JP00590 5

TX-205
Ignition Exciter
Unison Honeywell
Part Number Part Number
9048700-7 3876195-7
9048700-8 3876195-8
9048700-9 3876195-9
COMPONENT MAINTENANCE MANUAL

WITH
ILLUSTRATED PARTS LIST
PROPRIETARY INFORMATION NOTICE
The information contained in this document is Unison proprietary information and is disclosed in confidence. It is the property
of Unison and shall not be used, disclosed to others or reproduced without the express written consent of Unison. If consent
is given for reproduction in whole or in part, this notice and the notice set forth on each page of this document shall appear
in any such reproduction in whole or in part.
This technical data is considered ITAR and/or EAR controlled pursuant to 22 CFR Part 120-130 and 15 CFR Parts 730‑774
respectively. Transfer of this data by any means to a Non-US Person, whether in the United States or abroad, without the
proper U.S. Government authorization (e.g., License, exemption, NLR, etc.), is strictly prohibited.
ECCN: 9E991
Unison Industries
7575 Baymeadows Way
Jacksonville, FL 32256
www.unisonaviation.com
Printed in U.S.A. © 2018 Unison Industries, LLC, U.S.A. JP00590-5
Feb 28/93
49-41-21
Revision 5
Aug 31/18
UNISON INDUSTRIES
Ignition Exciter 9048700
HIGHLIGHTS
To: Holders of Component Maintenance Manual 49-41-21, Revision Number 4, dated Mar 31/16.
Subj: Revision Number 5, dated Aug 31/18.
1. All pages of this manual are new.
2. Revised pages that have important changes are listed below. Technical changes are indicated
by revision bars in the left-hand margin of each affected page.
Page Number Change
303 Added NOTE to paragraph 2.B.
708 Added NOTE to paragraph 3.A.
Highlights
49-41-21 Page 1/2

Aug 31/18
UNISON INDUSTRIES
RECORD OF REVISIONS
REV DATE DATE REV DATE DATE

NO. ISSUED INSERTED BY NO. ISSUED INSERTED BY
Basic Feb 28/93 --- ---
1 May 31/96 --- ---
2 Jan 31/05 --- ---
3 Jun 30/15 --- ---
4 Mar 31/16 --- ---
5 Aug 31/18
Keep this record in the front of manual. When you get revisions, replace the affected pages in
manual with the revised pages. On this page, write the revision number, date issued, date inserted,
and incorporator's initials.
Record of Revisions
49-41-21
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Aug 31/18
UNISON INDUSTRIES
RECORD OF TEMPORARY REVISIONS
INCORPORATED
REV. CHAP/SECT/SUBJ DATE DATE DATE INTO MANUAL
NO. PAGE NO. ISSUED INSERTED BY REMOVED BY BY REV. NO.
Keep this record in the front of manual. When you get temporary revisions, put them in manual
(the temporary revision will be later replaced by a revision to the manual). On this page, write the
revision number, chap/sect/subj/page no., date issued, date inserted, and incorporator's initials.
Record of Temporary Revisions
49-41-21
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Aug 31/18
UNISON INDUSTRIES
SERVICE BULLETIN LIST
These Service Bulletins are applicable to this manual.
Service Date Service Date

Bulletin Incorporated Bulletin Incorporated
9048700-49-16 May 31/96
9048700-49-17 Jan 31/05
Service Bulletin List
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Aug 31/18
UNISON INDUSTRIES
LIST OF EFFECTIVE PAGES
Subject Page Date
Title Page --- Aug 31/18
Highlights 1 Aug 31/18

2 Aug 31/18
Record of Revisions 1/2 Aug 31/18
Record of Temporary Revisions 1/2 Aug 31/18
Service Bulletin List 1/2 Aug 31/18
List of Effective Pages 1 Aug 31/18

2 Aug 31/18
Table of Contents 1/2 Aug 31/18
Introduction 1 Aug 31/18

2 Aug 31/18
Description and Operation 1 Aug 31/18

2 Aug 31/18
3/4 Aug 31/18
Testing and Fault Isolation 101 Aug 31/18

102 Aug 31/18
103 Aug 31/18
104 Aug 31/18
105 Aug 31/18
106 Aug 31/18
107 Aug 31/18
108 Aug 31/18
Disassembly 301 Aug 31/18

302 Aug 31/18
303 Aug 31/18
304 Aug 31/18
305 Aug 31/18
306 Aug 31/18
Cleaning 401 Aug 31/18

402 Aug 31/18
List of Effective Pages
49-41-21
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Aug 31/18
UNISON INDUSTRIES
LIST OF EFFECTIVE PAGES (Continued)
Subject Page Date
Check 501 Aug 31/18

502 Aug 31/18
503 Aug 31/18
504 Aug 31/18
505 Aug 31/18
506 Aug 31/18
507 Aug 31/18
508 Aug 31/18
509 Aug 31/18
510 Aug 31/18
Repair 601 Aug 31/18

602 Aug 31/18
603/604 Aug 31/18
Assembly 701 Aug 31/18

702 Aug 31/18
703 Aug 31/18
704 Aug 31/18
705 Aug 31/18
706 Aug 31/18
707 Aug 31/18
708 Aug 31/18
709 Aug 31/18
710 Aug 31/18
Special Tools, Fixtures and Equipment 901 Aug 31/18

902 Aug 31/18
Illustrated Parts List 1001 Aug 31/18

1002 Aug 31/18
1003 Aug 31/18
1004 Aug 31/18
1005/1006 Aug 31/18
List of Effective Pages
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UNISON INDUSTRIES
TABLE OF CONTENTS
Topic Page
Description and Operation 1
Testing and Fault Isolation 101
Automatic Test Requirements (section #200) N/A
Disassembly 301
Cleaning 401
Check 501
Repair 601
Assembly 701
Fits and Clearances (section #800) N/A
Special Tools, Fixtures and Equipment 901
Illustrated Parts List 1001
Table of Contents
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UNISON INDUSTRIES
INTRODUCTION
1. General.
A. This manual contains complete maintenance instructions with Illustrated Parts List for Ignition
Exciter part numbers 9048700‑7, ‑8, and -9 made by Unison Industries, Jacksonville, FL 32256.
B. It can be more convenient and cost effective to have these exciters overhauled or exchanged by
the Unison Service Center, which offers factory quality through extensive upgrade and exchange
programs that are not described in this manual. These programs increase component reliability
and decrease operating costs. Contact the Unison Service Center, 7575 Baymeadows Way,
Jacksonville, FL 32256, Phone 904-739-4106 (Fax 904-739-4444).
C. This manual is prepared in accordance with Air Transport Association Specification No. 100. All
reasonable attempts were made to make this manual as complete and accurate as possible.
If you have questions, comments, corrections, or require clarification of information contained
herein, please call or write Unison Industries, Product Support Supervisor, 7575 Baymeadows
Way, Jacksonville, FL 32256, Phone 904-739-4000 (Fax 904‑739‑4006).
D. Copyright Statement.
The information and designs contained in this document are proprietary to Unison Industries,
and will not, in whole or in part, be duplicated, disclosed, or used without the written consent of
Unison Industries. This document is protected as an unpublished work under the U.S. Copyright
Act of 1976, as well as under all other pertinent domestic and international intellectual property
provisions. All rights reserved.
E. Good established shop practices and safety precautions must be obeyed at all times to prevent
damage to equipment and/or injury to persons.
WARNING: IMPROPER OR UNAUTHORIZED APPLICATIONS OF INFORMATION CONTAINED

IN THIS MANUAL MAY RESULT IN LOSSES OR DAMAGES TO THE USER.
All technical documentation and information contained herein, with respect to Assembly and Disassembly,
Cleaning, Inspection methods and limits, Repair methods and limits, Operational limits, life limits and the
like, have been developed and approved for use with parts that have been manufactured and/or approved
by Unison Industries and that have been maintained in accordance with Unison Industries technical
documentation and recommendations. Unison Industries has no contractual or legal obligation for, nor
knowledge of, non-Unison-approved parts and repairs. Accordingly, this document is not intended to
apply to non-Unison-approved parts or repairs.
When performing installation, maintenance, replacement, adjustment, inspection, or overhaul of any

Unison assembly, component, or part, it is imperative that the latest revision of the appropriate manual
or product support document be referenced. Contact Unison Industries to be sure you have the latest
manual or support document revision before performing any work. Unison assumes no liability for any
actual, consequential, or other types of damages directly or indirectly resulting from the unauthorized use
of this manual for other than its stated purposes.
Introduction
49-41-21
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Aug 31/18
UNISON INDUSTRIES
F. Warnings for hazardous materials are written from Material Safety Data Sheets (MSDS), when
available. Make sure you obey these safety precautions.
• Read and obey specified instructions in MSDS for use and types of personal protective
equipment (safety glasses, gloves, aprons, etc.), ventilators or respirators, fire extinguishers,
and procedures for a medical emergency.
• Read and obey the hazardous materials label on the container of hazardous material, and
the MSDS supplied by the manufacturer.
• Obey standard shop practices and procedures when you use hazardous materials, and when
you put hazardous materials in storage.
• When you discard hazardous materials, obey all federal, state, and local regulations.
G. Values in this manual are given in US Standard Units, followed in parentheses by equivalent
values for the International System of Units (Metric or SI units).
2. List of Abbreviations.
ABBREVIATION DEFINITION ABBREVIATION DEFINITION
AMP ampere ms millisecond

AR as required mV/DIV millivolt/division
Assy assembly N/A not applicable
BIT built-in-test NO number
DC direct current nSEC/DIV nanosecond/division
EMI electro-magnetic PCB printed circuit board
interference P/N part number
FADEC full authority digital RF reference
electronic control SPEC specification
FIG figure µF microfarad
IPL illustrated parts list µs microsecond
kV kilovolt VDC volts, direct current
Introduction
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UNISON INDUSTRIES
DESCRIPTION AND OPERATION
1. General.
A. This manual contains maintenance instructions with Illustrated Parts List for Ignition Exciter,
Unison part number 9048700-7, ‑8, -9; Honeywell part number 3876195-7, ‑8, -9.
B. The procedures in this manual are applicable to the 9048700‑7, ‑8, and -9 Exciters. The
9048700‑8 Exciter has some manufacturing process improvements that are not included in
the 9048700‑7. It is recommended that 9048700‑7 and -8 Exciters be modified to 9048700‑9.
9048700‑7 Exciters must be sent to Unison Industries because this is a factory‑only modification.
Refer to Unison Service Bulletin 9048700‑49‑16.
C Engine Application: Operators must use the approved installation manual or engine parts list to
make sure the part number of the ignition exciter is the correct part for installation on a specific
engine/airframe.
2. Description (See Figure 1).
A typical ignition system consists of an exciter, igniter lead, and igniter plug. This Ignition Exciter is a
solid state, two channel unit that provides redundant channel spark energy to two igniter plugs. The
Exciter is designed for intermittent duty operation. The unit also has on-board diagnostics for detection
of a failed igniter plug, ignition lead, or exciter.
The exciter contains six printed circuit boards (PCBs). It has a Diagnostic PCB, an Electro-magnetic
Interference (EMI) PCB, and two PCB Modules (each PCB Module has two circuit boards). The two
PCB Modules are redundant circuits, and are mounted on an aluminum chassis with screws and spacers.
9048700-9 Shown
Ignition Exciter P/N 9048700‑7, -8, -9

Figure 1
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49-41-21 Aug 31/18
UNISON INDUSTRIES
The Ignition Exciter has three electrical connectors: one input connector which connects to the aircraft
power bus and FADEC diagnostic interface, and two output connectors.
The components of the Ignition Exciter are contained in a plated aluminum housing that is hermetically
sealed for operation at high altitude and high humidity.
3. Table of Exciter Characteristics.
Table 1
Exciter Characteristics
NUMBER OF PLUGS FIRED Two

