Open GND Open GND Open A ON 5.7 to 6.7vdc
9 28vdc Open Open GND GND GND Open A OFF 0vdc
1 0vdc Open Open GND GND GND Open A ON 5.7 to 6.7vdc

0
1 28vdc GND 28vdc GND GND GND Open B OFF 0vdc
1
* 0vdc GND GND GND GND GND Open B OFF 0vdc
1
2
1 0vdc 28vdc GND GND GND GND 28vdc B OFF 0vdc
3
1 0vdc 28vdc GND GND GND GND Open B ON 5.7 to 6.7vdc
4
NOTE: * Step #12 must be preformed after step #11.
NOTE: * Switch #11
A: Jumpers Pins (J1-13 to J1-14) and (J1-15to J1-16)

B: Jumpers Pins (J1-13 to J1-15)
Page 107
RADIANT POWER CORP.
PART NUMBER RPS1-B
Bench Test Set Up

Figure 101
NOTES: CAUTION:
1. REPLACE BATTERY HOLDER ASSEMBLY POWER SUPPLY E1 VOLTAGE MUST NOT
WITH POWER SUPPLY E1 (AND THE EXTERNAL EXCEED 12.0 VDC. HIGH VOLTAGE CAN
PRELOAD, IF USED) FOR THE CHARGING AND DAMAGE THE UUT. VOLTAGE MEASUREMENT
BATTERY DISCHARGE TESTS. POINTS ARE AS FOLLOWS:
28 VDC POWER SUPPLY D(+) AT J1-2
2. A MOMENTARY DROP IN DC POWER SUPPLY C(-) AT J1-1
VOLTAGE WHEN THE LAMP LOAD IS BATTERY VOLTAGE B(+) AT J2-1
INITIALLY APPLIED CAN CAUSE THE UUT TO B(-) AT J2-2
GO INTO LOW BATTERY CUTOFF OUTPUT VOLTAGE A(+) AT J1-9
PRELOADING THE DC POWER SUPPLY MAY C(-) AT J1-1
BE REQUIRED TO PREVENT THIS.
Page 108
RADIANT POWER CORP.
PART NUMBER RPS1-B
3. Fault Isolation Procedures
A. Fault isolation procedures for the tests given in this section are provided in Table 102.
The procedures isolate faults to the board level only. With exception of the SIT
components identified in the IPL, Radiant Power Corp. recommends that the PCB
assemblies be returned to Radiant Power Corp. for repair by technicians familiar with the
layout and function of the card. PCB assemblies repaired at facilities other than Radiant
Power Corp. are not guaranteed by Radiant Power Corp.
B. Any test procedure step that does not pass is considered a failure. After fault isolation
and replacement of the damaged component, repeat the entire test procedure to verify
that the problem has been corrected.
C. The most likely failure mode in the unit is one or all of the output line fuses being blown.
These are F1, F2, and F3, (40 or 40A) which are 5 amp “Pico” fuses listed in the parts list
as figure 3 item # 40. The fuses are located between the battery pack and the
electronics “brick”. Remove the battery pack according to the normal procedure to
access the fuses. The three fuses are located as shown below, and on the PCB
assembly drawing on Page 1018.
FUSES listed from top to bottom:

F1, F2, and F3. Each fuse is
inserted into a socket and can be
removed and inserted with needle
nose pliers.
WARNING: If the unit has a blown fuse, then the most likely cause is a wiring, or
electrical short on the aircraft. The aircraft wiring must be investigated to determine
the cause of the failure. The maximum load for each output line is 2.5 amps. Do not
reinstall the RPS1-B on the aircraft until the cause of the fuse failure is determined.
Fuse Location
Figure 102
Page 109
RADIANT POWER CORP.
PART NUMBER RPS1-B
Bend replacement fuses as shown below:
Fuse Bending
Figure 103
4. Schematic Diagrams
Schematic diagrams of the BPS battery pack electronic circuits are provided in DESCRIPTION
AND OPERATION.
5. SIT Resistor Replacement
This Test Plan details the procedure to select the proper value for R21 on the A2 board of the
RPS1-B.
A. Instrumentation
All measurements shall be made with instruments and methods whose accuracy have
been verified to the satisfaction of the buyer. All instruments and test equipment shall
conform to laboratory standards whose calibration is traceable to the prime standards at
the National Institute of Standards and Technology.
B. Test Equipment Requirement
The following test equipment or equivalent shall be

used in accomplishing the test specified herein:
Quantity Equipment Model or Mfg. Range Accuracy

P/N
Three Multi-meter, Model 77 John Fluke Mfg. * 2%
Digital Co., Inc.
one Power Supply 6631 Agilent. 0 to 8 VDC *
one Power Supply E3641A Agilent 0 to 32 *
VDC
one Charging RT-801 Radiant Power * *
cable Corp
one Test Fixture RT 909 Radiant Power * *
Corp
Page 110
RADIANT POWER CORP.
PART NUMBER RPS1-B
C. Procedure
(1) Set the 0-12 volt power supply to 8.0 volts.
(2) Start with an 806-Ohm resistor for R21.
(3) Install the unit in the test set.
(4) OPEN switches 1-7 lights should come on.
(5) Verify the output voltage is between 6.5 to 6.7 volts.
(6) If the output voltage is out of range adjust R21 to get the correct output voltage.
NOTE: To increase the output voltage increase R21 (732 to 900 ohms)
Fault Isolation Procedures

Table 103 (Sheet 1 of 3)
Trouble Probable Cause Corrective Action

INSULATION RESISTANCE
TEST
The insulation resistance is not as Cut or cracked wire insulation; Check the wire circuits, solder
specified. open or short circuit or solder connections, and pin and
connection; solder flux path to socket contacts for damage;
ground. verify wire routing per
ASSEMBLY, Table 702 and
DESCRIPTION AND
OPERATION, Figure 3; refer to
REPAIR to replace damaged
pin contacts in connector J1.
Excessive moisture inside the Dry the UUT thoroughly with

cover assembly (110, IPL compressed shop air; examine
Figure 1). the unit carefully for corrosion
or other moisture damage.
CONTROL LOGIC TEST
The UUT did not turn off (no Damaged component in test Replace logic PCB assembly
output voltage) in test 2 in Table switch circuit on logic PCB A1 (15 or 15A).
102. assembly A1 (15 or 15A, IPL
Figure 2).
The UUT did not turn on (output One or more Fuses blown, Check if F1, F2, F3 (40 or 40A)
voltage) in tests 1, 3, 6, 7, 8 and possibly F1, F2 or F3. is blown with a continuity meter.
10 in Table 102.
Damaged transistor Q2 (35) or Replace the damaged
damaged component in component.
regulator circuit on PCB
assembly A2 (10).
Page 111
RADIANT POWER CORP.
PART NUMBER RPS1-B
CONTROL LOGIC TEST Damaged component in logic Replace logic PCB assembly A1
(continued) output or low voltage disconnect (15 or 15A).
circuits on logic PCB assembly A1
(15 or 15A).
The UUT did not turn off (no Damaged component in 28 VDC Replace logic PCB assembly A1
output voltage) in tests 4, 5 and 9 sensing circuit on logic PCB (15 or 15A).
in Table 102. assembly A1 (15 or 15A).
TEST SWITCH TEST
The test lamps do not turn on and One or more Fuses blown, Check if F1, F2, F3 (40 or 40A)is
off as specified. possibly F1, F2 or F3. blown with a continuity meter.
If one or more lamps did not turn If there is no output voltage at pin
on, blown fuse F1, F2 or F3 (100, 9, replace fuse F1 (40 or 40A); if
IPL Figure 3). there is no voltage at pin 10,
replace fuse F2 (40 or 40A); if
there is no voltage at pin 11,
replace fuse F3 (40 or 40A).
Damaged TEST switch SW1 (100, Replace the damaged component.

IPL Figure 2) or solder lug (105).
Damaged component in test Replace logic PCB assembly A1

switch circuit on logic PCB (15 or 15A).
assembly A1 (IS or 15A).
LOW BATTERY CUTOFF TEST
All test lamps do not turn on as One or more Fuses blown, Check if F1, F2, F3 (40 or 40A) is
specified (para. 2.D, Step (4)). possibly F1, F2 or F3. blown with a continuity meter.
Damaged component in control Replace logic PCB assembly A1

logic circuit on logic PCB (15 or 15A)
assembly A1 (15 or 15A, IPL
Figure 2).
The low battery cutoff voltage is Damaged component in low Replace logic PCB assembly A1
lower than specified (para. 2.D, voltage disconnect circuit on (15 or 15A).
Step (5)). logic PCB assembly A1 (15 or
15A).
Page 112
RADIANT POWER CORP.
PART NUMBER RPS1-B


CHARGING TEST
The charging current is not as Damaged resistor R1 or R2 Replace the damaged

specified (para. 2.E, Steps (6) (65, IPL Figure 2), transistor component.
and (7)). Q1 (30), or component in
charging circuit on regulator
PCB assembly A2 (10).
Damaged or improperly Reinstall the battery holder

installed battery holder assembly (5) and make sure
assembly (5, IPL Figure 1). connector pins J2-1 and J2-2
are inserted fully into the
sockets; if the test fails again,
disassemble and repair the
BATTERY DISCHARGE TEST
The output voltage is not as One or more Fuses blown, Check if F1, F2, F3 (40 or 40A)
specified (para. 2.F, Step (6)). possibly F1, F2 or F3. is blown with a continuity meter.
If the output voltage is greater Decrease the resistance of SIT

than 6.5 VDC, the resistance of resistor R21 within the range
SIT resistor R21 (35, IPL 732 to 900 and retest; solder
Figure 3) is too high. the resistor leads in place after
final selection.
If the output voltage is less Increase the resistance of SIT

than 6.1 VDC, the resistance of resistor R21 within the range
SIT resistor R21 (35) is too low. 732 to 900 and retest; solder
the resistor leads in place after
final selection.
Damaged transistor Q2 (35, Replace transistor Q2 (35).

IPL Figure 2).
Damaged component in Replace regulator PCB

regulator circuit on regulator assembly A2 (10).
PCB assembly A2 (10).
Page 113
RADIANT POWER CORP.
PART NUMBER RPS1-B
BATTERY MAINTENANCE AND STORAGE
1. General
A. Testing schedule and procedure should be in accordance with the operator’s procedures
approved by a certification authority. If an operator wishes guidance on changing the
intervals from the operator’s previously established intervals, the operator may contact
Radiant Power or the aircraft manufacturer for specific recommendations.
B. This section also includes sample methods for battery charging and storage when
batteries are to be returned to immediately-dispatched aircraft. Because the Emergency
Passenger Egress Lighting Systems are must-work systems for aircraft dispatch, the
operators should assure that the batteries installed on the aircraft have enough charge to
power the emergency lights. The sample procedures provide the guidance for operators’
procedures.
2. Storage Requirements for Battery Packs
Battery Packs may be stored without damage in a charged or discharged condition over the
temperature range of –30°C to +70°C (-22°F to +158°F). Long term storage (over 3 months)
should be at temperatures less than +35°C (+95°F).
3. New Stock Maintenance Exemption
New stock purchased from Radiant or Radiant’s authorized distributors has a seven year no-
maintenance-required shelf life for the electronics and 38 month no-maintenance-required
shelf life for the battery pack and batteries.
If the components remain in the purchaser’s stock beyond the shelf life, simple inspection,
testing, or conditioning may be required. Testing and conditioning may be done at the
discretion of the purchaser in accordance with their procedures based on their previous
experience with parts in long-term storage.
Date Code Locations:
Date Code: Month/Year
Page 114
RADIANT POWER CORP.
PART NUMBER RPS1-B
4. Battery Pack Removal Recommendation
Removal and Bench testing
Removal and bench-testing of 2013-1A Battery Packs is suggested at 18-month intervals for
most operators of large commercial transport aircraft or similar aircraft applications.
Recommended test/reconditioning procedures are detailed in Testing and Fault Isolation
section/paragraph 2.F.
The battery capacity test is normally done with a fully charged battery pack.
5. On-Aircraft Testing/Maintenance
A. RPS1-B systems should be tested periodically on-aircraft to remove built-up “memory

effect”.
For operators seeking new procedures or using new type aircraft, the following sample
procedure explains what a procedure may include. The operator may also contact
Radiant Power or the aircraft manufacturer for specific recommendations.
Sample On-Aircraft Testing/Maintenance procedure
(1) Three times per year, the lighting system is tested for a period of 10 minutes
minimum, 15 minutes maximum.
(2) At the end of the illumination period, the aircraft electrical system is powered for at
least 3.5 hours before the next gate departure to recharge the batteries.
Acceptance criteria for 1:

