I I

1

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I

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. *TM 11-6130-479-13&P

TECHNICAL MANUAL NO. 11-6130-479-13&P

HEADQUARTERS DEPARTMENT OF THE ARMY Washington, DC, 1 June 1995

OPERATOR'S, UNIT, AND DIRECT SUPPORT MAINTENANCE MANUAL (INCLUDING REPAIR PARTS AND SPECIAL TOOLS LIST) POWER SUPPLY ASSEMBLY OP-177(V)1/U

(NSN 6130-01-317-2328) (EtC: N/A)

and

POWER SUPPLY ASSEMBLY OP-177(V)2/U (NSN 6130-01-412-1320) (EtC: N/A)

..

REPORTING ERRORS AND RECOMMENDING IMPROVEMENTS

You can help improve this manual. If you find any mistakes, or if you know of a way to improve the procedures, please let us know. Mail your letter, DA Form 2028 (Recommended Changes to Publications and Blank Forms), or DA Form 2028- 2 located in the back of this manual direct to: Commander, US Army Communications-Electronics Command and Fort Monmouth, ATTN: AMSEL-LC-LML T, Fort Monmouth, New Jersey 07703-5007. In either case a reply will be furnished to you.

TM It-6130-479-13&P

WARNING

INJURY CAN OCCUR IF THE FOLLOWING ARE NOT OBSERVED WHEN USING THE POWER SUPPLY ASSEMBLY.

" I WARNING

HIGH TEMPERATURES

Solar Panels can reach temperatures of 160-170 OF when c;»perating in bright sun in hot environments. Panel can cause burns to the skin.

I WARNING BATTERY CHARGING

Do not attempt to charge any batteries other than those authorized In this manual.

Do not charge batteries without using the PSA. unless the battery has , Internal overcharge protection (e.g .• BB-542/U).

I WARNING ELECTRICAL SERIES LIMITATION

Do not put more than two Solar Cell P8Iteis together in series. Personal injury may result from high voltage.

I WARNING I

KEEP AWAY FROM LIVE CIRCUITS

Do not touch contacts of the DC Generator when it is being cranked.

Do not touch contacts of a cable when it is plugged into a DC Generator being operated. .

Do not touch contacts of any charged battery or one being charged by this

equipment. .:

~,~. ":

1M 11-'130-4"..13&1'

WARNING

USE OF COMPRESSED AIR

Compressed air Is dangerous and can cause serious bodily harm if protective means or methods are not observed to prevent a chip or particle (of whatever size) from being blown into the eyes or unbroken skin of the operator or other personnel. Compressed air shall not be used for cleaning purposes except where reduced to less than 30 pounds per square inch gauge (30 psig) and then only with effective chip guarding and personnel protective equipment (industrial safety glasses and full faceshield).

WARNING

USE OF CLEANING SOLVENT

Trichlorotrifluoroethane, thrichloroethane and similar chemical solvents will no longer be used for ordinary cleaning of equipment. These substances threaten public health and the environment by destroying ozone in the-earth's upper atmosphere. Suitable nonhazardous cleaning materials will be used instead, such as a clean cloth, water and mild detergent.

I WARNING MERCURY HANDLING

Mercury spills will be cleaned up in accordance with guidance provided by Industrial Hygiene and the MEDDAC Safety Manager. All mercury contaminated waste will be turned over to the Environmental Natural Resource Division of DEH for proper disposal.

CAUTION

Do not use the DC Generator to power equipment.

Do not use feet to crank the DC Generator, unit can be damaged by excessive force.

Do not use vehicle batteries or vehicle sources as inputs to the Power Supply Adapter (PSA) as it has no current limiting capabilities.

Use only Solar Panels, DC Generator, or Power Converter as inputs to the PSA.

The PSA contains 1 gram of mercury metal. To dispose of the PSA, contact your Defense Reutilization and Marketing Office (DRMO).

TM 11-6130-479-13&P

@CAUTION@ THIS EQUIPMENT CONTAINS PARTS SENSITIVE TO DAMAGE

BY ELECTROSTATIC DISCHARGE (ESD).

USE PRECAUTIONARY PROCEDURES WHEN TOUCHING, REMOVING OR INSERTING PRINTED CIRCUIT BOARDS.

GENERAL HANDLING PROCEDURES FOR ESD ITEMS

USE WRIST GROUND STRAPS OR MANUAL GROUNDING PROCEDURES. KEEP ESD ITEMS IN PROTECTIVE COVERING WHEN NOT IN USE. GROUND ALL ELECTRICAL TOOLS AND TEST EQUIPMENT.

PERIODICALLY CHECK CONTINUITY AND RESISTANCE OF GROUNDING SYSTEM. USE ONLY METALIZED SOLDER SUCKERS. HANDLE ESD ITEMS ONLY IN PROTECTED AREAS.

I CAUTION I

MANUAL GROUNDING PROCEDURE

MAKE CERTAIN EQUIPMENT IS POWERED DOWN.

TOUCH GROUND PRIOR TO REMOVING ESD ITEMS.

TOUCH PACKAGE OF REPLACEMENT ESDS ITEM TO GROUND BEFORE OPENING. TOUCH GROUND PRIOR TO INSERTING REPLACEMENT ESD ITEMS.

ESD PROTECTIVE PACKAGING AND LABELING

INTIMATE COVERING OF ANTISTATIC MATERIAL WITH AN OUTER WRAP OF EITHER TYPE 1 ALUMI NIZE D MATERIAL OR CONDUCTIVE PLASTIC FILM OR HYBRID LAMINATED BAGS HAVING AN INTERIOR OF ANTISTATIC MATERIAL WITH AN OUTER LAYER OF METALIZED MATERIAL. LABEL WITH SENSITIVE ELECTRONIC SYMBOL AND CAUTION NOTE, AS ABOVE.

E/CF Blan

*TM 11-6130-479-13&P

TECHNICAL MANUAL NO. 11-6130-479-13&P

HEADQUARTERS DEPARTMENT OF THE ARMY Washington, DC, 1 June 1995

OPERATOR'S, UNIT, AND DIRECT SUPPORT MAINTENANCE MANUAL (INCLUDING REPAIR PARTS AND SPECIAL TOOLS LIST) POWER SUPPLY ASSEMBLY OP-177(V)1/U

(NSN 6130-01-317-2328) (EIC: N/A)

and

POWER SUPPLY ASSEMBLY OP-177(V)2/U (NSN 6130-01-412-1320) (EIC: N/A)

REPORTING ERRORS AND RECOMMENDING IMPROVEMENTS

You can help improve this manual. If you find any mistakes, or if you know of a way to improve the procedures, please let us know. Mail your letter, DA Form 2028 (Recommended Changes to Publications and Blank Forms), or DA Form 2028- 2 located in the back of this manual direct to: Commander, US Army Communications-Electronics Command and Fort Monmouth, A TIN: AMSEL-LC-LML T, Fort Monmouth, New Jersey 07703-5007. In either case a reply will be furnished to you.

!

CHAPTER 1

Section I Section II Section III

CHAPTER 2

Section I

Section II

Section III Section IV

CHAPTER 3

Section I Section II

TABLE OF CONTENTS

PAGE

HOW TO USE THIS MANUAL V

INTRODUCTION 1-1

General Information . . . . . . . . . . . . . . . . . . . . . . . .. 1-1

Equipment Description and Data 1-3

Principles of Operation . . . . . . . . . . . . . . . . . . • . .. 1-13

OPERATING INSTRUCTIONS 2-1

Description and Use of Operator's Controls and

Indicators 2-1

Operator Preventive Maintenance Checks and

Services (OPMCS) . . . . . . . . . . . . . . . . . . . . . . . . .. 2-4 Operation Under Usual Conditions . . . . . . . . . . . . . .. 2-5

Operation Under Unusual Conditions 2-75

OPERATOR MAINTENANCE INSTRUCTIONS 3-1

Lubrication Instructions 3-1

Troubleshooting Procedures . . . . 3-1

• This manual supersedes TM 1 1-6130-419-12&P. dated 15 Aug 93.

i

TM 11-6130-479-13&P

CHAPTER 4

Section I

Section II Section III Section IV Section V

CHAPTER 5

Section I

Section II Section III Section IV Section V

APPENDIX A

APPENDIX B

Section I Section II

Section III

UNIT MAINTENANCE .•••.•••••••••••.•••••••• . 4-1

Repair Parts, Tools, Special Tools, Test Measurement, and Diagnostic Equipment (TMDE), and

Support Equipment ;........................ 4-1 Service Upon Receipt • . • . . • • • . • • . • • • . . • • . • . . . 4-1 Unit Preventive Maintenance Checks and Services •.. . 4-3 Troubleshooting . . . . . . . . . . . • . • . • . • • . . . . . . . . . 4-5 Maintenance Procedures • • . • • • . . • • . . • . . • . . . . . 4-10

DIRECT SUPPORT MAINTENANCE •••••......•..••• 5-1

Repair Parts, Tools, Special Tools, Test Measurement,

and Diagnostic Equipment, and Support Equipment .... 5-1 Service Upon Receipt . . . . . . . . . . . . . . . . . . . . . . . • 5-1

Preventive Maintenance Checks and Services 5-1

Direct Support Troubleshooting .•..............• 5-2 Direct Support Maintenance Procedures ..•....... 5-14

REFERENCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. A-1

MAINTENANCE ALLOCATION ...................• 8-1

Introduction ...•.......................... B-1

Maintenance Allocation Chart for Power Supply

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4

Tools and Test Equipment for Power Supply

Section IV Remarks for Power Supply Assembly, OP-177(V)/U .•. B-7

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6

APPENDIX C REPAIR PARTS AND SPECIAL TOOLS LIST (RPSTL) .... C-1

APPENDIX D COMPONENTS OF END ITEM AND BASIC ISSUE

ITEMS LIST . . . . . . . . • . . . • . . . . . . . . . . . • . . . . . .. 0-1

Section I Section II

APPENDIX E

Section I Section II

Introduction .........••.............••... 0-1

Components of End Item . • • . . • . . . . . . • • . • • . . .. 0-1

EXPENDABLE SUPPLIES AND MATERIALS ....•..•.... E-1

Introduction ..............•..............• E-1

Expendable Supplies and Materials List E-2

INDEX " Index-1

ii

, ;

TM 11-6130-479-13&P

LIST OF ILLUSTRATIONS

NUMBER TITLE

PAGE

1-1 Power Supply Assembly, OP-, 77(V)/U ..•••.••••••••..•• 1-0

1-2 Solar Cell Panel •.•.•..•.••••••••••••••••••••••.•• 1-4

1-3 DC Generator 1-5

1-4 AC to DC Power Converter •••.••.•.••••.•.•.•....... 1-6

1-5 Power Supply Adapter (PSA) •.•.•••.•.......... . . . . .• 1-7

1-6 DCIDC Adapter •.••.••...••...•...••............• 1-7

1-7 International Wall Socket Adapter Kit ...••...••••.....•• 1-7

1-8 Power Supply Assembly Cables •..••..•••.•••.••.•..•• 1-8

1-9 International Adapter Bag ...••......•••••..........• 1-8

1-10 Solar Panel Assembly Bag • . . • • • . • • . . . . . . . . . . . . . . . . •• 1-9

1-11 DC Generator Bag •..............................• 1-9

1-12 AC to DC Power Converter Kit Bag . . . . . . . . . . . . . . . . . . . .. 1-9

1-13 Power Supply Assembly Bag 1-10

2-1 DC Generator Controls and Indicators ....•. . . . . . . . . . . . .. 2-1

2-2 Power Converter Controls and Indicators . . • . . . . . . . . . . . . .• 2-2

2-3 Power Supply Adapter (PSA) Controls and Indicators •.....•• 2-3

2-4 Single Panel Set-Up, Open Circuit Voltage Measurement ....• 2-11

2-5 Dual Panel Parallel Connection Diagram . . . . . . . . . . . . . . . .. 2-12

2-6 Dual Panel Series Connection Diagram 2-13

2-7 Quad Panel Series/Parallel Connection Diagram . . . . . . . . . . .. 2-13

2-8 DC Generator Set Up Procedure While Sitting on Stirrup ..... 2-14

2-9 DC Generator Set Up Procedures, Standing/Kneeling Position .. 2-20

2-10 DC Generator Set Up Procedures, Alternate Operating Position . 2-25

2-11 DC Generator Hookup for Charging BB-590/U . . • . . • . . . . . .. 2- 28

2-12 Single Panel Operation, Current Measurement 2-29

2-13 Dual Panel Parallel Operation Current Measurement . . . . . . . .. 2-30

2-14 AC to DC Power Converter Hookup for Charging the BB-590/U. 2-32

2-15 DC Generator Hookup for Charging BB-490/U . . . . . . . . . . . .. 2-34

2-16 Single Panel Operation, Current Measurement 2-35

2-17 AC to DC Power Converter Hookup for Charging the BB-490/U. 2-37

2-18 DC Generator Hookup for Charging BB-542/U . . . . . . . . . . . .. 2-39

2-19 Dual Panel Series Connection Diagram 2-40

2-20 Dual Panel Series Operation . . . . . . . . . . . . . . . . . . . . . . . .. 2-41

2-21 Quad Panel Series/Parallel Connection Diagram . . . . . . . . . . .. 2-42

2-22 Quad Panel Series/Parallel Operation . . . . . . . . . . . . . . . . . .. 2-43

2-23 AC to DC Power Converter Hookup for Charging the BB-542/U. 2-45

2-24 AC to DC Power Converter Hookup for Charging the BB-586/U. 2-47

2-25 Single Panel Operation, Current Measurement 2-48

2-26 Dual Panel Parallel Operation . . . . . . . . . . . . . . . . .. 2-49

2-27 AC to DC Power Converter Hookup Charging the BB-588/U . .. 2-51

2-28 Single Panel Operation for Charging the BB-588/U 2-53

2-29 OA-8990/P and BB-5590/U Connection Diagram. . . . . . . . . .. 2-53

2-30 OA-8990/P Connection Diagram . . • . . . . . . . . . . . . . . . . . .. 2-55

iii

TM 11-6130-479-13&P

LIST OF ILLUSTRATIONS (CONT'D)

NUMBER TITLE

PAGE

2-31 OA-8990/P and BB-542/U Connection Diagram .•••••••.•.• 2-55

2-32 Dual Panel Parallel Operation •••••••••.•••.••••••.•.• 2-57

2-33 . Quad Panel Series/Parallel Operation .....••••••.....••• 2-58

2-34 AC to DC Power Converter Hookup for Charging the BB-590/U • 2-60

2-35 Dual Panel Parallel Operation ........•.••..•....•.••. 2-61

2-36 AC to DC Power Converter Hookup for Charging the BB-586/U • 2-63

2-37 AC to DC Power Converter Hookup for Charging the BB-588/U . 2-65

2-38 DC Generator Preparation for Movement or Storage . . . . . . . . . 2-67

2-39 DC Generator Preparation for Movement or Storage . . .. ..•• 2-68

2-40 DC Generator Preparation for Movement or Storage • . •. ...• 2-70

2-41 Power Supply Assembly Packaging (Typical) . . . . . . . . . . . . . . 2-74

4-1 Power Supply Assembly Packing (Typical) 4-2

4-2 PSA Diagram ....................•.............•. 4-7

4-3 PSA Test ..........••...........••.............. 4-7

4-4 Testing the DC Generator ........•.......•........... 4-9

4-5 Starting Position for Replacement Procedures ..••..•...... 4-10

4-6 Removal and Replacement of Foot Support Assembly .•...•.. 4-11

4-7 Removal and Replacement of Outer Tube Assembly 4-13

4-8 Removal and Replacement of DC Generator Head and

Crank Assembly . . . . . . . . . . . 4-15

4-9 Removal and Replacement of Handle/Crank Arm Assembly .... 4-17

4-10 Removal and Replacement of Stand . . . . . . . . . . . . . . . . . . . . 4-18

4-11 Removal and Replacement of Inner Tube, Hinge, Foot Pad,

Sleeve, Stirrup, Thumbwheels and Snap Button ••.•........ 4-20

5-1 Testing the Power Converter ...•........•.••.......•• 5-5

5-2 Testing the AC Input Line Cord . . • . . . . . . . . • . . • . . . . . . • • • 5-6

5-3 Testing the Output Cable Assembly . . . . . . . . . . . . . . . . . . . . . 5-7

5-4 Testing the Control and Power Board Assemblies . . . . . . . . . . . . 5-9

5-5 Testing the Secure Lighting Indicators 5-10

5-6 12V Cable Test . . . . . . . . . . . . . • . . . . . . . . . . . . . . . . . . . . 5-1 1

5-7 24V Cable Test ..............•........•.......... 5-12

5-8 Testing the DC Generator Cable ....•.••..•...•....... 5-13

5-9 Removal and Replacement of Control Board Assembly 5-16

5-10 Removal and Replacement of Power Board Assembly . . . . . . . . 5-17

5-11 Removal and Replacement of Secure Lighting Indicators 5-18

5-12 Removal and Replacement of AC Input Line Cord and

Output Cable Assembly .....................•...•.. 5-20

iv

TM 11-6130-479-1'&1'

LIST OF TABLES

NUMBER TITLE

PAGE

1-1 Average Available Charging Energy for 12V

Batteries in AH/Day .••••.••.••••••.••.••.••••.••. 1-1'

1-2 Charging Output Per Panel for Different Light Conditions

for Batteries Charged at 12 Volts .•••••..•..•......•.. 1-15

1-3 Effect of Load Resistance on Solar Panel Output . • • • • • . . • •. 1-15

2-1 DC Generator Controls and Indicators .••. . . • . • . • • • • • • • .• 2-2

2-2 Power Converter Controls and Indicators • • • • • • • • • • • . . • • .. 2-3

2-3 PSA Controls and Indicators .•••••••.•••..•..•...••.• 2-4

2-4 Recommended Battery Recharging Methods . . • • • • • • • . . • . •. 2-6

2-5 Fast Battery Recharging Methods . . . . • . . • . • • . • • • • • • . • .. 2-7

3-1 Troubleshooting • . . . . • . . . • . . . . . . . . . • • • . • • . . • . . . . . . 3-2

HOW TO USE THIS MANUAL

CONTENT OF MANUAL

The manual contains all the data required for operating and maintaining the Power Supply Assembly. The following paragraphs give a brief description of each chapter.