INPUT VOLTAGE 28 VDC nominal
INPUT CURRENT 1.0 amps maximum
SPARK RATE 1.0 sparks/second minimum at 14 VDC
3.0 sparks/second maximum at 32 VDC
STORED ENERGY 1.25 joules per channel
DUTY CYCLE Intermittent (2 minutes on, 2 minutes off)
OUTPUT VOLTAGE 2700 to 3000 Volts (2500 min. @ 14 VDC)
4. Theory of Operation (See Figure 2).
The Ignition Exciter is a solid-state device that provides the spark energy to two igniter plugs. The unit is
a capacitor discharge ignition circuit that can store 1.25 joule of energy per channel at an output voltage
of 2.7 to 3.0 kV. The Ignition Exciter is classified as a low tension device, and is designed for use with
semiconductor (shunted surface gap) plugs.
The exciter circuit can be broken into five main areas: the EMI filter circuit, the diagnostic circuit, the
converter circuit, the trigger circuit, and the output circuit.
Channel 1 Control DC/DC Storage Output To

Circuit Converter Capacitor Circuit Igniter
INPUT
CONNECTOR
Voltage Trigger
1 Pos. EMI Sense Circuit
One-Shot
2 Neg. Filter Time Delay
3 BIT A Diagnostic Output Detector
4 Circuit Output Detector

BIT B
5 One-Shot
Time Delay
Voltage Trigger
Sense Circuit
Control DC/DC Storage Output To

Channel 2 Circuit Converter Capacitor Circuit Igniter
Ignition Exciter Block Diagram

Figure 2
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49-41-21 Aug 31/18
UNISON INDUSTRIES
5. Circuit Description.
A. EMI Filter Circuit.
The electro-magnetic interference (EMI) circuit is an input power filter. The circuit keeps the
EMI created inside the exciter box from exiting via the direct current (DC) input power leads.
The circuit also prevents transients present on the aircraft's electrical system from entering the
exciter and causing damage to its components. A single EMI circuit serves both exciter channels.
B. Diagnostic Circuit.
Fault detection protocol first detects insufficient output voltage. This is diagnosed as an ignition
system failure if either channel of the dual channel exciter fails to deliver an output pulse of
sufficient amplitude. That is, when one side fails the total ignition system is indicated as failed.
Secondly, fault detection protocol looks for an open circuit output caused by a faulty lead or
plug. In this condition the plug no longer breaks down even though sufficient output voltage
is delivered by the exciter. Failed igniter lead or plug detection is performed on each module
independently.
Ignition system failures caused by an insufficient output voltage level from either channel result
in both BITs effectively open circuited 5 ± 1 seconds after the fault has occurred. Igniter lead or
plug failures in either module result in an open circuited BIT corresponding to the faulty side of
the dual output exciter. The BIT output voltage level changes from normally grounded (low) to
open circuited (high) after 9 consecutive output events have failed to breakdown the plug. High
and low voltage levels are established by applying the exciter input (28 volt) bus line to each of
the BIT circuits through a voltage divider.
C. Converter Circuit.
The converter circuit generates high voltage DC to charge the storage capacitor.
D. Trigger Circuit.
The trigger circuit senses the voltage level on the storage capacitor and discharges the output
when a preset voltage of 2700-3000 volts is reached. The trigger circuit also feeds the one-shot
time delay which controls the charging cycle and maintains a constant spark rate.
E. Output Circuit.
The output circuit is an electronic switch network that discharges the stored energy of the storage
capacitor to the igniter plug. The combined effect of the trigger circuit and output circuit is similar
to the arc-gap tube used in other exciters. An open circuit is maintained until the preset voltage
is reached. Then the switch closes, allowing a high current discharge from the storage capacitor.
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UNISON INDUSTRIES
TESTING AND FAULT ISOLATION
Table 101
Equipment and Materials
EQUIPMENT USED FOR
11-10803 Input Test Adapter Electrical tests
11-10842 Input Lead (included with 11-20300) Electrical tests
11-10873 Burn-in Fixture Burn-in of exciter
11-20200 Multiload Module Electrical tests
11-20220 LOW TENSION PLUG Load Panel (2 necessary) Electrical tests
11-20235 OPEN LOAD Load Panel Electrical tests
11-20238 31 K‑OHM Load Panel Electrical tests
11-20300 Power Module (includes a Digital Oscilloscope, Electrical tests

1000X High Voltage Probe, and AC Power Source with
Precision Variable Oscillator)
11-20501 Output Lead (2 necessary) Electrical tests
Model 77 Fluke Multimeter Electrical tests
NOTE: Equivalent alternative equipment and materials can be used for the items that follow.
P6015A Tektronix Probe (1000X) Output voltage test
TDS360 Tektronix Oscilloscope Output voltage test
Model 77 Fluke Multimeter Electrical tests
MATERIALS USED FOR AVAILABLE FROM
Entek NR-40 Wetting Agent Reduce surface tension Enthone, P.O. Box 1900
during leak test New Haven CT 06508
Tank of N2 Nitrogen Leak Test Locally available
1. General Instructions.
A. Equipment and materials are shown in Table 101. Refer to Table 901 for equipment sources.
B. The exciter must satisfactorily complete all tests in this section before it is sent back to
service. Also visually examine the exciter for physical damage or defects that show repair or
replacement is necessary. Refer to CHECK for visual inspection steps.
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UNISON INDUSTRIES
C. Do electrical tests in sequence written in Test Procedures. The initial hook-up and control settings
of tester are changed only as necessary for each test. Troubleshooting information follows the
electrical tests. Refer to CHECK for test of components.
D. Ambient temperature and humidity during all tests must be the conditions that are usual in an
approved avionics maintenance workshop.
E. All numbers in parentheses refer to IPL Figure 1 item numbers unless differently shown.
2. Leakage Test.
NOTE: Two leakage tests are available - a recommended test and an alternative test. Do one of the
two tests.
A. Recommended Leakage Test.
(1) Put exciter in a sealed pressure chamber. Exciter must be at room temperature.
(2) Pressurize the chamber with 15 ± 2 PSI (103 kPa, gage) of dry nitrogen for 15 minutes
minimum.
(3) Remove exciter from pressurization chamber and immediately put exciter fully into a
tank of water kept at a temperature of 140 to 200°F (60 to 93°C). Keep exciter in the
water for two minutes minimum. Add sufficient Entek NR‑40 wetting agent to prevent
surface tension bubbles.
(4) Look at all exterior surfaces for leaks, and look carefully at input and output connectors,
screw holes, and cover seal area. If leaks (bubbles) are seen, exciter is defective.
WARNING: COMPRESSED AIR.

• PUT ON APPROVED SAFETY EQUIPMENT TO PREVENT INJURY TO EYES
AND FACE WHEN COMPRESSED AIR IS USED.
• MAXIMUM PERMITTED AIR PRESSURE IS 30 PSIG (207 kPa, GAGE).
• DO NOT POINT AIR OUTLET AT YOURSELF OR OTHER PERSONS.
(5) Remove exciter from water, then dry with compressed air at 30 psig (207 kPa, gage)
maximum pressure. Make sure connectors are fully dry.
B. Alternative Leakage Test.
(1) Put exciter for one minute fully into a tank of water kept at a temperature of 180 to 200°F
(82 to 93°C). Exciter must be at room temperature before test. Add sufficient
Entek NR‑40 wetting agent to prevent surface tension bubbles.
(2) Look at all exterior surfaces for leaks, and look carefully at input and output connectors,
screw holes, and cover seal area. If leaks (bubbles) are seen, exciter is defective.

(3) Remove exciter from water, then dry with compressed air at 30 psig (207 kPa, gage)
maximum pressure. Make sure connectors are fully dry.
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3. Electrical Tests.
WARNING: HIGH VOLTAGE.

• DO NOT TOUCH EXPOSED LEADS OR COMPONENTS WHILE TESTER IS
ENERGIZED.
• OBEY THE USUAL PRECAUTIONS WHEN HIGH VOLTAGE EQUIPMENT IS
OPERATED.
• THE OUTPUT OF EXCITER CAN GIVE A DANGEROUS ELECTRICAL SHOCK.
A. Case Ground Test. See Figure 101.
(1) Use a Fluke Multimeter set to lowest ohms range. Measure resistance between input
connector pin 5 and a non-painted area of exciter mounting bracket. Resistance must
be 0.025 ohms maximum.
ENLARGED 1 2
VIEW 5
3
4
INPUT MASTER
LABEL KEYWAY
FLAT
Input Connector Pins

Figure 101
B. Diagnostic Circuit Test. See Figure 102.
(1) Connect 11-10803 Input Test Adapter to input connector of exciter.
(2) Connect 11-10842 Input Lead between adapter and Power Module.
(3) Connect 11-20501 Output Lead between Channel "A" of exciter and 11‑20220 LOW
TENSION PLUG Load Panel.
(4) Connect 11-20501 Output Lead between Channel "B" of exciter and 11‑20220 LOW
(5) Connect Fluke voltmeter to "common" and "Bit A" jacks of 11-10803 Input Adapter.
(6) On 11-10803 Input Adapter, set polarity switch to NORMAL.
(7) On tester,
• Set CONTROL POWER switch to ON, then

• Set U.U.T. AC / DC switch to DC, then
• Set DC AMPS switch to 5A, then
• Adjust DC ADJUST control to 28V
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UNISON INDUSTRIES
Power Module Multiload Module
Oscilloscope Load Load Load Load

Panel Panel Panel Panel 11-20220
Low Tension Plug
11-10842 Load Panel
INPUT
LEAD
11-20235
Open Load
Load Panel
VOLT
METER 11-20501
OUTPUT
LEAD
11-10803
INPUT B
TEST
ADAPTER A
Diagnostic Test Set-Up

Figure 102
(8) On tester, set U.U.T. ON / OFF switch to ON. Monitor voltmeter indication for 10 seconds
minimum. Voltage must be 3.4 to 3.8 volts. Voltage not in the 3.4 to 3.8 range is a
failure. Indication of 28 VDC (source voltage) is also a failure.
(9) On tester, set U.U.T. ON / OFF switch to OFF.
(10) Connect Fluke voltmeter to "common" and "Bit B" jacks.
(11) Do step (7) above for test of Channel "B".
(13) Disconnect Channel "A" output lead from the 11‑20220 LOW TENSION PLUG Load
Panel, then connect the output lead to 11‑20235 OPEN LOAD Load Panel.
(14) Connect Fluke voltmeter to "common" and "Bit A" jacks of 11-10803 Input Adapter.
(15) On tester, set U.U.T. ON / OFF switch to ON. Listen and count the pulses in the firing
channel. The voltage as measured in the open-circuited channel must be 3.4 to 3.8
volts for the initial 8 pulses. At the 9th pulse, the measured voltage must change to and
stay at 28 VDC (source Voltage). A failure is indicated by any of the following:
• Voltage is not 3.4 to 3.8 volts for initial 8-pulses.