Observation (that is, no numerical data required; only need mechanic signoff
that lighting system was turned on for 10-15 minutes)
Acceptance criteria for 2:
Observation or aircraft schedule (that is, no numerical data required; only
need signoff that ground power was applied to aircraft or the aircraft was
powered for 3.5 hours before gate departure)
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RADIANT POWER CORP.
PART NUMBER RPS1-B
B. Commentaries
(1) Acceptance Criteria
Acceptance Criteria commentary:
The intention of the acceptance criteria is to minimize the burden put on the operators. All that is
supposed to happen is that the mechanic turns on lights for 10-15 minutes and the batteries get
recharged for 3-1/2 hours.
The emergency lighting system load is 7 Amperes and it must run for 10 minutes by FAR
requirement. This corresponds to 7 A x 1/6 hour = 1.16 A-hr. The charging rate on the RPS1-B is
0.35A so it takes 1.16/0.35 = 3.3 hours to replenish the battery with the minimum amount of energy
required. Normal aircraft operations will completely “top-off” the batteries.
Neither the 10-15 minute time, nor the 3-1/2 hour time is critical. There is a reasonable expectation
that if the times are slightly shorter or longer than required the system would maintain its flight-
readiness.
For example, the batteries will still have more reserve energy after the 10-15 minute discharge
because the batteries have a relatively high capacity relative to the FAR requirements. Thus, if the
recharge time is only 3 hours, the battery capacity will meet the FAR requirements with the
combination of the recharge energy and reserve energy.
If the aircraft schedule is such that it is powered for at least 3-1/2 hours before departure, the
batteries will be recharged. For example, if the mechanics schedule the 10-minute test at the
beginning of another maintenance activity, and then recharge the batteries (by having ground
power applied to the aircraft) while continuing the maintenance activity, the batteries will have the
required energy. There is no need to record the time intervals, just simply note that the aircraft was
powered for at least the minimum interval. In another example, if the 10-minute test is done as soon
as the passengers deplane from the last flight of the day, and the operator knows that the aircraft
will be powered for another 2 hours during normal cabin cleaning and at-gate maintenance tasks,
plus the aircraft will be powered up for 1-1/2 hours in the morning before the first departure, the
“schedule” criteria is met. No data needs to be recorded other than that the battery was recharged
in accordance with a schedule that would provide the recharge time.
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PART NUMBER RPS1-B
(2) Memory Effect
Engineering commentary – “Memory Effect”:
Nickel Cadmium batteries exhibit a characteristic called “battery memory”. Battery memory makes
good cells appear to have less capacity than they should. Continuously charging a battery or
partially discharging a battery causes battery memory. Battery memory is worse at high ambient
temperatures.
Battery memory is removed by periodically discharging the batteries. The discharge process
removes the battery memory down to the level of discharge.
Deep-cycling batteries (which can only be done on the bench because the battery undervoltage
protection circuit in the RPS1-B needs to be defeated) completely removes all memory-effect
residue and reconditions the battery to its maximum capacity.
> 10 min.
>15 min.
> 30 min.
2-3 min.
New Battery "Memory Effect" After On-Board After Bench Testing/

(over 30 minutes run time) (2-3 minutes Maintenance Deep-cycling
of run time) (at least 10 (maximum run time,
minutes of run time) based on battery
lifetime, no memory-
affected areas)
Prime Power
(battery capacity not
affected by memory)
Usable Power
(mixed normal and
memory-affected areas of
battery)
Power not available

(memory-effect has made
battery voltage too low)
"W orn-out" area of battery

(due to battery life time)
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PART NUMBER RPS1-B
6. Charging Batteries for Return-to-Service
If a stored Battery Pack is to be installed on an aircraft that is returning to service, the Battery
Pack must be charged before the aircraft is deemed ready for passenger service. That is, a
fully discharged battery pack will not meet the requirements of US FAA FAR 25.812 paragraph
(i), which requires that the Battery Pack must provide 10 minutes’ worth of energy.
Charging of the Battery Pack may be accomplished in different ways. Some samples are listed
below:
A. Charge on-aircraft for at least 6 hours. Six hours is the time in which completely
discharged batteries will absorb the minimum amount of energy required to meet the 10
minutes FAR requirement. Charging is accomplished by aircraft ground power, aircraft
idling, or aircraft ferrying. Battery packs in this condition are not fully charged, but do
contain enough energy to meet the requirements; the batteries will be fully charged
during normal aircraft operations of the first flight day.
B. Charge on bench for 16 hours at nominal current (330-370 mA) within the 31 days
previous to the installation on the aircraft and maintain the stored batteries at an average
room temperature. Average room temperature simply means a controlled environment;
no monitoring of temperature is required because failure of environmental controls will be
obvious to personnel working in the area.
C. Charge on bench for 16 hours at nominal current (330-370 mA) within the 123 days
previous to the installation on the aircraft and maintain the stored batteries at an average
refrigerator temperature. Average refrigerator temperature simply means the normal
controlled environment of a home or industrial refrigerator (0°C to +5°C / 32°F to 41°F);
no monitoring of temperature is required because failure of environmental controls will be
obvious to personnel working in the area.
D. Fast-charge on bench for 20 minutes at high rate current (5 A) before installation on

aircraft. This procedure is used when an immediate dispatch of the aircraft is required
and no previously charged stored batteries exist. Radiant Power and other manufacturers
can provide dedicated equipment to perform this function. This procedure should be done
only with dedicated test equipment or specially trained operators because the battery
voltage and temperature must be monitored continuously during this fast charge.
Operators may provide alternative or additional charging and testing procedures if desired.
These other procedures may be done to provide consistent maintenance or battery-shop
procedures between aircraft types, for example. Specific recommendations can be provided
from Radiant Power or the aircraft manufacturer.
Sample Storage/Charge Options for Batteries Returning to Service on Passenger Aircraft
123 Days maximum 31 Days maximum 6 hours 20 minutes

minimum
Charge on Bench @ Charge on Bench @ Charge on Fast Charge on Bench
350 mA for 16 hours; 350 mA for 16 hours; Aircraft @5A
store in refrigerator store at room
temperature
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PART NUMBER RPS1-B
7. Battery Charging Procedure
The purpose of this section to provide new users with typical procedures for bench charging.
Established users should use their approved procedures.
A. Use a power supply with a minimum voltage of 12 volts and an adjustable current limit.
Hook up the power supply, meters, etc, as shown on the drawing below.
CAUTION: DO NOT HOOK UP THE BATTERY PACK YET!
Battery Discharge
Figure 104
B. Adjust the output voltage to 10 volts for every battery pack that is in series, and turn the
current limit all the way down. Now hook up the battery pack. Adjust the current limit on
the power supply to 350 milliamps +/- 20 milliamps. Leave the batteries charging for 15-
20 hours (16 hours nominal). After the 16 hours of charge disconnect the battery from
the charger. Measure the battery pack voltage with a meter and ensure that the battery
has fully charged to a normal value of 7.5 to 8.8 volts.
Number of 1 2 3 4 5
battery packs
Voltage 10 volts 20 volts 30 volts 40 volts 50 volts
Current 350 milliamps 350 milliamps 350 milliamps 350 milliamps 350 milliamps
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RADIANT POWER CORP.
PART NUMBER RPS1-B
8. Battery Discharging Procedure
The purpose of this section is to provide new users with typical procedures for bench
discharging. Established users should use their approved procedures.
A. Battery Discharge Hookup:
YOU MUST MONITOR THE BATTERY VOLTAGE CONTINUOUSLY!
Battery Charge
Figure 105
B. Turn on the discharge switch and allow the battery to discharge until it reaches a voltage
of 4.8 – 5.6 volts. Do not allow the voltage to go any lower. This discharge time can take
anywhere from a few minutes to 35 minutes, depending on the battery’s state of charge.
The voltage normally holds very steady for most of the discharge curve, followed by a
steep decrease in voltage at the very end of the discharge. Pay attention!
C. Once the battery cutoff voltage is reached then turn the switch off, and allow the battery
pack to cool for 30 minutes before charging.
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PART NUMBER RPS1-B
OPTIONAL ON-AIRCRAFT TESTING FOR RPS1-B
NOTE: These tests may be performed on-aircraft in the event of problems reported by flight crew or
mechanics.
1. General
In response to requests from operators, Radiant Power Corp. has made an on-aircraft test set
available. The Battery Housing Analyzer (BHA) provides quick GO/NO-GO and qualitative
testing for the RPS1-B. The purpose of this test set is to allow mechanics to diagnose the
problems that flight crew or mechanics might report when operating the Emergency Egress
Lighting System or when performing a daily test on it.
The BHA is a portable instrument designed to be carried on-board the aircraft by the
mechanic. It allows the mechanic to check the RPS1-B charger for proper operation while the
RPS1-B remains installed on the aircraft.
The BHA also can perform a quick test of the battery pack as well. This test is not a full
capacity check of the battery, since that would require a 16-hour recharge of the battery on-
aircraft after the test. It tests for grossly under-performing batteries, as could cause a test
failure during the daily checks of the Emergency Egress Lighting System.
Specifically, the BHA provides measurement of the battery charging current, charging open-
circuit voltage, battery no-load voltage, and the battery loaded voltage. The BHA kit includes
the analyzer, a two-foot battery tester cable and a 6.5-foot charging fixture cable. This cable is
long enough that the mechanic can use the analyzer from a convenient location while testing
an RPS1-B in an inconvenient location.
Instructions for the Analyzer are reproduced below.
Battery Housing Analyzer

Figure 106
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RADIANT POWER CORP.
PART NUMBER RPS1-B
2. Aircraft Charging Test
NOTE: IF THE AIRCRAFT CHARGER BEING TESTED FALLS OUTSIDE OF THE

SPECIFIED TOLERANCES, FURTHER MAINTENANCE IS REQUIRED.
A. Remove the battery holder assembly (5, IPL Figure 1), as follows:
(1) Turn the 1/4-turn fastener (25) counterclockwise approximately 90° to the stop. The
fasteners should retract from the force of the retraction springs (30).

SLIDING IT AWAY FROM THE ELECTRONICS ASSEMBLY. DOING
(2) Carefully slide the battery holder assembly (5) out away from the electronics
assembly (120 or 120A) to disconnect pin contacts J3-1 and J3-2 on regulator PCB
assembly A2 from pin sockets J2-1 and J2-2 (60 and 65). Remove the battery holder
assembly.
B. Ensure analyzer power & load switches are in the off position.
C. Install the charging fixture cable in place of the removed battery holder assembly (5).
Connect the charging fixture cable leads to the BHA input jacks.
CAUTION: ENSURE PROPER POLARITY. IF AT ANY TIME THE REVERSE

POLARITY LED FLASHES, CORRECT BEFORE PROCEEDING.
D. Turn on aircraft power to the charger assembly.
E. Switch power ON/OFF switch to the ON position with the load switch in the OFF position.
The voltage must be 13.8 volts to 15.0 volts.
F. Switch the load ON/OFF switch to the ON position. The voltage must be 6.8 volts to 8.0
volts. Charge current must indicate 300 mA or greater.
G. Depress the battery condition switch and read the battery voltage on the battery voltage
meter. (The LED lights are for quick reference only.) Voltage must be greater than 6.8
volts but less than 8.0 volts.
Low < 6.8 volts (Amber) FAILURE

Normal > 6.8 volts (Green) PASS
High > 8.0 volts (Red) FAILURE
H. Release battery condition switch.
3. Battery Pack Test
NOTE: IF THE BATTERY PACK BEING TESTED FALLS OUTSIDE OF THE SPECIFIED
TOLERANCES FURTHER MAINTENANCE IS REQUIRED.
A. Ensure analyzer power & load switches are in the off position.
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RADIANT POWER CORP.
PART NUMBER RPS1-B
B. Attach battery tester cable from the BHA input jacks to the battery pack to be tested.
CAUTION: ENSURE PROPER POLARITY. IF THE REVERSE POLARITY LED

FLASHING, CORRECT BEFORE PROCEEDING.
C. Switch power ON/OFF switch to the ON position with the load switch in the OFF position.
D. Depress the battery condition switch and read the battery voltage on the battery voltage
meter. (The LED lights are for quick reference only.) Voltage must be greater than 6.8
volts.
Low < 6.8 volts (Amber) FAILURE

Normal > 6.8 volts (Green) PASS
High > 8.0 volts (Red) OK
E. Release battery condition switch.
F. Switch load ON/OFF switch to the ON position. The voltage meter must read 6.8 volts or
greater, and current meter must read 300 mA or greater.
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RADIANT POWER CORP.
PART NUMBER RPS1-B
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RADIANT POWER CORP.
PART NUMBER RPS1-B
DISASSEMBLY
1. General
A. This section contains disassembly instructions in the same sequence as the IPL. Before
disassembly, refer to TESTING AND FAULT ISOLATION or CHECK to identify the
damaged components. Disassemble the BPS battery pack only as far as necessary to
remove the damaged or worn parts.
NOTE: With the exception of the Select In Test (SIT) components identified in the IPL,
Radiant Power Corp. recommends the PCB assemblies be returned to Radiant
Power Corp. for repair by technicians familiar with the layout and function of the
card. PCB assemblies repaired at facilities other than Radiant Power Corp. are
not guaranteed by Radiant Power Corp.
B. This CMM covers maintenance of the RPS1-B configuration only. Contact Radiant Power

C. Two electrically identical but physically different logic PCB assemblies are used in the
this CMM.
11-0041-1 0626 and subsequent 2-15

11-0041-2 0053 through 0625 2-15A
D. Note the methods of insulation (shrink sleeving, etc.) and routing of electrical wire leads
for assembly reference. Unsolder the wire leads from the terminals or pads and tag all
wires to aid assembly.
E. Refer to IPL Figure 1 for an exploded-view illustration of the BPS battery pack. Refer to
DESCRIPTION AND OPERATION, Figure 2, for assembly views.
2. Tools and Materials
A. All repair work on PCB must be done at an Electrostatic Discharge (ESD) safe
workbench. Refer to paragraph 3, below, for general ESD handling instructions and
workbench requirements.
B. The recommended materials are given in Table 301.
NOTE: Equivalent materials can be used.
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RADIANT POWER CORP.
PART NUMBER RPS1-B
3. Handling Instructions for Electronic Devices
The BPS battery pack contains electronic components that can be damaged by ESD and
rough handling. The general handling precautions and instructions given below will help
minimize or eliminate possible damage.
WARNING: THE BPS BATTERY PACK CONTAINS HIGH VOLTAGE CIRCUITS WHICH
CAN CAUSE DEATH OR SEVERE SHOCK. FOLLOW THE SAFETY
PRECAUTIONS GIVEN IN THE INTRODUCTION TO THIS CMM TO PREVENT
INJURY
CAUTION: THE PCB ASSEMBLIES CONTAIN ESD SENSITIVE DEVICES. HANDLE THE
PCB ASSEMBLIES IN ACCORDANCE WITH STATIC CONTROL
PROCEDURES TO PREVENT COMPONENT DAMAGE.
THE BPS BATTERY PACK CONTAINS SENSITIVE ELECTRONIC