Chapter 1 - This chapter provides the user with information for completing forms and records/familiarizes the user with the equipment. A functional and physical description of the equipment and its major components is also provided.

Chapter 2 - This chapter provides the user with information needed to operate the equipment. An explanation of the controls and indicators necessary to operate the equipment, a preventive maintenance checks and services table, and instructions for operating the Power Supply Assembly under usual and unusual conditions are in this chapter.

Chapter 3 - This chapter provides operator maintenance instructions procedures. Information for troubleshooting the Power Supply Assembly are in this chapter.

Chapter 4 - This chapter provides unit maintenance procedures. Information for testing the components of the Power Supply Assembly and repairing them at the unit level are in this chapter.

Chapter 5 - This chapter provides direct support maintenance procedures. Information for testing the components of the Power Supply Assembly and repairing them at the direct support level are included in this chapter.

v

'1M 11-6130-479-13&P

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Figure 1-1. Power Supply Assembly, OP-177(V)/U

1-0

I .

TM 11-6130-479-13kP

CIlAPl'ER 1

INTRODUCTION

PAGE

Section I.

General Information ..........•.............•........ 1-1

Section n.

Equipment Description and Data . . • • . . • . . . • . . • • • • • • • • • • • • • 1-3

Section m.

Principles of Operation •.••••••••.........••.•••.•... 1-13

SECTION I. GENERAL INFORMATION

1-1. SCOPE

This operator's, unit, and direct support maintenance manual with repair part special tools list is for the OP-177(V)/U Power Supply Assembly. The Power Supply Assembly provides power for field recharging of Nickel-Cadmium and Lead Acid battery systems used to power military communications/electronics equipment. This technical manual primarily addresses the OP-177(V)lIU, which is designed to satisfy Army Special Operations Forces (SOF) field requirements. A majority of the information in this Technical Manual also addresses the OP-177(V)2iU, which is designed specifically for training use only. The OP-177(V)2/U does not satisfy certain SOF field requirements. OP-177(V)2/U variations from the primary (field) version are outlined in TB 11-6115-478-10.

1-2. CONSOLIDATED INDEX OF ARMY PUBLICATIONS AND BLANK FORMS

Refer to the latest issue of DA Pam 25-30 to determine whether there are new editions, changes, or additional publications pertaining to the equipment.

1-3. MAINTENANCE FORMS, RECORDS AND REPORTS

a. Reports of Maintenance and UnsatisfactoQ' Eqyipment. Department of the Army

forms and procedures used for equipment maintenance will be those prescribed by DA Pam 738- 750, as contained in Maintenance Management Update.

b. Reportin~ of Item and Packa~in~ Discrepancies. Fill out and forward SF 364 (Report

of Discrepancy (ROD» as prescribed in AR 735-U-2/DLAR 4140.55ISECNAVINST 4355. 18/AFR 4oo-54/MCO 4430.3J.

c. Transportation Discrepancy Report (TOR) (SF 361>' Fill out and forward

Transportation Discrepancy Report (TOR) (SF 361) as prescribed in AR 55-38/NAVSUPINST 461O.33C/AFR 75-18/MCO P4610.19D/DLAR 4500.15.

1-1

TM 11-6130-479-13&P

1-4. DESTRUCTION OF ARMY ELECTRONICS MATERIAL

Destruction of Army electronics material to prevent enemy use shall be in accordance with TM 750- 244-2.

1-5. ADMINISTRATIVE STORAGE

Administrative storage of equipment issued to, and used by, Army activities will have preventive maintenance performed in accordance with the Preventive Maintenance Checks and Services (PMCS) charts. When removing the equipment from administrative storage, the PMCS should be used to assure the operational readiness of the equipment.

1-6. REPORTING EQUIPMENT IMPROVEMENT RECOMMENDATIONS (EIR)

If your Power Supply Assembly needs improvement, let us know. Send us an EIR. You, the user, are the only one who can tell us what you don't like about your equipment. Let us know why you don't like the design or performance. Put it on an SF 368 (product Quality Deficiency Report). Mail it to: Commander, US Army Communications-Electronics Command and Fort Monmouth, ATTN: AMSEL-LC-ED-CFO, Fort Monmouth, New Jersey 07703-5023. We'll send you a reply.

1-7. OFFICIAL NOMENCLATURE CROSS-REFERENCE LIST

Common Name

Power Supply Assembly DC Generator

Solar Panel Assembly Power Converter

Power Supply Adapter (PSA) Adapter Kit

Adapter Kit Bag

Power Supply Assembly Bag Solar Panel Bag

Power Converter Bag DC/DC Adapter

12V DC Cable

24V DC Cable

Parallel Cable

BB-490/U

BB-542/U

BB-586/U

BB-588/U

BB-590/U

BB-5590/U

OA-8990/P

AN/PRC-132

1-2

Official Nomenclature

Power Supply Assembly OP-177(V)/U Generator, Direct Current G-67B/G & G-67TlIG Solar Cell Panel Assembly

AC to DC Power Converter Kit Adapter, Power Supply

Adapter Kit, International Wall Socket Bag, Adapter Kit

Bag, Power Supply Assembly Bag, Solar Panel Assembly

Bag, AC to DC Power Converter Kit Adapter, DC/DC

Cable, 12V DC

Cable, 24V DC

Cable, Parallel

Battery Rechargeable Sealed Lead Acid BB-490/U Battery Rechargeable Sealed Nickel Cadmium BB-542/U Battery Rechargeable Sealed Nickel Cadmium BB-586/U Battery Rechargeable Sealed Nickel Cadmium BB-588/U Battery Rechargeable Sealed Nickel Cadmium BB-590/U Battery Primary Lithium

Digital Message Device Group OA-8990/P Radio Set, AN/PRC-132

TM 11-6130-479-13&P

1-8. WARRANTY INFORMATION

There is no warranty associated with the Power Supply Assembly.

SECTION n. EQUIPMENT DESCRIPTION AND DATA

1-9. GENERAL

a. The Power Supply Assembly is a lightweight electrical generation system used in the

field to charge 12 and 24 Volt Lead-Acid, and Nickel-Cadmium rechargeable communications batteries such as the BB-590/U, or the BB-542/U. The Power Supply Assembly consists of three subassemblies; Solar Cell Panel Assembly, DC Generator Assembly, and the Power Converter.

b. The Solar Cell Panel Assembly can be operated anywhere in the field where there is

enough sunlight to produce minimum acceptable outputs.

c. The DC Generator Assembly can be operated on the ground without mounting to any

structure or while strapped to an upright pole or tree to provide the desired output.

d. The Power Converter can be operated from any AC source that provides 9O-240V,

50-400 Hz, that can interface with the Power Converter's standard 3-prong US power plug or any of its wall socket adapters.

1-10. EQUIPMENT CHARACTERISTICS, CAPABILITIES, AND FEATURES

a. The Power Supply Assembly is a lightweight, portable, durable, and non-depleting

electrical power source to perform the recharging of the following typical battery types in a field environment:

• BB-490/U (MPS-590) 12/243.6/1.8 AH sealed Lead Acid

• BB-542/U 24V, 2 AH fast charge sealed NiCad

• BB-586/U 13.2V, 4 AH sealed NiCad

• BB-588/U 13.2V, .55/1 AH sealed NiCad

• BB-590/U 12124V, 3.0/1.5 and 12124V, 4.0/2.0 AH sealed NiCad

b. The Solar Panel may be used to recharge the 6V, lAH sealed NiCad battery in the

Digital Message Device Group Processor OA-8990/P.

c. The Power Supply Assembly provides both passive (unmanned) and active (manned)

recharging capabilities. The Solar Panel and Power Converter are both passive units and require minimal operator intervention. The DC Generator Assembly is an active unit and requires the operator to crank the DC Generator manually to provide the appropriate electrical output. The units provide three methods for recharging batteries depending on the time of day, weather conditions, terrain, and location.

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TM 11-613O-479-13&P

d. Because of the requirements for stealth, when operating the DC Generator, the Power

Supply Assembly will not produce more than 60 decibels at seven meters distance, while providing the rated 56 Watt output.

e. When using the Solar Panel, a full-time operator is not always required which allows

other mission duties to be performed. Intermittent operator attention is required to remove fully charged batteries and to reposition panels periodically for maximum output.

f. When charging in the 12V parallel mode, using the Solar Panel or Power Converter

in the 17V mode, the Power Supply Adapter (PSA) will automatically limit the input current to the BB-590/U to 200mA. This feature prevents damaging the battery by overcharging when the system is operating unattended from solar sources or the Power Converter.

g. The PSA provides a dual miniature ammeter/voltmeter which can be used by the

operator to estimate charging requirements and approximate battery condition. Switching between the ammeter and voltmeter functions is accomplished by tilting the entire PSA.

h. The PSA is diode protected to prevent damage due to reversal of input and output or

reversed polarity on the input. The adapter can safely carry input currents of 3 amps.

i. When using the Power Converter, a timer provides various operating times. The

timer, which can be set for 1 to 6 hours, allows the operator to charge batteries while sleeping or attending to other duties. The timer will automatically reduce the charge current to 1/3 of the current setting, trickle charge mode, when the time expires.

j. The Power Converter is voltage and current selectable. The output can be set to

provide current outputs of 100, 200, 400, 800, 1000, or 1500 rnA and voltage outputs of 14, 17, or 32 Volts.

1-11. POWER SUPPLY ASSEMBLY MAJOR COMPONENTS

a. Solar Panel. The Solar Panel (figure 1-2) provides approximately 800mA (under full

bright sun) at IS-17Vdc for charging batteries. Each panel contains two sections that function independently. If one side of the Solar Panel is not functioning, Ih of the current will be lost. Two panels can be connected in series to charge 24V batteries, or in parallel to increase the current.

Four small holes are located in the comers of the Solar Panel for tie down purposes. Velcro is provided on the outside of the panel to fold up and secure for transport.

Figure '·2. Solar Cell Panel

1-4

TM 11-6130-479-13&1»

b. DC Generator. The DC Generator (figure 1-3) is a lightweight handcrank DC

Generator used in the field to charge 24-VoIt rechargeable batteries. The DC Generator consists of three assemblies and a DC Generator Cable. The DC Generator can be folded when assembled to make it easily transportable. The following is a brief description of the three assemblies and the DC Generator Cable:

(I) DC Generator Head and Crank Arm Assembly. The DC Generator Head and

Crank Arm Assembly consists of a DC Generator Head, Crank Arm, and Handles. The DC Generator Head contains a Voltage Meter and power conditioning circuitry. The two Handles are cranked to generate power.

(2) Lei Stand Assembly. The Leg Stand Assembly consists of the Bracket and

Outer Tube, and Stand. It supports the DC Generator Head and Crank Arm Assembly and provides lateral support when attached to the Foot Support Assembly.

(3) Foot SYllport ASsembly. The Foot Support Assembly consists of an Inner

Tube and Hinge, Foot Pad, and Stirrup. It provides support and adjustment for selecting mode and position of operation.

(4) DC Generator Cable. The DC Generator Cable provides a connection from

the DC Generator Output Binding Posts to the rechargeable battery (BB-S42/U) or the PSA.

Figure 1-3. DC Generator

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TM 11-6130-479-13&P

c. Power Converter. The AC to DC Power Converter is used to convert 90 - 240 volts

(50 - 400 Hz) AC to 14, 17 or 32 volts DC (l00mA - 1500 rnA). (It may be used anywhere in the world where AC outlets are available by utilizing the International Wall Socket Adapter Kit). The AC to DC Power Converter is capable of charging a wide variety of rechargeable batteries. It has 3 operator controls for setting a battery charge; Output Voltage, Output Current, and Time Selector with a ResetlUntimed position. The front panel has a yellow Power On LED indicator and a green Output Current LED indicator. The yellow Power On LED illuminates when AC power is applied. The green Output Current LED indicator blinks when the DC current flows to the battery during the charge time. When the timer expires, the Output Current LED burns steady and the current output is 113 the set current. The Power Converter will retain the elapsed time if the AC power is reapplied. The timer will not reset if AC power is removed. To reset the timer, the Time Selector switch must be switched to the RESEr position and then to the desired time setting.

a.RtDIT TIC

(1M) 0 (HOURS)

.. MOe .. I

.... g ... - .. ' '.'

... I.

,.. 1~'"

Figure 1-4. AC to DC Power Converter

d. £SA. The PSA (figure 1-5) provides an active interface between the Solar Panel, DC

Generator, or Power Converter and the batteries. It also provides an interface from a BB-590/U type or BA-5590/U battery to the OA-89901P. If a DC Generator or the Power Converter set to 32V is connected to the PSA to charge a BB-590/U type battery, the PSA will activate an internal relay which switches the BB-590/U type battery into its series position (24V mode). With a Solar Panel or the Power Converter set to 17V position, connected to the PSA to charge a BB-490/U type battery, the PSA will charge the battery in the parallel position (12V mode). The PSA will also provide overcharge protection through the PSA battery connector in the 12V mode only. The PSA will reduce charging current to 200 rnA when the battery voltage reaches 15.5V. The 15.5V limiter turn on point is temperature compensated to drop by 25mV/oC from 20°C. Full charging current will be restored when the battery voltage falls by 2V from the 15.5V point. The PSA has a dual purpose meter. When the meter on the PSA is facing uprightit provides the user with an estimate of the current being generated by the DC Generator, Solar Panel, or the Power Converter. When the meter on the adapter is facing on its side it provides the user with a rough estimate (by displaying the battery voltage) of the battery state-of-charge. The PSA will also measure input voltage from the DC Generator, Solar Panels and the Power Converter if no battery is connected.

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TM 11-6130-479-13&P

•

Figure 1-5. Power Supply Adapter (PSA)

e. DC/DC Adapter. The DC/DC Adapter (figure 1-6) allows the Solar Panel, and

Power Converter to charge the BB-5881U by providing an interface between the PSA and the BB- 588/U battery.