• 28 VDC does not start at 9th pulse (starts at 8 or less pulses, or 10 or more pulses).
• 28 VDC does not stay constant after 9th pulse, or voltage is other than 28 VDC.
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(17) Connect Fluke voltmeter to "common" and "Bit B" jacks of 11-10803 Input Adapter.
(18) Change connections of the two output leads from one to the other at the two output
connectors of exciter.
(21) Remove voltmeter from test setup.
C. Reverse Polarity Test. See Figure 103.
(1) Connect 11-20501 Output Lead between Channel "B" of exciter and 11‑20220 LOW
(2) On 11‑10803 Input Adapter, set polarity switch to REVERSE.
(3) On tester, adjust DC ADJUST control to 32V.
(4) On tester, set U.U.T. ON / OFF switch to ON. Exciter must not spark.
Oscilloscope
11-10842 Load Load Load Load
Panel Panel Panel Panel
INPUT 11-20220
LEAD Low Tension Plug
Load Panel
11-20501
OUTPUT
LEAD
11-10803
INPUT B
TEST
ADAPTER A
Reverse Polarity and Spark Rate Test Set-Up

Figure 103
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D. Spark Rate Test. See Figure 103.
(1) On 11‑10803 Input Adapter, set polarity switch to NORMAL.
(2) On Multiload Module, set display of the spark rate meters to "R" (for rate).
(4) On tester, set U.U.T. ON / OFF switch to ON, then read spark rate on Multiload Module.
Spark rate must be 1.0 to 3.0 sparks/second.
(7) On tester, set U.U.T. ON / OFF switch to ON, then read spark rate on Multiload Module.
Spark rate must be 1.0 to 3.0 sparks/second.
E. Output Voltage Test. See Figure 104.
(1) Connect 11-20501 Output Lead between Channel "A" of exciter and 11‑20238 31 K‑OHM
Load Panel.
(2) Connect 11-20501 Output Lead between Channel "B" of exciter and 11‑20235 OPEN
LOAD Load Panel.
(3) Connect P6015A High Voltage Probe between oscilloscope and load panel that is
connected to Channel "A" of exciter.
Oscilloscope
11-10842 Load Load Load Load
INPUT
Panel Panel Panel Panel 11-20238
LEAD 31 K-Ohm
Load Panel
11-20235
Open Load
Load Panel
P6015A
High-Voltage Ground
Probe Wire
11-10803 11-20501
INPUT B OUTPUT
TEST LEAD
ADAPTER A
Output Voltage Test Set-Up

Figure 104
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(4) Connect ground wire of Probe to ground jack of the same load panel.
(5) Adjust controls on oscilloscope for output voltage test.
• Set Horizontal scale to 500 nanoseconds/division

• Set Vertical scale to 500 millivolts/division
• Set trigger level to 2.0 volts
• Set coupling to DC
• Set slope (in trigger menu) to Positive
(7) Set U.U.T. ON / OFF switch to ON, then measure the output voltage of the maximum
waveform magnitude (5 pulses minimum) as shown on oscilloscope at 10 ± 0.2 micro-
seconds after start of pulse. Output voltage must be 2500 V minimum.
(9) Change connections of the two output leads from one to the other at the two output
connectors of exciter.
4. Burn‑In and "BIT" Activation Test
A. Primary Tester (Power Module and Multiload Module). See Figure 105.
(1) Connect 11‑10873 Burn‑in Fixture to the two 11‑20501 Output Leads.
(2) On 11-10803 Input Adapter, set polarity switch to NORMAL.
Power Module
11-10842
INPUT
LEAD Oscilloscope
11-10873
BURN-IN
VOLT
11-20501 FIXTURE
METER
OUTPUT
LEAD
11-10803
INPUT B
TEST
ADAPTER A
Burn‑In Setup
Figure 105
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(3) On tester, adjust DC ADJUST control to 28V, then set U.U.T. ON / OFF switch to ON.
(4) Connect Fluke voltmeter to "common" and "Bit A" jacks of 11-10803 Input Adapter and
measure voltage of "Bit A". Then change connection of voltmeter to "Bit B" jack and
measure voltage of "Bit B". Voltage must be 3.4 to 3.8 volts for "Bit A" and "Bit B".
Voltage not in 3.4 to 3.8 range is a failure. Indication of 28 VDC (source voltage) is also
a failure.
(5) Let exciter operate continuously for 16 hours minimum, then let exciter continue to
operate for step 4.A.(6) below. Do not remove input‑power to exciter.
(6) While exciter is still firing, measure voltage at "Bit A" and "Bit B". Voltage must be
3.4 to 3.8 volts for "Bit A" and "Bit B". Voltage not in 3.4 to 3.8 range is a failure.
Indication of 28 VDC (source voltage) is also a failure.
(8) Remove 11‑10873 Burn‑in Fixture from test setup.
5. Fault Isolation.
Use Table 102 to help find cause of malfunction. If a problem is in one channel only, identify and do
tests for the components in that channel.
Table 102
Fault Isolation Table
Symptom Probable Defective Component Action
No Input Current Input Connector

EMI Board Assembly
No Output One Channel PCB Module Assembly

Capacitor Assembly
Inductor Assembly Do a test of component.
Use test procedures
Low Output One Channel PCB Module Assembly in CHECK.
Inductor Assembly Replace if defective.
Capacitor Assembly
No Output Two Channels * PCB Module Assembly

Capacitor Assembly
Inductor Assembly
High or Low Spark Rate PCB Module Assembly

Inductor Assembly
Diagnostic Test Failure, Diagnostic Board Assembly

no other fault confirmed EMI Board Assembly
* Possible a different defect in each channel
NOTE: The Inductor Assembly is tested as part of the whole exciter assembly. A defective inductor can
be identified by the process‑of‑elimination method.
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DISASSEMBLY
Table 301
EQUIPMENT USED FOR
Propane Torch External solder removal
Soldering Iron, 30 Watt Soldering/unsoldering on PCB's
Soldering Iron, 200 Watt Unsolder bus wire (150) from chassis
& connector assembly (140)
Heat Sink (make locally) Protect connectors during unsoldering
Flux‑Off CZ Cleaning Solvent Cleaning Chemtronics.

Kennesaw GA 30152
MIL-F-14256, Type RMA (paste), Aid in external solder removal Locally available
Mildly Activated Rosin Flux
Paint Remover, Remove paint Locally available

Federal Spec. TT-R-248
B. All numbers in parentheses refer to IPL Figure 1 item numbers unless differently indicated. All
reference points refer to Figure 504 in CHECK.
C. Before disassembly, examine and test exciter per TESTING AND FAULT ISOLATION to find
probable cause of malfunction. Disassemble exciter only as necessary to find and correct
malfunction.
D. Do a test of each component as it is removed from exciter, use procedures in CHECK.
E. Disassembly steps are written in component removal sequence. To remove a single component,
use the disassembly steps for that component, and also use as necessary more steps that have
come before to get access, remove wires, etc. For two components that are the same, do again
the disassembly steps for the second component (inductor assembly, capacitor assembly, etc.).
F. Before soldering/unsoldering any items protected by conformal coating, remove coating covering
the solder area by scraping, then clean area with Flux‑Off CZ Cleaning Solvent.
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G. Use a phenolic or nylon tool to remove RTV adhesive from wires and parts to permit removal of
parts as disassembly continues. Use care not to cut wire insulation or cause damage to parts.
H. Use this caution for all soldering of semi‑conductors.
CAUTION: USE A HEAT SINK WHEN SOLDERING SEMI-CONDUCTORS TO PREVENT

DAMAGE TO COMPONENTS.
I. Use this warning for all disassembly steps where heat is included. This includes soldering/
brazing/welding, hot-water for tests or flushing, heat-shrinking of tubing, and drying/curing parts
in an oven.
WARNING: HOT PARTS.

• WEAR APPROVED GLOVES WHEN YOU TOUCH HOT PARTS.
• TOUCHING WITH BARE HANDS CAN CAUSE BLISTERS OR BURNS.
• IF SKIN IS BURNED, PUT IN COLD WATER FOR 10 MINUTES. GET MEDICAL
AID IMMEDIATELY IF PAIN CONTINUES, OR IF BLISTERS START.
2. Disassembly Procedures.

• DO NOT TOUCH, DIRECTLY OR THROUGH UNINSULATED TOOLS, LEAD
CONNECTIONS AND COMPONENTS UNTIL CAPACITOR ASSEMBLY HAS BEEN
GROUNDED AND YOU KNOW IT IS FULLY DISCHARGED.
• CAPACITORS CAN GIVE A DANGEROUS ELECTRICAL SHOCK.
CAUTION: ELECTROSTATIC SENSITIVE DEVICES (ESD).

• USE APPROVED ESD PROTECTIVE C ONTROLS.
• KEEP PARTS AWAY FROM ELECTROSTATIC FIELDS UNLESS PROTECTED BY A
STATIC-SHIELDED CONTAINER.
• THIS UNIT CONTAINS ELECTRONIC PARTS THAT CAN BE DAMAGED BY
ELECTROSTATIC D
ISCHARGE.
A. Identification Plate (25), Input Label (15), Warning Label (20), and Barcode Label (27) Removal.
(1) Write and keep data that is marked on used identification plate and barcode label for
later use when a new plate and label are installed.
NOTE: Discard the factory identification plate. A Yellow replacement plate must be
used to indicate a field repair, and the repair station number.
(2) Bend up nameplate bracket ears and remove identification plate.
(3) Remove and discard input label and warning label.
(4) 9048700-9 Only: Remove and discard clear overlaminate (26) and barcode label.
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UNISON INDUSTRIES
B. Paint Removal.
NOTE: 9048700-9 Revision F exciters are manufactured without paint. The unit may be painted
if the painting was performed in a repair shop as an optional procedure.
WARNING: PAINT REMOVER FEDERAL SPECIFICATION TT-R-248

• USE ONLY WHERE THERE IS A GOOD FLOW OF AIR. DO NOT BREATHE
VAPORS BECAUSE THEY ARE HARMFUL.
• DO NOT USE NEAR WELDING AREAS, NEAR OPEN FLAME, OR ON VERY
HOT SURFACES.
• USE PROTECTIVE CREAMS AND WEAR APPROVED GLOVES, BOOTS,
APRON, CHEMICAL GOGGLES, AND FACE SHIELD TO PROTECT SKIN
FROM CONTACT.
• IF SPILLED ON CLOTHING, WASH CLOTHES BEFORE WEARING AGAIN.
(1) Install protective caps (5, 10) on input and output connectors, then soak exciter in paint
remover.
(2) Wash off paint and paint remover using a brush and hot water.
C. Input Cover (30) Removal. Make a heat-sink/puller as shown in Figure 301.
(1) Install heat-sink/puller on input connector, then tighten by hand. (The heat‑sink prevents
solder around input connector from melting when heat is applied.)
CAUTION: WORK QUICKLY AND APPLY HEAT ONLY TO EDGES OF COVER. TOO
MUCH HEAT CAN BURN OFF PLATING OR CAUSE DAMAGE TO INTERNAL
COMPONENTS.
(2) Use a low temperature flame to melt solder at edges of input cover, then brush away
unwanted solder.
(3) As solder melts, use heat-sink/puller to remove input cover.

0.6875-24 UNEF-2B thread,
0.50 (12.7 mm) minimum
0.25-28 full thread.
0.25-28 thread,
through
0.75 (19 mm) minimum
full thread. thread
0.760
(19.3 mm)
diameter
Weld "T" handle. Make from

0.25 (6.4 mm) diameter steel
rod. Length of shaft and
handle optional.
0.50 0.25 Steel Jam Nut

Heat Sink: (12.7 mm) (6.4 mm)
Make from 1.20 (30.5 mm) 0.25-28 thread
diameter copper rod. 1.25
(31.7 mm)
Heat Sink/Puller
Figure 301
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UNISON INDUSTRIES
D. Input Connector (35) and Sleeving (40, 45) Removal.
(1) Move the sleeving at rear of connector pins to get access.
(2) Unsolder all wires from connector pins.
(3) Remove four pieces of sleeving and 1-piece larger sleeving from wires.
(4) Use a low temperature flame to melt solder around nut, then brush away unwanted
solder and remove nut.
(5) Remove connector.
E. Ground Wire (55) Removal.
(1) Unsolder white wire from cover (30) by applying heat to front side of cover.
F. Diagnostic Board (90), Screws (75A), Lockwashers (85), and Washers (80) Removal.