COMPONENTS THAT CAN BE DAMAGED BY ROUGH HANDLING AND
EXPOSURE TO HIGH HUMIDITY, WATER OR OTHER LIQUIDS, CIGARETTE
SMOKE, AND OTHER CONTAMINATION. USE THE BPS BATTERY PACK IN
AN ENVIRONMENT SUITABLE FOR ELECTRONIC COMPONENTS AND
HANDLE THE UNIT WITH CARE TO PREVENT DAMAGE.
A. If liquid or grease is spilled on or in the BPS battery pack, immediately remove power and
wipe off the liquid or grease. Do not touch the BPS battery pack until power has been
removed.
B. Do not use or store the BPS battery pack in a high humidity environment or in direct
sunlight. High humidity can short or corrode electronic components.
C. All integrated circuits (ICs), surface mounted devices, and many other semiconductors
are susceptible to ESD. Careless handling during repair can drastically decrease the
component life.
D. When handling ESD sensitive devices, work at an ESD safe workbench. The workbench
should include:
(1) A grounded conductive sheet covering the bench work area.
(2) A grounded wrist strap in contact with skin.
(3) If the chair or the floor is nonconducting, the chair must have a ground strap.
(4) ESD safe tools and equipment. Use plastic instead of metal tools where possible to
prevent short circuits.
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PART NUMBER RPS1-B
Disassembly Materials
Table 301
Nomenclature Source
Number
Alcohol, Isopropyl Federal Specification TT-I-735 Commercially Available
Cloth, Lint-Free Military Specification Commercially Available
MIL-C-85043
Stripper, Conformal Humiseal No. 20 Columbia Chase Corp. (99109)
Coating
* Refer to Table 1001 in the IPL for the address.
E. Store the PCB assemblies in protective antistatic shipping bags until ready for use. Do
not store the PCB assemblies in conventional plastic snow, Styrofoam, or plastic trays.
F. Once removed from the bags; PCB assemblies must be handled in accordance with
static control procedures. The preferred method is to handle PCB assemblies with clean
lint-free cloths or rubber gloves only on the edge of the board. If gloves or cloths are not
available, wash your hands to remove oils and handle the boards only on the edges; do
not touch the conductive patterns or components.
G. Do not stack PCB assemblies. Stacking can damage surface mounted components.
H. The work station must be clean. To prevent contamination of PCB assemblies, there
must be no smoking, eating, or drinking in the work area.
4. Disassembly Instructions
NOTE: Refer to REPAIR for instructions to replace the adhesive-backed labels (15, IPL
Figure 1), damaged clinch nuts (160 Figures) (32 IPL Figures), all riveted
components, and all bonded components.
CAUTION: UNITS UNDER WARRANTY SHOULD BE RETURNED TO RADIANT POWER

CORP. FOR REPAIR. REMOVAL OF THE TOP COVER WILL VOID THE
WARRANTY.
CAUTION: THE PCB ASSEMBLIES CONTAIN SENSITIVE ELECTRONIC COMPONENTS

THAT CAN BE DAMAGED BY ESD AND ROUGH HANDLING. HANDLE THE
PCB ASSEMBLIES WITH CARE TO PREVENT DAMAGE.
CAUTION: DO NOT OVERHEAT ELECTRONIC COMPONENTS WHEN UNSOLDERING

WIRE LEADS. USE A HEAT SINK AND LOW WATTAGE SOLDER GUN TO
PREVENT DAMAGE. USE A SOLDER SUCKER AND/OR SOLDER WICK TO
REMOVE EXCESS SOLDER.
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PART NUMBER RPS1-B
A. Battery Holder Assembly (5, IPL Figure 1)
(1) Remove the battery holder assembly (5), as follows:
(a) Turn the 1/4-turn fastener (25) counterclockwise approximately 90° to the stop.
The fasteners should extend from the force of the retraction springs (30).

SLIDING IT AWAY FROM THE ELECTRONICS ASSEMBLY DOING
SO CAN DAMAGE THE PIN CONTACTS ON REGULATOR PCB
ASSEMBLY A2.
CAUTION: AS SOON AS THE BOTTOM HALF OF THE BATTERY CASE IS

REMOVED, INSERT A PIECE OF INSULATING MATERIAL BETWEEN PIN
SOCKETS J2-1 AND J2-2 TO, PREVENT SHORTING DURING
MAINTENANCE.
(2) Disassemble the battery holder assembly (5), as follows:
(a) Refer to REPAIR to replace the adhesive-backed battery holder label (15).
(b) Remove the nuts (40A), the flat washers (45), and the screws (50). Turn the
battery case (20) over and remove the bottom half case. Insert a piece of
insulating material (tape, paper, etc.) between pin sockets J2-1 and J2-2 (60
and 65).
(c) Remove the split ring retainers (35) or the Teflon flat washers (35A), the 1/4-
turn fasteners (25), and the retraction springs (30).
(d) Unsolder the wire braid (90) on the end of the batteries (55) opposite pin
sockets J2-1 and J2-2 (60 and 65).
CAUTION: DISASSEMBLY OF THE BATTERY PACK TO REPLACE

INDIVIDUAL BATTERIES IS NOT RECOMMENDED. THIS CAN
RESULT IN A MISMATCH OF CELL CAPACITY SUFFICIENT TO
CAUSE CELL REVERSAL AND PERMANENT CELL DAMAGE.
RADIANT POWER CORP. RECOMMENDS REPLACEMENT OF ALL
SIX BATTERIES IF ANY ONE BATTERY IS DAMAGED.
(e) Remove the batteries (55) from the top half of the battery case (20). Unsolder
the remaining wire braid (90) only if the batteries are damaged and must be
replaced. Replace all six batteries if any one battery is damaged.
NOTE: Instructions are given in ASSEMBLY to reconnect the batteries.
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PART NUMBER RPS1-B
CAUTION: DO NOT REMOVE THE INSULATING MATERIAL FROM BETWEEN

PIN SOCKETS J2-1 AND J2-2 UNTIL AFTER THE REAR WIRE BRAID
(90) OR THE BATTERIES HAVE BEEN REMOVED.
(f) Remove the insulating material from between pin sockets J2-1 and J2-2 (60
and 65).
(g) Remove the nuts (70), the washers (80 and 85), and pin sockets J2-1 and J2-2
(60 and 65).
CAUTION: DO NOT USE SOLVENT CLEANERS ON THE BATTERY CASE.

SOLVENTS CAUSE DAMAGE TO THE LEXAN MATERIAL.
(h) Peel or cut the fuse retainer pad (95) off the battery case (20) only if the pad is
damaged. Clean the battery case with alcohol and lint-free cloths to remove
any adhesive film.
B. Battery Charger Assembly (100, IPL Figure 1)
NOTE: Refer to REPAIR for instructions to replace damaged clinch nuts (160, IPL
Figure 1 and 32, IPL Figure 3), the adhesive-backed labels, and the riveted
components.
CAUTION: DO NOT OVERHEAT ELECTRONIC COMPONENTS WHEN

UNSOLDERING WIRE LEADS. USE A HEAT SINK AND LOW WATTAGE
SOLDER IRON TO PREVENT DAMAGE. USE A SOLDER SUCKER AND/
OR SOLDER WICK TO REMOVE EXCESS SOLDER.
(1) Refer to REPAIR to replace the adhesive-backed chassis nameplate (105).
CAUTION: PCB ASSEMBLIES A1 AND A2 CONTAIN SENSITIVE ELECTRONIC

COMPONENTS THAT CAN BE DAMAGED BY ESD AND ROUGH
HANDLING. HANDLE THE PCB ASSEMBLIES WITH CARE TO PREVENT
DAMAGE.
(2) Remove the screws (115) and carefully lift the cover assembly (110) off the
electronics assembly (120 or 120A).
CAUTION: DO NOT LIFT THE ELECTRONICS ASSEMBLY BEFORE SLIDING IT

AWAY FROM THE BATTERY HOLDER ASSEMBLY DOING SO CAN
DAMAGE THE PIN CONTACTS ON REGULATOR PCB ASSEMBLY A2.
(3) Remove the screws (125). Carefully slide the electronics assembly (120 or 120A) out
away from the battery holder assembly (5) to disconnect pin contacts J3-1 and J3-2
on regulator PCB assembly A2 from pin sockets J2-1 and J2-2 (60 and 65).
CAUTION: DO NOT PULL OR TWIST THE WIRE LEADS WHILE REMOVING

COMPONENTS. PULLING OR TWISTING THE WIRE LEADS CAN BREAK
SOLDER CONNECTIONS AND DAMAGE WIRE LEADS.
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RADIANT POWER CORP.
PART NUMBER RPS1-B
(4) Disassemble the electronics assembly (120 or 120A), as follows:
(a) Refer to REPAIR to replace the adhesive-backed TEST switch label (5, IPL
Figure 2).
(b) Remove the screws (95) from the front panel (125). Do not move the front
panel until specified below.
(c) Remove the screws (20) and the washers (25) from logic PCB assembly A1
(15 or 15A). Do not move PCB assembly A1 until specified below.
(d) Remove the screws (20), the washers (25), and the insulator (12) from
regulator PCB assembly A2 (10). Do not move PCB assembly A2 until
specified below.
(e) Unfold the electronics assembly as needed for access to the damaged
components. Use caution to avoid damage to solder connections on
components that do not require replacement.
NOTE: The PCB assemblies are conformal coated. The wire leads can be
unsoldered through the conformal coating, or the coating can be
stripped off with Humiseal stripper (Table 301). Instructions are given
in ASSEMBLY to reapply the conformal coating.
(f) Tag and unsolder the wire leads from TEST switch SW1 (100) to pads 16 and
22 on logic PCB assembly A1 (15 or 15A). Remove the hex nut and the switch
from the front panel (125). Reinstall the hex nut on the switch body for reuse.
(g) Tag and unsolder the wire lead from connector J1 (110) to the solder lug (105).
Remove the solder lug.
CAUTION: PCB ASSEMBLIES REPAIRED AT FACILITIES OTHER THAN

RADIANT POWER CORP. ARE NOT GUARANTEED BY RADIANT
POWER CORP.
(h) Tag and unsolder the wire leads from logic PCB assembly A1 (15 or 15A).
Remove logic PCB assembly A1.
NOTE: With exception of the SIT components identified in the IPL, Radiant
Power Corp. recommends that PCB assemblies A1 and A2 be
returned to Radiant Power Corp. for repair by technicians familiar
with the layout and function of the cards. PCB assemblies repaired at
facilities other than Radiant Power Corp. are not guaranteed by
Radiant Power Corp.
(i) Tag and unsolder the wire leads from regulator PCB assembly A2 (10).
Remove PCB assembly A2. Remove the screws (10, IPL Figure 3), the
washers (15), transistor Q3 (5), the Thermal insulator pad (20), the bracket
assembly (30), and the insulator strip (25) from the printed circuit board (130).
Discard the mica insulator. Refer to REPAIR to replace damaged clinch nuts
(32). Replace PCB assembly A2 if any other components are damaged.
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PART NUMBER RPS1-B
(j) Tag and unsolder the wire leads for transistor Q1 (30) and the solder lug (60).
Remove the screws (45), the nuts (40), transistor Q1, the Thermal insulator
pad (50), the insulator strip (55), and the solder lug. Discard the mica insulator.
(k) Tag and unsolder the wire leads for transistor Q2 (35) and the solder lug (60).
Remove the screws (45), the nuts (40), transistor Q2, the Thermal insulator
pad (50), the insulator strip (55), and the solder lug. Discard the mica insulator.
(l) Tag and unsolder the wire leads to resistor R1 and/or R2 (65). Remove the
screws (80 or 80A), the washers (75), the nuts (70), and the resistor(s).
C. Chassis Assembly (130, IPL Figure 1)
(1) Refer to REPAIR to replace the riveted brackets (140).
(2) Refer to REPAIR to replace damaged clinch nuts (160).
(3) Replace the chassis assembly (130) if any other components are damaged.
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PART NUMBER RPS1-B
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RADIANT POWER CORP.
PART NUMBER RPS1-B
CLEANING
1. Cleaning Materials
The recommended cleaning materials are given in Table 401.
2. Cleaning Instructions
WARNING: THE CLEANING SOLVENTS ARE VERY FLAMMABLE AND CAN IRRITATE
YOUR EYES AND NOSE. USE THE SOLVENTS ONLY IN WELL VENTILATED
AREAS AWAY FROM OPEN FLAMES. FLUSH IRRITATED EYES WITH
WATER.
CAUTION: THE PCB ASSEMBLIES CONTAIN SENSITIVE ELECTRONIC COMPONENTS

THAT CAN BE DAMAGED BY ESD AND ROUGH HANDLING. HANDLE PCB
ASSEMBLIES WITH CARE TO PREVENT DAMAGE.
DO NOT GET THE ELECTRONIC AND ELECTRICAL COMPONENTS TOO

WET. EXCESS MOISTURE CAN DAMAGE THE COMPONENTS.
Cleaning Materials
Table 401
Nomenclature Source
Number
Alcohol, Isopropyl Federal Specification Commercially Available
TT-I-735
Brush, Stiff-Bristle, Federal Specification Commercially Available

Nonmetallic H-B-1490
Cleaning Solvent, Formula 409 Clorox Co. (4T284)

(Recommended) Calla 301A Baker Chemicals (19457)
815MX Brulin and Co. (94058)
Cloth, Lint-Free Military Specification Commercially Available

MIL-C-85043
Goggles, Safety --- Commercially Available
Swab, Cotton --- Commercially Available
Tank Compressed Air, --- Commercially Available

20 psig (140 kPag)
Page 401
RADIANT POWER CORP.
PART NUMBER RPS1-B
A. Use clean cotton swabs and isopropyl alcohol (Table 401) to clean the circuit boards and
the electrical/electronic components. Wipe the components dry with clean, lint-free
cloths.
CAUTION: DO NOT USE CLEANING SOLVENTS ON THE BATTERY HOLDER

ASSEMBLY OR THE BATTERY CASE ASSEMBLY. THE SOLVENTS CAN
CAUSE CRACKING OF THE LEXAN MATERIAL.
B. Use clean cotton swabs and isopropyl alcohol (Table 401) to clean the battery holder
assembly (5, IPL Figure 1) and the battery case assembly (20). Wipe the components dry
with clean, lint-free cloths.
WARNING: WEAR SAFETY GOGGLES OR GLASSES WHEN YOU USE COMPRESSED