Figure 1-6. DC/DC Adapter

f. International Wall Socket Ac4mter Kit. The-Adapter Kit (figure 1-7) consists of five

adapters used for plugging the Power Converter into foreign and domestic outlets. Each Adapter Kit includes a European, Australian, United Kingdom, Indian, and 3 to 2 prong adapter.

Figure '-7. International Wan Socket Adapter Kit

1-7

TM 11-6130-479-13&P

g. Cables. The Cables (figure 1-8) used in the operation of the Power Supply Assembly

are as follows:

• 12V DC CABLE - The 12V DC cable connects a Solar Panel and the PSA together to provide a 12 Volt mode of operation to recharge BB-490IU, BB-5881U, and BB- 586/U type batteries.

• 24V DC CABLE - The 24V DC Cable connects two Solar Panels together in series to recharge a BB-542/U battery directly or to provide a 24 Volt mode of operation when connected to the PSA for charging the BB-590/U battery.

• PARALLEL CABLE - The Parallel Cable connects two Solar Panels together in parallel to provide a doubling of current under low light conditions, or to recharge larger batteries.

• DC GENERATOR CABLE - The DC Generator Cable provides a connection from the DC Generator output binding posts to the rechargeable battery (BB-542/U) or the PSA to charge the BB-5901U battery.

12V

PARALLEL

: )"..-=GE:::lIN -=~[[J

Figure 1-8. Power Supply Assembly Cables

h. International Adapter Ba&. The Adapter Bag (figure 1-9) is a canvas bag that holds

the five International Wall Socket Adapters used for powering the Power Converter. It is stored in the Power Converter Bag.

Figure 1-9. International Adapter Bag

1-8

TM 11-6130-479-13&P

i. Solar Panel Assembly Bae. Each of the two Solar Panel Assembly Bags (figure 1-10)

are used to house two Solar Panels, two PSAs, two 12 Volt Cables, one 24 Volt Cable, one Parallel Cable, and two DCIDC Adapters.

Figura 1-10. Solar Panel Assembly Bag

j. DC Generator Ba&. The DC Generator Bag (figure 1-l1) is used to house the DC

Generator and the DC Generator Cable.

Figure 1-11. DC Generator Bag

k. Power Converter Bu. The Power Converter Bag (figure 1-12) is used to house the

Power Converter and the International Wall Socket Adapter Kit in the International Adapter Bag.

Figure 1-12. AC to DC Power Converter Kit Bag

1-9

1M 11-4iI30-479-13&P

1. Power Syp'ply Assembly Bu. The Power Supply Assembly Bag (figure 1-13) is used

to house the four individual bags that make up the Power Supply Assembly; two Solar Panel Assembly Bags, one DC Generator Bag and one Power Converter Bag.

Figure 1-13. Power Supply Assembly Bag

1-12. EQUIPMENT DESCRIPTION AND DATA

a. Power Syp'ply Assembly

Weight . . . . . . . . . . . • . . . • . . . . . . . . . 25 lbs max (excluding carrying bags)

Bag size ..........•.......•............... 20. 75"x9 .S"x15 .25"

Temperature

Operating -50°F(-45°C) to + 120°F(49°C)

Non-operating -60°F(-51°C) to 160°F(71 °C)

Humidity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-100% Relative Humidity Altitude

Operating . . . . . . . . . . . . . . . . . . . . . . .. 15,000 Ft Above Sea Level Non-operating ...................•. 40,000 Ft Above Sea Level

b. Solar Panel

Output .. . . . . . . . . . . . . . . . . . . . . . . . . . .. Full Sun: 800 rnA at 15-17 V Overcast: 200 - 500 rnA Heavy Clouds: 50 - 100 rnA Moonlight or Artificial Lighting: Negligible energy is obtained Open Circuit Voltage .......••.••••...... 17 V at HO°F (Approximate) 19 V at 70°F (Approximate) 23 V at 30°F (Approximate)

Temperature Range

Operating ...............•...... -50°F(-45°C) to + 120°F(49°C) Non-operating ................•.. -60°F(-Sl°C) to + 160°F(71 °C)

Weight . . . . . . . . . . . . . . . . . . . . . . . . . . • . . • . . . . . . . • •. 1.9 Ibs max.

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TM ll-liI30-479-13&P

Altitude

Operating ..•..••..............•..• 15,000 Pt Above sea level Non-operating . . . . . . . . . . . . . . . • . . . . . . • 40,000 Pt Above sea level Dimensions

Open ....................•........... :Length 18.2 inches

Width 0.45 inches Height 13.0 inches

Closed. Length 9.2 inches

Width 0.6 inches Height 13.0 inches Humidity. . . . . . • . . . . . . . • . . . . . . . . .. 0-100% Relative Humidity

c. DC Generator Assembly (G-67B/G only)

(G-67f1lG data is contained in TB 11-6115-478-10)

Cranking Speed Range . . . . . . . . . . . . . . . . . . . . . . . . . . .. 70 to 100 RPM

Rated Output (at 85 RPM minimum) 2.3 A at 23 Vdc

Output Voltage (thru cranking

speed range) 22 to 32 Vdc

Regulated Output (at ambient temperature) . . . . . . . . . . . . . . .. 31 to 32.4 Vdc Overload Capabilities . . . . . . . . . . . . . . . . . . . . . . . . . .. 3.5 A for 1 minute

Overall Efficiency (cranking speed 85 RPM @ rated load) 53 %

Indicator Scale . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . " 20 - 40 V de Temperature Range

Operating -500P(-45°C) to + 1200P(49°C)

Non-operating -600P(-51°C) to + 1600P(71 °C)

Weight 7.0 Ibs max

Humidity 0-100% Relative Humidity

d. Power Converter

AC Input Power. . . . . . . . . . . . . . . . . . • . . . . . . .. 90-240 Vac, 50-400 Hz DC Power Output. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 0 to 50 Watts Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Length 7 inches max

Width 7 inches max Height 3 inches max.

Weight 2.5 Ibs max.

Temperature Range

Operating -500P(-45°C) to + 1200P(49°C)

Non-operating -600P(-51°C) to + 1600P(71 °C)

Humidity 0-100% Relative Humidity

Altitude

Operating 15,000 Ft Above sea level

Non-operating 40,000 Ft Above sea level

1-11

1M 11-4iJ.30.479-13&P e. W

Max. Input Currerlt II .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. • • .. .. .. .. • • .. • • .. .. • .. .... 3 A

Indicator Scale (Upright) •....••. . . . . . . . . . . . . . . . . • • • • • .• 0 to 3 A Indicator Scale (Side) ...............•.............. 0 to 30 Volts

Weight .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .... O.S lbs max

Dimensions 'Length 4.00 inches max

Width 1.25 inches max Height 2.10 inches max

Temperature Range

Operating -500P(-45°C) to + 120°F(49°C)

Non-operating ....•.............. -60°P(-51°C) to + 160°F(71 °C) Altitude

Operating . . . . . . . . . . . . • . . . . . . . • • . .• U,OOO Ft Above sea level Non-operating ..................•..• 40,000 Ft Above sea level Humidity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-100% Relative Humidity

f. DC/PC Adapter

Temperature Range -50°F to 185°F

g. Adapter Kit

Temperature Range ...........................•.. -40°F to 185°F European Adapter

Mate with . . . . . . . . . . . . .. 4.0-4.8 mm, 10Al16 A 250 V non-polarized

Denmark 10 A, 250 V polarized

Italy 10A/16 A, 250 V polarized

Switzerland . . . . . . . . . . . . . . . . . . . . . . . . .. 10 A, 250 V polarized

France/Belgium 10Al16 A, 250 V polarized

Australian Adapter . . . . . . . . . . . . . . . . . . . . . . . . .. 10 A, 250 V polarized

United Kingdom ...........................•..... 13 A, 250 V

Indian Plug 15 A, 250 V

3 to 2 Prong Adapter ............................•. 15 A, 125 V

h. Cables

12V DC Cable ...................................•. 36 inches

24 V DC Cable 36 inches

Parallel Cable .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. 28 inches

DC Generator Cable .. .. .. .. .. .. .. .. .. .. .. .. • .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. 72 inches

1-12

TM 11-6130-419-13&P

SECTION m. PRINCIPLFS OF OPERATION

1-13. GENERAL OPERATION

a. The Power Supply Assembly, used in conjunction with rechargeable batteries,

provides a higbly reliable source of direct current power to operate various portable electronic equipment in the field. It eliminates the need to supply large numbers of disposable batteries for extended mission times. Rechargeable batteries are the electricity storage elements and provide power on demand.

b. The Solar Cell Panel, DC Generator, and Power Converter are the sources of the

electrical power stored in the batteries. These three units allow the operator to produce electrical power in any environment, at any time all around the world.

c. Of the three energy sources, the Solar Panel and the Power Converter require the

least amount of effort to use. The Solar Panel and Power Converter require minimum operator attention, while the DC Generator must be cranked by the operator to produce electrical power.

d. The Solar Panel will not always produce a continuous source of power. No power is

provided at night or in heavy cloud conditions. Power output can be temporarily reduced or stopped due to shading of the panels.

e. The Power Converter is limited in use by the need of an electrical outlet. The

operator must set the Power Converter for the proper current and voltage levels prior to use. A timer allows the operator to set the appropriate time needed to charge the battery while attending to other responsibilities.

f. The DC Generator can function as a source of power regardless of weather conditions

provided the manpower is available.

g. The Power Supply Assembly, is man-portable and user-friendly. The Power Supply

Assembly is very versatile and provides the operator with a wide range of operational choices depending on operational conditions at any time.

1-14. SOLAR PANEL ENERGY CONVERSION

a. The Solar Panel is a device used to convert solar energy to electrical energy. The

solar energy is provided by the sun and collected by the photovoltaic cells of the Solar Panel. The electrical energy from the Solar Panel is used to charge 12 or 24 Volt batteries. Panels may be connected in series or parallel to provide higher voltages or current as required.

b. Each Solar Panel is designed to provide approximately 800 rnA (under full bright sun)

at 15-17 Volts for the charging of batteries. For this type of use, a Solar Panel is, essentially, a constant current device with the current generated dependent on the amount of light received by the Solar Panel.

1-13

TM 11-6130-479-13&P

c. For battery charging, the minimum useful energy is about 100 rnA which is obtained

under medium overcast conditions. (One hour before sunset and one hour after sunrise only provide enough energy as medium overcast conditions). No useful energy can be expected under moonlight, heavy overcast, or rainfall conditions.

d. The time needed to fully charge batteries with the Solar Panel depends on the

following four conditions:

(1) Number of panels used

(2) Time of day

(3) Weather

(4) Ability to track the sun

e. If damage occurs to individual solar cells, this will reduce the output, and extend the

time it takes to recharge a battery. Each Solar Panel is configured as two parallel sections with cells in each section connected in series to provide adequate voltage for charging batteries, at temperatures up to 120oP. Very high temperatures on the Solar Panel can lower its output voltage such that the charge rate will be reduced, thereby extending charge time. Solar Panel voltage is lowered by approximately 0.4V for every lOoP/5.5°C rise in temperature. Charge rate can be maintained by providing airflow access to the panel in extremely hot climates.

f. Typical battery charging characteristics for one Solar Panel is shown in Table 1-1.

Table 1-1 assumes that the panel is tilted toward the sun, and one BB-490/U battery requires an average of 4.6 AH for a full charge at 12 Volts. Microclimates may exists within any climate area due to fog and precipitation that may cause less then average outputs.

Table 1-1. Average Available Charging Energy for 12V Batteries in AHlDay

LOCATION SPRING SUMMER AUTUMN WINTER
Alaska (Fairbanks) 6.2 5.9 2.5 0.7
Arizona 8.4 8.4 7.3 5.6
Massachusetts 4.5 5.7 3.7 2.6
North Africa 6.7 7.1 6.5 5.3
Okinawa 4.4 3.9 4.4 3.4
Panama 6.5 6.0 5.3 5.1
Tennessee 4.7 6.0 4.2 2.6
Texas 5.6 6.5 S.2 4.2
Western Europe 4.2 S.8 3.9 2.3 1-14

TM 11-6130-479-13&tP

g. Table 1-2 shows typical charging current at different sun strength for batteries

charged at 12 Volts.

Table 1-2. Charging Output Per Panel for Different Light Conditions for Batteries Charged at 12 Volts

SUN STRENGTH CHARGING CURRENT
(mA)
Sunny (1000 w/meter-) 800
Partly Cloudy (700 w/metert) 560
Partly Sunny (250 w/meter-) 200
Heavy Clouds (100 w/meter-) 80
Moonlight 0 h. At typical temperature conditions in bright sun, the Solar Panel will provide about 19

Volts under no/low load conditions. Increasing the load (reducing load resistance) will cause only slight reductions in voltage until the peak power point is reached. Further attempts to increase power by reducing load resistance will only result in quickly reducing the voltage and power output. Table 1-3 demonstrates this effect for full sun conditions.

Table 1-3. Effect of Load Resistance on Solar Panel Output

LOAD RESISTANCE VOLTAGE CURRENT WATTS TO LOAD
(Ohms) (Volts) (Amps)
100 19.0 .19 3.6
50 18.6 .37 6.9
25 18 .72 13.0
20 16.8 .84 14.1
15 12.9 .86 11.1
10 8.8 .88 7.7
1 0.9 .90 0.8 I-IS. DC GENERATOR ENERGY CONVERSION

a. The DC Generator is a device used to convert mechanical energy to electrical energy.

The mechanical energy is provided by an operator hand-cranking the DC Generator. The electrical energy is used to charge 24 Volt batteries.

1-15

TM 11-6130-479-13&P

b. The operation of the mechanical to electrical conversion is labor intensive. An

uneven, jerky, cranking motion causes the operator to tire more quickly than a smooth, steady motion. Operating the DC Generator is straightforward, but practice and exercise will greatly increase the amount of electrical energy an operator can produce. The time needed to fully charge a battery depends on the following three things:

(1) The amount of time the DC Generator is being cranked.

(2) The cranking speed.

(3) The condition of charge prior to starting.

c. The capacity ampere-hour rating of the batteries is 2 ampere-hours for the BB-542/U

and 1.5 ampere-hours for the BB-590/U. Both are charged as 24 Volt batteries.

1-16. POWER CONVERTER ENERGY CONVERSION

a. The Power Converter is a device used to convert AC voltage to DC voltage. The AC

voltage is provided by a wall outlet. The DC output voltage is used to charge 12 and 24 Volt batteries. The Power Converter can be used world wide by utilizing the International Wall Socket Adapter Kit, which consists of five adapters for plugging the Power Converter into foreign outlets.

b. The Power Converter can be set to provide 14, 17, or 32 volts DC (lOOmA - 1500

rnA) depending on the battery being charged. The Power Converter has a timer which can be set for 1 to 6 hours or untimed. The setting depends on the type of battery being charged and its condition of charge prior to starting. The timer enables the operator to tend to other duties while the battery is being charged.

1-17. OP-177(V)/u VARIABLE CONFIGURATION DIFFERENCES

a. The OP-177(V)/U Power Supply Assembly has two established versions, (V)1 and

(V)2. The only difference between these two versions is the DC Generator. The (V)1 includes the G-67B/G and the (V)2 includes the G-6ifllG. All other system components are interchangeable.

b. The OP-177(V)lIU (with G-67B/G) is designed to satisfy specific reliability,

environmental and performance requirements. All OP-177(V)lIU capabilities are described in this Technical Manual. The OP-177(V)2/U (with G-6ifllG) is designed for training use only, and therefore has different reliability/durability characteristics. To achieve these unique reliability characteristics, design changes were required which reduced certain environmental and performance capabilities.

•

c. Most technical data and operator/maintainer procedures contained in this Technical

Manual concerning the G-67B/G, apply to the G-6ifllG; however, the G-6ifl/G has significant differences. The differences include lubrication, immersion, cold temperature, noise and torque characteristics. These differences are outlined in TB 11-6115-478-10.

1-16

TM 11-6130-479-13&P

CHAPI'ER2

OPERATING INSTRUCTIONS

PAGE

Section I.

Description and Use of Operator's Controls and Indicators . . . . . . . . . . 2-1

Section ill.

Operator Preventive Maintenance Checks and Services (OPMCS) . . . . • • 2-4 Operation Under Usual Conditions ••..••..•.....•...•..... 2-5

Section U.