• KEEP PARTS AWAY FROM ELECTROSTATIC FIELDS UNLESS PROTECTED
BY A STATIC-SHIELDED CONTAINER.
ELECTROSTATIC D ISCHARGE.
(1) Unsolder two white wires, red wire (50), and black wire (60) from terminals W1, W2,
W5, W6. Then make the wires straight for later assembly. Remove sleeving (95) from
red and black wires.
(2) Remove four screws, lockwashers, and washers.
(3) Remove diagnostic board. Remove sleeving (95) from EMI board assembly (100) red
and black leads.
NOTE: Earlier exciters have four spacers that are attached to the four corners of
diagnostics board. Take care and do not remove the spacers. Later exciters
have removable spacers (91).
(4) Unsolder and remove yellow wire (65) and green wire (70) from diagnostic board
terminals W3, W4. It is not necessary to remove these wires unless damaged.
NOTE: Remove the two wires if shorter than approximately 6.0 in. (152.4 mm).
G. EMI Board Assembly (100) Removal and Disassembly.
(1) Unsolder two red wires at terminal W3, and two black wires at terminal W4. Then make
the wires straight for later assembly. (see Figure 506, points 08 and 09)
(2) Remove EMI board assembly.
(3) Unsolder and remove red wire (50) from terminal W6, and black wire (60) from
terminal W7.
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UNISON INDUSTRIES
(4) Unsolder and remove capacitor (IPL Fig 2, item 5) from printed circuit board (IPL Fig 2,
item 35).
(5) Unsolder and remove coils (IPL Fig 2, items 10, 15) from printed circuit board.
(6) Unsolder and remove transzorb (IPL Fig 2, item 20) from printed circuit board.
(7) Unsolder and remove red wire (IPL Fig 2, item 30) from terminal W1 of printed circuit
board, and black wire (IPL Fig 2, item 25) from terminal W2.
H. Chassis and Connector Assembly (140) Removal.
(1) Install heat sink on both output connectors finger tight.
NOTE: This keeps solder around output connector and the output pin insulator from
softening when heat is applied.
(2) Apply soldering flux to edge of end-plate and apply heat until solder is completely
softened.
(3) Use a low temperature flame to apply heat equally around solder joint. As solder melts,
pull chassis and connector assembly from housing. Continue to apply heat to housing
as necessary until exciter comes out freely.
I. Bracket (115) and Capacitor Assembly (120) Removal.
CAUTION: CAPACITORS
• DO NOT EXPOSE CAPACITORS TO THE AIR FOR MORE THAN 12 HOURS
AFTER REMOVAL FROM EXCITER, PACKING ENVELOPE OR CONTAINER.
• IF FINAL ASSEMBLY CANNOT BE COMPLETED IN LESS THAN 12 HOURS,
KEEP CAPACITOR IN A NON-METALLIC CONTAINER WITH A DOUBLE
SEALING COVER, WITH SUFFICIENT DESICCANT TO KEEP RELATIVE
HUMIDITY AT LESS THAN 30%.
• HUMIDITY/MOISTURE CAN CAUSE CONTAMINATION OF C APACITOR.
(1) Unsolder wires from turrets of PCB module (125), Figure 504, points 03 and 04.
(2) Remove four screws (110A) and lockwashers (85) that hold bracket, capacitor, and
PCB module to chassis (140).
(3) Use a razor‑knife to cut RTV adhesive at six places between capacitor and PCB module,
then remove bracket and capacitor. See Figure 302 for adhesive points.
(4) Use a razor‑knife to cut RTV adhesive at four places between bracket and capacitor.
See Figure 302 for adhesive points.
J. PCB Module (125, 125A) and Mica Insulator (130) Removal.
(1) Unsolder bus wire (150) from PCB module at Figure 504, point 10.
(2) Remove two screws (110B) from center holes on sides of PCB module.
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UNISON INDUSTRIES
Output End
0.125 in. (3.18 mm)

RTV Adhesive Dots
Between Module Assembly Between Capacitor Assembly

and Capacitor Assembly and Bracket
(6 Places) (4 Places)
RTV Adhesive Points
Figure 302
(3) Lift PCB module off chassis and connector assembly.
NOTE: It can be easier to lift end of PCB module at outlet‑end of exciter first.
(4) Remove mica insulator from PCB module (Figure 506, point 11).
K. Inductor Assembly (145) Removal.
(1) Use a 30 watt soldering iron to unsolder white wire from pin of output connector.
(2) Pry inductor assembly from chassis.
L. Remove the following parts. It is not necessary to remove these parts unless damaged.
(1) Remove grommets (135) from hole in end-plate.
(2) Remove yellow tapes (155, 160) from chassis.
(3) Bus wire (150) removal from chassis. Apply soldering flux, then unsolder bus wire from
chassis using 200 watt soldering iron.
M. Clean any remaining thermal grease and thermal epoxy from chassis and connector
assembly (140) and PCB module (125).
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CLEANING
Table 401
EQUIPMENT USED FOR
Propane Torch (locally available) Remove unwanted solder
Flux‑Off CZ Cleaning Solvent Clean components Chemtronics.

Kennesaw, GA 30152
MIL-F-14256, Type RMA (paste), Remove unwanted solder Locally available

Soft-bristled Brush Clean components Locally available
Lint-free Cloth Clean components Locally available
B. All numbers in parentheses refer to IPL Figure 1 item numbers unless differently indicated.
C. Clean housing and other parts with a clean, dry cloth. Whenever this does not fully clean parts,
use a cloth or soft-bristled brush moist with cleaning solvent. Remove soldering flux with cleaning
solvent.
2. Cleaning Procedures.
A. Printed Circuit Boards.
WARNING: FLUX-OFF CZ CLEANING SOLVENT.

• CLEAN COMPONENTS IN WELL VENTILATED AREA.
• DO NOT BREATHE VAPORS.
• WASH HANDS IMMEDIATELY AFTER CONTACT WITH SOLVENTS. USE
OF PROTECTIVE GLOVES IS RECOMMENDED.

• KEEP PARTS AWAY FROM ELECTROSTATIC FIELDS UNLESS PROTECTED
BY A STATIC-SHIELDED CONTAINER.
ELECTROSTATIC D ISCHARGE.
CAUTION: DO NOT USE CHLORINATED SOLVENTS ON PRINTED CIRCUIT BOARDS.
(1) Clean PCB's with a soft-bristled brush moist with cleaning solvent.
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Aug 31/18
UNISON INDUSTRIES
(2) Carefully remove remaining RTV adhesive from surfaces by scraping. Then clean with
a soft-bristled brush moist with cleaning solvent.
(3) Clean all repaired areas and solder joints with cleaning solvent before conformal coating
is applied.
B. Connectors.
CAUTION: DO NOT CLEAN CONNECTORS WITH METHYLETHYLKETONE, FEDERAL

SPECIFICATION TT‑M‑261. IT CAN CAUSE DAMAGE TO INSERTS.

(1) Clean input and output connectors, and the insulators and contacts. Use a small,
soft-bristled brush moist with cleaning solvent, then dry with clean compressed air.
C. Chassis-mounted Components.

• PUT ON APPROVED SAFETY EQUIPMENT TO PREVENT INJURY TO EYES AND
FACE WHEN COMPRESSED AIR IS USED.
• MAXIMUM PERMITTED AIR PRESSURE IS 30 psig (207 kPa, GAGE).
(1) Clean with a clean lint-free cloth or soft-bristled brush moist with cleaning solvent. Then
dry with clean compressed air.
D. Chassis and Connector Assembly (140) and Bracket (115).
(1) Remove remaining RTV adhesive from chassis and bracket by scraping.
(2) Clean with a clean, lint-free cloth or soft-bristled brush moist with cleaning solvent.
E. Unwanted Solder Removal. Remove unwanted solder from housing assembly (105), input cover
(30), and chassis and connector assembly (140) as follows.
(1) Apply soldering flux to areas that have unwanted solder.
(2) Apply a low-temperature flame to the fluxed areas. Brush away solder as it melts. This
procedure also pre‑tins these areas for later assembly.
(3) Remove soldering flux with cleaning solvent.
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CHECK
Table 501
EQUIPMENT USED FOR
11-10842 Input Lead (included with 11-20300) Test of components
11-20300 Power Module (includes a Digital Oscilloscope, Test of components

1000X High Voltage Probe, and AC Power Source with
Precision Variable Oscillator)
11-20400 Components Test Module Test of components
11-20426 Capacitor Fixture Test of Capacitor
NOTE: The 11-20426 Capacitor Fixture is used with the 11-20400 Component Test Module serial
number 0301 to 1300. Contact Unison Industries for procedures using earlier or later models
of the tester.
11-6528 Input Adapter (modified) Test of components
NOTE: Equivalent alternative equipment and materials can be used for the items that follow:
Model 77 Multimeter Test of components
TDS360 Oscilloscope Test of components
GR1657 RLC Digibridge Capacitor test
P6015 Probe, 1000X PCB Module (125) test
PM 8931 Probe, 100X Test of inductor (145)
Model 1864 Megohmmeter Test of components
10-395463 Socket Contact Test of inductor (145) Unison Industries
18 AWG insulated wire, (10-180070-18) Test of inductor (145) Unison Industries
20 AWG insulated wire, (10-180079-22) Test of inductor (145) Unison Industries
ULV3, 0.035 ohm Resistor Test of inductor (145) RCD Components

520 East Industrial Park Dr.
Manchester NH 03103
46F3810, Alligator Clips Test of inductor (145) Mueller Electric Co.

1583 E. 31st St.
Cleveland OH 44114
49-41-21
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Aug 31/18
UNISON INDUSTRIES
A. This section contains visual and electrical checks to make sure of serviceable limits.
B. Equipment and materials are shown in Table 501. Refer to Table 901 for equipment sources.
C. All numbers in parentheses refer to IPL Figure 1 item numbers unless differently indicated. All
exciter reference points refer to Figure 504.
D. Visually examine all parts for physical defects or damage. To aid visual inspection, use an
illuminated bench magnifier or equivalent. Replace damaged items.
E. Disassemble subassemblies / components as necessary, use procedures in DISASSEMBLY.
2. Visual Examination.
A. Using adequate light, and under moderate magnification, visually examine all parts for scratches,
nicks, cracks, corrosion, contamination, or obvious damage. Repair/replace damaged parts.
B. Examine all threaded surfaces for cross-threading, stripping, galling, or contamination. Replace
damaged parts.
C. Examine wiring for loose/defective connections. Examine wires/sleeving for nicked, cut,
compressed, damaged, or worn insulation/sleeving. Resolder defective connections and replace
damaged wire/sleeving.
D. Examine input and output connectors for signs of arcing or electrical failure. Also look for loose,
bent, burnt or corroded pins, and for contamination between pins. Replace damaged parts.
E. Examine chassis-mounted components for damaged sleeving, shorted wires, or other damage.
Repair or replace damaged parts.
F. Examine cover and housing for cracks, dents, or other damage. Cracks are not permitted.
Small dents can be removed if no cracks are started. Examine plating for burned or lifted areas.
Replace cover or housing as necessary.
3. Check Procedures.