AIR. POINT THE AIR STREAM AWAY FROM OTHER PEOPLE.
C. Clean all other components in a sonic bath or use lint-free cloths and the solvent (Table
401). Use a nonmetallic, stiff-bristle brush if necessary to scrub the parts. Dry the parts
with clean, lint-free cloths or clean shop air at less than 20 psig (140 kPag) pressure.
D. Store the nonelectronic components in clean plastic bags or on clean, lint-free cloths until
they are needed for CHECK and ASSEMBLY. Store the PCB assemblies as specified in
DISASSEMBLY.
Page 402
RADIANT POWER CORP.
PART NUMBER RPS1-B
CHECK
Component check procedures are given in Table 501. Use bright light and a 5 power or
greater magnifier to aid visual examinations.
Check Procedures
Method of
Component Check For Corrective Action
Inspection
Threaded Parts Visual Crossed or stripped threads; Replace damaged
loose attaching hardware. components.
Solder Connections Visual Loose or broken solder

connections; cracked or Refer to REPAIR to repair
deteriorated wiring insulation; solder connections.
burns or other signs of open or
short circuits.
Electrical Wire Leads Visual Cracked or cut insulation; cut Refer to ASSEMBLY to
wire strands; check all wires for replace damaged wire
continuity; verify that all wires are leads during final
properly routed and bundled. assembly.
Battery Holder Visual Crossed or stripped head on the Replace the damaged
Assembly (5, IPL 1/4-turn fasteners (25); fasteners (25).
Figure 1) deformation.
Visual Unreadable label (15); cut or torn Refer to REPAIR to

edges; loose adhesive bond. replace the adhesive-
backed labels.
Dimensional Deformed or permanently set Replace the damaged

retraction spring (30); the nominal spring.
free length is 0.75 inch (1.9 cm);
the ends must be square within
2deg.and the spring must roll
smoothly on a flat surface.
Visual Cracked or chipped battery case Replace the battery case

assembly (20). assembly (20).
Page 501
RADIANT POWER CORP.
PART NUMBER RPS1-B
Check Procedures
Method of
Inspection
Battery Holder Visual Leakage from a cracked or Replace the batteries (55)
Assembly (5, IPL corroded battery (55) cell; cut or or battery holder assembly
Figure 1)(continued) detached battery tab. (5); instructions to connect
new batteries are given in
ASSEMBLY.
Chassis Nameplate Visual Cut wire braid (90). Replace the wire braid (90).
(105)
Visual Unreadable; cut or torn edges; Refer to REPAIR to replace
loose adhesive bond. the adhesive-backed
nameplate.
Cover Assembly (110) Visual Corrosion; chemical film finish Refer to REPAIR to remove
scratched or worn to base metal. corrosion and apply Alodine
over the damaged areas.
Visual Deformation; check mounting Replace the cover

holes for cracks. assembly (110).
Visual Unreadable silkscreen markings; Refer to REPAIR to replace

damaged insulated tape. the silkscreen markings and
tape.
Electronics Assembly Visual Deformed front panel (125, IPL Replace the front panel
(120 or 120A) Figure 2); check mounting holes (125).
for cracks.
Visual Bent or damaged pin contacts in Refer to REPAIR to replace

connector J1 (110); sheared or damaged pin contacts or
deformed locking tabs; damaged wire leads, or replace the
shell or corroded seal. damaged connector (110).
Visual Crossed or stripped threads on the Replace switch SW1 (100).

switch SW1 (100) housing or in
the hex nut; damaged terminals or
push button switch mechanism.
Page 502
RADIANT POWER CORP.
PART NUMBER RPS1-B
Check Procedures
Method of
Inspection
Electronics Assembly Visual Cracked or burned resistor R1 or Replace the damaged
(120 or 120A) R2 (65). resistor (65).
Visual Loose or damaged board Replace logic PCB

mounted components or assembly A1 (15 or 15A);
damaged circuit traces on logic Radiant Power Corp.
PCB assembly A1 (15 or 15A); recommends that
discolored, cracked, or chipped damaged PCB assemblies
circuit board; warpage or twist be returned to Radiant
greater than 1.5%. Power Corp. for repair;
other than replacement of
SIT components, PCB
assemblies repaired at
facilities other than Radiant
Power Corp. are not
guaranteed by Radiant
Power Corp.
Visual Loose or damaged board Replace regulator PCB

mounted components or assembly A2 (10); Radiant
damaged circuit traces on Power Corp. recommends
regulator PCB assembly A2 (10); that damaged PCB
discolored, cracked, or chipped assemblies be returned to
circuit board; warpage or twist Radiant Power Corp. for
greater than 1.5%. repair; other than
replacement of SIT
components, PCB
assemblies repaired at
facilities other than Radiant
Power Corp. are not
guaranteed by Radiant
Power Corp.
Chassis Assembly Visual Loose or damaged clinch nuts Refer to REPAIR to

(130) (160) in the bracket assemblies replace the damaged
(140); stripped threads in the clinch nuts (160), or
clinch nuts; bent bracket. replace the damaged
bracket assembly (140).
Visual Loose or crooked standoffs (150 Replace the chassis

and 155); stripped internal assembly (130).
threads.
Visual Deformed chassis (165); cracks Replace the chassis

around the mounting holes. assembly (130).
Visual Corroded chassis (165); chemical Refer to REPAIR to

film finish scratched or worn to remove corrosion and
base metal. apply Alodine over the
damaged areas.
Page 503
RADIANT POWER CORP.
PART NUMBER RPS1-B
Page 504
RADIANT POWER CORP.
PART NUMBER RPS1-B
REPAIR
1. General
A. Use the appropriate procedures given below to repair damaged parts. Refer to
ASSEMBLY to replace damaged wire leads and repair solder connections during final
assembly of the BPS battery pack.
Paragraph Repair Action
2 Tools and Materials

3 Repair Minor Thread Damage
4 Replace Pin Contacts in Connector J1
5 Replace Clinch Nuts
6 Repair Cover Assembly
7 Repair Chemical Film Finishes
8 Replace Riveted Components
CAUTION: UNITS UNDER WARRANTY SHOULD BE RETURNED TO RADIANT POWER
CORP. FOR REPAIR. REMOVAL OF THE TOP COVER WILL VOID THE
WARRANTY
THE PCB ASSEMBLIES CONTAIN SENSITIVE ELECTRONIC COMPONENTS

THAT CAN BE DAMAGED BY ESD AND ROUGH HANDLING. HANDLE THE
PCB ASSEMBLIES WITH CARE TO PREVENT DAMAGE.
PCB ASSEMBLIES REPAIRED AT FACILITIES OTHER THAN RADIANT

POWER CORP. ARE NOT GUARANTEED BY RADIANT POWER CORP.
B. If the BPS battery pack is under warranty, return it to Radiant Power Corp. for repair.
Removal of the top cover in the warranty period will void the warranty.
C. For field repair, refer to TESTING AND FAULT ISOLATION and/or CHECK to identify the
damaged component, and then refer to DISASSEMBLY and ASSEMBLY to replace the
components. Refer to the referenced IPL figure, and item number to order replacement
components.
D. Follow industry standard practices to solder components and wire leads.
E. PCB assemblies A1 and A2 contain fragile electronic components and circuits. The
handling precautions and instructions given below will minimize or eliminate possible
damage.
NOTE: With exception of the Select In Test (SIT) components identified in the IPL,
Radiant Power Corp. recommends that the PCB assemblies be returned to
Radiant Power Corp. for repair by technicians familiar with the layout and
function of the cards. PCB assemblies repaired at facilities other than Radiant
Power Corp. are not guaranteed by Radiant Power Corp.
Page 601
RADIANT POWER CORP.
PART NUMBER RPS1-B
(1) All integrated circuits (ICs), surface mounted devices, and many other
semiconductors are susceptible to ESD (electrostatic discharge). Careless handling
during repair can drastically decrease the component life.
(2) All work on PCB must be done at an electrostatic discharge (ESD) safe work bench.
Refer to REPAIR for general ESD handling instructions and work bench
requirements.
(3) Store the PCB assemblies in protective antistatic shipping bags until ready for use.
Do not store the PCB assemblies in conventional plastic snow, Styrofoam, or plastic
trays. Once removed from the bags, PCB assemblies must be handled in
accordance with static control procedures. The preferred method is to handle PCB
assemblies with clean lint-free cloths or rubber gloves only on the edge of the
board. If gloves or cloths are not available, wash your hands to remove oils and
handle the boards only on the edges; do not touch the conductive patterns or
components.
(4) Once removed from the bags, PCB assemblies must be handled in accordance with
static Component Maintenance Manual control procedures. The preferred method is
to handle PCB assemblies with clean lint-free cloths or rubber gloves only on the
edge of the board. If gloves or cloths are not available, wash your hands to remove
oils and handle the boards only on the edges; do not touch the conductive patterns
or components.
(5) Do not stack the PCB assemblies. Stacking can damage surface mounted
components.
(6) The work station must be clean. To prevent contamination of the PCB assemblies,
there must be no smoking, eating, or drinking in the work area.
A. The recommended tools and materials are given in Table 601.
Page 602
RADIANT POWER CORP.
PART NUMBER RPS1-B
Repair Tools and Materials

Table 601
Nomenclature Source (CAGE)*
Number
Abrasive Cloth, Aluminum Oxide Federal Specification Commercially Available
P-C-451
Alodine, Brush No. 120 Henkel Corp. (84063)
Ink, Epoxy (Black) Hysol 50-700R
Insertion/Extraction Tool, Pin Military Specification Commercially Available

Contact MS24256R12
Pin Contact, Electrical Military Specification Commercially Available

Connector MIL-C-26636
Press Hydraulic or Mechanical --- Commercially Available
Silkscreen Template, Nameplate 11-0054 Radiant Power Corp.

and ESD Caution
Solder, Resin Core, Composition Federal Specification Commercially Available

Sn63 QQ-S-571
Solder Iron, Low Wattage (24 to --- Commercially Available

40 Waft)
Tape, Glass Fiber Insulated Military Specification Commercially Available

MIL-1-1966
Wire, Electrical, 20 and 24 AWG BMS13-48C or MIL-W-22759 Commercially Available

(select size and color per Table (Raychem 55A0111-20, -24)
602)
*Refer to Table 1001 in the IPL for the address
Page 603
RADIANT POWER CORP.
PART NUMBER RPS1-B
The BPS battery pack contains electronic components that can be damaged by ESD and
rough handling. The general handling precautions and instructions given below will help
minimize or eliminate possible damage.
WARNING: THE BPS BATTERY PACK CONTAINS HIGH VOLTAGE CIRCUITS WHICH
CAN CAUSE DEATH OR SEVERE SHOCK. FOLLOW THE SAFETY
PRECAUTIONS GIVEN IN THE INTRODUCTION TO THIS CMM TO PREVENT
INJURY.
CAUTION: THE PCB ASSEMBLIES CONTAIN ESD SENSITIVE DEVICES. HANDLE THE
PCB ASSEMBLIES IN ACCORDANCE WITH STATIC CONTROL
PROCEDURES TO PREVENT COMPONENT DAMAGE.
A. THE BPS BATTERY PACK CONTAINS SENSITIVE ELECTRONIC COMPONENTS

THAT CAN BE DAMAGED BY ROUGH HANDLING AND EXPOSURE TO HIGH
HUMIDITY, WATER OR OTHER LIQUIDS, CIGARETTE SMOKE, AND OTHER
CONTAMINATION. USE THE BPS BATTERY PACK IN AN ENVIRONMENT SUITABLE
FOR ELECTRONIC COMPONENTS AND HANDLE THE UNIT WITH CARE TO
PREVENT DAMAGE.
B. If liquid or grease is spilled on or in the BPS battery pack, immediately remove power and
wipe off the liquid or grease. Do not touch the BPS battery pack until power has been
removed.
C. Do not use or store the BPS battery pack in a high humidity environment or in direct
sunlight. High humidity can short or corrode electronic components.
D. All integrated circuits (ICs), surface mounted devices, and many other semiconductors
are susceptible to ESD. Careless handling during repair can drastically decrease the
component life.
E. When handling ESD sensitive devices, work at an ESD safe work bench. The work
bench should include:
F. Store the PCB assemblies in protective antistatic shipping bags until ready for use. Do
Page 604
RADIANT POWER CORP.
PART NUMBER RPS1-B
G. Once removed from the bags, PCB assemblies must be handled in accordance with
4. Repair Minor Thread Damage,
Repair damaged threads with an appropriate die or tap if less than 50 percent of one thread is
damaged. Replace non-repairable parts.
5. Replace Pin Contacts in Connector J1
NOTE: Refer to DESCRIPTION AND OPERATION, Figure 3 for a schematic diagram. A wire
list for connector J1 is given in Table 602.
A. Use the insertion/extraction tool to insert the pin contacts into the appropriate connector
J1 (110) sockets. Refer to Table 602.
6. Replace Clinch Nuts
Use this procedure to replace damaged clinch nuts (160, IPL Figure 1 and 32, IPL Figure 3).
A. Support the bracket or heatsink on the press (Table 601) so it does not move or bend.
B. Use a punch and the press to push out the damaged nut. Do not bend or crimp the
bracket or heatsink around the mounting hole.
C. Install a new clinch nut in the mounting hole. Put the shank on the punch side as shown
in Figure 601.
CAUTION: DO NOT CRUSH THE NUT OR DAMAGE THE THREADS. THE HOLE IN THE
PUNCH OR ANVIL MUST CLEAR THE THREADS.
D. With the punch and anvil surfaces parallel, apply force until the shank of the clinch nut is
flush with the underside of the bracket or heatsink.
NOTE: The punch or anvil must apply force to the knurled collar of the nut but must
have a cavity that fits over the threads so force is not applied to the barrel. Refer
to Figure 601.
E. Examine the clinch nut and the bracket or heatsink for deformation or other damage.
(1) The clinch nuts must be aligned and mounted flush with each other.
(2) There must be no deformation or cracks around the bracket or heatsink mounting
holes.
Page 605
RADIANT POWER CORP.
PART NUMBER RPS1-B
Connector J1 Wire List
Table 602
Wire Wire Size Connector J1 From

Color (AWG) Pin Component
Orange 20 J1-1 A2-16
Orange 24 J1-4 A1-2
Orange 20 J1-5 A2-2
Orange 24 J1-7 Solder Lug
Orange 20 J1-9 A2-6
Orange 24 J1-12 A1-12
Orange 24 J1-13 A1-13
Orange 24 J1-14 A1-10
Orange 24 J1-18 A1-18
Orange 24 J1-22 A1-14
Clinch Nut Installation

