Aei Fmeca Example

Proprietary and Confidential
FMECA Analysis
FMECA ANALYSIS
Battery Charger board

Final Report
PREPARED FOR
xxx
PREPARED BY
AEi Systems, LLC

5933 W. Century Blvd. Suite 1100
Los Angeles CA 90045
September 27, 2006
Portions of this document may be proprietary to

AEi Systems, LLC
Revision Date: 9/27/06
FMECA Analysis
1.0
Failure Modes, Effects, and Criticality Analysis (FMECA)
1.1
Scope
This document contains the failure modes, effects, and criticality for all parts on the Battery
Charger (Board xxx-1). This FMECA analysis consists of an outlining of all possible Failure
Modes of all elements, and then a determination of the Effects and Criticality of these failure
modes.
Analysis:
FMECA Analysis
9/27/06
Last Rev Date:
Board 335BC102-1
Assembly:
Subassemblies
Excel File:
FMECA Modes List.xls, FMECA_Criticality_Risks.xls
Report Files:
FMECA_Criticality.doc, Fmcea.doc
Relex File
1.2
(71C_FMECA.RPJ
Assumptions
The following assumptions were made in order to complete this analysis.
In situations where there are several failure results for one component failure mode, the most
severe failure mode was documented in the analysis.
Single component failures only were investigated. If the single component failure would
cause another component to fail, this was taken into account. Otherwise, each component is
considered as failing individually and not simultaneously with any other component.
MIL-STD-1629A and Mil-Handbook-217 were used as the basis for the definition of the
FMECA and component failure modes.
1.3
FMECA Analysis
Analysis Results
Potential failure mode(s) for each part are listed in Excel and analyzed for local and higher level
effects on the board and finally to the system. Tables are ranked according to the influence of
severity and probability of occurrence. Severity is defined as the consequences of a failure as a
result of a particular failure mode. Severity considers the worst potential consequence of a
failure, determined by the degree of injury, property damage, or system damage that could
ultimately occur. The severity of the failure mode is defined in
Table 1.3-1.
This classification is assigned to provide a qualitative measure of the worst potential

consequences resulting from design error or item failure. Classifications are assigned to each
identified failure mode and each item analyzed in accordance with the loss statements below. It
may not be possible to identify an item or a failure mode according to the loss statements in the
four categories, but similar loss statements based on various inputs and outputs can be developed
and included in the ground rules for the FMECA activity. Severity classification categories that
are consistent with MIL-STD-882 are defined as follows:
Table 1.3-1: Severity Type Description

Severity
Description
I. Catastrophic
A failure which may cause converter and system loss
II. Critical
A failure which may cause converter loss
III. Marginal
A failure which may cause degraded converter performance,

reduced converter reliability, or reduced converter lifetime.
IV. Minor
A failure not serious enough to significantly affect the system

or the converter performance.
Mode Criticality
FMECA Analysis
Mode criticality is one of the more quantified methods used to analyze criticality. Mode
criticality is a numerical value that can be calculated and applied to each failure mode. Mode
criticalities are based on the FMECA approach defined in MIL-STD-1629. The mode criticalities
are based on actual failure rate values. Initially, the failure rate of a component is established,
then, a mode percentage is assigned to each possible failure mode of the component. For
example, if a component has two failure modes, one occurring 75% of the time, and the other
occurring 25% of the time. Using this information, a mode failure rate can be calculated by
multiplying the component failure rate by the mode percentage. The analyst must also assess the
failure effect probability, or the probability that the given failure effect is likely to occur. The
equation for mode criticality is therefore given by:
Mode Criticality = Failure Effect Probability * Mode Failure Rate * Operating Time of the System
The criticality for each item is obtained by summing the criticalities for each failure mode that
have been identified for each item.
The results of all mode criticalities are reported in FMECA_Criticality_Risks.xls.
Risk Level
Risk Level analysis allows failure modes to be grouped into established categories to ensure that
the most critical items are evaluated. A graphical representation is used, where the x axis is a
specified risk value such as severity. The y axis is a secondary risk factor such as occurrence.
The graph is broken into three distinct areas by lines that intersect both axes. By graphing each
failure mode, they will fall into one of the three graph areas: high, medium, or low (risks).
The analytical results of the FMECA analysis are shown in Table 1.3-2 and 1.3-3, as well as the
following figures. For added usefulness, the results of Table 1.3-2 were sorted by criticality and
reprinted in Table 1.3-3.
FMECA Analysis
Table 1.3-2: FMECA Analysis Results