Section IV.

Operation Under Unusual Conditions . . . . . . • . . • • . • . . . • . . . .• 2-75

SECTION I. DESCRIPTION AND USE OF OPERATOR'S CONTROLS AND INDICATORS

2-1. DESCRIPl'ION AND USE OF OPERATOR'S CONTROlS AND INDICATORS

a. General. The controls and indicators of the Power Supply Assembly main

components are shown and described below.

b. DC Generator. The controls and indicators of the DC Generator are shown in figure

2-1. A brief functional description is given in table 2-1 for each DC Generator item referenced in

figure 2-1. .

Figure 2-1. DC Generator Controls and Indicators

2-1

TM 11-6130-4":13&P

Table 2-1. DC Generator Controls and Indicators

Nomenclature Function
Voltage Meter The voltmeter (8) is calibrated in 1 volt increments from 20-40
Vdc. The voltmeter does not indicate voltage below 20 Vdc.
The voltmeter Will read voltage above 20 Vdc.
Binding Posts There are color coded binding posts on DC Generator used for
output power connections. The B1ack Binding Post (1)
connects to Black Phone Tip Plug (2) on Black Wire (3) of DC
Generator Cable (7). The Red Binding Post (4) connects to Red
Phone Tip Plug (5) on Red Wire (6) of DC Generator Cable
(7). c. Power Converter. The controls and indicators of the Power Converter are shown in

figure 2-2. A brief functional description is given in table 2-2 for each Power Converter item referenced in figure 2-2.

2

Figure 2-2. Power Converter Controls and Indicators

TM 11-613O-479-13&P

Table 2-2. Power Converter Controls and Indicators

Fig. 2-2 Nomenclature Function
Index No.
1 Current Selector A six position switch (1) selects DC current output to
Switch charge different types of batteries. The selectable
current settings are 100, 200, 400, 800, 1000, and 1500
mAo
2 Output Voltage A three position switch (2) selects the Power Converter
Selector Switch output voltage settings of 14, 17 or 32 Vdc.
3 Time Selector Switch A seven position switch (3) selects the Power Converter
charging time in one hour increments from 1 to 6 hours,
as well as, being able to be set to untimed. ~t must
be selected prior to selecting desired timed setting.
4 Green Indicator LED A green output indicator light (4) indicates output. A
blinking light indicates DC current flow to the battery
during charging time. A steady light indicates trickle
charge mode (1/3 output current setting) at time out.
The light does not light if current does not flow to
output load. A dimmer cap enables the light to be
dimmed.
5 Yellow Indicator LED A yellow indicator light (5) indicates power on. A
dimmer cap enables the light to be dimmed. d. Power SuWly Adapter. The controls and indicators of the PSA are shown in figure

2-3. A brief functional description is given in table 2-3.

rar TO ROO VOI..TAGE

SOlAA/HC GEN 3A MAX INPUT ONLY

~ +(E) SOlAA 12-1GY J (0)+ OJ

+(0) HC GEN 24-3011 U T

-(B) \l (0)- P

12/24'1 U

B.\TT'ER'!' T

Figure 2-3. Power Supply Adapter (PSAt Controls and Indicators

2-3

TM 11-6130-479-13&P

Table 2-3. PSA Controls and Indicators

Nomenclature Function
Current/Voltage When facing upright PSA will read current provided by Solar
Meter Panel, DC Generator or Power Converter from 0 to 3 amperes.
Each division is 0.10 ampere. When facing on its side PSA
will read battery voltage (or input voltage if no battery
connected). The scale is 0 to 30V. This is obtained by
multiplying the scale by 10. Each division is 1.0V.
Current Limit/ Provides overcharge protection through its battery connector in
Overcharge the 12V mode only. Reduces charging current to 200,mA when
Protection battery voltage reaches approximately lS.SV. SECTIONll.

OPERATOR PREVENTIVE MAINTENANCE CHECKS AND SERVICES (OPMCS)

2-2. ROUTINE SERVICES

Routine services are a collection of checks and observations performed by the operator at all times. The following should be performed as necessary.

Clean Dust

Check for cut or frayed cables

Check for dented, bent, or broken components Cover unused receptacles

Check for loose connectors

Check for completeness of equipment

Check to see that items not in used are properly stored Check for corrosion

NOTE

Before taking the DC Generator into an operating environment, perfonn a functional check by cranking at 7S RPM. If cranking is difficult or excessively noisy, do not use the DC Generator and refer it to the next higher level of maintenance.

2-4

TM 11-6130-479-13&P SECTION m. OPERATION UNDER USUAL CONDITIONS

2-3. BATTERY CHARACTERISTICS

The Power Supply Assembly is designed to charge various 12Vand 24V rechargeable batteries used to power communications-electronics equipment. Each battery type and size has unique characteristics that should be considered to obtain the optimum service from each subassembly used under different environmental conditions. Table 2-4 lists the battery types and the Recommended methods of recharging. Table 2-S lists the battery types and the fast methods of recharging.

a. BB-S90/U Sealed Nickel-Cadmium. This battery contains 20 sealed Nickel-Cadmium

cells. Through its external connector it maybe connected in series to provide a nominall.S AH at 24V or 3.0 AH at 12V. This battery has no internal controls. Batteries manufactured after Jan 1991 will have nominal capacity of 2 AH.

(1) Advantaies of BB-S90/U.

(a) Can be discharged at pulse currents up to 18A (400 Watts) and sustained high currents of 9A (210 Watts).

(b) Can be discharged at temperatures to _2SoP (-32°C).

(c) Both capacity BB-S90/U batteries can be charged at currents of up to 3A (either 12V or 24V mode) until full charge is reached. The batteries may be further charged (overcharged) for a limited period at .SA (24V mode) or 1.0A (12V mode). (Note that the normal output current of a single solar panel is below the I.OA overcharge current limit.)

(d) Can be stored in any state without damage.

(2) pisadyanta~es of BB-S90/U.

(a) Self discharges on stand. Typical rates are 0.5-1 %/day at 77°P (2S0C) increasing to 2-4%/day at 113°F (4S0C).

(b) Capacity is reduced by charging at elevated temperatures. Only 70% of rated capacity is obtained when charging at 113°P (4S0C) and 40- SO% when charging at 141°P (60°C).

(c) Requires approximately 20-30% more capacity input than output for full charge.

2-S

TM 11-6130-479-13&P

2-6

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2-7

(

TM 11-6130-479-13&P

b. BB-5421U Sealed Nickel-Cadmium Fast Chaw; Battery. This battery contains 20

sealed Nickel-Cadmium cells connected in series to provide a nominal 2 AH at 24V. It contains an internal pressure switch which permits full recharge in less than one hour safely. Maximum power output of the Power Supply Assembly will normally limit charge time to 1.5 hours or more. Heaters are also included in the BB-'42/U, but they are not effective nor directly useable with the Power Supply Assembly.

(1) Adyanta~es of BB-5421U.

(a) Can be discharged at currents to lOA (240 watts). (Battery fuse limit).

(b) Can be discharged at temperatures to -25°F (-32°C).

(c) Can be charged at all currents within limits of Power Supply Assembly (3A). BB-542/U has internal controls that will prevent excessive overcharge.

(d) Provides a direct connector for charging internal battery in OA-8990/P.

(e) Terminates discharge at 19.5 V automatically.

(t) Can be stored in any state without damage.

(2) Disadyanta~es of BB-542/U.

(a) Self discharges on stand. Typical rates are 0.5-1 'Yo/day at 77°F (25°C) increasing to 2-4%/day at 113°F (45°C).

(b) Capacity is reduced by charging at elevated temperatures with a fast charge. Only 75 % of rated capacity is obtained when charging at 113°F (4'OC) and 50-60% when charging at 141°F (60DC). BB-542 cannot be discharged or charged above 160°F (70DC) due to an internal thermal switch.

(c) BB-542/U batteries manufactured prior to 1991 cannot be charged by the Power Supply Assembly when temperatures below 32 OF are encountered. BB-542/U batteries manufactured after 1991 have internal circuitry to bypass an internal limiting resistor which is connected in series with charge input, which allows charging in temperatures below 32D.

TM 11-6130-479-13&P

c. BB-49O/U Sealed Lead Acid. This battery contains 12 sealed Lead Acid cells.

Through its external connector it may be connected in series to provide a nominal 1.8AH at 24V or 3.6AH at 12V. The BB-490/U is physically interchangeable with the BB-590/U.

(1) Adyanta&es of BB-490/U.

(a) Will lose its energy (capacity) very gradually while it is being stored.

Typical values are 3%/month at 68°F (20°C) and 12%/month at l04°P (40°C).

(b) The open circuit voltage of BB-490/U provides a rough estimate of its state-of-charge. For example, at 77°F if voltage is above 13V, the battery is 90-100% charged. A voltage above 12.SV would indicate that BB-490/U is between SO and 70% charged. Readings below 12V would indicate that the battery is less than 40 % charged and should be recharged.

(c) Can be discharged at temperatures to SOF (-IS0C).

(d) Shows a large increase in voltage at end of charge which provides a signal for limiting current. A voltage higher than 15V during charge would normally indicate that the BB-490/U is fully charged.

(e) Overcharge requirements are low, compared to the BB-590/U, particularly at temperatures above 90°F (32°C).

(2) DisadYanta&es of BB-490/U.

(a) Must be recharged after use and periodically after extended storage to prevent degradation.

(b) Cannot be stored for long periods of time in the discharged state without damage.

(c) For high rate (more than lA) continuous discharges and/or low temperature operations, capacity will be considerably less than for the BB-S90/U. However, BB-490/U's capacity will be considerably improved by intermittent operation.

d. Other Batteries Recharple by the Power Sup_ply Assembly.

(1) BB-586/U. This is a 13.2V 4AH sealed Nickel-Cadmium battery containing

11 series connected cells. It may be recharged directly from one solar cell panel using a locally fabricated cable. Typical charge times at O.8A will be 6 hours or less. Because the BB-586/U contains a thermal switch set a 113°P to limit charging, the battery should be shaded during solar charging in warm environments.

2-9

TM 11-6130-479-13&P

(2) BB-588/U. This is a 13.2V 0.55/1 AH sealed Nickel-Cadmium battery

containing 11 series connected cells. Maximum charge current, until full charge/capacity is reached, for the 0.55AH battery is 1.5A and the 1.0AH battery is 3.0A. The 0.55AH-capacity battery cannot be overcharged at 200mA for more than roughly 30 minutes before sustaining cell damage and gradual performance degradation.

(3) OA-8990/P Dieital Messaee Device Group. This device contains a 6V lA

sealed Nickel-Cadmium battery which is recharged through internal circuitry of OA-8990/P, from de input voltage sources of 10-30V. Input current to the battery is limited to a maximum of 0.8A and is terminated automatically by OA-8990/P. The OA-8990/P may be charged directly from a BB- 542/U battery, however, a more power efficient charge is provided by the Power Supply Assembly, using PSA output connector.

2-4. PREPARATION FOR USE

This section has important information about setting up the Solar Panel, DC Generator, and Power Converter in different configurations.

a. Solar Panel Set-Up.

(1) Open Solar Panel and fold back velcro tape, on itself, out of the way.

(2) In order to obtain best results from the Solar Panel, ensure panels are kept

clean and do not allow panels to become shaded by grass, trees, cables, or other obstructions. Shading several cells on a panel could cut current generation by as much as 50 %. While making voltage/current measurements ensure your body does not shade panel(s). This will affect readings.

I WARNING I

Solar Panels can reach temperatures of 160-170°F when operating In bright sun In hot environments. Panels can cause burns to skin if touched with bare hands.

(3) Aim panel(s) directly at sun for maximum power using rocks, rucksack or

anything at hand to prop panel(s) up at proper angle. Move panel(s) as often as needed to follow sun. Up to 40% more energy can thus be obtained, depending on the season, time of day and weather conditions. Use the current mode on PSA to provide an indication of current being generated by the panel. This will aid in panel placement. You can then approximate charging time that will be needed. Make sure that when connecting equipment together, proper polarity is observed. On the PSA make sure that you observe correct input, output, and battery conditions.

2-10

TM 11-'130-479-13&P

(4) Single Panel Set-Up. Single Panel Operation is conducted in bright sunshine

or partly cloudy conditions and is used to charge BB-490/U and BB-590/U type batteries.

(a) Position Solar Panel directly at sun and prop it up to maintain proper angle. Tie it down if required. Periodically reposition Solar Panel to follow the sun.

(b) Observing polarity, connect banana plug end of a 12V cable to a Solar Panel. Connect five-pin bayonet connector of the 12V Cable to input connector of the PSA. Tilt PSA to read voltage. The open circuit voltage should read approximately 19.5 +/- IV (see figure 2-4). Remember, the hotter the Solar Panel, the lower the open circuit voltage will be. If the correct voltage is not obtained, see Table 3-1 for corrective action.

Figure 2-4. Single Panel Set-Up, Open Circuit Voltage Measurement

(5) Dual Panel Parallel Set-Up. Dual Panel Parallel operation can be conducted

under full-sun conditions or with overcast skies, from sunrise to 1 hour after sunrise, or 2 hours before sunset. This charging mode may be used to charge the BB-590/U, BB-490/U, BB-586/U and the BB-542/U batteries.

2-11

TM 11-6l30-479-13&P

(a) Perform Single Panel set-up as described in paragraph 2-4.a.(4).

(b) Retrieve a second Solar Panel and one Parallel Cable from Solar Panel Bag. Observing polarity, connect one banana plug end of Parallel Cable to second Solar Panel. Observing polarity, connect the other banana plug end of Parallel Cable "piggyback" to 12V Cable (see figure 2-5).

(c) Tilt PSA to read voltage. The open circuit voltage of the Solar Panel should read approximately 19.5 +1- IV. Remember, the hotter the Solar Panel, the lower the open circuit voltage will be. If the correct voltage is not obtained, see Table 3-1 for corrective action.

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Figure 2-5. Dual Panel Parallel Connection Diagram

(6) Dual Panel Series Set-Up. Dual Panel Series Operation is conducted in bright

sunshine or partly cloudy conditions and is used to charge BB-5421U batteries.

(a) Position two Solar Panels directly at sun and prop them up to maintain proper angle. Tie down panels if required. Periodically, reposition Solar Panels to follow the sun.

(b) Observing polarity, connect the banana plug ends of a 24V cable to the two Solar Panels.

(c) Connect five-pin bayonet connector of the 24V Cable to input connector of the PSA. Tilt PSA to read voltage. The PSA voltage meter should be at the maximum position, indicating that the voltage is greater than 30 volts (see figure 2-6). If the voltage meter does not max out, see Table 3-1 for corrective action.

2-12

TM 11-6130-479·13&P

Figure 2-6. Dual Panel Series Connection Diagram

(7) OUad Panel Series/Parallel Set-Up. This Quad Panel Series/Parallel Operation

is conducted in all light conditions and is used to recharge BB-542/U and BB-590/U batteries as quickly as possible.

(a) Position four Solar Panels directly at sun and prop them up to maintain proper angle. Tie down panels if required. Periodically, reposition Solar Panels to follow the sun.

(b) Observing polarity, connect one of banana plug ends of Parallel Cable I to Solar Panel I and one of banana plug ends of Parallel Cable 2 to Solar Panel 2. Then, observing polarity, connect remaining banana plug end of Parallel Cable I to Solar Panel 3 and then connect remaining banana plug end of Parallel Cable 2 to Solar Panel 4 (see figure 2-7).

1

pARAllEL ,

CASU: 2

-.

2

3

PARAllEL CABLE 1

4

Figure 2-7. Quad Panel Series/Parallel Connection Diagram

(c) Observing polarity, connect the two banana plug ends of the 24V cable "piggyback" to the banana plug ends of parallel cables 1 and 2 where they are connected to solar panels 3 and 4.

2-13

TM 11-6130-4?9-13&P

b. DC Generator Set-Up.

(1) Set-Up For Use With Operator Sittin~ On Stirrup. The following procedures

provide instruction for preparing the DC Generator for operation while sitting on Stirrup. Refer to figure 2-8 for the following set-up procedures:

(a) Remove the DC Generator from its Carrying Bag (2, figure 2-8, sheet 1) and place it on a flat surface with meter facing up.