Figure 601
Page 606
RADIANT POWER CORP.
PART NUMBER RPS1-B
7. Repair Cover Assembly
NOTE: This procedure repairs the nameplate and ESD caution silkscreen markings and the
insulating tape on the cover assembly (110, IPL Figure 1). Do this procedure after
repair of the chemical film finish.
WARNING: PAINT THINNER IS VERY FLAMMABLE AND CAN DAMAGE YOUR EYES
AND NOSE. USE THE MATERIALS ONLY IN WELL VENTILATED AREAS
AWAY FROM OPEN FLAMES. WEAR RUBBER GLOVES AND GOGGLES TO
PROTECT YOUR HANDS AND EYES.
A. Use paint thinner (Table 601) to remove the damaged ink markings.
B. Refer to CLEANING to clean the repair area.
C. Use the template and black ink (Table 601) to reapply silkscreen markings.
D. Replace the insulated tape (Table 601) as needed on the inner surface of the cover. The
tape is used in two places to insulate the cover from the electronics assembly.
8. Repair Anodized Finishes
WARNING: ALODINE IS VERY FLAMMABLE AND CAN DAMAGE YOUR EYES AND
NOSE. USE ALODINE ONLY IN WELL VENTILATED AREAS AWAY FROM
OPEN FLAMES. WEAR RUBBER GLOVES, AN APRON, AND GOGGLES FOR
SAFETY.
A. Repair damaged anodized finishes with No. 120 brush Alodine (Table 601) as specified
below.
NOTE: This procedure gives general instructions for skilled technicians. Refer to
Technical Process Bulletin No. 1161, available from the Henkel Corp. (CAGE
84063), for complete instructions.
B. The Alodine is light brown to orange in color. It is not available in other colors, so the
repaired area may not match the original anodize finish.
C. Clean the component to remove grease, oil, and corrosion.
D. Apply undiluted Alodine liberally to the aluminum surface. Apply as many coats as
needed. Allow approximately one minute reaction time between the applications.
NOTE: The Alodine will dry faster when the Alodine and the part are at room
temperature (approximately 65°F to 75°F). One to five minutes is normally
required for the coat to dry. The Alodine can be applied with an acid-resistant
brush, swab, synthetic sponge, or portable spray equipment..
E. Remove any excess Alodine with clean water and lint-free cloths.
Page 607
RADIANT POWER CORP.
PART NUMBER RPS1-B
F. Use lint-free cloths or compressed air at less than 20 psig (138 kPag) to dry the part. Pay
close attention to the seams, joints, and crevices.
9. Replace Riveted Components
NOTE: Use this procedure to replace cracked or loose rivets or to replace damaged
components attached with rivets.
CAUTION: DO NOT ENLARGE THE RIVET MOUNTING HOLE.
A. Drill out the damaged rivet with a drill bit smaller than the diameter of the rivet (145, IPL
Figure 1) shank. Do not enlarge the mounting hole beyond the minimum needed to
remove the rivet.
NOTE: The diameter of the rivet shank is given in the NOMENCLATURE column of the
IPL. The size of the rivet holes are controlled by standard shop-practice use of
oversize replacement rivets. The minimum pitch and edge distances for rivets
are determined by the original design and should be closely matched during
repair.
B. Install new rivets (145) as needed to secure the battery mounting brackets (140).
Page 608
RADIANT POWER CORP.
PART NUMBER RPS1-B
ASSEM BLY (INCLUDING STORAGE)
1. General
A. This section contains reassembly, packaging, and storage instructions. The procedures
are arranged in the reverse sequence of DISASSEMBLY and the IPL. Skip procedures
and/or procedure steps as applicable if the BPS battery pack is already partially
assembled.
NOTE: Refer to REPAIR for instructions to replace the 15, IPL Figure 1), damaged
clinch nuts (160 IPL Fig. 1 (32 IPL Fig. 3), all riveted components, and all
bonded components.
B. Refer to IPL Figure 1 for an exploded-view illustration of the BPS battery pack. Refer to
DESCRIPTION AND OPERATION, Figure 3, for wire routing.
C. This CMM covers maintenance of the RPS1-B configuration only. Contact Radiant Power

D. Two electrically identical but physically different logic PCB assemblies are used in the
this CMM.
11-0041-1 0626 and subsequent 2-15

11-0041-2 0053 through 0625 2-15A
E. All work must be done at an electronics work bench. Refer to paragraph 2, below, for
general handling instructions and work bench requirements. No other special tools or
equipment are required.
A. The recommended tools and materials are given in Table 701.
B. All work on PCB must be done at an electrostatic discharge (ESD) safe work bench.
Refer to REPAIR for general ESD handling instructions and work bench requirements.
No other special tools or equipment are required.
Page 701
RADIANT POWER CORP.
PART NUMBER RPS1-B
PCB assemblies A1 and A2 contain fragile electronic components and circuits. The handling
precautions and instructions given below will minimize or eliminate possible damage.
A. All integrated circuits (ICs), surface mounted devices, and many other semiconductors
are susceptible to ESD (electrostatic discharge). Careless handling during repair can
drastically decrease the component life.
B. When handling ESD sensitive devices, work at an ESD safe work bench. The bench
should include:
C. Store the PCB assemblies in protective antistatic shipping bags until ready for use. Do
D. Once removed from the bags, PCB assemblies must be handled in accordance with
E. Do not stack PCB assemblies. Stacking can damage surface mounted components.
F. The work station must be clean. To prevent contamination of PCB assemblies, there
must be no smoking, eating, or drinking in the work area.
Page 702
RADIANT POWER CORP.
PART NUMBER RPS1-B
4. Electrical Wire Replacement
NOTE: This procedure provides general instructions to select and solder new wire leads
during assembly. Refer to MIL-STD-454, Requirement 5 for soldering instructions.
CAUTION: DO NOT OVERHEAT ELECTRONIC COMPONENTS WHEN SOLDERING

WIRE LEADS. USE A HEAT SINK AND LOW WATTAGE SOLDER IRON TO
PREVENT DAMAGE. USE A SOLDER SUCKER AND/OR SOLDER WICK TO
REMOVE EXCESS SOLDER.
PCB ASSEMBLIES A1 AND A2 CONTAIN SENSITIVE ELECTRONIC

COMPONENTS THAT CAN BE DAMAGED BY ESD AND ROUGH HANDLING.
HANDLE THE PCB ASSEMBLIES WITH CARE TO PREVENT DAMAGE.
A. Trim new wire leads as needed to the length given in Table 702. Select the wire color
and gage to match.
NOTE: All wire lengths to be ±1/16 inch (±1.6 mm). Pre-strip all wire ends to 1/8 inch
(3.2 mm).
B. Solder the wire leads to the applicable terminals given in Table 703 with the solder given
in Table 701. Duplicate the original wire routing as closely as possible. Refer to REPAIR
to replace the connector J1 wire leads and pin contacts.
NOTE: Refer to DESCRIPTION AND OPERATION, Figure 3, for wire routing.
5. Assembly Instructions
A. Chassis Assembly (130, IPL Figure 1)
(1) Refer to REPAIR to replace the riveted battery assembly brackets (140).
(2) Refer to REPAIR to replace the clinch nuts (160).
B. Battery Charger Assembly (100, IPL Figure 1)
NOTE: This procedure contains information for wire routing. Duplicate the original wire
routing, insulation, and soldering methods as closely as possible. A point-to-
point wire list is given in Table 703. A schematic diagram showing all
connections is given in DESCRIPTION AND OPERATION, Figure 3.
C. Install resistors R1 and R2 (65, IPL Figure 2), as follows:
(1) Solder the wire leads to resistor R1 and/or R2 (65). Refer to paragraph 3, above,
and Figure 701.
(2) Lightly coat the threads of the screws (80) with thread lock compound (Table 701).
Secure the resistors to the bracket assemblies (85 and 90) with the screws, the
washers (75), and the nuts (70).
Page 703
RADIANT POWER CORP.
PART NUMBER RPS1-B
D. Install transistor Q2 (35), as follows:
(1) Solder the wire leads between transistor Q2 (35) and the solder lug (60) and
regulator PCB assembly A2 (10). Refer to paragraph 3, above and Table 703.
(2) Secure transistor Q2 (35), Thermal insulator pad, and an insulator strip (55) to the
bracket assembly (85) with the screws (45A or 45B) and the nuts (40). Install the
solder lug (60) under the upper nut as shown in Figure 701.
NOTE: Install a new Thermal insulator pad (50) at each overhaul.
Resistor R1/R2 Wiring Diagrams

Figure 701
Page 704
RADIANT POWER CORP.
PART NUMBER RPS1-B
E. Install transistor Q1 (30), as follows:
(1) Solder the wire leads between transistor Q1 (30), the solder lug (60), and regulator
PCB assembly A2 (10). Refer to paragraph 3, above and Table 703.
(2) Solder the wire lead from the transistor Q1 (30) emitter to resistor R2 (65).
(3) Secure transistor Q1 (30), Thermal insulator pad, and an insulator strip (55) to the
bracket assembly (90) with the screws (45A or 45B) and the nuts (40). Install the
solder lug (60) under the upper nut as shown in Figure 701.
F. Install transistor Q3 (5, IPL Figure 3) on regulator PCB assembly A2, as follows:
(1) Refer to REPAIR to replace the damaged clinch nuts (32).
(2) Secure transistor Q3 (5), Thermal insulator pad, the bracket assembly (30), and an
insulator strip (25) to the swaged standoffs on regulator PCB assembly A2 with the
screws (10) and the washers (15).
G. Solder the wire leads between logic PCB assembly A1 (15 or 15A, IPL Figure 2) and
regulator PCB assembly A2 (10). Refer to paragraph 3, above and Table 703.
NOTE: With exception of the SIT components identified in the IPL, Radiant Power Corp.
recommends that PCB assemblies A1 and A2 be returned to Radiant Power
Corp. for repair by technicians familiar with the layout and function of the cards.
PCB assemblies repaired at facilities other than Radiant Power Corp. are not
guaranteed by Radiant Power Corp..
H. Solder the connector J1 (110) wire leads to the PCB assemblies (10 and 15 or 15A).
I. Solder the wire leads between TEST switch SW1 (100) and logic PCB assembly A1 (15
or 15A).
J. Solder the wire lead from connector J1 (110), pin 7, to the solder lug (105).
K. Visually examine all solder connections, wire leads, and wire routing. Refer to Table 703
and Figure 3 in DESCRIPTION AND OPERATION.
WARNING: THE CONFORMAL COATING CAN IRRITATE YOUR EYES AND NOSE.
APPLY THE COATING ONLY IN A WELL VENTILATED AREA. FLUSH
IRRITATED EYES WITH WATER.
CAUTION: THE WORK AREA AND BRUSH MUST BE CLEAN TO PREVENT

CONTAMINATION.
Page 705
RADIANT POWER CORP.
PART NUMBER RPS1-B
L. Touch-up the conformal coating (Table 701) on the electronics assembly (120 or 120A,
IPL Figure 1) as given below.
NOTE: This step applies conformal coating to the electronics assembly using a
synthetic fiber brush. This is the preferred method for repairs over aerosol
sprays or dipping the assembly in a dip tank.
(1) Fold open the circuit boards and other components as needed to access the
conformal coated surfaces.
(2) Use a stiff bristle brush, plastic blade, or an equivalent tool to remove loose particles,
ridges of coating material, and other defects in the conformal coating. The coated
areas must have no visible blisters, cracking, peeling, pin holes or wrinkles. There
must be no bubbles in contact with or bridging conductive surfaces.
(3) Flood the area with isopropyl alcohol (Table 701) to wash off particles and soluble
contamination.
(4) Allow the electronics assembly to air dry for 30 minutes.
(5) Examine the electronics assembly under black, ultraviolet light. Identify bare areas,
other than solder connections, where the conformal coating has been worn through
or scraped off.
(6) Pour the necessary amount of Humiseal conformal coating (Table 701) from the
sealed container into a temporary container.
NOTE: The Humiseal conformal coating must be stored in a sealed container or it

will form a skin of solid material after approximately four hours. The skin
can be dissipated by pouring a 1/16 to 1/8 inch layer of thinner, Humiseal
No. 20, over the material and covering the container with a tightly fitting
cover.
(7) Apply the conformal coating material with a synthetic (not natural) fiber brush. Coat
all solder connections and the nonconductive areas of the PCB assemblies,
including both sides of the printed circuit board, all board mounted components and
their leads, and all exposed conductors. Do not coat electrical and mechanical
mating surfaces, such as connector contact points, screw threads, bearing surfaces,
etc. Mask the surfaces and components before application of the coating material,
and carefully remove any tape residue and other contamination after the material
has been applied. The coating must be 0.001 to 0.003 inch (0.025 to 0.076 mm)
thick, when measured on a flat, unobstructed surface.
(8) The coated areas must have no visible blisters, cracking, peeling, pin holes or
wrinkles. There must be no bubbles in contact with or bridging conductive surfaces.
(9) Examine the electronics assembly under black, ultraviolet light. Identify bare areas
that require conformal coating. Reapply conformal coating to cover defective or bare
areas, as required.
Page 706
RADIANT POWER CORP.
PART NUMBER RPS1-B
(10) Allow the conformal coating to cure in accordance with the manufacturer's
instructions.
M. Lightly coat the threads of TEST switch SW1 (100, IPL Figure 2) with thread lock
compound (Table 701). Install the switch through the solder lug (105) and the front panel
(125) with the hex nut provided.
N. Lightly coat the threads of the screws (20) with thread lock compound. Secure regulator
PCB assembly A2 (10) and the insulator (12) to the mounting brackets (85 and 90) with
the screws and the washers (25).
NOTE: Install the insulating washers (25) on both sides of the printed circuit board.
Install new washers at each overhaul.
O. Lightly coat the threads of the screws (20) with thread lock compound. Secure logic PCB
assembly A1 (15 or 15A) to the mounting brackets (85 and 90) with the screws and the
washers (25).
NOTE: Install the insulating washers (25) on both sides of the printed circuit board.
Install new washers at each overhaul.
P. Install connector J1 (110) in the front panel (125) with the screws (115) and the nuts
(1 20A).
Q. Secure the front panel (125) to the mounting brackets (85 and 90) with the screws (95).
CAUTION: DO NOT LIFT THE ELECTRONICS ASSEMBLY AFTER MATING THE PIN
CONTACTS AND SOCKETS. DOING SO CAN DAMAGE THE PIN CONTACTS
ON REGULATOR PCB ASSEMBLY A2.
R. Install the electronics assembly (120 or 120A, IPL Figure 1), as follows:
(1) Lightly coat the bottoms of the transistor Q1, and Q2 and Q3 mounting brackets with
thermal compound (Table 701).
(2) Insert the electronics assembly (120 or 120A) into the chassis assembly (130).
(3) Press the electronics assembly (120 or 120A) against the chassis and carefully slide
it inward to insert pin contacts J3-1 and J3-2 on regulator PCB assembly A2 into pin
sockets J2-1 and J2-2 (60 and 65) in the battery holder assembly (5).
(4) Lightly coat the threads of the screws (125) with thermal compound (Table 701).
Install the screws through the chassis assembly (130) and into the electronics
assembly (120 or 120A).
S. Refer to REPAIR to replace the adhesive-backed chassis nameplate (105) or the

silkscreen markings, as applicable.
T. Install the cover assembly (110) with the screws (115).
Page 707
RADIANT POWER CORP.
PART NUMBER RPS1-B
6. Battery Holder Assembly (5, IPL Figure 1)
A. Bond the fuse retainer pad (95, IPL Figure 1) to the top half of the battery case (20), as
follows:
CAUTION: DO NOT USE SOLVENT CLEANERS ON THE BATTERY CASE (20).