ELECTROSTATIC D
ISCHARGE.
A. Diagnostic Board Assembly (90) Test.
(1) Diagnostic board assembly is checked in paragraph 3.B of TESTING AND FAULT
ISOLATION. If a failure is indicated, replace diagnostic board assembly.
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B. EMI Board Assembly (100) Test. Use 11‑20300 Power Module. Test points refer to Figure 504.
(1) Use a modified 11-6528 Input Adapter. Connect (+) clip to red wire (point 12), and
connect (–) clip to black wire (point 13) of EMI board assembly.
NOTE: Modify Input Adapter by replacing terminal lug on red lead with alligator clip.
(2) Connect 11-10842 Input Lead between 11-6528 Input Adapter and 11‑20300 Power
Module.
(3) On Power Module (DC-input to exciter),

• Set U.U.T. AC / DC switch to DC
• Set DC AMPS switch to 5A
(4) Adjust DC ADJUST control to 30 VDC, then set U.U.T. ON / OFF switch to ON.
(5) Use a multimeter to measure voltage between positive post (point 08) and ground post
(point 09). Voltage must be 30 VDC.
(6) Set U.U.T. ON / OFF switch to OFF.
(7) If the EMI board assembly failed test, check the components as shown in paragraph
3.C. Replace individual components that are faulty. If all electrical components pass
tests, the printed circuit board is faulty. Replace entire EMI board assembly.
C EMI Board Assembly Components. Use 11‑20300 Power Module.
(1) Transzorb (IPL Fig 2, item 20).
(a) Parallel resistance test. Use the RCL meter in the 11‑20400 Components Tester.
For setup of the RCL meter, use the instructions in the manual supplied with
the 11‑20400 Components Tester.
1 Carefully remove conformal coating and RTV adhesive to gain access

to component solder connections. Unsolder and remove one lead
from printed circuit board (IPL Fig 2, item 35).
2 Connect RCL meter leads to transzorb leads.
3 Select program to measure parallel resistance (Rp), then press START.
4 Change connections of the RCL meter leads to check resistance in the

other direction.
5 Select program to measure parallel resistance (Rp), then press START.
6 Measured resistance in both directions must be 1 megohm minimum.
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UNISON INDUSTRIES
(2) Capacitor (IPL Fig 2, item 5).
(a) Carefully remove conformal coating and RTV adhesive to gain access to
component solder connections. Unsolder and remove one lead from printed
circuit board (IPL Fig 2, item 35).
(b) Capacitance test. Use the RCL meter in the 11‑20400 Components Tester.
For setup of the RCL meter, use the instructions in the manual supplied with
the 11‑20400 Components Tester.
1 Measure capacitance between lead wires. Capacitance should be 1.2

to 1.8 microfarads.
(c) Breakdown Voltage Test. Use the 11‑20400 Components Tester and the in-
struction manual supplied with it.
1 On tester, go to the "CAPACITOR" LCD screen, then set the values as

shown below for first test.
• Set "Test Voltage" to test voltage to "100".

• Set "Leakage Current" to "100 µA".
• Set "Time" to 15 s.
2 Make connections from lead wire to lead wire.

• DO NOT TOUCH TEST LEADS OR COMPONENTS WHILE
TESTER IS ENERGIZED.
• OBEY THE USUAL PRECAUTIONS WHEN YOU OPERATE
HIGH VOLTAGE EQUIPMENT.
• THE OUTPUT OF TESTER CAN GIVE A DANGEROUS
ELECTRICAL SHOCK.
3 Put the ">" at START, then push the SELECT/OPERATE knob to start
the test.
4 At the end of test, the tester will give an indication of "PASSED" or

"FAILED".
5 At the end of test, let the high‑voltage charge of capacitor decrease

to zero (the tester has a automatic discharge circuit that decreases
the high‑voltage charge of capacitor to zero after test is completed).
A capacitor will be safely discharged after approximately 1‑second for
each microfarad.
6 After test is done, open door and remove component.
(3) Coil (IPL Fig 2, items 10, 15).
(a) Carefully remove conformal coating and RTV adhesive to gain access to
component solder connections. Unsolder and remove one lead from printed
circuit board (IPL Fig 2, item 35).
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UNISON INDUSTRIES
(b) Inductance/Resistance test. Use the RCL meter in the 11‑20400 Components
Tester. For setup of the RCL meter, use the instructions in the manual supplied
with the 11‑20400 Components Tester.
1 Select program to measure inductance and resistance (LsRs

1.000kHz), then press START.
2 Measure inductance and resistance between lead wires. Iinductance

and resistance should be as shown in Table 502.
Table 502
Coil Tests
Item Resistance Inductance

(IPL Fig 2) (microohms) (microhenries)
Coil (10) 83 - 123 225 - 264
Coil (15) 150 - 185 252 - 308
(4) If all components pass tests, the printed circuit board is faulty. Replace EMI board
assembly.
(5) If individual components are faulty, replace per REPAIR.
D. PCB Module Assembly (125, 125A) Test. Use 11‑20300 Power Module. Test points refer to
Figure 505.
(1) Connect P6015 High Voltage Probe to oscilloscope. Use a jumper wire to connect tip
of probe to point 03, then connect ground wire of probe to point 10.
(2) Use a modified 11-6528 Input Adapter. Connect (+) clip to red wire (point 01),
and connect (–) clip to black (point 02) wire of PCB assembly module.
(3) Connect 11-10842 Input Lead between 11-6528 Input Adapter and 11‑20300 Power
Module.
(4) On Power Module (DC-input to exciter),

• Set U.U.T. AC / DC switch to DC
• Set DC AMPS switch to 5A
(5) Adjust DC ADJUST control to 14 VDC, then set U.U.T. ON / OFF switch to ON.
(6) Oscilloscope trace must show 2700 to 3000 volts peak, measured at 10 ± 0.2
microseconds after start of pulse.
(7) Set U.U.T. ON / OFF switch to OFF.
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UNISON INDUSTRIES
E. Capacitor Assembly (120) Test. Use the 11‑20400 Components Tester.
CAUTION: CAPACITORS
• DO NOT EXPOSE CAPACITORS TO THE AIR FOR MORE THAN 12 HOURS
AFTER REMOVAL FROM EXCITER, PACKING ENVELOPE OR CONTAINER.
• IF FINAL ASSEMBLY CANNOT BE COMPLETED IN LESS THAN 12 HOURS,
KEEP CAPACITOR IN A NON-METALLIC CONTAINER WITH A DOUBLE
SEALING COVER, WITH SUFFICIENT DESICCANT TO KEEP RELATIVE
HUMIDITY AT LESS THAN 30%.
• HUMIDITY/MOISTURE CAN CAUSE CONTAMINATION OF C APACITOR.
(1) Capacitance test. Use the RCL meter in the 11‑20400 Components Tester. For setup
of the RCL meter, use the instructions in the manual supplied with the 11‑20400
Components Tester. Measure capacitance between the two wires of capacitor.
Capacitance must be 0.297 to 0.363 microfarads.
(2) Breakdown Voltage Test. Use the 11‑20400 Components Tester and the instruction
manual supplied with it.
(a) On tester, go to the "CAPACITOR" LCD screen, then set the values as shown
below for first test.
• Set "Test Voltage" to 6250 volts.

• Set "Leakage Current" to "100 µA".
• Set "Time" to 15 s.
(b) Attach capacitor assembly to 11-20426 Capacitor Fixture.

• DO NOT TOUCH TEST LEADS OR COMPONENTS WHILE TESTER
IS ENERGIZED.
• OBEY THE USUAL PRECAUTIONS WHEN YOU OPERATE HIGH
VOLTAGE EQUIPMENT.
• THE OUTPUT OF TESTER CAN GIVE A DANGEROUS ELECTRICAL
SHOCK.
(c) Put the ">" at START, then push the SELECT/OPERATE knob to start the test.
(d) At the end of test, the tester will give an indication of "PASSED" or "FAILED".
(e) At the end of test, let the high‑voltage charge of capacitor decrease to zero
(the tester has a automatic discharge circuit that decreases the high‑voltage
charge of capacitor to zero after test is completed). A capacitor will be safely
discharged after approximately 1‑second for each microfarad.
(f) After test is done, open door and remove component.
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UNISON INDUSTRIES
F. Input Connector (35) and Input Cover (30) Test.
CAUTION: DISCONNECT INPUT COVER FROM DIAGNOSTIC BOARD (90) BEFORE

DOING THIS TEST.
CAUTION: DO NOT APPLY MORE THAN 100 VDC TO INPUT CONNECTOR TO

REVENT DAMAGE TO CONNECTOR.
P
(1) Set Model 1864 Megohmmeter to 100 volts, then measure resistance between Pin 1
and all other pins (Pin 2, 3, 4, 5), and between Pin 1 and shell. Resistance must be 10
megohms minimum.
(2) Do same procedure for Pin 2, 3, 4, and 5. Measure resistance from each pin to all other
pins, and between each pin and shell. Resistance must be 10 megohms minimum.
(Pin 5 is connected to cover and will be a dead‑short to shell.)
G. Inductor Assembly (145) Test. Use the 11‑20400 Components Tester.
NOTE: Do a test of both inductors before PCB Module is returned to service.
NOTE: The inductor must be connected in the circuit of exciter for this test. Only the EMI PCB
(100) and Diagnostics PCB (90) can be disconnected from the circuit.
CAUTION: IF EXCITER WAS OPERATED WITH A DEFECTIVE INDUCTOR, THE PCB

MODULE (125) MUST BE THOUGHT OF AS OVERSTRESSED (INDUCED
LATENT DEFECT). EVEN A SHORT TIME CAN CAUSE DAMAGE. THE PCB
MODULE AND INDUCTOR MUST BE REPLACED WITH NEW PARTS.
(1) Make an inductor test tool as shown in Figure 501.
Solder 18 AWG Stranded Alligator

Insulated Wire Clip
10-395463 0.035 Ohm

Resistor Approximately 6 inches
Socket Contact
Inductor Test Tool

Figure 501
(2) Make test connections. See Figure 502.
(a) Connect inductor test tool. Put socket contact on Channel “B” output connector
pin, then attach alligator clip to housing assembly (105).
(b) Attach PM8931 probe across resistor of inductor test tool, then connect probe
to oscilloscope.
(c) Connect 11-10803 Input Adapter to input connector of exciter.
(d) Connect 11-10842 Input Lead between input adapter and tester.
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UNISON INDUSTRIES
(e) Connect 11-20501 Output Lead between Channel "A" of exciter and 11‑20238
31 K‑OHM Load Panel.
(3) Do test of Channel “B” Inductor as follows.
(a) Adjust controls on oscilloscope for inductor waveform test.
(b) On tester, adjust DC input voltage to 24V, then set U.U.T. ON / OFF switch to
ON.
Oscilloscope Load Load Load Load

Panel Panel Panel Panel
11-10842
Input 11-20235
Lead Open Load
PM 8931 Load Panel
Probe
Probe
Ground
Wire
11-10803
Input B Inductor
Test Test Tool
Adapter A
11-20501
Output
Lead
Inductor Assembly Test

Figure 502
(c) Adjust oscilloscope setting, then monitor oscilloscope for inductor waveform.
See Figure 503 for waveforms.
(d) Set UNIT TEST switch to OFF.
(4) Do test of Channel “A” Inductor as follows.
(a) Change connections at output connectors of exciter from one to the other.
(b) Do steps in paragraph (3) above.
(c) Set UNIT TEST switch to OFF, then remove all test equipment.
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49-41-21 Aug 31/18
UNISON INDUSTRIES
“A” — Good Inductor “B” — Bad Inductor
Inductor Test Oscilloscope Waveforms

Figure 503
10 (BUS WIRE GROUND)
04
03
14 WHT
01 RED
02 BLK
11
PCB MODULE ASSEMBLY

Exciter Reference Points (Sheet 1 of 2)
Figure 504
Page 509
49-41-21 Aug 31/18
UNISON INDUSTRIES
10
14 (WHT)
04 (TURRET) 03 (TURRET)
02 (BLK)
01 (RED)
PCB MODULE ASSEMBLY (125)
10
14 (WHT)
02 (BLK)
03 (TURRET)
01 (RED)
04 (TURRET)
PCB MODULE ASSEMBLY (125A)
13 (BLK) 12 (RED)
COIL
(IPL FIG 2,
ITEM 15)
TRANSZORB
(IPL FIG 2,
ITEM 20)
CAPACITOR
(IPL FIG 2,
ITEM 5)
09
COIL
(IPL FIG 2,
ITEM 10)
08
W6 W7
EMI BOARD ASSEMBLY
Exciter Reference Points (Sheet 2 of 2)

Figure 504
Page 510
49-41-21 Aug 31/18
UNISON INDUSTRIES
REPAIR
Table 601
EQUIPMENT USED FOR
Soldering Iron, 30 watt (locally available) Soldering operation
1-2577 Conformal coating Protection of components Dow Corning Corp.