(b) Place Handles (3) out to the side of their respective Crank Arms (4).

(c) Remove the Quick Release Pin (5) from the Stirrup Shaft (6), then unfold the Stirrup 180°.

NOTE

The DC Generator must be assembled followin& the sequence of the steps outlined. In spite of the apparent simplicity of the DC Generator, there are several critical mechanical alignments required in order to assemble the DC Generator.

Figure 2-8. DC Generator Set Up Procedure While Sitting On Stirrup (1 of 4)

2-14

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Figure 2-8. DC Generator Set Up Procedure While Sitting On Stirrup (2 of 4)

2-15

TMU...Q30..4?9.13&P

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Figure 2-8. DC Generator Set Up Procedure While Sitting On Stirrup (3 of 4)

'1M 11-4lJO..4'79..U&P

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Figure 2-8. DC Generator Set Up Procedure While Sitting On Stirrup (4 of 4)

2-17

2-18

TM U-6130-479-13&P

(d) Rotate the Stand (14, figure 2-8 sheet 2) about 90° to expose the Snap Button (12).

(e) Press the Snap Button (12) to unlock the Outer (2) and Inner Tubes (3) and pull the Inner Tube (3) out about two inches.

NOTE

,.

Alignment circles and Index I.infs.are provided on the Inner Tube, Outer Tube, and Stand to belp. with aUgnment durin& set-up.

(£) Rotate the Stand (14) back to its original orientation.

(g) While keeping Foot Pad Assembly (6) flat on Stirrup Shaft (7), rotate Foot Pad Assembly (6) 180° (Foot Pad Assembly (6) should be flat on working surface).

(h) Still keeping the Foot Pad Assembly (6) flat on the Stirrup Shaft (7), raise the Stirrup (8) to an angle of about 60° and insert the Quick Release Pin (9) into t1u~ Hinge (4).

(i) Rotate the Foot Pad Assembly (6) about 45° (to prevent the Snap Button (12) from locking into the wrong holes) and slide the Inner Tube (3) out until the second Alignment Circle (13) appears at the tip of the Outer Tube (2). Keeping this circle aligned with the tip of the Outer Tube (2) rotate the Foot Pad Assembly (6) back again until the Index Line on the Inner Tube (3) aligns with the Index Line on the Outer Tube (2) and the Snap Button (12) locks into place.

(j) Slide Stand (2, figure 2-8 sheet 3) downward until you can push the Quick Release Pin (5) from front to back through aligned holes in Outer Tube (1), and Inner Tube (4).

(k) Unscrew both Thumbwheels (7) until you meet resistance.

(I) While aligning the index line on the Stand Collar (2) with the index lines on the Outer (1) and Inner Tubes (4), slide the Stand Collar (2) toward the Foot Pad Assembly (8) until the Stand Collar (2) reaches the alinement circle on the Outer Tube (1), the snap button grips (but does not lock) the Stand Collar (2) and the Slot in the stand collar slides part way over the Quick Release Pin (5). At the same time, guide the slots in the stand legs over the threaded screws between the Thumbwheels (7) and the thumbwheel flanges on either side of the Foot Pad Assembly (8).

(m) Hand tighten both Thumbwheels (7).

TM 11-6130-479-13&P

(n) Raise the assembled DC Generator and place it on working surface with Voltage Meter (1, figure 2-8, sheet 4) facing you. Stand on Stirrup (7) to keep DC Generator upright.

(0) Insert C2Ch handle (3) into its Crank Arm (6) using the following steps:

1 Push and hold Slide Knob (5).

2 Align Handle Shaft (4) with hole in Crank Arm (6). Insert Handle Shaft (4) then release Slide Knob (5).

l Try to pull out Handle (3) to ensure that it is locked into place.

(P) Unscrew handle nut (2) and pull it away from shaft until stopped by Retaining Screw (8).

(q) Pull Right Crank Arm (6) away from square portion of DC Generator shaft and rotate it 1800•

(r) Slide Right Crank Arm (6) onto square portion of shaft.

(s) Screw on handle nut (2) and hand tighten.

I WARNING I

Do not touch contacts of the DC Generator when it is being cranked. FJectrical shock may result.

(t) Crank the DC Generator at 75 rpm (approximately 12 turns every 10 seconds) to ensure that the DC Generator can be cranked with ease and comfort, and that the voltage meter indicates about 30 V dc.

(u) If everything is functioning properly, the unit is ready for use. If voltage meter does not work, perform troubleshooting in Chapter 3. For any setup difficulty, retrace steps to assure that setup procedures were properly followed. If cranking at 75 RPM is difficult or excessively noisy, elevate to next higher level of maintenance.

2-19

TM 11-6130-479-13&P

(2) Set-UP For use With Qperator Standin& Or Kneelin&. The following procedures

provide instructions for preparing the DC Generator for operation while standing or kneeling. Refer to figure 2-9 for the following set-up procedures:

(a) Remove DC Generator from its carrying bag (2, figure 2-9, sheet 1) and place it on a flat surface with the meter facing up.

(b) Place handles (3) out to the side of their respective crank anns (4).

(c) Remove the Quick Release Pin (8) from the Stirrup Shaft (9).

NOTE

The DC Generator must be assembled foHowiD& the sequence of steps outlined. In spite of the apparent simplicity of

the DC Generator, there are several critical mechanical alignment required in order to assemble the DC Generator.

(d) Unfold the Stirrup (10) 1800 while holding the Foot Pad Assembly (1) perpendicular to the Stirrup Shaft (9).

Figure 2-9. DC Generator Set Up Procedure, Standing/Kneeling Position (1 of 3)

TM 11-6J.30..479-13&P

1

Figure 2-9. DC Generator Set Up Procedure, Standing/Kneeling Poaldon (2 of 3)

J..21

TM 11~130-479-13&P

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Figure 2-9. DC Generator Set Up Procedure, Standing/Kneeling Position (3 of 3)

TM 11-6130-479-13&P

(e) Align Holes (3, figure 2-9, sheet 2) in Hinge and Stirrup Shaft (4) then insert Quick Release Pin (6).

(t) Rotate the Stand Collar (10) about 900 to expose the snap button and press the snap button to unlock the Inner (2) and Outer Tubes (9), and pull the Inner Tube (2) out about 2 inches.

(g) Rotate the Stand Collar (10) another 900 in the same direction. The index line on the Stand Collar (10) should be facing away from the operator.

(h) Pull the Inner Tube (2) out further until the first alignment circle appears below the tip of the Outer Tube (9). The snap button will lock into place.

(i) Slide the Stand Collar (10) about 2 inches toward the Foot Pad Assembly (7) and push the Quick Release Pin (1) from front to back through the alined holes in the Outer (9) and Inner Tubes (2).

G> Unscrew both thumbwheels (5) until you meet resistance.

NOTE

The stand collar is designed to slide downward over the exposed snap button but extra force is required.

(k) Continue lowering the Stand Collar (10) until the slot in the Stand Collar (10) rests on the Quick Release Pin (1). At the same time, guide the slots in the leg stand (8) over the threaded screws between the Thurnbwheels (5) and the thumbwheel flanges on either side of the Foot Pad Assembly (7).

(1) Hand tighten both Thumbwheels (5).

(m) Raise DC Generator to the upright position with Voltage Meter (1, figure 2-9, sheet 3) facing you.

(n) Insert your foot into Stirrup (6) and rest assembly against your skin.

(0) Insert each Handle (7) into its Crank Arm (3) using the following procedure:

1 Push and hold Slide Knob (4).

2 Align Handle Shaft (8) with Hole (5) in Crank Arm (3). Insert Handle Shaft (8) then release Slide Knob (4).

J Try to pull out Handle to ensure that it is locked into place.

2-23

TM 11-6130-479-13&P

(P) Unscrew handle nut (2) and pull it away from shaft until stopped by retaining screw (9).

(q) Pull Right Crank Ann (3) away from square portion of DC Generator Shaft and rotate it 1800•

(r) Slide Right Crank Arm (3) onto square portion of shaft.

(s) Screw on Handle Nut (2) and hand tighten.

I WARNING I

Do not touch contacts or the DC Generator when it is beiDa cranked. Electrical shock may result.

(t) Crank the DC Generator at 7S rpm (approximately 12 turns every 10 seconds) to ensure that the DC Generator can be cranked with ease and comfort, and that the voltage meter indicates about 30 Vdc.

(u) If everything is functioning properly, the unit is ready for use. If voltage meter does not work, perform troubleshooting in Chapter 3. For any setup difficulty, retrace steps to assure that setup procedures were properly followed. If cranking at 7S RPM is difficult or excessively noisy, elevate to next higher level of maintenance.

(3) Set-Up For Alternate Operatinl Position. The following procedures provide

instruction for preparing the DC Generator for an alternate operating position. Refer to figure 2-10 for the following set-up procedures:

(a) The DC Generator may be lashed to a tree for operation.

(b) In order to lash the DC Generator to a tree, it must be assembled in the position for operating while sitting on Stirrup as described in paragraph 2- S.b.(l).

(c) Gather material to securely lash the DC Generator to a tree (e.g., a rope or strap).

(d) Attach the material around Stirrup Assembly as shown in figure 2-10.

c. Power Converter Set-Up. Setting-up the Power Converter for use outside of North America requires the International Wall Adapter Kit. Connect the applicable wall adapter to the Power Converter AC input line cord before following the operating procedures in paragraphs 2-S and 2-6.

2-24

TM 11-6130-4~13"P

Figure 2-10. DC Generator Set Up Procedure, Alternate Operating Position

2-25

TM 11-6130-479-13&P

2-5. RECOMMENDED PROCEDURES FOR CHARGING BATTERIES

Before operating the Power Supply Assembly for the first time, familiarize yourself with the contents of this section and the previous section. When performing a procedure for the first time, familiarize yourself with the entire procedure before beginning.

I WARNING I

Do not attempt to charge any batteries other than those authorized in this manual.

I WARNING I

Do not charge batteries without using the PSA unless the battery has internal overcharge protection (e.g., BB-S42M.

NOTE

Most of the procedures contained in this manual are based upon "Recommended" manufacturers charging specifications which permit longer battery life and most efficient battery performance. There are also "Fast" charging procedures for timecritical situations which may slightly degrade battery performance over the life of the battery (see paragraph 2-6 for Fast charging procedures).

a. Hook-up Procedures For Char~ing Battezy Sealed. Nickel Cadmium. BB-590/U. The following procedures provide instruction for charging the BB-590/U using the most efficient ways available.

(1) Char~in~ BB-590/U Usin~ the DC Generator. Refer to figure 2-11 for the

following operating procedures:

(a) Connect PSA (7, figure 2-11) to the BB-S90/U. Tilt battery and PSA onto its long face to read battery voltage. A voltage less than 13 volts may indicate need for charging.

(b) Connect DC Generator cable (4) to DC Generator. Connect red phone tip plug (5) to DC Generator red binding post (6) and black phone tip plug (3) to black binding post (2).

(c) Connect DC Generator cable (4) to receptacle on PSA (7) labeled "INPUT".

(d) Charge the battery by cranking the DC Generator at 7S to SS rpm, noting that the voltage indicated on the DC Generator voltmeter is 28 to 32 volts and the current reading on PSA (7) (upright position) is from 1.2 to 1.S amps.

2-26

TM 11-6130-479-13&P

CAUTION

Do not exceed currents of 3.0 amps except for periods of less than one minute.

CAUTION

There Is no overcharge protection in this mode; therefore, frequent operator monitoring may be necessary.

NOTE

To fuUy charge the BB-590IU wiD take approximately 1.25 to 2 hours from the fully discharged state. Rest periods will extend the time to reach rull charge. A rise in battery volta&e on the DC Generator voltmeter followed by a decrease whUe at the same current, and an increase in battery temperature indicates that the battery Is rully charged. Do not exceed actual cranking time or 2 hours on a BB-590/U without checkln& battery.

(e) Every 5 minutes, stop cranking the DC Generator. Immediately tilt the BB-590/U battery and PSA to read the battery open circuit voltage. Check battery temperature by hand for any increases. Use PSA voltmeter as an indicator of approximate battery condition only.

NOTE

When the DC Generator is not being cranked, the DC Generator voltmeter will Dot show a reading.

(t) If battery voltage, temperature or total charge time shows the battery is not charged, then repeat steps d and e above until the BB-590/U becomes fully charged.

(g) Disconnect DC Generator cable (4) from PSA (7).

(h) Disconnect DC Generator cable (4) from DC Generator.

2-27

TM 11-6130-479-13&P

figure 2-11. DC Generator Hookup for Charging BB-590/U

(2) Char&iDl: BB-S9OlU Usin& Sina:1e Solar Panel Set-Up. Refer to figure 2-12 for the following operating procedures:

(a) Refer to 2-4.a.(4) for Single Panel Set-up procedures.

(b) Remove PSA from Solar Panel if connected.

(c) Connect the PSA to BB-59O/U battery connector before charging. Tilt the battery forward and confirm the battery voltage is between 12-14V on the PSA voltmeter.

(d) Connect the Solar Panel to the input connector of the PSA. Place the battery and PSA upright and observe current flow. With a measured current of O.8A it will take about 5-6 hours to fully charge a BB-590/U 2AH battery and 4-5 hours to fully charge a 1.5AH battery. A partially charged battery will take less time to charge. In less than full-sun conditions charging time will be longer. If correct amperage reading is not obtained, as defined in Table 1-2, see Table 3-1 for corrective action.

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TM 11-6130-479-13&P

(e) The following are indicative of a fully charged BB-5901U: Charge time at O.SA exceeds 6 hours for the 2AH battery and charge time at O.SA exceeds 5 hours for the 1.5AH battery; the battery shows internal heating; the battery voltage falls by 0.5-1.0 volt without a drop in current flow. Remove fully charged battery.

Figure 2-12. Single Panel Operation, Current Measurement

(3) Cbariini BB-59O!U Usini Dual Panel Parallel Set-Up. Refer to figure 2-13 for the

following Low-light operating procedures:

(a) Refer to 2-4.a. (5) for Dual Panel Parallel set-up procedures.

(b) Remove the PSA from the Solar Panel if connected.

(c) Connect the PSA to the BB-590/U battery connector before charging. Tilt the battery forward to confirm the battery voltage is between 12-14V on the PSA voltmeter.

(d) Connect the Solar Panel to the input connector of the PSA. Place the battery and PSA upright and observe current flow. This procedure is for charging in other than full-sun conditions. Sunlight may vary significantly causing changes in solar panel charge current. Varying charge current will result in longer charging times. Charging times can be anywhere from - 2.5-5 hours to fully charge a 1.SAH battery and 3-6 hours to fully charge a 2AH battery. A partially charged battery will take less time to charge. In less than full-sun conditions charging time will be longer. If correct amperage reading is not obtained, as defined in Table 1-2, see Table 3-1 for corrective action.

2-29

TM 11-6130-479-13&P

(e) Periodic monitoring of the BB-S901U is required using this charging procedure since there is no overcharge protection in this mode. The PSA may invoke the 200 rna overcharge protection but this is not a reliable means to protect the BB-S90/U.

CAUTION

There is no overcharge protection in this mode; therefore, frequent operator monitoring may be necessary.

(t) The following are indicative of a fully charged BB-S901U: the battery shows internal heating; the battery voltage falls by 0.5-1.0 volt without a drop in current flow. The battery must be removed from charge.

8B-59ItU

Figure 2-13. Dual Panel Parallel Operation, Current Measurement

(4) Char&in& BB-590/U Using Power Converter. The Power Converter 32 Volt charging

mode is used to charge the BB-S90/U battery under any condition in which a 90-240 V AC, S0-400 Hz supply is available. Refer to figure 2-14 for the following operating procedures.

(a) On the Power Converter, select the 32V position and connect the output connector to the input of the PSA.

(b) Connect the AC Power Source to the Power Converter via the AC input line cord. A voltage of greater than 30V should be observed on the PSA voltmeter and the power input LED on the Power Converter will be illuminated. If the correct voltage reading is not obtained, see Table 3-1 for corrective action.

(c) Remove the PSA from the Power Converter.