SOLVENTS CAN DAMAGE THE LEXAN MATERIAL.
(1) Clean the mounting area on the top half of the battery case (20) with isopropyl
alcohol and lint-free cloths (Table 701).
(2) Bond the fuse retainer pad (95) to the top half of the battery case (20) with adhesive
(Table 701).
CAUTION: DO NOT SOLDER THE WIRE BRAID (90) ON THE END OF THE BATTERY
PACK OPPOSITE PIN SOCKETS J2-1 AND J2-2 UNTIL THE SOCKETS ARE
CONNECTED AND INSULATED.
B. Solder the batteries (55) in series as shown in Figure 702. Do not connect the wire braid
(90) opposite pin sockets J2-1 and J2-2 (60 and 65) until the pin sockets are soldered
and insulated (step (6), below).
NOTE: Replacement batteries (55) are shipped with integral solder tabs. All six
batteries should be replaced if any one battery is damaged or corroded.
Battery Connection Diagram

Figure 702
Page 708
RADIANT POWER CORP.
PART NUMBER RPS1-B
C. Cut two 1.375-inch (3.49 8.9 cm) lengths of wire braid (90). Solder one wire braid to the
positive tab on the battery pack and one to the negative tab. Refer to Figure 702.
D. Install two shoulder washers (85) back to back through each pin socket (60 and 65)
mounting hole in the top half of the battery case (20). Insert the pin sockets through the
shoulder washers and install the flat washers (80) and the nuts (70).
E. Turn the top half of the battery case (20) upside down and install the batteries (55) with
the solder tabs facing up (out away from the case). Loop the positive and negative wire
braids (90) up along the outside and over the top of pin sockets J2-1 and J2-2 (60 and
65).
NOTE: The wire braid (90) from the positive battery pack terminal connects to red pin
socket J2-1 (60). The wire braid from the negative terminal connects to black pin
socket J2-2 (65). Refer to Figure 701.
CAUTION: DO NOT TIN THE BRAID MORE THAN 1/4 INCH (6 MM) FROM THE PIN
SOCKET TINNING CAN DECREASE THE FLEXIBILITY OF THE BRAID.
F. Solder the positive and negative wire braids (90) to pin sockets J2-1 and J2-2 (60 and
65). Refer to paragraph 3, above.
CAUTION: INSERT A PIECE OF INSULATING MATERIAL BETWEEN PIN SOCKETS J2-1

AND J2-2 TO PREVENT SHORTING DURING MAINTENANCE.
G. Insert a piece of insulating material (tape, paper, etc.) between pin sockets J2-1 and J2-2
(60 and 65).
H. Solder the rear wire braid (90) to the applicable battery (55) tabs. Refer to Figure 701.
I. Rotate each group of three batteries (55) inward, tucking the intermediate solder tabs
behind the integral insulators in the top half of the battery case (20). Loop the rear wire
braid (90) inward between the batteries.
J. Install the 1/4-turn fasteners (25) and the retraction springs (30) in the pockets in the top half
of the battery case (20). Install the Teflon washers (35A) on the fasteners inside the
case.
CAUTION: MAKE SURE THERE IS NO CONTACT BETWEEN PIN SOCKETS J2-1 AND
J2-2 OR ANY OTHER OPPOSITELY CHARGED COMPONENT BEFORE THE
INSULATING MATERIAL IS REMOVED.
K. Remove the insulating material from between pin sockets J2-1 and J2-2 (60 and 65).
Page 709
RADIANT POWER CORP.
PART NUMBER RPS1-B
L. Install the bottom half of the battery case (20), with the insulator inserted between pin
sockets J2-1 and J2-2 (60 and 65). The Teflon washers (35A) must be installed between
the top and bottom half cases. The 1/4-turn fasteners (25) must extend through the
matching holes in the bottom half.
CAUTION: DO NOT OVERTIGHTEN THE SCREWS (50) AND THE NUTS (40A). THE
BATTERY CASE IS MADE OF A LIGHTWEIGHT PLASTIC MATERIAL THAT
CAN CRACK.
M. Install the screws (50) and the nuts (40A) to secure the top and bottom halves of the
battery case (20) together. Tighten the nuts snug but not enough to damage the battery
case.
CAUTION: DO NOT LIFT THE BATTERY HOLDER ASSEMBLY AFTER MATING THE PIN
CONTACTS AND SOCKETS. DOING SO CAN DAMAGE THE PIN CONTACTS
ON PCB ASSEMBLY A2.
N. Install the battery holder assembly (5), as follows:
(1) Insert the battery holder assembly (5) into the chassis assembly (130).
(2) If the electronics assembly (120 or 120A) is installed, press the battery holder
assembly (5) against the chassis and carefully slide it inward to insert pin contacts
J3-1 and J3-2 on regulator PCB assembly A2 into pin sockets J2-1 and J2-2 (60
and 65).
(3) If the electronics assembly (120 or 120A) is not installed, press the battery holder
assembly (5) against the chassis and carefully slide it inward to a position over the
receptacles (135) in the chassis brackets.
CAUTION: DO NOT TURN THE 1/4-TURN FASTENERS PAST THE DETENT.
(4) Turn the 1/4-turn fasteners (25) clockwise approximately 90° to the stop. An audible
click will be heard when the stop is reached. The fasteners should compress the
retraction springs (30).
O. Refer to TESTING AND FAULT ISOLATION to bench test the BPS.
Page 710
RADIANT POWER CORP.
PART NUMBER RPS1-B
7. Packaging Instructions
Protect the BPS battery pack from humidity and shock by packaging the unit when it is not in
use or for transport. Repack the BPS battery pack in the original shipping container when
possible.
CAUTION: THE PCB ASSEMBLIES CONTAIN ESD SENSITIVE DEVICES. REFER TO

REPAIR FOR ESD SAFE HANDLING PROCEDURES.

A. Refer to REPAIR for ESD safe handling procedures.
B. If loose components must be shipped, pack the PCB assemblies in antistatic shipping
bags. Pack all other components in clean plastic bags. The materials given below are
unacceptable and prohibited from use in any packaging where they could come into
direct contact with the PCB assemblies.
(1) Untreated styrofoam, polyform or polystyrene sheets, black inserts, and foam filler
pieces (for example, foam peanuts).
(2) Untreated plastic boxes.
(3) Static-generating plastic wrap, bags, or bubble pack.
(4) Pink poly foam and bubble wrap that is not certified Amine-free.
(5) Untreated connector plastic dust covers.
C. If the original shipping containers are not available, pack the BPS battery pack, as
follows:
(1) Write the maintenance data and dates on a tag. Attach the tag to the battery pack.
(2) Install a protective cap (Table 7023) on connector J1.
(3) Overwrap the battery pack in nylon film or bubble wrap to cushion the unit and
prevent damage to the barrier bag.
(4) Pack the battery pack in a corrugated paper box. Fill all voids with cellulose wadding
or brown Kraft paper.
(5) Add a sufficient amount of desiccant and sea the box with packing tape.
(6) Write the BPS battery pack nomenclature, part number, and maintenance/test dates
on the box.
Page 711
RADIANT POWER CORP.
PART NUMBER RPS1-B
8. Storage Instructions
CAUTION: THE PCB ASSEMBLIES CONTAIN ESD SENSITIVE DEVICES. REFER TO

REPAIR FOR ESD SAFE HANDLING PROCEDURES.

A. Refer to REPAIR for ESD safe handling procedures.
B. Refer to ASSEMBLY, paragraph 6 to package the BPS battery pack for storage.
C. Store the BPS battery pack in an area suitable for electronic equipment. The storage
area must have adequate ventilation with low humidity, dust, and protection from direct
sunlight and high heat.
(1) Store the BPS in a cool, dry area, as follows:
(a) Battery Packs may be stored without damage in a charged or discharged

condition over the temperature range of –30°C to +70°C (-22°F to +158°F).
Long term storage (over 3 months) should be at temperatures less than +35°C
(+95°F).
(b) The batteries will self-discharge at a rate dependent on time and temperature.
At room temperature of 72°F (22°C), the rate is approximately 1.5% every 24
hours. The rate increases as the storage temperature increases, and
decreases as the temperature decreases. The batteries should always be
recharged for 16 hours at a constant current of 350 milliamperes before use.
(c) To store the BPS charged and ready for immediate use, fully charge the BPS
at 350 milliamperes for 16 to 20 hours and store the unit for no more than 30
days at an ambient temperature of 77°F (25°C). After 30 days, the BPS should
be discharged to the cutoff voltage of 5.4 VDC, and then recharged at 350
milliamperes for 16 to 24 hours. Repeat this cycle to maintain charged
batteries ready for immediate use.
Page 712
RADIANT POWER CORP.
PART NUMBER RPS1-B
Assembly Tools and Materials

Table 701
Nomenclature Source
Number
Adhesive RTV 102 General Electric Supply Co.
(9G944)
Alcohol, Isopropyl Federal Specification TT-I-735 Commercially Available
Brush, Synthetic Fiber --- Commercially Available
Conformal Coating, Brush Military Specification Columbia Chase Corp. (99109)

Application MIL-1-46058, Class C, Type UR
(Humiseal 1A20)
Solder, Resin Core, Federal Specification Commercially Available

Composition Sn63 QQ-S-571
Solder Iron, Low Wattage --- Commercially Available

(24 to 40 Waft)
Thermal Compound 120-2 The Wakefield Corp. (92218)
Thread Lock Compound Military Specification Loctite Corp. (05972)

MIL-S-22437(Loctite Grade H)
Ultraviolet Light, Black --- Commercially Available
Wire, Electrical, 20 and 24 BMS13-48C or MIL-W-22759 Commercially Available

AWG (select size and color (Raychem 55A0111-20, -24)
per Table 702)
Storage Materials
Table 702
Part Number or Specification

Description Source (CAGE)*
Number
Bag, Polyethylene Military Specification Commercially Available

MIL-B-117
Box, Corrugated Paper Federal Specification Commercially Available

PPP-B-636
Cover, Protective --- Protective Closures Inc. (99017)
Tape, Packing Federal Specification Commercially Available

JAN-P-127
Tag, Identification --- Commercially Available

Page 713
RADIANT POWER CORP.
PART NUMBER RPS1-B
Assembly Wire List
Table 703
Wire Wire Size From To

Color (AWG) Component Component
Orange 24 A1-1 J1-17
Orange 24 A1-2 J1-4
Orange 24 A1-10 J1-14
Orange 24 A1-12 J1-12
Orange 24 A1-13 J1-13
Orange 24 A1-14 J1-22
Orange 24 A1-15 A2-17
Orange 24 A1-16 TEST Switch S1
Orange 24 A1-18 J1-18
Orange 24 A1-19 A2-20
Orange 24 A1-20 A2-14
Orange 24 A1-21 A2-12
Orange 24 A1-22 TEST Switch S1
Orange 20 A2-1 Q2-E (Emitter)
Orange 20 A2-2 J1-5
Orange 20 A2-3 Q2-C (Collector)
Orange 20 A2-6 J1-9
Orange 24 A2-7 Q1-B (Base)
Orange 20 A2-8 Resistor R1
Orange 24 A2-12 A1-21
Orange 24 A2-14 A1-20
Orange 24 A2-17 A1-15
Orange 24 A2-19 Q2-B (Base)
Orange 24 A2-20 A1-19
Orange 20 Resistor R2 Q1-E (Emitter)
Page 714
RADIANT POWER CORP.
PART NUMBER RPS1-B
SPECIAL TOOLS, FIXTURES AND EQUIPMENT
The recommended special tools, fixtures, and test equipment are given in Table 901.
Special Tools, Fixtures, and Equipment

Nomenclature Part Number Source (CAGE)* Use

Bright Light --- Commercially Available To assist in the inspection of
parts.
Brush, Synthetic Fiber --- Commercially Available To apply Humiseal conformal

coating.
Connector, Electrical BACC45FN1 The Boeing Co. (81205) Mating connector to connect
6-24S or Amphenol Corp. (77820) test equipment to BPS for
48-16R16- bench tests.
24S
Diode, Light Emitting 83SF5LR Chicago Miniature To indicate VCC power

Lamp Inc. (71744) during bench tests.
Insertion/Extraction Tool, MS24256R12 Commercially Available To replace damaged pin

Pin Contact contacts in connector J1.
Lamp, Incandescent No.82 General Electric Co. Load to simulate emergency