Midland, MI 48686
10-157921-B Wire, Black, 22 AWG Repair of PCB module wires Unison Industries
10-157921-2 Wire, Red, 22 AWG Repair of PCB module wires Unison Industries
10-157921-9 Wire, White, 22 AWG Repair of PCB module wire Unison Industries
10-178946-2 Wire, White, 20AWG Repair of inductor Unison Industries
Flux‑Off CZ Cleaning Solvent Clean solder joints and remove Chemtronics.

soldering flux Kennesaw, GA 30152
MIL-F-14256, Type R or Soldering aid (locally available)

RMA (liquid), Non‑Activated or
Mildly‑Activated Rosin Flux
Sn63 Solder Soldering operation (locally available)

(63% tin, 37% lead)
Sn50 Solder Soldering operation (locally available)

(50% tin, 50% lead)
DC3145 RTV Adhesive, Repair of capacitor assembly Dow Corning Corp.

(no alternative permitted) Box 0994, Midland, MI 48686
10-90066-33 Insulation Tape Repair of capacitor assembly Unison Industries
10-90600-101 Insulation Sleeving Repair of inductor Unison Industries
A. This section gives the procedures necessary to repair damaged parts in the exciter.
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UNISON INDUSTRIES
C. All numbers in parentheses refer to IPL Figure 1 item numbers unless differently indicated.
D. Reference points refer to Figure 504 in CHECK.
E. Before soldering/unsoldering any items protected by conformal coating, remove coating covering
the area to be soldered by scraping. Clean area with cleaning solvent.
F. All solder must conform to requirements of Federal Specification QQ-S-571. Use Sn63 (63% tin,
37% lead) solder for all electrical soldering unless differently indicated.
G. Use this warning for all assembly steps that include heat.
WARNING: HOT PARTS.

• PUT ON APPROVED GLOVES WHEN YOU TOUCH HOT PARTS.
• HOT PARTS ON BARE HANDS CAN CAUSE BLISTERS OR BURNS.
• GET MEDICAL AID IMMEDIATELY IF SKIN IS BURNED.
2. Repair Procedures.

ELECTROSTATIC D
ISCHARGE.
A. Repair PCB Module Assembly (125, 125A) Input Wires (Figure 504, points 01, 02, and 14) as
follows.
(1) Apply soldering flux and unsolder the three input wires from printed circuit boards.
Discard unsoldered wires.
(2) Remove unwanted solder from the two boards. Refer to procedures in CLEANING.
(3) Cut a 3.5 in. (38.1 mm) length of 10-157921-2 red wire and 10-157921-B black wire,
and a 10.0 in. (254.0 mm) length of 10-157921-9 white wire. On innermost board, put
red wire into hole at point 01, and black wire at point 02. On outermost board, connect
white wire to terminal at point 14.
(4) Cut end of wires that come through boards to 0.13 in. (0.32 mm), then bend 90° to be
against solder pads.
(5) Apply soldering flux to wire ends, then solder to pads and terminal. Use 63/37 solder.
(6) Carefully bend the free end of wires parallel to boards.
(7) Apply conformal coating on solder joints. Let air‑dry for 24 hours.
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UNISON INDUSTRIES
B. Repair capacitor assembly (120) as follows.
(1) Repair damaged insulation as follows.
(a) Remove damaged insulation from bottom of capacitor. Clean RTV from
capacitor.
(b) Cut a 3.50 in. (88.9 mm) length of insulation, part number 10-90066-33.
(c) Apply four 0.13 in. (3.30 mm) dots of RTV adhesive to capacitor, then bond
insulation on RTV adhesive dots.
(d) Let air-cure for 24 hours minimum.
(2) Repair damaged insulation at ends of capacitor as follows.
(a) Cut a 1.88 in. (47.75 mm) length of insulation 10-90063-15. Bend the long side
90° to make a flange 0.44 in. (11.18 mm) in width.
(b) Cut a 2.0 in. (50.8 mm) length of tape 10-90016-15.
(c) Put insulation on capacitor as shown in IPL Figure 1 ( insulation is shown as

part of capacitor). Apply tape to hold insulation in position.
C. Repair inductor assembly (145) wires as follows.
(1) Remove sleeving from solder joint, apply soldering flux, then unsolder wires.
(2) Cut two 2.25 in (57.15 mm) lengths of 10-178946-2 white wire.
(3) Strip the two ends of each wire 0.25 in. (6.35 mm), and pretin one end of each wire.
Use 50/50 solder.
(4) Attach non-pretin end to inductor, apply soldering flux, and solder. Use 50/50 solder.
(5) Remove soldering flux with Flux-Off CZ Cleaning Solvent.
(6) Cut two 0.5 in. (12.7 mm) lengths of 10-90600-101 sleeving, and install sleeving on
solder joint.
D. Repair EMI board assembly (100) components as follows.
(1) Carefully remove conformal coating and RTV adhesive to gain access to solder points.
(2) Apply soldering flux and unsolder component leads from printed circuit board per
paragraph 2.G of DISASSEMBLY. Remove unsoldered component.
(3) Remove unwanted solder from the board. Refer to procedures in CLEANING.
(4) Assemble new EMI board assembly component to printed circuit board (IPL Fig 2, item
35) per paragraph 2.E of ASSEMBLY.
49-41-21
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Aug 31/18
UNISON INDUSTRIES
ASSEMBLY
Table 701
Equipment and Materials (Sheet 1 of 2)
EQUIPMENT USED FOR
Soldering Iron, 30 watt (locally available) Soldering operations
Soldering Iron, 200 watt (locally available) Used to solder bus wire (150)
Propane Torch (locally available) Soldering operations outside housing
Model 120/CDB Dryblast, Pencil Blaster Grit blast of chassis
Zebra 105 SL Barcode Printer Used to print barcode labels
Catalyzed Epoxy Primer Prime exciter surface for painting The Sherwin-Williams Company
E61 R C22 101 West Prospect Ave
Cleveland OH 44115
Polane T Polyurethane Enamel Paint used on exciter surface The Sherwin-Williams Company
F63TX-L0710-2241
Catalyst V66 V29 Catalyst for primer/paint The Sherwin-Williams Company

E61 R C22
Reducer #54 Reducer The Sherwin-Williams Company
DC3145 RTV Adhesive, Bond components to chassis Dow Corning Corp.

(no alternative permitted) Box 0994, Midland, MI 48686
Loctite, Grade 222 Screw lock compound Loctite Corp.

Newington, CT 06111
Flux‑Off CZ Cleaning Solvent General cleaning, and vapor Chemtronics.

degreaser cleaning Kennesaw, GA 30152
MIL-F-14256, Type R or Soldering aid within housing Locally available

RMA (liquid), Non‑Activated or
MIL-F-14256, Type RMA (paste), Soldering aid outside housing Locally available
QQ-S-571, Sn63 Solder Soldering operations Locally available

(63% tin, 37% lead)
49-41-21
Page 701
Aug 31/18
UNISON INDUSTRIES
Table 701
Equipment and Materials (Sheet 2 of 2)
QQ-S-571, Sn50 Solder Soldering operations Locally available

(50% tin, 50% lead)
QQ-S-571, Sb5 Solder Soldering chassis bus wire (150) Locally available
(95% tin, 5% antimony)
Thermalbond 4952 Thermal Epoxy Used on PCB (125, 125A) Thermalloy

heat sink Dallas TX 75234
DC 340 Heat Sink Compound Used on Mica Insulator (130) Dow Corning Corp.
50-100R White Paint Used to ink stamp The Dexter Corporation

B-3 Catalyst housing assembly (105) Dexter Electronics Materials
Industry CA 91746
A. All numbers in parentheses refer to IPL Figure 1 item numbers unless differently indicated.
C. All reference points refer to Figure 504 in CHECK.
D. Clean components before assembly. Use procedures in CLEANING.
E. Before soldering any items protected by conformal coating, remove coating from area to be
soldered by scraping. After soldering, clean solder area with cleaning solvent.
F. All solder must conform to requirements of Federal Specification QQ-S-571.
• Use Sb5 (95% tin, 5% antimony) solder for the bus wire (150) to chassis (140).
• Use Sn50 (50% tin, 50% lead) solder for the inductor (145) lead to output-connector pin, and
for ground wire connections to an exterior surface.
• Use Sn63 (63% tin, 37% lead) solder for all other electrical soldering operations
• For exterior structural joints/seams, use Sn50 (50% tin, 50% lead) solder.
G. Assembly steps are written for each component. For two components that are the same, do
again the assembly steps for the second component (inductor, capacitor, etc.).
H. Use this warning for all assembly steps that include heat. This includes soldering, hot water for
tests or flushing, heat shrinking of tubing, and drying/curing parts in an oven.
WARNING: HOT PARTS.

• WEAR APPROVED GLOVES WHEN YOU HANDLE HOT PARTS.
• HANDLING WITH BARE HANDS CAN CAUSE BLISTERING OR BURNS.
• IF SKIN IS BURNED, PUT IN COLD WATER FOR 10 MINUTES. GET MEDICAL
AID IMMEDIATELY IF PAIN CONTINUES, OR IF BLISTERS START.
Page 702
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UNISON INDUSTRIES
2. Assembly Procedures.

ELECTROSTATIC D
ISCHARGE.
WARNING: SOME OF THE MATERIALS USED IN THE ASSEMBLY OF THIS EXCITER MAY BE
TOXIC. USE IN AN AREA WITH A GOOD FLOW OF AIR. PREVENT CONTACT WITH
EYES AND SKIN AND DO NOT BREATHE FUMES. IN CASE OF EYE CONTACT,
FLUSH EYES WITH WATER AND GET MEDICAL HELP. IN CASE OF SKIN CONTACT,
CLEAN WITH SOAP AND WATER.
A. Assemble inductor assembly (145) to chassis and connector assembly (140). See Figure 701.
(1) Use masking tape to protect all surfaces adjacent to area where inductor will be bonded.
Install protective caps (5) on connectors.
145
Inductor Assembly Position

Figure 701

(2) Lightly grit‑blast the area where inductor will be bonded. Use only sufficient blasting to
make the surface rough.
(3) Remove masking tape and protective caps, then blow away all remaining grit with clean
compressed air.
49-41-21
Page 703
Aug 31/18
UNISON INDUSTRIES
(4) Clean the chassis and connector assembly in a vapor degreaser.
(5) Connect bottom wire of inductor (nearest to chassis base plate) to pin of output
connector, then solder. Use 50/50 solder. Make sure the inductor wire is not too long,
and does not have loops or kinks. (The other inductor wire is connected later.)
(6) Apply RTV adhesive to rear of inductor and bond to grit‑blasted area in position shown.
Let air‑cure for 24 hours minimum.
B. Assemble Chassis and Connector Assembly (140) as follows.
(1) Cut two 1.50 in. (38.0 mm) lengths of white bus wire (150) and strip the two ends of
each wire 0.25 in. (6.35 mm). Bend one end of each wire 90° into a L-shape 0.25 in.
(6.35 mm) long.
(2) Put one wire in each hole in chassis and connector assembly as shown in Figure 506
and IPL Figure 1. The wires are attached from opposite sides of the chassis, and extend
straight-out. The L‑shape stripped end is against the chassis.
(3) Apply soldering flux, then solder with a 200-watt soldering iron. Use 95/5 solder. (Other
end of each wire is later soldered to PCB module.)
(4) Cut two 2.50 in. (63.5 mm) lengths of tape (160), then put one piece on each side of
chassis divider-plate. The two pieces of tape must be directly opposite each other.
(5) Cut two 1.50 in. (38.0 mm) lengths of tape (155), then put one piece on each side of
chassis divider-plate. The two pieces of tape are staggered (not opposite each other).
Make sure each piece will be under the transformer of the PCB module, but not between
the heat sink and chassis.
(6) Install two grommets (135) into end‑plate of chassis as shown in IPL Figure 1.
C. Install PCB Module (125, 125A) and Mica Insulator (130) as follows.
CAUTION: DO THESE STEPS CONTINUOUSLY FOR ASSEMBLY OF MICA INSULATOR