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TM 11-6130-479-13&P

(d) Connect the PSA to the BB-590/U battery connector.

(e) Connect the output connector of the Power Converter to the input connector of the PSA.

(f) Observe the current output LED is illuminated green and is blinking, indicative of a charging condition.

(g) For 1.5AH batteries set the current control knob to 400 rnA. Set the timer knob first to Reset and then to 5 hours. A charging current of 400 rnA should be verified on the PSA current meter.

For 2AH batteries set the current control knob to 400 mAo Set the timer knob first to Reset and then to 6 hours. A charging current of 400 rnA should be verified on the PSA current meter.

(h) At the conclusion of the specified time period when the timer has expired, observe the current output LED is illuminated green and bums steady.

(i) The following are indicative of a fully charged BB-590/U: Charge time at 400 rnA exceeds 5 hours for the 1.5AH battery; charge time at 400 rnA exceeds 6 hours for the 2AH battery; the battery shows internal heating;

the battery voltage falls by 0.5-1.0 volt without a drop in current flow. The battery may be removed for use or left on charge without damage.

2-31

Figure 2-14. AC to ,DC Power Converter Hookup for Charging the BB-590/U

TM 11-6130-479-13&P

b. Hook-up Procedures For Char&in& BatteD' Sealed. Lead Acid. BB-490IU. The following procedures provide instruction for charging the BB-4901U using the most efficient ways available.

(1) Char&in& BB-4901U Usjn& the DC Generator. Refer to figure 2-15 for the

following operating procedures:

(a) Connect PSA (7, figure 2-15) to the BB-490/U. Tilt battery and PSA onto its long face to read battery voltage. A voltage less than 12.5 volts may indicate the need for charging.

(b) Connect DC Generator Cable (4) to DC Generator. Connect red phone tip plug (5) to DC Generator red binding post (6) and black phone tip plug (3) to black binding post (2).

(c) Connect DC Generator Cable (4) to receptacle on PSA (7) labeled ·INPUT".

(d) Charge battery by cranking DC Generator at 70 to 85 rpm, noting that the voltage indicated on DC Generator Voltmeter is 28 to 32 Volts and the current reading on PSA (7) (upright position) is from .8 to 1.2 amps.

CAUTION

There is no overcharge protection in this mode; therefore, frequent operator monitoring may be necessary.

NOTE

To charge the BB-490/U will take approximately_ 2 hours from the fully discharged state. Rest periods will extend the time to reach full charge. A rise in battery voltage to 30 Volts and a sharp drop in charging current while maintaining the same cranking speed indicates the BB-490/U is fully charged.

NOTE

After two hours, continued charging of the BB-490/u battery with the DC Generator is not recommended because charging emciency is significantly reduced.

NOTE

Do not exceed 1.S ampere continuously, especially in hot weather conditions at the end of charge (battery voltage on PSA is 29-30 Volts).

TM 1l..(j130-479-13&P

Figure 2-15. DC Generator Hookup for Charging BB-490/U

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TM 11-6130-479-13&P

(2) Charging the BB-490/U Usine Sinele Solar Panel Set-Up. Refer to figure 2-16

for the following operating procedures:

(a) Refer to 2-4.a.(4) for Single Panel Set-up procedures.

(b) Remove PSA from the Solar Panel if connected.

(c) Connect the PSA to BB-490/U battery connector before charging. Tilt the battery forward and confirm the battery voltage is between 12-14V on the PSA voltmeter.

(d) Connect the Solar Panel to the input connector of the PSA. Place the battery and PSA upright and observe current flow. With a measured current of O.8A it will take about 3.5-4 hours to fully charge (> 90%) a BB-490/U. A partially charged battery will take less time to charge. In less than full-sun conditions charging time will be longer. If correct amperage reading is not obtained, as defined in Table 1-2, see Table 3-1 for corrective action.

(e) When the battery being charged reaches a voltage of IS.SV at 70°F (21°C) or 14.5V at 122°F (50°C) a current limitation of 200mA is applied to the solar input by internal circuitry of PSA. The purpose of this circuitry is to prevent excessive overcharging of the BB-490/U during unattended solar operation.

(t) The application of 200mA current limit indicates a fully charged BB-4901U battery. The battery may be removed for use or left on charge without damage.

BB·<l9CW

Figure 2-16. Single Panel Operation, Current Measurement

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TM 11-6130-479-13&P

(3) CbAI&in; BB-49Q/U Usin& POWer Converter. The Power Converter 17 Volt

charging mode is used to charge the BB-490/U battery in which a 90-240 VAC, 50-400 Hz supply is available. Refer to figure 2-17 for the following operating procedures.

(a) On the Power Converter, select the 17V position and connect the output connector to the input of the PSA.

(b) Connect the AC Power Source to the Power Converter via the AC input line cord. A voltage of 17 VDC should be observed on the PSA voltmeter and the power input LED on the Power Converter will be illuminated. If the correct voltage reading is not obtained, see Table 3-"1 for corrective action.

(c) Remove the PSA from the Power Converter.

(d) Connect the PSA to the BB-4901U battery connector.

(e) Connect the output connector of the Power Converter to the input connector of the PSA.

(d) Observe the current output LED is illuminated green and is blinking, indicative of a charging condition.

(e) Set the current control knob to 1000 mAo Set the timer knob first to Reset and then to the 5 hour position. It should take 5 hours to charge the BB- 490/U battery. A charging current of 1000 rnA should be verified on the PSA current meter at this time. The PSA may invoke the 200mA limiter during charge but this is not an indication of a fully charged battery.

Leave on charge for the duration of the timed setting.

(f) After 5 hours, the BB-490/U may be removed for use or left on charge without damage to the battery.

TM 11-6l»479-13&P

II:; POWER SOURCE

Figure 2-17. AC to DC Power Converter Hookup for Charging the BB-490/U

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TM 11..6130-479-13&P

c. Hook-up Procedures For Chargin& Batten' Sealed. NiCad. BD-5421U. The following procedures provide instruction for charging the BB-S42/U. Refer to figure 2-18 for the following operating procedures:

(1) Char&in& BB-542/U Usin& the DC Generator.

(a) Remove DC Generator Cable from pouch in Carrying Bag.

(b) Connect DC Generator Cable (4, figure 2-18) to DC Generator. Connect Red Phone Tip Plug (5) to DC Generator Red Binding Post (6) and Black Phone Tip Plug (3) to Black Binding Post (2).

(c) Connect other end of DC Generator Cable (4) to battery connector Receptacle (7).

(d) The Voltage Meter (1) should indicate battery voltage. If Voltage Meter (I) does not indicate voltage, crank DC Generator vigorously two to three times to close the BB-S42/U intemallatch relay. If Voltage Meter (1) still does not indicate voltage, refer to Chapter 3 for troubleshOQUng procedures.

WARNING I

Do not touch tenninals or the DC Generator ",bea It Is beIna cranked. Electrical shock may result.

(e) Charge the BB-S421U by cranking DC Generator rapidly enough to maintain about 30 Vdc on Voltage Meter. Do not exceed 100 rpm or use excessive force at high temperature conditions; it may not be possible to reach 30 Volts, particularly with a discharged·battery.

NOTE

To fully charge a discharged BB-S42IU, the DC Generator must be cranked at 7S to 8S rpm for 1.2 to 1.5 hours. Rest periods will lengthen the time proportionally. Refer to TM 11-6140-224-13&P.

(t) Discontinue charging when cranking suddenly becomes easy. The BB- 542/U should be fully charged at this time and battery open circuit voltage should be 29 V dc. If battery fails to shut-off, increase cranking speed to 100-110 rpm. If effort is only increased slightly, DC Generator is in voltage limiting mode and battery is mostly charged. Further cranking will not increase battery charge significantly for the effort expended.

2 .. 38

TM 11-6130-479-13&P

CAUTION

Do not allow phone plue tips to touch one another while cable is attached to battery eoDDeCt1oD receptacle. Hi&h currents can be lenerated and battery BB-SCIU fuse blown.

(g) Disconnect DC Generator Cable from the battery first, then from the DC Generator.

Figure 2-18. DC Generator Hookup for Charging the BB-542JU

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TM 11-6130-4'79-13&P

0) Cbauine BB-S42/U Usina Dual Panel Series Set-Ug.

(a> Refer to 2-4.a.(6) for Dual Panel Series set-up procedures.

CAUTION

Always make connection to the BB-542/U last, since the battery can. dischar&e at hip currents If banana plua ends or 24V Cable are shorted.

(b) Observing polarity, connect banana plug ends of a 24V Cable to two Solar Panels. Connect five-pin bayonet connector of 24 Volt Cable directly to BB--S421U (see figure 2-19).

Rgur. 2-19. Dual Panel Series Connection Diagram

(c) Normal charging time to fully recharge a BB-S42IU is approximately 3-3.5 hours in bright sun. In less than full-sun conditions charging time will be longer. Because the BB-S42/U is internally protected against overcharge, it does not have to be removed from the charging circuit until it is ready for use.

(d) The state of battery charge can be determined by using the PSA as a voltmeter. To do this, follow the steps below.

(I) Connect bayonet plug end of 12V Cable to input connector of PSA.

(2) Disconnect one banana plug end of 24V Cable from a Solar Panel.

TM 11-&130-4'9-13&P

(3) Observing polarity, connect banana plug end of 12V Cable into vacant Solar Panel connector.

(4) Read voltage on PSA. It should read 17-19V if the BB-5421U is fully charged.

(5) Observing polarity, reconnect free banana plug end of 24V Cable ·piggyback· into banana plug connector of 12V Cable.

(6) If internal pressure switch control of the BB-542IU has activated, no current will flow and voltage from Solar Panels will be open circuit voltage (17-19V) (see figure 2-20). The BB-5421U is fully charged and may be removed and returned to service.

NOTE

A BB-5421U in good condition will cycle on and off every few minutes.

BB-541JU

Figure 2-20. Dual Panel Series Operation

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TM 11-6130-479-13&P

(~) Cbar&illi~ BB-5421U Psjn, Ouad 'Panel Setjes!pm1\el Set-Jm.

(a) Refer to 2-4.a.(7) for Quad Panel SerieslPara1lel set-up procedures.

(b) Connect battery to five-pin bayonet connector of 24V Cable. (xe figure 2- 21).

1

PARA'lEL CMLE2

2

3

4

Figure 2-21. Quad Panel Series/Parallel Connection Diagram

(c) Normal charging time to fully recharge a BB-542/U is approximately 1.5-2 hours in bright sun. In less than full-sun conditions charging time will be longer. Because the BB-S42/U is internally protected against overcharge, it does not have to be removed from the charging circuit until it is ready for use.

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TM 11-6130-479-13&P

(d) The state of battery charge can be determined by using PSA as a voltmeter. To do this, follow the steps below.

(I) Connect bayonet plug end of 12V Cable to input connector on PSA.

(2) Observing polarity, connect banana plug end of 12V Cable "piggyback" on banana plug end of Parallel Cable connected to Solar Panel 1 (see figure 2-22).

1

2

3

4

BB-5421U

Figure 2-22. Quad Panel SeriesJParallel Operation

TM 11-6130-479-13&P

(3) If internal pressure switch control of the BB-5421U has activated, no current will flow and voltage from Solar Panels will be open circuit voltage. The BB-542/U is fully charged with a PSA reading of 17-19V and may be returned to service.

NOTE

A BB-S42IU in good condition will cycle on and off every few minutes.

(4) Char&in, BB-542/U Usin, Power Cooyerter. The Power Converter 32 Volt

charging mode is used to charge the BB-542/U battery under any condition in which a 90-240 V AC, 50-400 Hz supply is available. Refer to figure 2-23 for the following operating procedures.

(a) On the Power Converter, select the 32V position and connect the output connector to the input of the PSA.

(b) Connect the AC Power Source to the Power Converter via the AC input line cord. A voltage of greater than 30V should be observed on the PSA voltmeter and the power input LED on the Power Converter will be illuminated. If the correct voltage reading is not obtained, see Table 3-1 for corrective action.

(c) Remove the PSA from the Power Converter.

(d) Connect the output connector of the Power Converter directly to the BB- 542/U.

(f) Observe the current output LED is illuminated green and is blinking,· indicative of a charging condition. Because the BB-5421U has internal protection against overcharging, it does not require monitoring during charge.

(g) Set the current control knob to 1500 mAe Set the timer knob first to Reset and then to 2 hours.

(h) If the battery reaches full charge prior to the 2 hour timer, the internal pressure switch in the BB-542/U will cycle on and off every few minutes. This can be observed by the green output current LED turning on off every several minutes. The battery may be removed for service at this time.

(i) The following are indicative of a fully charged BB-542/U: Charge time at 1500 rnA exceeds 2 hours; the charge current cycles on and off every few minutes. The battery may be removed for use or left on charge without damage.

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'I'M 11-&130-4."...U&P

sc POWER SOURCE

BB-S42/U

Figure 2-23. AC to DC Power Converter Hookup for Charging the BB-542JU

TM 11-6130-479-13&P

d. Hook-up Procedures For Char&in& Battery. Sealed. NiCad. BB-586JU. The following procedures provide instruction for charging the BB-586/U using the most efficient way a.vailable, Do not use the DC Generator to charge the BB-586/U.

NOTE

Use a locally Cabricated cable to charge the BB-S861U. Cable will connect Crom PSA output connector to battery connector oC BB-S861U. Cable must be signed to have the following connections: (1) positive (+) pin of battery connector to D (+) pin of PSA output connector; (2) negative (-) pin of battery connector to B (-) pin of PSA output connector. See figure 2-24.

(1) Char&in& BB-586/U Usini: the Power CQnyerter. The Power Converter 17 volt charging mode is used to charge the BB-586/U battery under any condition in which a 90-240 V AC, 50-400 Hz supply is available. Refer to figure 2-24 for the following operating procedures:

(a) On the Power Converter, select the 17V position and connect the output connector to the input of the PSA.

(b) Connect the AC Power Source to the Power Converter. via the AC input line cord. A voltage of approximately 17 VDC should be displayed on the PSA voltmeter and the power input LED on the Power Converter will be illuminated. If the correct voltage reading is not obtained, see Table 3-1 for corrective action,

(c) Remove the PSA from the Power Converter.

(d) Connect the locally fabricated cable from the output connector of the PSA to the BB-586/U battery connector.

(e) Connect the output connector of the Power Converter to the input connector of the PSA.

(t) Observe the current output LED is illuminated green and is blinking, indicative of a charging condition.

(g) Set the current control knob to 1000 rnA. Set the timer knob first to Reset and then to 5 hours. It should take approximately S hours to char&e the BB-S86IU battery. A charging current of 1000 rnA should be verified on the PSA current meter at this time. At the conclusion of the S hour time period the current output LED will be illuminated green and bum steady.

(h) The following are indicative of a fully charged BB-SS6IU: Char&e time at 1000 mA exceeds 5 hours; the battery shQWS internal heatin& (which may be indicated by a voltage rise of approximately 1 volt due to opening of battery internal thermal switch); the battery voltage falls by 0.5-1.0 volt without a drop in current flow. The battery should be removed from char&e at the completion of charging.

TM 11-6l3O-4'79-13&P

N:; POWER SOURCE

LOCALLY FABRICATED CABLE

~ c::=::=fT1IlTrIIl~\

BB-586/U

Figure 2-24. AC to DC Power Converter Hookup for Charging the BB-586/U

(2) Charging the BB-586/U Using Single Solar Panel Set-Up. Refer to figure 2-25 for

the following operating procedures:

NOTE

Because the 88-586/U contains a thermal switch set at 113 OF to limit charging, the battery should be shaded during solar panel charging in warm environments.

2-47

TM 11-6~79-13&P

(a) Refer to 2-4.a.(4) for Single Panel Set-up proceduteS.

(b) Remove PSA from the Solar Panel if connected.

(e) Connect the locally fabricated cable from the output connector of the PSA to the BB-S86/U battery connector.

(d) Connect the Solar Panel to the input connector of the PSA. Place the battery and PSA upright and observe current flow. With a measured current of O.SA it will take about 6-8 hours to fully charge a BB-S861U. A partially charged battery will take less time to charge. In less than full-sun conditions charging times will be longer. If correct amperage reading is not obtained, as defined in Table 1-2, see Table 3-1 for corrective action.