(Test Load) (7 Required) (0EE74) lights for bench tests.
Megohmmeter, Model 1644- Quadtech Inc. (0PK96) To measure the insulation

100 megohms, 500 VDC, 9701 resistance of the BPS
±2% Full Scale circuits.
Multimeter (Ohmmeter, Model 8010A John Fluke Mfg. Co., To measure voltage, current,
Ammeter or Voltmeter can or 8012A Inc. (89536) and resistance for bench
be used), 0 to 10 Amps tests.
DC (±2% Full Scale), 0 to
100 VDC (3-1/2 digits);
200 to 300 kilohms
Power Supply, 0 to Model Agilent. (28480) DC power source E1 for

8 VDC 6631B bench tests.
Power Supply, 0 to Model Agilent. (28480) DC power source E2 for

32 VDC (E2) E3641A bench tests.
Page 901
RADIANT POWER CORP.
PART NUMBER RPS1-B
Special Tools, Fixtures, and Equipment
Nomenclature Part Number Source (CAGE)* Use

Press, Hydraulic or --- Commercially Available To press new clinch nuts in the
Mechanical brackets and heatsink..
RPS1-B Battery Housing 550-13057-00 Radiant Power Corp. To perform on-aircraft testing of
Analyzer Kit (1MXA1) RPS1-B battery and charger.
Switch, Momentary --- Commercially Available Switch for bench test setup.
Contact, SPST (S1)
Switch, Toggle SPST --- Commercially Available Switch for bench test setup.
(S4 through S7)
(4 Required)
Switch, Toggle SPST --- Commercially Available Switch for bench test setup.
on, off, on
(S2 &, S3)
Switch, Toggle DPDT --- Commercially Available Switch for bench test setup.
(S11)
Solder Iron, Low Wattage --- Commercially Available To solder wire connections to
(24 to 40 Waft) the circuit board pads and other
electronic/electrical
components.
Tank or Shop Compressed --- Commercially Available To clean and dry BPS
Air, 20 psi (140 Pkg) components.
Thread Chaser --- Commercially Available To repair damaged threads.
Page 902
RADIANT POWER CORP.
PART NUMBER RPS1-B
ILLUSTRATED PARTS LIST
1. Introduction
A. Purpose
This IPL illustrates and lists authorized replacement parts.
B. Guide to Use of the IPL
(1) If the part number is not known:
(a) Find the part in the exploded-view illustrations.
(b) Refer to the parts list and find the item number in the FIG. ITEM column.
(2) If the part number is known:
(a) Refer to the parts list, numerical index, or equipment designator index and find
the part in the PART NUMBER column.
(b) Refer to the exploded-view illustration to identify the attaching hardware and
related assembly parts.
2. Manufacturer Names and Addresses
The CAGE codes for the companies that make the parts, the materials, the special tools, and
the test equipment referenced in this CMM are given in Table 1001. The codes are taken from
Cataloging Handbook H4/H8. No code is given in the parts list when the part is made by
Radiant Power Corp. or to a Radiant Power Corp. Source Control Drawing (SCD).
3. Equipment Designator Index
The Equipment Designator Index is an aid to find electronic and electrical components in the
Detail Parts List by equipment designator. The equipment designator, the figure number, and
the item number are given for each entry.
The equipment designators are sorted one character at a time, from left to right. The correct
sequence is (1) dash, (2) letters A through Z, and (3) numerals 0 through 9.
4. Numerical Index
The Numerical Index is an aid to find the parts in the Detail Parts List by part number. The
figure number, the item number, and the total quantity are given for each entry.
The part numbers are sorted one character at a time, from left to right. The correct sequence is
(1) dash, (2) letters A through Z, and (3) numerals 0 through 9.
Page 1001
RADIANT POWER CORP.
PART NUMBER RPS1-B
Manufacturer Names and Addresses
CAGE Name and Address CAGE Name and Address

28480 Agilent Technologies 4T284 Clorox Co.
3000 Minuteman Rd. Food Service Products Div.
Andover, MA 01810-1032 1221 Broadway
Oakland, CA 94612-1637
00779 Amp Inc.
2800 Fulling Mill Road 46384 Penn Engineering and Mfg. Corp.
(P.O. Box 3608) Old Easton Road (P.O. Box 1000)
Harrisburg, PA 17105 Danboro, PA 18916
0EE74 General Electric Co. 49956 Raytheon Co.
GE Lighting Div. 141 Spring St.
4400 ox Ad. (P.O. Box 4705) Lexington, MA 02173-7801
Glen Allen, VA 23060
53894 Aham-Tor Inc. (ATI)
1MXA1 Radiant Power Corp. Inc. 27901 Front St.
11001 US Hwy 41 N. Temecula, CA 92390-0739
Palmetto, FL 34221
56964 USECO
0PK96 Quadtech Inc. 444 S. Tustin NO K6
45 Main St. (P.O. Box 6407)
Bolton, MA 01740-1107 Orange, CA 92667-7723
05276 ITT Pomona Electronics Div. 71744 Chicago Miniature Lamp Inc.
1500 E. 9th St. (P.O. Box 2767) Chevy Chase Business Park
Pomona, CA 91766-3835 1080 Johnson Dr.
Buffalo Grove, IL 60089
05972 Loctite Corp.
705 N. Mountain Rd. 75345 Kirkhill Rubber Co.
(P.O. Box 11915) 300 E. Cypress St.
Newington, CT 06111-1411 Brea, CA 92621-4007
12405 Dexter Corp. (formerly Hysol) 75915 Littelfuse Tracor Inc.
Dexter Electronic Materials Div. 800 E. Northwest Highway
15051 E. Don Julian Rd. Des Plaines, IL 60016-3049
Industry, CA 91746
77820 Amphenol Corp.
16428 Cooper Industries Inc. Bendix Connector Operations
Belden Division, Richmond Plant 40-6- Delaware St.
350 NW N St. Sidney, NY 19838-1395
Richmond, IN 47374
79963 Zierick Mfg. Co.
18565 Chromerics Inc. Radio Circle
77 Dragon Court Mount Cisco, NY 10549
Woburn, MA 01888
81073 Grayhill Inc.
19457 Baker Performance Chemicals Inc. 561 Hillgrove Ave. (P.O. Box
Calla Chemical Operations 10373)
11808 S. Bloomfield La Grange, IL 60525-5914
Sante Fe Springs, CA 90670
81205 The Boeing Company
39425 McNab Inc. 7755 E. Marginal Way (P.O. Box
20 W. MacQueston Parkway 3707)
Mount Vernon, NY 10550-1841 Seattle, WA 98124
Page 1002
RADIANT POWER CORP.
PART NUMBER RPS1-B
Manufacturer Names and Addresses

CAGE Name and Address CAGE Name and Address

84063 Henkel Corp. 92218 The Wakefield Corp.
Horsham Business Center 29 Foundry St.
300 Welsh Road, Building 2, Suite I Wakef ield, MA 01880-3206
Horsham, PA 19044
94222 Southco Inc.
86928 Seastrom Mfg. Co. Inc. 210 N. Brinton Lake Rd.
701 Sonora Ave. Concordville, PA 19331
Glendale, CA 91201-2431
94058 Brulin and Co. Inc.
89536 John Fluke Mfg. Co., Inc. 2920 Dr. Andrew J. Brown Dr.
6920 Seaway Boulevard (P.O. Box 270)
(P.O. Box 9090) Indianapolis, IN 46206
Everett, WA 98206-9090
99017 Protective Closures Co. Inc.
89954 General Electric Co. Caplugs Division
Aircraft Control Systems Dept. 2150 Elmwood Avenue
600 Main St. Buffalo, NY 14207-1910
Johnson City, NY 13790
99109 Columbia Chase Corp. Humiseal Div.
9G944 General Electric Supply Co. 26-60 Brooklyn/Queens Expressway
200 W. River Ave. P.O. Box 445
Pittsburgh, PA 15212-5725 Woodside, NY 11377-0445
5. Explanation of Detail Parts List Entries
The Detail Parts List is arranged in general sequence of disassembly. The parts are illustrated
in an exploded-view illustration and listed in the related parts list.
A. FIG. ITEM Column
(1) The first number at the top of each FIG. ITEM column is the figure number of the
exploded view illustration. The number given opposite each part number is the item
number given to the part in the illustration.
(2) A dash (-) is put before the item number when it is not illustrated.
(3) Alpha-variants A through Z (except I and O) are given to item numbers when
necessary to identify added parts, alternative parts, and service bulletin modified
parts.
B. PART NUMBER Column
This column contains the part number for each part, as modified to satisfy ATA 200/2000.
The modifications can include:
(1) Removal of blank spaces and special characters, with the possible exception of
dashes. Dashes are permitted only between numeric characters.
(2) Use of a shorter part number compatible with ATA 200/2000 if the part number is
longer than 15 characters. The full part number is given in the NOMENCLATURE
column.
Page 1003
RADIANT POWER CORP.
PART NUMBER RPS1-B
C. NOMENCLATURE Column
(1) This column contains the name of each part. The column can also contain the CAGE
code of the company that made the part (if it is not made by Radiant Power Corp.),
the full part number (if it is longer than 15 digits or modified to ATA 200/2000), any
service bulletins that apply to the part, and any obsolete part numbers.
(2) The indenture system used in the NOMENCLATURE column shows how each part
is related to the others, as follows:
123
End Item or Major Assembly
.Detail Parts for End Item or Major Assembly
.Subassemblies
ATTACHING PARTS
.Attaching Parts for Subassemblies
***
. . Detail Parts for Subassemblies
ATTACHING PARTS
. . Attaching Parts for Detail Parts
***
(3) Assemblies, subassemblies and detail parts subject to modification, deletion,
addition or replacement by an issued service bulletin are annotated to indicate both
pre- and post-service bulletin configurations. The term (PRE SB XXXX) in the
NOMENCLATURE column designates the original configuration, and the term
(POST SB XXXX) identifies assemblies and parts after the modification has been
completed.
(4) The terms defined below are used when applicable to show the interchangeability of
parts.
Term Abbreviation Definition
Superseded By SUPSD BY The part is replaced by and is not
interchangeable with the item number
designated in the notation.
Supersedes SUPSDS The part replaces and is not
Replaced By REPLCD BY The part is replaced by and is
Replaces REPLCS The part replaces and is
D. EFF CODE Column
This column contains effectivity codes (A, B, etc.) to show the alternative models or
configurations of the end item to which the parts apply. This column is left blank when the
parts apply to all models or configurations in the parts list.
E. UNITS PER ASSY Column
The quantity given in this column shows the number of units necessary for one NHA or,
when you refer to attaching parts, the quantity to attach one such item. The abbreviation
RF (reference) is given to end items and subassemblies.
Page 1004
RADIANT POWER CORP.
PART NUMBER RPS1-B
EQUIPMENT DESIGNATOR INDEX
PART
DESIGNATOR FIGURE ITEM
NUMBER
A1 11-0042-1 2 15
A1 11-0042-2 2 -15A
A2 11-0045 2 10
A2 11-0045 3 -1
BT1 2013-1A 1 5
F1 251005 3 40
F1 276005 3 -40
F2 251005 3 40
F2 276005 3 -40
F3 251005 3 40
F3 276005 3 -40
J1 BACC45FN16-24P 2 110
J1 48-10R16-24P 2 -110A
J2-1 3542-2 1 60
J2-2 3542-0 1 65
Q1 JANTX2N3716 2 30
Q2 JANTX2N4399 2 35
Q3 JANTX2N3741 3 5
R1 RER60F14R0R 2 65
R2 RER60F14R0R 2 65
R21 RNC55H7320FR 3 -35A
R21 RNC55H7500FR 3 -35B
R21 RNC55H7680FR 3 -35C
R21 RNC55H7870FR 3 35
R21 RNC55H8060FR 3 -35D
R21 RNC55H8250FR 3 -35E
SW1 39-1 2 100
Page 1005
RADIANT POWER CORP.
PART NUMBER RPS1-B
NUMERICAL INDEX
(Sheet 1 of 2)
AIRLINE TTL
PART NUMBER FIGURE ITEM
STOCK NO. REQ
BACC45FN16-24PN 2 110 1
BACN10JC04 2 120A 4
BACN10JC06 1 40A 3
BACN10JC06C 2 45A 4
BACR15BA4AD4 1 145 4
BBI-03G 2 55 2
BBI-066G 3 25 1
BSM1-60A 1 -95 1
DM101 2 50 2
FE0-440 1 160 12
FE0-440 3 32 2
JANTX2N3716 2 30 1
JANTX2N3741 3 5 1
JANTX2N4399 2 35 1
MS21043-06 2 -45B 4
MS21043-06 2 40A 4
MS24693-1 1 -125 6
MS24693-C1 1 125A 6
MS35649-224 2 70 4
MS35649-224 1 80A 4
MS51957-12 1 115 4
MS51957-12 2 95 4
MS51957-13 2 20 8
MS51957-13 2 115 4
MS51957-27 3 10 2
MS51957-28 2 45C 4
MS51957-29 2 -45 4
MS51957-3 2 -80 2
MS51957-34 1 50 4
NAS549FL4 2 25 16
NAS620C2 2 75 4
NAS620C6 1 45 6
NAS620C6 3 15 4
NAS620C8 1 80 2
NAS679A04 2 -120 4
NAS679C06 1 -40 3
NAS679C06 2 -40 4
RER60F14R0R 2 65 2
RNC55H7320FR 3 -35A 1
RNC55H7500FR 3 -35B 1
RNC55H7680FR 3 -35C 1
RNC55H7870FR 3 35 1
RNC55H8060FR 3 -35D 1
RNC55H8250FR 3 -35E 1
RPS1B 1 -1 RF
S0S440-4 1 150 4
S0S440-6 1 155 4
Page 1006
RADIANT POWER CORP.
PART NUMBER RPS1-B
NUMERICAL INDEX
(Sheet 2 of 2)
AIRLINE TTL
PART NUMBER FIGURE ITEM
STOCK NO. REQ
S0S440-4 1 150 4
S0S440-6 1 155 4
TA2402A 3 20 1
081-001-006 1 70 4
11-0042-1 2 15 1
11-0042-2 2 -15A 1
11-0045 2 10 1
11-0048 1 130 1
11-0048-1 1 165 1
11-0049 1 100 1
11-0050-1 1 120 1
11-0050-1 2 -1 RF
11-0050-2 1 -120A 1
11-0050-2 2 -1A RF
11-0051 1 105 1
11-0052 1 110 1
11-0061 2 12 1
2007-1 1 140 2
2007-2 2 85 1
2007-3 2 90 1
2008 2 125 1
2009 3 30 1
2013-1A 1 5 1
2017 1 55 6
2020 1 10 1
2022 1 30 2
2025 2 5 1
2042 1 20 1
20442339 1 15 1
276005 1 95A 1
3542-0 3 40 3
3542-2 1 65 1
39-1 1 60 1
48-10R16-24P 2 100 1
2 -110A 1
5607-88
5612-26-31 1 85 4
805-144 1 35A 2
805-169 2 60 2
82-19-1040-16 2 105 1
82-32-101-20 1 25 2
82-35-307-55 1 -35 2
8654 1 135 2
1 90 2
Page 1007
RADIANT POWER CORP.
PART NUMBER RPS1-B