(130), THERMAL EPOXY, THERMAL GREASE, AND PCB MODULE.
(1) Apply thermal epoxy to heat sink on bottom of innermost printed circuit board of
PCB module.
(2) Put mica insulator on the thermal epoxy.
(3) Apply a layer of heat sink compound to mica insulator.
(4) Carefully install PCB module on chassis and connector assembly. The red, white, and
black wires go through grommet (135) in chassis end-plate, and the bus wire (150) goes
through hole in innermost printed circuit board.
(5) Apply Loctite Grade 222 to threads of two screws (110B), then install screws in center
holes of PCB module and chassis and connector assembly. Torque screws 4 to 5 in.‑lbs
(0.056 to 0.067 N‑m).
Page 704
49-41-21 Aug 31/18
UNISON INDUSTRIES
(6) Put end of white bus wire through hole in outermost printed circuit board at Figure 506,
point 10, then solder.
(7) Attach remaining white wire from inductor (145) to terminal on outermost printed circuit
board at Figure 506, point 03. Make sure the inductor wire is not too long, and has no
loops or kinks. Do not solder at this time.
(8) Let thermal epoxy air‑cure for 24 hours.
D. Install Capacitor Assembly (120) and Bracket (115) onto PCB Module Assembly (125) as follows.
(1) Apply four 0.13 in. (3.18 mm) dots of RTV adhesive to bracket as shown in Figure 302
in DISASSEMBLY, then bond capacitor to bracket.
(2) Apply six 0.13 in. (3.18 mm) dots of RTV adhesive to outermost printed circuit board
of PCB module as shown in Figure 302 in DISASSEMBLY. Turn capacitor so that the
outside foil lead (indicated by a black dot) is pointed to input‑end of exciter, then bond
capacitor and bracket to PCB module.
(3) Apply Loctite Grade 222 to threads of four screws (110A), then use screws and lock-
washers (85) to secure capacitor and bracket to chassis and connector assembly (140).
Torque screws 4 to 5 in.‑lbs (0.056 to 0.067 N-m).
(4) Solder one capacitor wire and inductor (145) wire to terminal at Figure 506, point 03.
Solder other capacitor wire to terminal at Figure 506, point 04.
(5) Let RTV adhesive air‑cure for 24 hours.
E. Assemble EMI Board Assembly (100) as follows.
(1) Cut 6.0 in. (152.4 mm) lengths of black wire (IPL Fig 2, item 25) and red wire (IPL Fig
2, item 30) and put into holes labeled W2 and W1 respectively in printed circuit board
(IPL Fig 2, item 35). See Figure 504, points 12 and 13.
(2) Cut end of wires that comes through printed circuit board to 0.13 in. (0.32 mm), then
bend 90° to be against solder pads.
(3) Apply soldering flux to wire ends, then solder to pads. Use 63/37 solder.
(4) Bend capacitor (IPL Fig 2, item 5) leads 90° so that when capacitor is mounted at the
edge of the printed circuit board as shown in Figure 504, the leads can be inserted in
the holes.
(5) Cut end of leads that comes through printed circuit board to 0.13 in. (0.32 mm), then
(6) Apply soldering flux to lead ends, then solder to pads. Use 63/37 solder.
(7) Place coils (IPL Fig 2, items 10, 15) into location shown in Figure 504. Insert coil leads
through holes in the printed circuit board.
Page 705
49-41-21 Aug 31/18
UNISON INDUSTRIES
(10) Bend transzorb (IPL Fig 2, item 20) leads 90° so that when transzorb is mounted on
the printed circuit board as shown in Figure 505, the leads can be inserted in the holes.
(13) Attach and solder one end of 4.0 in. (101.6 mm) red wire (IPL Fig 1, item 50) to hole
labeled W6. See Figure 505.
(14) Attach and solder one end of 4.0 in. (101.6 mm) black wire (60) to hole labeled W7.
(15) Apply RTV adhesive between both coils and the printed circuit board, and between the
capacitor and both coils. Let RTV adhesive air‑cure for 24 hours.
NOTE: Make sure hole W6 is not blocked.
(16) Apply conformal coating on solder joints. Let air‑dry for 24 hours.
F. Assemble EMI Board Assembly (100) and Housing Assembly (105) to Chassis and Connector
Assembly (140) as follows. See Figure 702.
(1) Put chassis assembly into housing and against internal brackets of housing.
WHITE
RED BLACK
L
RN YE WH
T
G
RED
BLACK
RED
BLACK
Board Position and Routing of Wires

Figure 702
Page 706
49-41-21 Aug 31/18
UNISON INDUSTRIES
(2) Put EMI board into housing and against internal brackets of housing assembly. The six
wires of PCB module must go through holes in EMI board assembly.
(3) Connect and solder wires from PCB module as follows.

The two red wires to terminal W3 (Figure 504, point 08) of EMI board.
The two black wires to terminal W4 (Figure 504, point 09) of EMI board.
NOTE: White wire from PCB module and white wire from EMI board are soldered later
to diagnostic board (90).
(5) Assemble four 0.75 in. (19.05 mm) lengths of sleeving (95) onto the two red and two
black wires of EMI board.
G. Assemble Diagnostic Board (90) as follows. See Figure 702.
NOTE: Attach wires to Terminals W3, W4, W5, and W6 so that the direction of each wire is
away from edge of diagnostic board.
(1) Attach and solder one end of 6.0 in. (152.4 mm) yellow wire (65) to terminal W3.
(2) Attach and solder one end of 6.0 in. (152.4 mm) green wire (70) to terminal W4.
(3) Put diagnostic board on top of EMI board (100). The six wires must go through holes
in diagnostic board.
(4) Attach and solder wires to diagnostic board as follows.

One white wire to terminal W1, the other white wire to terminal W2.
Red wire to terminal W5 of diagnostic board (from terminal W6 of EMI board).
Black wire to terminal W6 of diagnostic board (from terminal W7 of EMI board).
NOTE: The remaining red and black wire from terminals W1 and W2 of EMI board are
later soldered to input connector (35).
(6) Install four spacers (91), screws (75A), lockwashers (85), and washers (80) to hold
the diagnostic board and EMI board to chassis. Torque screws 4 to 5 in.-lbs (0.056 to
0.067 N-m).
NOTE: Earlier exciters have four spacers that are attached to the four corners of
diagnostics board. Later exciters have removable spacers (91).
H. Assemble Input Connector (35) and Ground Wire (55) to Input Cover (30). Use 50/50 solder.
(1) Apply soldering flux to bottom of connector threads and around hole in cover.
(2) Assemble connector to cover with nut. The master keyway of connector must be in the
9-o'clock position ± 10°. See Figure 101 in TESTING AND FAULT ISOLATION.
(3) Apply soldering flux around joint at inside and outside of nut, then solder with a low-
temperature flame. Use 50/50 solder.
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UNISON INDUSTRIES
(4) Put white wire through hole in cover, then solder wire to outside of cover. Apply heat
to outside of cover with soldering iron. Use 50/50 solder.
I. Connect and solder wires to input connector (35) as follows.
(1) Put a 0.5 in. (12.7 mm) length of sleeving (45) over each of these four wires: yellow,
green, red, and black (no sleeving on white wire).
(2) Put a 1.5 in. (38.1 mm) length of sleeving (40) over the group of four wires with sleeving.
NOTE: Temporarily move all the sleeving down the wires to get access.
(3) Apply soldering flux to rear of connector pins, then solder wires as follows.
• Red wire from EMI board to connector pin 1

• Black wire from EMI board to connector pin 2
• Green wire (70) from diagnostic board to connector pin 3
• Yellow wire (65) from diagnostic board to connector pin 4
• White ground wire (55) to connector pin 5.
(4) Remove soldering flux using cleaning solvent.
(5) Put the four pieces of sleeving on connector pins, then put the larger sleeving on the
four smaller pieces of sleeving.
(6) Install input cover on housing. As you install the cover, turn it so that the four wires stay
in a smooth circular curve on top of diagnostics board. Also make sure the four wires
are kept away from wall of housing.
J. Do all the electrical tests in TESTING AND FAULT ISOLATION except environmental stress
test.
K. Solder input cover (30) and chassis and connector assembly (140) to housing assembly (105)
as follows. Use 50/50 solder.
(1) Put heat sink (see Figure 301) on input connector, then tighten by hand.
CAUTION: APPLY HEAT ONLY TO EDGES. WORK QUICKLY, TOO MUCH HEAT CAN
BURN OFF PLATING OR CAUSE DAMAGE TO INTERNAL COMPONENTS.
(2) Apply soldering flux to joints at the two ends of housing, then solder with a low-
temperature flame. Use 50/50 solder. Remove heat sink.
L. Do the hot‑water leak test in TESTING AND FAULT ISOLATION.
3. Final Assembly Procedures.
A. Paint Procedures.
NOTE: 9048700-9 Revision F exciters are manufactured without paint. Painting is not required,
but the unit may be painted as an option.
(1) Fully clean surfaces of exciter with cleaning solvent.

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UNISON INDUSTRIES
(2) Clean exciter in vapor degreaser containing Flux‑Off CZ or equivalent. It is best if exciter
is painted immediately after it is cleaned.
(3) Put masking tape on threads of input and output connectors, and install protective caps
(5, 10) on input and output connectors. Put a square piece of masking tape, 0.5 in.
x 0.5 in. (12.7 mm x 12.7 mm), on four mounting pads on top surface of mounting plate.
Put masking tape on all of bottom surface of mounting plate.
(4) Follow manufacturer's instructions and apply one coat of catalyzed epoxy primer,
thinned to proper spraying consistency with Reducer #54, and allow to air dry for one
hour minimum.
NOTE: Primer may be forced dried in an oven at 140°F (60°C) for 30 minutes.
(5) Follow manufacturer's instructions and apply uniform coat of Blue Enamel and allow to
air dry for 10 to 30 minutes.
(6) Apply a second coat of Blue Enamel and allow to air dry for one hour at room temperature.
NOTE: Enamel may be forced dried in an oven at 200°F (93°C) for 30 minutes.
(7) Allow coating to air cure at room temperature for 12 hours minimum.
(8) Remove masking tape.
B. Assemble Identification Plate (25), Input Label (15), Warning Label (20), and Barcode Label
(27) as follows.
(1) Stamp a new identification plate with data from old plate. Also stamp the "REPAIR
STATION NUMBER" in the space provided.
NOTE: A Yellow replacement plate must be used to show a field repair and the repair
station that last did repairs. Does not apply to Unison factory repair.
(2) Put plate in nameplate bracket on cover (30) then bend (crimp) over tabs.
(3) 9048700-9 Only: Use a barcode printer to put information from old barcode label onto
new label. See Figure 703.
0.08 IN.
Letters
(2.0 MM)
Spacing 0.04 IN.

(1.0 MM)
Barcode 0.20 IN.