(e) The following are indicative of a fully charged BB-SS6IU: Charge time at 0.8A exceeds 8 hours, the battery shows internal heating, the battery voltage falls by 0.5-1.0 volt without a drop in current flow. The battery should be removed from charge.

LOCALLY FABRICATED CABLE

~~---aIllJ[::::D I

BB-588IU

Figure 2-25. Single Panel Operation, Current Measurement

2-48

TM 11-6130-479-13&P

(3) Charging BB-586/U Using Dual Panel Parallel Set-Up. Refer to figure 2-26 for the

following low-light operating procedures:

NOTE

Because the BB-S86IU contains a thermal switch set at 113°F to limit charging, the battery should be shaded during solar panel charging in warm environments.

(a) Refer to 2-4.a.(S) for Dual Panel Parallel set-up procedures.

(b) Remove the PSA from the Solar Panel if connected.

(c) Connect the locally fabricated cable from the output connector of the PSA to the BB-S86/U battery connector.

(d) Connect the Solar Panel to the input connector of the PSA. Place the battery and PSA upright and observe current flow. This procedure is for charging in other than full-sun conditions. Sunlight may vary significantly causing changes in solar panel charge current. Varying charge current will result in longer charging times. Charging times can be anywhere from 4-8 hours to fully charge a BB-586/U battery. A partially charged battery will take less time to charge. In less than full-sun conditions charging time will be longer. If correct amperage reading is not obtained, as defined in Table 1-2, see Table 3-1 for corrective action.

(e) The following are indicative of a fully charged BB-586/U: the battery shows internal heating; the battery voltage falls by 0.5-1.0 volt without a drop in current flow. The battery should be removed from charge.

LOCALLY FABRICATED CABLE

/

B8-S86IU

Figure 2-26. Dual Panel Parallel Operation

2-49

TM 11·6130-479·13&P

e. Hook-up Procedures For ChaTiin& Battery. Sealed. NiCad. BD-5SS/U. The following procedures provide instruction for charging the BB-S88/U using the most efficient ways available.

(1) Charging BB-588/U Using the Power Converter. The Power Converter 32 volt charging mode is used to charge the BB-S88/U battery under any condition in which a 90-240 VAe, SO-4oo Hz supply is available. Refer to figure 2-27 for the following operating procedures:

(a) Connect the AC Power Source to the Power Converter via the AC input line cord. Set the voltage control knob to 32 volts. Tilt the PSA forward, a voltage on the PSA voltmeter of greater than 30 VDC should be displayed on the PSA and the power input LED on the Power Converter will be illuminated yellow. Disconnect the PSA from the Power Converter. If the correct voltage reading is not obtained, see Table 3-1 for corrective action.

(b) Connect the PSA to the BB-S88/U battery connector via the DC/DC adapter.

(c) For the lAH battery set the current control knob to 200 rnA. Set the timer knob first to Reset and then to 6 hours. Verify that the voltage control knob is set to 32V.

For the O.SSAH battery set the current control knob to 100 rnA. Set the timer knob first to Reset and then to 6 hours. Verify that the voltage control knob is set to 32V.

(d) Connect the Power Converter output connector to the input connector of the PSA. Observe the current output LED is illuminated green and is blinking, indicative of a charging condition. If the current LED is not illuminated and the PSA makes a buzzing sound (expected from extremely low battery voltage), switch the Power Converter to the 17V position to initiate the charge. After approximately 5-10 minutes of charging, switch the Power Converter to the 32V position.

(e) For the 1.0AH BB-S88/U observe and monitor a charge current reading of 200 rnA on the PSA meter. For the O.SSAH BB-S88/U observe and monitor a charge current reading of 100 mA on the PSA meter.

(t) At the conclusion of the 6 hour time period when the timer has expired, observe the current output LED is illuminated green and bums steady.

(g) The following are indicative of a fully charged BB-S88/U: Charge time exceeds 6 hours; the battery shows internal heating; the battery voltage falls by O.S-l.O volt without a drop in current flow. The battery should be removed from charge at the completion of charging.

2-50

TM 11-61JO..4"-13&P

AC POWER SOURCE

FIgUre 2-27. AC to DC Power Converter Hookup Cbargina the BB-S881U

2-51

1M 11-6130-479-13&P

(2) Cllar£in& the BB-588/V Sin&le Panel Set-up. Refer to figure 2-28 for the following operating procedures:

CAUTION

Charging the O.SSAH BB-S88/U with a Solar Panel for more than 1 hour at currents higher than 100 rnA will cause permanent damage to the battery.

(a) Refer to 2-4.a.(4) for Single Panel Set-up procedures.

(b) Remove PSA from the Solar Panel if connected.

(c) Connect the PSA to the BB-588/V via the DCIDC Adapter. Tilt the BB- 588/U, DC/DC Adapter and the PSA forward and verify the battery voltage is between 12-15Von the PSA voltmeter.

(d) Connect the Solar Panel to the input connector of the PSA. Place the BB- 588/U, DCIDC Adapter and the PSA upright and verify current flow on the PSA ammeter.

(e) Partially shade the Solar Panel to regulate the charge current reading on the PSA ammeter. The current is 200 rnA for lAH BB-588/V or 100 rnA for O.55AH BB-588/V. The amount of shading of the Solar Panels will vary depending on available sunlight, battery voltage and temperature. In less than full-sun conditions charging time will be longer. Periodic monitoring of the PSA ammeter is required for the 0.55AH battery. If correct amperage reading is not obtained, as defined in Table 1-2, see Table 3-1 for corrective action.

CAUTION

There is no overcharge protection in this mode; therefore, frequent operator monitoring may be necessary.

(f) The following are indicative of a fully charged BB-588/U: approximately 6 hours of charge at 200 rnA for lAH batteries or approximately 3.5 hours at 100 rnA for 0.55AH batteries; the battery shows internal heating; the battery voltage falls by 0.5-1.0 volt without a drop in current flow. The battery is ready for operation and must be removed from the Solar Panel.

2-52

TM 11-6130-479-13&P

.b JIUJ II
r-' _Q_
BB·588I\J DClDC ADAPTER

Rgure 2-28. Single Panel Operation for Charging the BB-588/U

f. Chargin& the battery in OA-8990tp. The sealed NiCad battery in OA-8990/P can be recharged by seeing TM 11-5820-887-10 and following the methods below.

(1) The first method of recharging the NiCad battery in OP-8990/P is, using a BB-590/U

type battery or the BA-5590/U. To do this, follow the steps below:

(a) Retrieve charging Cable CX-13158/GR from OA-8990/P Carrying Bag and PSA from Solar Panel Bag.

(b) Connect small end of CX-13158/GR charging Cable to either connector A2J4 HF or SAT A2J3 whichever is not in use at rear of OA-8990/P. Connect other end of charging Cable CX-13158/GR to Output Connector on PSA.

(c) Connect battery connector on PSA to a BB-590/U type battery or a BA- 5590/U battery (see figure 2-29).

CX·131581GR

I

BB·59O/U OR BA·5590/U

Figure 2-29. OA-8990/P and BB-5590IU Connection Diagram

2-53

TM 11-61~79-13&P

(d) Each BB-590/U can charge approximately three OA-8990/P batteries before requiring recharge itself.

(e) Each BB-490/U can charge approximately two OA-8990/P batteries before requiring recharge itself.

(0 Each BB-55901U can charge approximately ten OA-8990/P batteries before it must be replaced.

NOTE

It is recommended that partially discharged BA-S590/U batteries be used for this purpose if available.

(g) Remove OA-8990/P from the BB-590/U type battery when power LED on OA-8990/P goes out. However, OA-8990/P may be left connected to the BB- 590/U to power equipment and trickle charge its internal battery.

(2) The second method of recharging the NiCad battery in OA-8990/P is by using a Solar

Panel. To do this, follow the steps below:

(a) Retrieve charging Cable CX-13158/GR from OA-8990/P Carrying Bag and one Solar Cell Panel, PSA, and 12V Cable from Solar Panel Bag.

(b) Connect small end of CX-13158/GR charging Cable to either connector A2J4 HF or SAT A2J3 whichever is not in use at rear of OA-8990/P. Connect other end of charging Cable to Output connector on PSA.

(c) Connect bayonet plug of 12V Cable to Input connector on PSA. Observing polarity, connect banana plug end of 12V Cable to Solar Panel. The PSA meter will show a pulsating voltage when OA-8990/P is being charged (see figure 2-30).

(d) The OA-8990/P may be charged at less than maximum current, if necessary, to recondition its internal battery. This is accomplished by blocking off part of Solar Panel or misaligning it from sun. Adjust panel or block off panel to provide a reading of .2 - .3A. Use a maximum charge time of S hours.

(e) Normal recharge following a reconditioning may be conducted without any limit on power output of Solar Panel and with a battery connected to PSA if so desired. Charge time, in this case, will be approximately 2 hours or less until power LED on OA-8990/P goes out. The OA-8990/P may be disconnected at this time or left connected to receive power from Solar Panel for operation and to trickle charge its battery.

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(3) The third and last method of recharging the NiCad battery in OA-8990/P is by using

a BB-542/U. To do this, follow the steps below:

NOTE

This is the least energy efficient method of the three described, since aD the voltage above 12V is dissipated in OA-8990/P's chargin& circuit.

''''CAB''/

Figure 2-30. OA-8990/P Connection Diagram

(a) Retrieve charging Cable CX-13158/GR from OA-8990/P Carrying Bag.

(b) Connect small end of CX-13158/GR charging Cable to either connector A2J4 HF or SAT A2J3 whichever is not in use at rear of OA-89901P.

(c) Connect other end of CX-13158/GR charging Cable to auxiliary power connector on side of the BB-5421U (see figure 2-31).

BB-542JU

Figure 2-31. OA-8990/P and 88-542/U Connection Diagram

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(d) Each BB-542/U can fully charge 1 OA-8990/P battery.

(e) When power LED on OA-8990/P goes out remove it from the charging circuit.

(4) Direct charging of the OA-8990/P from the DC Generator is not recommended except

in an emergency. Power is not efficiently generated by the DC Generator at the low voltage required by the OA-8990/P. The most efficient way to use the DC Generator would be to first charge a BB-590/U at 28-30 VDC and then use the BB-590/U to power OA-8990/P since twice the energy would then be available.

2-6. FAST PROCEDURES FOR CHARGING BA TTERIF.S

Before operating the Power Supply Assembly for the first time, familiarize yourself with the contents of this section and the previous section. When performing a procedure for the first time, familiarize yourself with the entire procedure before beginning.

I WARNING I

Do not attempt to charge any batteries other than those authorized in this manual.

I WARNING I

Do not charge batteries without using the PSA unless the battery has internal overcharge protection (e.g., BB-S42fU).

NOTE

Most of the procedures contained in this manual are based upon "Recommended" manufacturers charging specifications which permit longer battery life and most efficient battery performance. There are also "Fast" charging procedures for time-critical situations which may slightly degrade battery performance over tbe life of the battery (see paragraph 2-6 for Fast charging procedures).

a. Hook-up Procedures For Charging Battery Sealed. Nickel Cadmium. BB-590/U. The following procedures provide instruction for charging the BB-590/U using the most efficient ways available.

(1) Charging BB-590/U Using the DC Generator. Refer to paragraph 2-5.a.(I).

(2) Charging BB-590/U Using Dual Panel Parallel Set-Up. Refer to figure 2-32

for the following operating procedures:

(a) Refer to 2-4.a.(5) for Dual Panel Parallel set-up procedures.

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.)

(b) Remove the PSA from the Solar Panel if connected.

(c) Connect the PSA to the BB-590/U battery connector before charging.

Tilt the battery forward to confmn the battery voltage is between 12- 14V on the PSA voltmeter.

(d) Connect the Solar Panel to the input connector of the PSA. Place the battery and PSA upright and observe current flow. With a measured current of 1.6A it will take 2-2.5 hours to fully charge a 1.5AH battery and 2.5-3 hours to fully charge a 2AH battery. A partially charged battery will take less time to charge. When the Solar Panel is delivering a lower current charge, charge time will be longer. In less than full-sun conditions charging time will be longer. If correct amperage reading is not obtained, as defined in Table 1-2, see 3-1 for corrective action.

(e) Periodic monitoring of the BB-590/U is required using this charging procedure since there is no overcharge protection in this mode. The PSA may invoke the 200 ma overcharge protection but this is not a reliable means to protect the BB-590/U.

CAUTION

There is no overcharge protection in this mode; therefore, frequent operator monitoring may be necessary.

(0 The following are indicative of a fully charged BB-590/U: the battery shows internal heating; the battery voltage falls by 0.5-1.0 volt without a drop in current flow. The battery must be removed from charge.

BB-5901U

Figure 2-32. Dual Panel Parallel Operation

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,.-

(b) Remove the PSA from the Solar Panel if connected.

(c) Connect the PSA to the BB-590/U battery connector before charging.

Tilt the battery forward to confirm the battery voltage is between 12- 14V on the PSA voltmeter.

(d) Connect the Solar Panel to the input connector of the PSA. Place the battery and PSA upright and observe current flow. With a measured current of 1.6A it will take 2-2.5 hours to fully charge a 1.5AH battery and 2.5-3 hours to fully charge a 2AH battery. A partially charged battery will take less time to charge. When the Solar Panel is delivering a lower current charge, charge time will be longer. In less than full-sun conditions charging time will be longer. If correct amperage reading is not obtained, as defined in Table 1-2, see 3-1 for corrective action.

(e) Periodic monitoring of the BB-590/U is required using this charging procedure since there is no overcharge protection in this mode. The PSA may invoke the 200 ma overcharge protection but this is not a reliable means to protect the BB-590/U.

CAUTION

There is no overcharge protection in this mode; therefore, frequent operator monitoring may be necessary,

(f) The following are indicative of a fully charged BB-590/U: the battery shows internal heating; the battery voltage falls by 0.5-1.0 volt without a drop in current flow. The battery must be removed from charge.

BB-5901U

Figure 2-32. Dual Panel Parallel Operation

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(3) Chargin& BB-59Q/U Usine Quad Panel Series/Parallel Set-Up.

(a) Refer to 2-4.a.(7) for Quad Panel Series/Parallel set-up procedures.

(b) Connect the PSA to the BB-590/U battery connector.

(c) Observing polarity, connect two banana plug ends of 24V cable "piggyback" to banana ends of Parallel Cables 1 and 2 where they are connected to Solar Panels 3 and 4.

(d) Connect the five-pin bayonet connector of 24V Cable to the PSA input connector (see figure 2-33).

PARAU.EL CABLE 1

1

3

Figure 2-33. Quad Panel Series/Parallel Operation

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2

4

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(e) Normal charging time, with a measured current of 1.6A, to fully recharge a 2AH BB-590/U is approximately 1.5 hours and approximately 1 hour to fully recharge a 1.5 AH battery. In less than full-sun conditions charging time will be longer. If correct amperage reading is not obtained, as defined in Table 1-2, see Table 3-1 for corrective action.

CAUTION

There is no overcharge protection in this mode; therefore, frequent operator monitoring is necessary.

(f) The following are indicative of a fully charged BB-590/U: the battery shows internal heating; the battery voltage falls by 0.5-1.0 volt without a drop in current flow. The battery must be removed from charge.

(4) Charging BB-590/U Using Power Converter. The Power Converter 32 Volt charging

mode is used to charge the BB-590/U battery under any condition in which a 90-240 VAC, 50-400 Hz supply is available. Refer to figure 2-34 for the following operating procedures.

(a) On the Power Converter, select the 32V position and connect the output connector to the input of the PSA.

(b) Connect the AC Power Source to the Power Converter via the AC input line cord. A voltage of greater than 30V should be observed on the PSA voltmeter and the power input LED on the Power Converter will be illuminated. If the correct voltage reading is not obtained, see Table 3-1 for corrective action.

(c) Remove the PSA from the Power Converter.

(d) Connect the PSA to the BB-590/U battery connector.

(e) Connect the output connector of the Power Converter to the input connector of the PSA.

(f) Observe the current output LED is illuminated green and is blinking, indicative of a charging condition.