IPL Figure 1 (Sheet 1 of 3)
Page 1008
RADIANT POWER CORP.
PART NUMBER RPS1-B

Page 1009
RADIANT POWER CORP.
PART NUMBER RPS1-B

Page 1010
RADIANT POWER CORP.
PART NUMBER RPS1-B
PARTS LIST
UNITS
FIGURE PART AIRLINE EFF
NOMENCLATURE PER
ITEM NUMBER STOCK NO. CODE
1234567 ASSY
1 -1 RPS1B BATTERY POWER SUPPLY RF
5 2013-1A . HOLDER ASSY, BATTERY (BT1) 1

10 2020 . . TAG, INSTRUCTION 1
15 2044 . . LABEL, BATTERY HOLDER 1
(ADHESIVE-BACKED)
20 2042 . . CASE, BATTERY 1
25 82-19-1040-16 . . FASTENER, 1/4-TURN (V94222) 2
30 2022 . . SPRING, RETRACTION 2
-35 82-32-101-20 . . RETAINER, SPLIT RING (V94222) 2
(PRE SB-004)
35A 5612-26-31 . . WASHER, FLAT, TEFLON (V86928) 2
(POST SB-004)
-40 NAS679C06 . . NUT, SELF-LOCKING HEX 3
(SUPSD BY ITEM 40A)
40A BACN10JC06 . . NUT, SELF-LOCKING HEX (V81205) 3
(SUPSDS ITEM 40)
45 NAS620C6 . . WASHER, FLAT 6
50 MS51957-34 . . SCREW, MACHINE-PAN HEAD 3
55 2017 . . BATTERY, NI-CD, 1.2V 6
60 3542-2 . . SOCKET, PIN (RED) (V05276) (J2-1) 1
65 3542-0 . . SOCKET, PIN (BLACK) (V05276) 1
(J2-2)
70 081-001-006 . . NUT, 8-32 HEX (V05276) 4
-75 146-001-002 . . DELETED
80 NAS620C8 . . WASHER, FLAT 2
85 5607-88 . . WASHER, SHOULDER (V86928) 4
90 8654 . . BRAID, TINNED COPPER WIRE, 2
1.375 +/- 0.125 INCH LG (V16428)
-95 BSM1-60A . . PAD, FUSE RETAINER, TYPE 1, 1
GRADE B (V75345)
95A 2339 . . PAD, FUSE RETAINER, TYPE 1, 1
GRADE B (V75345) (SUPSDS ITEM 95)
100 11-0049 . CHARGER ASSY, BATTERY 1
105 11-0051 . . NAMEPLATE, CHASSIS 1
110 11-0052 . . COVER ASSY 1
ATTACHING PARTS
115 MS51957-12 . . SCREW, MACHINE-PAN HEAD 4
***
- ITEM NOT ILLUSTRATED
Page 1011
RADIANT POWER CORP.
PART NUMBER RPS1-B
PARTS LIST
UNITS
NOMENCLATURE PER
1234567 ASSY
1 120 11-0050-1 . . ELECTRONICS ASSY 1
(S/N 0626 AND SUBSEQUENT)
(SUPSDS ITEM 120A)
(RF IPL FIG. 2 FOR DETAILS)
-120A 11-0050-2 . . ELECTRONICS ASSY 1
(S/N 0053 THROUGH 0625)
(SUPSD BY ITEM 120)
ATTACHING PARTS
-125 MS24693-1 . . SCREW, FLAT-COUNTERSUNK 6
HEAD
125A MS24693-C1 . SCREW, FLAT-COUNTERSUNK 6
HEAD (ALT TO ITEM 125)
130 ***
135 11-0048 . . CHASSIS ASSY 1
140 82-35-307-55 . . . RECEPTACLE (V94222) 2
2007-1 . . . BRACKET, BATTERY MOUNTING 2
145 ATTACHING PARTS

BACR15BA4AD4 . . . RIVET, 1/8 FLAT HEAD X 1/4 LG 4
(V81205)
150 ***
S0S440-4 . . . STANDOFF, SELF-CLINCHING, 4
155 1/8 INCH (V46384)
S0S440-6 . . . STANDOFF, SELF-CLINCHING, 3/16 4
160 INCH (V46384)
FE0-440 . . . NUT, CLINCH, 4-40 SELF- 12
165 LOCKING (V46384)
11-0048-1 . . . CHASSIS 1
- ITEM NOT ILLUSTRATED
Page 1012
RADIANT POWER CORP.
PART NUMBER RPS1-B
Page 1013
RADIANT POWER CORP.
PART NUMBER RPS1-B
Electronics Assembly
IPL Figure 2
Page 1014
RADIANT POWER CORP.
PART NUMBER RPS1-B
PARTS LIST
UNITS
NOMENCLATURE PER
1234567 ASSY
2 -1 11-0050-1 ELECTRONICS ASSY (P/N 11-0050) A RF
(S/N 0626 AND SUBSEQUENT)
(SUPSDS ITEM 1 A)
(RF IPL FIG. 1 FOR NHA)
-1A 11-0050-2 ELECTRONICS ASSY B RF
(S/N 0053 THROUGH 0625)
(SUPSD BY ITEM 1)
5 2025 . LABEL, TEST SWITCH 1

(ADHESIVE-BACKED)
10 11-0045 . PCB ASSY, REGULATOR (A2) 1
12 11-0061 . INSULATOR, NOMEX 1
(POST SB RPS1-B-33-01)
15 11-0042-1 . PCB ASSY, LOGIC (A1).(P/N 11-0042) A 1
(SIN 0626 AND SUBSEQUENT)
(SUPSDS ITEM 15A)
-15A 11-0042-2 . PCB ASSY, LOGIC (A1) B 1
(S/N 0053 THROUGH 0625)
(SUPSD BY ITEM 15)
ATTACHING PARTS
20 MS51957-13 . SCREW, MACHINE-PAN HEAD 8
25 NAS549FL4 . WASHER, NONMETALLIC 16
INSULATING
***
30 JANTX2N3716 . TRANSISTOR (Q1) 1

ATTACHING PARTS
40 NAS679C06 . NUT, HEX SELF-LOCKINGNUT, HEX 4
40A MS21043-60 SELF-LOCKING 4
. (SUPSDS ITEM 40)
-45 MS51957-29 SCREW, MACHINE-PAN HEAD 4
(SUPSD BY ITEM 45A OR 45B)
-45A BACN10JC06C . SCREW, MACHINE-PAN HEAD 4
(V81205) (SUPSDS ITEM 45)
-45B MS21043-06 . SCREW, MACHINE-PAN HEAD 4
(ALT TO ITEM 45A)
45C MS51957 . SCREW, MACHINE-PAN HEAD 4
(ALT TO ITEM 45A)
***
50 DBX-101 . THERMAL INSULATOR PAD, 2

55 BBI-03G . STRIP, INSULATOR (V39425) 2
60 805-144 . LUG, SOLDER (V79963) 2
-ITEM NOT ILLUSTRATED
Page 1015
RADIANT POWER CORP.
PART NUMBER RPS1-B
PARTS LIST
UNITS
NOMENCLATURE PER
1234567 ASSY
2 65 RER60F14R0R . RESISTOR (R1, R2) 2
ATTACHING PARTS
70 MS35649-224 . NUT, PLAIN HEX 2
75 NAS620C2 . WASHER, FLAT 2
-80 MS51957-3 . SCREW, FLAT-COUNTERSUNK HEAD 2
80A MS35649-224 . SCREW, FLAT-COUNTERSUNK HEAD 2
(ALT TO ITEM 80)
***
85 2007-2 . BRACKET ASSY, Q2 TRANSISTOR 1

MOUNTING
90 2007-3 . BRACKET ASSY, Q1 TRANSISTOR 1
MOUNTING
ATTACHING PARTS
***
100 39-1 . SWITCH, PUSHBUTTON (V81073) 1

(SW1)
105 805-169 . LUG, SOLDER, NO. 8 (V79963) 1
110 BACC45FN16- . CONNECTOR, 24 PIN (V81205) 1
24PN (J1)
-110A 48-10R1624P . CONNECTOR, 24 PIN (V77820) 1
(J1)(ALT TO ITEM 110)
ATTACHING PARTS
-120 NAS679A04 . NUT, HEX SELF-LOCKING (SUPSD BY 4
ITEM 120A)
120A BACN10JC04 . NUT, HEX SELF-LOCKING (V81205) 4
(SUPSDS ITEM 120)
***
125 2008 . PANEL, FRONT 1
Page 1016
RADIANT POWER CORP.
PART NUMBER RPS1-B
Page 1017
RADIANT POWER CORP.
PART NUMBER RPS1-B
Regulator PCB Assembly A2

IPL Figure 3
Page 1018
RADIANT POWER CORP.
PART NUMBER RPS1-B
PARTS LIST
UNITS
NOMENCLATURE PER
1234567 ASSY
3 -1 11-0045 PCB ASSY, REGULATOR (A2) RF
ATTACHING PARTS
15 NAS620C6 . WASHER, FLAT 2
***
20 DBX-66 . THERMAL PAD INSULATOR 1
25 BBI-066G . STRIP, INSULATOR (V39425) 1

30 2009 . BRACKET ASSY, TRANSISTOR 1
MOUNTING
32 FE0-440 . . NUT, CLINCH, 4-40 SELF-LOCKING 2
(V46384)
35 RNC55H7870FR . RESISTOR, 1
(R21) (SELECT IN TEST)
-35A RNC55H7320FR . RESISTOR, 1
(ALT TO ITEM 35)
-35B RNC55H7500FR . RESISTOR, 1
(ALT TO ITEM 35)
-35C RNC55H7680FR . RESISTOR, 1
(ALT TO ITEM35)
-35D RNC55H8060FR . RESISTOR, 1
(ALT TO ITEM 55)
-35E RNC55H8250FR . RESISTOR, 1
(ALT TO ITEM 55)
-40 251005 . FUSE, SUBMINIATURE, (V75915) 3
(F1, F2, F3)
40A 276005 . FUSE, SUBMINIATURE, (V75915) 3
(F1, F2, F3) (SUPSDS ITEM 40)
Page 1019
RADIANT POWER CORP.
PART NUMBER RPS1-B
Page 1020

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RADIANT POWER CORP.

COMPONENT MAINTENANCE MANUAL

TO: HOLDERS OF COMPONENT MAINTENANCE MANUAL 25-60-03, REVISION 15

REVISION NO. 16, DATED AUGUST 2009

CHAPTER/SECTION AND WAS IS NOW

THIS PAGE INTENTIONALLY LEFT BLANK

RADIANT POWER CORP.

(FORMERLY DERLAN INC.)

Component Maintenance Manual

Part Number: RPS1-B

THIS MANUAL CONTAINS PROPRIETARY INFORMATION OF RADIANT POWER

THIS PAGE INTENTIONALLY LEFT BLANK

REVISION REVISION DATE BY REVISION REVISION DATE BY

THIS PAGE INTENTIONALLY LEFT BLANK

RECORD OF TEMPORARY REVISIONS

REVISION REVISION DATE BY REVISION REVISION DATE BY

THIS PAGE INTENTIONALLY LEFT BLANK

SERVICE BULLETIN LIST

SERVICE ISSUE DATE BY SERVICE ISSUE DATE BY

THIS PAGE INTENTIONALLY LEFT BLANK

LIST OF EFFECTIVE PAGES

Assembly (including 701 Aug 2009

Special Tools, Fixtures, 901 Aug 2009

Illustrated Parts List 1001 Aug 2009

Description and Operation 1

1 Battery Power Supply 3

701 Assembly Tools and Materials 713

Part Number Serial Numbers

Part Number Serial Numbers IPL Figure-item Number

11-0041-1 0626 and subsequent 2-15

2. Product Support Services

Radiant Power Corp. Telephone: (941) 739-3200

(4) Cleaning contains procedures to clean the BPS battery pack.

C. WARNINGS, CAUTIONS and NOTES

(1) WARNINGS are provided before potentially dangerous procedures, materials,

4. General Safety Precautions

ELECTROSTATIC DISCHARGE All Integrated Circuits (ICs), surface mounted devices,

Follow the PCB handling procedures given in REPAIR to

DO NOT SERVICE OR ADJUST Only qualified maintenance personnel are authorized to

Visually check for pinched, out of place, or frayed wiring

Do a safety check of the entire unit before returning the

Disassembly Jan 15/87

Assembly Jan 15/87

7. Abbreviations and Unit Symbols

Assy Assembly kPag kiloPascal - gage

DESCRIPTION AND OPERATION

A. The primary components of the BPS are shown in Figure 1.

C. The battery holder assembly consists of six nickel-cadmium batteries mounted in a

F. A single 24-pin BACC45FN16-24P or 48-10-R16-24P (Amphenol) electrical connector

Part Number Serial Numbers

Part Number Serial Numbers IPL Figure-item Number

4. Functional Description (Figures 2 and 3)

E. The slow turn-on circuit made up of resistor/capacitor combinations at the input of

H. Fuses F1 through F3 limit the output voltage at pins 9 through 11 of connector

Battery Power Supply