Size (5.0 MM)
MFR 59501
SER YY02180XXXXX
Spacing 0.16 IN.
(4.0 MM)
PNR 99193-3876195-9
Barcode Label Printing

Figure 703
Page 709
49-41-21 Aug 31/18
UNISON INDUSTRIES
(4) Attach input label, warning label, and barcode label as follows.
(a) Clean surface of exciter where labels will go and let dry.
(b) Carefully remove backing paper and put each label in position as shown in
IPL Figure 1. Start at one end and apply thumb pressure evenly across label and
rub until firmly attached. Make sure all air bubbles and wrinkles are smoothed
out.
(c) Carefully remove clear overlaminate (26) from liner and place over barcode
label. There must be 0.25 in. (6.35 mm) overlap on all sides.
C. Ink stamp ignition exciter as follows:
NOTE: This procedure is used for new housing assemblies or for used housings with worn ink.
(1) Clean surface of exciter to be marked with a clean, lint-free cloth or soft-bristled brush
moist with cleaning solvent. Do not touch surface after it has been cleaned.
(2) Follow the directions supplied with the ink to mix catalyst and ink. Roll a thin film of ink
on glass or metal plate.
(3) Mark the exciter with “A” and “B” in approximate locations shown in Figure 704. Use
a rubber, neoprene, or urethane stamp. Letters must be approximately 0.25 in. (6.35
mm) high.
A B
Ink Stamp Housing Assembly

Figure 704
4. Storage Instructions.
A. Sealed exciters – usual storage is satisfactory. Packaged storage is recommended.
B. Exciter that is not sealed, or a capacitor assembly – keep in an airtight container that has
sufficient desiccant to keep relative humidity at 30% or less.
C. Before an exciter is used that has been in storage for one year or more, do all the electrical tests
in TESTING AND FAULT ISOLATION to make sure of satisfactory operation.
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UNISON INDUSTRIES
SPECIAL TOOLS, FIXTURES, AND EQUIPMENT
1. General.
A. Special tools, fixtures, and equipment are shown in Table 901.
B. Items 1 thru 11 are made by Unison Industries. For more information, refer to Table 101 in
TESTING & FAULT ISOLATION and Table 501 in CHECK.
Table 901
Special Tools, Fixtures, and Equipment (Sheet 1 of 2)
ITEM PART NUMBER NAME OF ITEM / AVAILABLE FROM USED FOR / (Section)
1 11-10803 Input Test Adapter TESTING & FAULT ISOLATION,
2 11-10873 Burn-in Fixture TESTING & FAULT ISOLATION
3 11-10842 Input Lead (included with 11-20300) TESTING & FAULT ISOLATION,
CHECK
4 11-20200 Multiload Module TESTING & FAULT ISOLATION
5 11-20220 LOW TENSION PLUG Load Panel TESTING & FAULT ISOLATION
(2 necessary)
6 11-20235 OPEN LOAD Load Panel TESTING & FAULT ISOLATION
7 11-20238 31 K-OHM Load Panel TESTING & FAULT ISOLATION
8 11-20300 Power Module TESTING & FAULT ISOLATION,

CHECK
9 11-20400 Components Test Module CHECK
10 11-20426 Capacitor Fixture CHECK
11 11-20501 Output Lead (2 necessary) TESTING & FAULT ISOLATION

-------------------------------------------------------------------------------------------------------------------------------------
NOTE: Equivalent alternative equipment can be used for the items that follow.
12 TDS360 Oscilloscope TESTING & FAULT ISOLATION,

Tektronix CHECK
Beaverton OR 97077
13 P6015A High‑Voltage Probe, 1000X TESTING & FAULT ISOLATION,

Tektronix CHECK
14 GR1657 RLC Digibridge Analyzer CHECK

Quad‑Tech
Bolton MA 01740
49-41-21
Page 901
Aug 31/18
UNISON INDUSTRIES
Table 901
Special Tools, Fixtures, and Equipment (Sheet 2 of 2)
ITEM PART NUMBER NAME OF ITEM / AVAILABLE FROM USED FOR / (Section)
15 Model 77 Multimeter TESTING & FAULT ISOLATION,

John Fluke Mfg. Co. CHECK
Everett WA 98206
16 Model 1864 Megohmmeter CHECK

Quad‑Tech
17 Model 120/CDB Dryblast Pencil Blaster ASSEMBLY

Trinco Tool Co.
Fraser MI 48026
18 Locally available Soldering Iron, 30 watt DISASSEMBLY, CHECK

ASSEMBLY
19 Locally available Soldering Iron, 200 watt DISASSEMBLY, ASSEMBLY
20 Locally available Propane Torch DISASSEMBLY, CLEANING,

ASSEMBLY
21 Zebra 105 SL Barcode Printer ASSEMBLY

Zebra Technologies International, LLC
International Headquarters
High-Performance & Mid-Range Center of Excellence
333 Corporate Woods Parkway
Vernon Hills Il 60061-3109
Page 902
49-41-21 Aug 31/18
UNISON INDUSTRIES
ILLUSTRATED PARTS LIST
1. General.
A. The Illustrated Parts List describes the parts for the Ignition Exciter, manufactured by Unison
Industries, Jacksonville, FL.
B. The parts are listed in disassembly order. Each assembly is listed, followed by its component
parts indented thereunder to show their relationship to the assembly. Component parts which are
not included in any subassembly, but are used in conjunction with or attached to a subassembly
are listed either preceding the first detail of the subassembly or in line with the main assembly.
C. Federal Supply Code for manufacturers, names and addresses is not applicable to this manual.
2. Detailed Parts List.
49-41-21
Page 1001
Aug 31/18
UNISON INDUSTRIES
160
110B 155
120
5
110A
85
140
115
125, 125A
130 150
25
20
135 145
105
27
26
80 50
85
75A
60
70 100
95
40
45
35
91
65 90
30
35
10 55
15
Ignition Exciter
IPL Figure 1
Page 1002
49-41-21 Aug 31/18
UNISON INDUSTRIES
FIG 1, PART AIRLINE 1234567 EFF UNITS

ITEM NUMBER PART NO. NOMENCLATURE CODE PER ASSY
–1 9048700-7 EXCITER, Ignition A RF
–1A 9048700-8 EXCITER, Ignition B RF
–1B 9048700-9 EXCITER, Ignition C RF
5 10-342216-10 . CAP, Protective 2
10 10-70557-11 . Cap, Protective 1
15 9048902 . LABEL, Input 1
20 9047843 . LABEL, Warning 1
25 10-70625-92 . PLATE, Identification 1
26 500497 . OVERLAMINATE, Clear C 1
27 500496 . LABEL, Adhesive (Barcode) C 1
30 9048773 . COVER, Input 1
35 9051005 . CONNECTOR, Input 1
40 10-83832-4 . SLEEVING AR
45 10-90600-131 . SLEEVING AR
50 10-177146-2 . WIRE, 20 AWG, Red AR
55 10-177146-9 . WIRE, 20 AWG, White AR
60 10-177146-B . WIRE, 20 AWG, Black AR
65 10-157921-4 . WIRE, 22 AWG, Yellow AR
70 10-157921-5 . WIRE, 22 AWG, Green AR
–75 9047857-8 . SCREW, Pan head 4

REPL by item 75A
75A MS51957-20 . SCREW, Pan head 4

REPLS item 75
80 10-92835-803 . WASHER, Flat 4
85 MS35338-135 . WASHER, Lock 12
( – ) Item Not Illustrated
Page 1003
49-41-21 Aug 31/18
UNISON INDUSTRIES

90 9053022 . DIAGNOSTIC Board Assembly 1
91 9047893-G24 . SPACER B, C 4
95 10-83832-9 . SLEEVING AR
100 9049441 . EMI Board Assembly 1

(See IPL Figure 2)
105 9049536 . HOUSING Assembly 1
–110 9047857-9 . SCREW, Pan Head 12

REPL by items 110A, 110B
110A MS51957-21 . SCREW, Pan Head 8

REPLS item 110
110B 9053789 . SCREW, Pan Head 4

REPLS item 110
115 9049427 . BRACKET, Module 2
120 9049481 . CAPACITOR Assembly 2
125 9048829 . MODULE, PCB Assembly A, B 2
125A 500477 . MODULE, PCB Assembly C 2
130 9047983 . INSULATOR, Mica 2
135 10-80436 . GROMMET, Silicone Rubber 2
140 9048823 . CHASSIS & Connector Assembly 1
145 9049594 . . INDUCTOR Assembly 2
150 10-163539-9 . . WIRE, Bus, 18 AWG, White AR
155 10-90182-19 . . TAPE, Insulation AR
160 10-90182-28 . . TAPE, Insulation AR
( – ) Item Not Illustrated
Page 1004
49-41-21 Aug 31/18
UNISON INDUSTRIES
10
15
20
25 35
30
Ignition Exciter
IPL Figure 2

–1 9049441 EMI Board Assembly RF
5 9047832 . CAPACITOR 1
10 9049404 . COIL 1
15 9049403 . COIL 1
20 ETSB01A75Z0 . TRANSZORB 1
25 10-157921-B . WIRE, 22 AWG, Black AR
30 10-157921-2 . WIRE, 22 AWG, Red AR
35 9053007-1 . CIRCUIT Board, Printed 1
Page 1005/1006
49-41-21 Aug 31/18
UNISON INDUSTRIES
Printed in U.S.A. Jacksonville, FL 32256

JP00590 5

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COMPONENT MAINTENANCE MANUAL

Printed in U.S.A. © 2018 Unison Industries, LLC, U.S.A. JP00590-5

Subj: Revision Number 5, dated Aug 31/18.

1. All pages of this manual are new.

Page Number Change

303 Added NOTE to paragraph 2.B.

708 Added NOTE to paragraph 3.A.

49-41-21 Page 1/2

REV DATE DATE REV DATE DATE

Basic Feb 28/93 --- ---

1 May 31/96 --- ---

2 Jan 31/05 --- ---

3 Jun 30/15 --- ---

4 Mar 31/16 --- ---

RECORD OF TEMPORARY REVISIONS

Record of Temporary Revisions

SERVICE BULLETIN LIST

These Service Bulletins are applicable to this manual.

Service Date Service Date

9048700-49-16 May 31/96

9048700-49-17 Jan 31/05

Service Bulletin List

49-41-21 Page 1/2

LIST OF EFFECTIVE PAGES

Subject Page Date

Title Page --- Aug 31/18

Highlights 1 Aug 31/18

Record of Revisions 1/2 Aug 31/18

Record of Temporary Revisions 1/2 Aug 31/18

Service Bulletin List 1/2 Aug 31/18

List of Effective Pages 1 Aug 31/18

Table of Contents 1/2 Aug 31/18

Introduction 1 Aug 31/18

Description and Operation 1 Aug 31/18

Testing and Fault Isolation 101 Aug 31/18

Disassembly 301 Aug 31/18

Cleaning 401 Aug 31/18

List of Effective Pages

LIST OF EFFECTIVE PAGES (Continued)

Subject Page Date

Check 501 Aug 31/18

Repair 601 Aug 31/18

Assembly 701 Aug 31/18

Special Tools, Fixtures and Equipment 901 Aug 31/18

Illustrated Parts List 1001 Aug 31/18

List of Effective Pages

Description and Operation 1

Testing and Fault Isolation 101

Automatic Test Requirements (section #200) N/A

Fits and Clearances (section #800) N/A

Special Tools, Fixtures and Equipment 901

Illustrated Parts List 1001

WARNING: IMPROPER OR UNAUTHORIZED APPLICATIONS OF INFORMATION CONTAINED

When performing installation, maintenance, replacement, adjustment, inspection, or overhaul of any

ABBREVIATION DEFINITION ABBREVIATION DEFINITION

AMP ampere ms millisecond

DESCRIPTION AND OPERATION

2. Description (See Figure 1).

Ignition Exciter P/N 9048700‑7, -8, -9

3. Table of Exciter Characteristics.

NUMBER OF PLUGS FIRED Two

4. Theory of Operation (See Figure 2).