(g) For both the 1.5AH and 2AH batteries set the current control knob to 1000 rnA. Set the timer knob first to Reset and then to 2 hours. Verify 1000 rnA on the PSA meter.

CAUTION

There is no overcharge protection in this mode; therefore, frequent operator monitoring is necessary.

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(h) During the 2 hour charge period, monitor for full charge indicators. At the conclusion of the 2 hour time period when the timer has expired, observe the current output LED is illuminated green and burns steady. Leave the 2AH BB-590fU on trickle charge for an additional 112 hour or until fully charged. The PSA current meter should read approximately 300 rnA during the trickle charge mode.

(i) The following are indicative of a fully charged BB-590/U: the battery shows internal heating or the battery voltage falls by 0.S-1.0 volt without a drop in current flow. When either of these indications occur, remove the battery from charge. Another indicator is that the charge time at 1000 rnA exceeds 2 hours (Plus an additional 1/2 hour of trickle charge for 2AH battery). When in trickle charge, the battery may be removed for use or left on charge without damage.

AC POweR SOURCE

Figure 2-34. AC to DC Power Converter Hookup for Charging the BB-590/U

b. Hook-up Procedures For Charging Battery Sealed. Lead Acid. BB-490/U. The following procedures provide instruction for charging the BB-490/U using the most efficient ways available.

(1) Charging BB-490/U Usin& the DC Generator. Refer to paragraph 2-S.b.(1).

(2) Charging BB-490/U Using Power Converter. Refer to paragraph 2-S.b.(3).

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(3) Charging BB-490/U Using Dual Panel Parallel Set-Up. Refer to figure 2-35

for the following operating procedures:

(a) Refer to 2-4.a.(5) for Dual Panel Parallel set-up procedures.

(b) Remove the PSA from the Solar Panel if connected.

(c) Connect the PSA to the BB-490/U battery connector before charging.

Tilt the battery forward to con finn the battery voltage is between 12- 14V on the PSA voltmeter.

(d) Connect the Solar Panel to the input connector of the PSA. Place the battery and PSA upright and observe current flow. With a measured current of 1.6A it will take 1.5-2 hours to fully charge (> 80%) a BB- 490/U. A partially charged battery will take less time to charge. In less than full-sun conditions charging time will be longer. If correct amperage reading is not obtained, as defined in Table 1-2, see Table 3-1 for corrective action.

(e) When the battery being charged reaches a voltage of 15.5V at 700P (21°C) or 14.5V at 122°F (50°C) a current limitation of 200 rnA is applied to the solar input by internal circuitry of the PSA. The purpose of the circuitry is to prevent excessive overcharging of the BB-490/U during unattended solar operation.

(t) The application of 200 rnA current limit indicates a fully charged BB- 490/U battery. The battery may be removed for use or left on charge without damage.

BB-49OIU

Figure 2-35. Dual Panel Parallel Operation

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c. Hook-up Procedures For Chan~ing Battery Sealed. NiCad. BB-S42/U. The following procedures provide instruction for charging the BB-S42/U.

(1) Charging BB-S421U Using the DC Generator. Refer to paragraph 2-5.c.(I).

(2) Charging BB-542/U Using Quad Panel Series/Parallel. Refer to paragraph 2- 5.c.(3}.

(3) Charging BB-S42/U Using Power Converter. Refer to paragraph 2-S.c.(4).

d. Hook-up Procedures For Charging Battery. Sealed. NiCad. BB-S86/U. The following procedures provide instruction for charging the BB-586/U using the fastest way available. Do not use the DC Generator to charge the BB-586/U.

NOTE

Use a locally fabricated cable to charge the BB-S86IU. Cable will connect from PSA output connector to battery connector of BBS86/U. Cable must be signed to have the following connections: (1) positive (+) pin of battery connector to D (+) pin of PSA output connector; (2) negative (-) pin of battery connector to B (-) pin of PSA output connector. See f'Igure 2-36.

(1) Char~ing BB-586/U Using Dual Panel Parallel Set-Up. Refer to paragraph 2- 5.d.(3). For full-sun conditions, with a measured current of 1.6A, it will take approximately 3-4 hours to fully charge a BB-586/U battery.

(2) Charging BB-586/U Using the Power Converter. The Power Converter 17 volt charging mode is used to charge the BB-S86/U battery under any condition in which a 90-240 VAC, 50-400 Hz supply is available. Refer to figure 2-36 for the following operating procedures:

(a) On the Power Converter, select the 17V position and connect the output connector to the input of the PSA.

(b) Connect the AC Power Source to the Power Converter via the AC

input line cord. A voltage of approximately 17 VDC should be displayed on the PSA voltmeter and the power input LED on the Power Converter will be illuminated. If the correct voltage reading is not obtained, see Table 3-1 for corrective action.

(c) Remove the PSA from the Power Converter.

(d) Connect the locally fabricated cable from the output connector of the PSA to the BB-586/U battery connector.

(e) Connect the output connector of the Power Converter to the input connector of the PSA.

TM 11-6130-479-13&P

(t) Observe the current output LED is illuminated green and is blinking,

indicative of a charging condition. .

(g) Set the current control knob to 1500 mAo Set the timer knob first to Reset and then to 3 hours. It should take approximately 3 hours to charge the BB-586/U battery. A charging current of 1500 rnA should be verified on the PSA current meter at this time. At the conclusion of the 3 hour time period the current output LED will be illuminated green and burn steady.

(h) The following are indicative of a fully charged BB-586/U: Charge time at 1500 rnA exceeds 3 hours; the battery shows internal heating (which may be indicated by a voltage rise of approximately 1 volt due to opening of battery internal thermal switch); the battery voltage falls by 0.5-1.0 volt without a drop in current flow. The battery should be removed from charge at the completion of charging.

AC POWER SOURCE

LOCAU.Y FASRICATED CABLE

-~\

~~c===fi ~==~

BB-586/U

Figure 2-36. AC to DC Power Converter Hookup for Charging the BB-S86/u

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e. Hook-up Procedures For Charging Battery. Sealed. NiCad. BB-588/U. The following procedures provide instruction for charging the BB-588/U using the most efficient ways available.

(1) Chaq~ing BB-588/U Using the Power Converter. The Power Converter 32 volt charging mode is used to charge the BB-588/U battery under any condition in which a 90-240 VAC, 50-400 Hz supply is available. Refer to figure 2-37 for the following operating procedures:

(a) Connect the AC Power Source to the Power Converter via the AC input line cord. Set the voltage control knob to 32 volts. Tilt the PSA forward, a voltage on the PSA voltmeter of greater than 30 VDC should be displayed on the PSA and the power input LED on the Power Converter will be illuminated yellow. Disconnect the PSA from the Power Converter. If the correct voltage reading is not obtained, see Table 3-1 for corrective action.

(b) Connect the PSA to the BB-588/U battery connector via the DC/DC adapter.

(c) For the 1AH battery set the current control knob to 400 rnA. Set the timer knob first to Reset and then to 2 hours. Verify that the voltage control knob is set to 32V.

For the 0.55AH battery set the current control knob to 200 rnA. Set the timer knob first to Reset and then to 2 hours. Verify that the voltage control knob is set to 32V.

(d) Connect the Power Converter output connector to the input connector of the PSA. Observe the current output LED is illuminated green and is blinking, indicative of a charging condition. If the current LED is not illuminated and the PSA makes a buzzing sound (expected from extremely low battery voltage), switch the Power Converter to the 17V position to initiate the charge. After approximately 5-10 minutes of charging, switch the Power Converter to the 32V position.

(e) For the 1.0AH BB-588/U observe and monitor a charge current reading of 400 rnA on the PSA meter. For the 0.55AH BB-588/U observe and monitor a charge current reading of 200 rnA on the PSA meter.

CAUTION

There is no overcharge protection in this mode; therefore, frequent operator monitoring is necessary

(f) At the conclusion of the 2 hour time period when the timer has expired, observe the current output LED is illuminated green and bums steady. At this time the Power Converter is in trickle charge mode and the current reading on the PSA meter should read 1/3 of the set current. Leave the BB-588/U on charge for an additional 1.5 hours to fully charge. After the additional 1.5 hours, the BB-588/U may be removed for service.

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(g) The following are indicative of a fully charged BB-SS8IU: Charge time exceeds 2 hours at the set current plus an additional 1.5 hours of trickle charge; the battery shows internal heating; the battery voltage falls by 0.5-1.0 volt without a drop in current flow. The battery should be removed from charge at the completion of charging.

AC POWER SOURCE

BB-588IU

Figure 2-37. AC to DC Power Converter Hookup for Charging the BB-5881U

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(2) Char.&ing BB-5881U Using the Single Panel Set-up. Refer to paragraph 2-S.e.(2).

f. Charging the batten' in OA-8990/P.

(1) BB-590/U. BA-5590/U. Refer to paragraph 2-5.f.{I).

(2) Solar Panel. Single Panel. Refer to paragraph 2-S.f.(2).

(3) BB-542/U. Refer to paragraph 2-S.f.(3).

2-7. PREPARATION FOR MOVEMENT OR STORAGE

a. Pr«paring the DC Generator For Moyement or Stora&e.

(1) Common Procedures For All Operating Set-ups.

(a) Disconnect DC Generator Cable from the battery.

(b) Disconnect DC Generator Cable from the DC Generator.

. .

(c) Unscrew Restraining Screw and Handle Nut (2, figure 2-38) from DC Generator Shaft.

(d) Pull Right Crank Arm (1) off DC Generator Shaft; rotate it 1800 so that it is pointed in the same direction as Left Crank Arm (3) and replace it on shaft.

(e) Replace Handle Nut (2) and Retaining Screw and hand tighten.

(t) Align the Crank Arms (1 and 3) parallel with the bracket and Outer Tube Assembly (6) and toward the Foot Support Assembly.

(g) Remove each Handle (4) from its Crank Arm (1 and 3) by sliding Slide Knobs (5) towards DC Generator Shaft; then pull Handles out of Crank Arms.

TM 11-4i13O-479-13&P

Figure 2-38. DC Generator Preparation for Movement or Storage

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(2) Refoldin& Procedures (operator sitting on stirrupl.

(a) Refer to paragraph 2-7.a.(I).

(b) Slowly remove your weight from Stirrup (5, figure 2-39, sheet 1) and gently place DC Generator Head and Crank Arm Assembly (9) on the ground or working surface with Voltage Meter (8) facing up.

(c) Loosen Thumbwheels (3) on Foot Pad Assembly (4).

(d) Remove the Quick Release Pin (6).

(e) Slide the Stand Collar (7) up against the Foot Support Bracket (10), keeping the index line on the Stand Collar (7) facing up in the same direction as the Voltage Meter (8). Extra force is required to overcome the snap button on the Stand Collar (7).

(f) Remove Quick Release Pin (11) that is inserted through Hinge (12) and lay Stirrup (S) flat on working surface.

• I

• I

: ,

I I

II {!II -_ ,!!~.,

--~

7

Figure 2-39. DC Generator Preparation for Movement or Storage (1 of 2)

TM 11-6130-479-13&P

(g) Press the snap button to unlock the Outer Tube (2, figure 2-39, sheet 2) and the Inner Tube (3) and rotate the Foot Support Assembly (1) about 90° (to prevent the snap button from locking into the wrong holes).

(h) Slide the Inner Tube (3) into the Outer Tube (2) until the index line on the Inner Tube (3) disappears under the tip of the Outer Tube (2).

(i) Continue rotating the Foot Pad Assembly (1) another 90° in the same direction as step g.

G) Slide the Inner Tube (3) further into the Outer Tube (2) until the snap button locks into place near the Foot Support Bracket (10, figure 2-39 sheet 1).

(k) While keeping the Foot Pad Assembly (1, figure 2-39 sheet 2) flat against the Stirrup Shaft (11) fold the Stirrup (6) onto the DC Generator Head (12). Adjust the position of the crank arms so that the ends point slightly above the Foot Pad Assembly (1).

(1) Stow The Quick Release Pin (7) by inserting it in the exposed hole in the Stirrup Shaft (11).

(m) Stow Handles (9) on each side of Foot Pad (1) between ThumbwheeI Flange (10) and Hinge (8).

(n) Slip DC Generator into its Carrying Bag.

(0) Replace DC Generator Cable in pouch in Carrying Bag.

,

12

8 7

Figure 2-39. DC Generator Preparation for Movement or Storage (2 of 2)

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TM 11-6130-479-13&P .

3. Refoldin.: Procedures (o,perator standin& or kneelin&l.

(a) Refer to paragraph 2-7.a.(I). Place DC Generator on the ground or working surface with Voltage Meter (1, figure 2-40, sheet 1) facing up.

(b) Loosen Thumbwheels (4) on Foot Pad Assembly (3).

(c) Remove the Quick Release Pin (5).

(d) Press in the snap button (10) and slide the Stand Collar (9) over the pressed snap button (10) until the Stand Collar (9) reaches the Foot Support Bracket (8). Rotate Stand Collar (9) 180° so that the index line on the Stand Collar (9) faces up in the same direction as the Voltage Meter (1).

(e) Press in the snap button again, slide the Inner Tube (6) about one inch toward the DC Generator head.

Figure 2-40. DC Generator Preparation for Movement or Storage (1 of 3)

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(t) Remove Quick Release Pin (6, figure 2-40, sheet 2) from Hinge (9).

(g) Raise Stirrup (5) until it is at a right angle to Inner Tube (4), turning Foot Pad Assembly (8) so that it is flat on the Stirrup Shaft (1).

(h) Continue sliding the Inner Tube (4) toward the DC Generator Head (lO) until the snap button (10, figure 2-40, sheet 1) locks into place near the Foot Support Bracket (1, figure 2-40, sheet 2).

(i) Still holding the Foot Pad Assembly (8) flat on the Stirrup Shaft (7), fold the Stirrup (5) onto the DC Generator Head (10). Adjust the position of the crank arms so that the ends point slightly above the Foot Pad Assembly (8).

6

Figure 2-40. DC Generator Preparation for Movement or Storage (2 of 3)

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(j) Stow Handles (2, figure 2-40 sheet 3) on each side of Footpad (1) between Thumbwheel Flange (3) and Hinge (4).

(k) Stow the Quick Release Pin (6) in the exposed hole in the Stirrup Shaft (7).

(I) Slip DC Generator into its Carrying Bag (5).

(m) Stow DC Generator Cable in pouch inside Carrying Bag.

Figure 2-40. DC Generator Preparation for Movement of Storage (3 of 3)

TM 11-6130-479-13&P

b. Preparin& the Solar Cell Panels For Movement or Stora~e.

(1) Disconnect the Solar Cell Panel cable from the input connector of the PSA.

(2) Disconnect the battery connector of the PSA from the connector of the battery.

(3) Disconnect all cables from the Solar Cell Panels. Coil all cables.

(4) Close the Solar Cell Panels and secure with the hook and loop (velcro) tape.

(5) Return all components to their respective bag.

NOTE

Each Solar Cell Panel Ba& shaD contain two Solar Cell Paneh, two PSAs, two U Volt Cables, two DCIDC Adapters, one 24 Volt Cable, and one Parallel Cable.

c. PrqJarlne the Power Converter For Movement or Stora~e.

(1)

(2) (3)

(4) (5) (6)

(7)

Disconnect the AC input line cord from the AC Power Source. Return any wall adapters, if used, to its International Adapter Bag.

Disconnect the battery connector of the PSA from the connector of the battery.

Disconnect the Power Converter output connector from the input connector of the PSA. Return the PSA to its Solar Cell Panel Bag.

Wrap the AC input line cord around the brackets on the Power Converter.

Place the Power Converter in its bag, face down.

Place the International Adapter Bag, housing the International WaIl Adapter Kit, next to the Power Converter.

Zip up the Power Converter bag.

d. Pre,parin~ the Power Supply Assembly For Movement or Storue. Refer to Figure 2-41.

(1) Ensure that all components are secured in their respective carrying bags. Refer to Section 2-7, a thru c.

(2) Place the DC Generator Bag, cover buttons up, in the Power Supply Assembly Bag.

(3) Place the Power Converter Bag, handle up, on top of the DC Generator Bag inside the Power Supply Bag.

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