Record
#
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
Ref.
Des.
C100
C100
C101
C101
C102
C102
C103
C103
C104
C104
C105
C105
C106
C106
C107
C107
C108
C108
C109
C109
C110
C110
C111
C111
C112
C112
C113
C113
C114
C114
C115
C115
C116
C116
Description
Part Type
Part #
235BC831,2200pf,1000V
235BC831,2200pf,1000V
235BC831,2200pf,1000V
235BC831,2200pf,1000V
235BC831,2200pf,1000V
235BC831,2200pf,1000V
M39014/02-1310,.1uf,100V,10%
M39014/02-1310,.1uf,100V,10%
M39014/02-1310,.1uf,100V,10%
M39014/02-1310,.1uf,100V,10%
M39014/02-1310,.1uf,100V,10%
M39014/02-1310,.1uf,100V,10%
M39014/02-1310,.1uf,100V,10%
M39014/02-1310,.1uf,100V,10%
M39014/02-1310,.1uf,100V,10%
M39014/02-1310,.1uf,100V,10%
M39014/02-1310,.1uf,100V,10%
M39014/02-1310,.1uf,100V,10%
M39014/02-1310,.1uf,100V,10%
M39014/02-1310,.1uf,100V,10%
M39014/02-1310,.1uf,100V,10%
M39014/02-1310,.1uf,100V,10%
M39014/02-1310,.1uf,100V,10%
M39014/02-1310,.1uf,100V,10%
M39014/02-1310,.1uf,100V,10%
M39014/02-1310,.1uf,100V,10%
M39014/02-1310,.1uf,100V,10%
M39014/02-1310,.1uf,100V,10%
M39014/02-1310,.1uf,100V,10%
M39014/02-1310,.1uf,100V,10%
M39014/02-1310,.1uf,100V,10%
M39014/02-1310,.1uf,100V,10%
M39014/02-1310,.1uf,100V,10%
M39014/02-1310,.1uf,100V,10%
Capacitor
Capacitor
Capacitor
Capacitor
Capacitor
Capacitor
Capacitor
Capacitor
Capacitor
Capacitor
Capacitor
Capacitor
Capacitor
Capacitor
Capacitor
Capacitor
Capacitor
Capacitor
Capacitor
Capacitor
Capacitor
Capacitor
Capacitor
Capacitor
Capacitor
Capacitor
Capacitor
Capacitor
Capacitor
Capacitor
Capacitor
Capacitor
Capacitor
Capacitor
235BC831-1B
235BC831-1B
235BC831-1B
235BC831-1B
235BC831-1B
235BC831-1B
M39014/02-1310
M39014/02-1310
M39014/02-1310
M39014/02-1310
M39014/02-1310
M39014/02-1310
M39014/02-1310
M39014/02-1310
M39014/02-1310
M39014/02-1310
M39014/02-1310
M39014/02-1310
M39014/02-1310
M39014/02-1310
M39014/02-1310
M39014/02-1310
M39014/02-1310
M39014/02-1310
M39014/02-1310
M39014/02-1310
M39014/02-1310
M39014/02-1310
M39014/02-1310
M39014/02-1310
M39014/02-1310
M39014/02-1310
M39014/02-1310
M39014/02-1310
Failure
Mode
open
shorted
open
shorted
open
shorted
open
shorted
open
shorted
open
shorted
open
shorted
open
shorted
open
shorted
open
shorted
open
shorted
open
shorted
open
shorted
open
shorted
open
shorted
open
shorted
open
shorted
Local Effect
Next Higher Effect
End Effect
Severity
Increase in EMI
Increase in EMI
Increase in EMI
Increase in EMI
Increase in EMI
Increase in EMI
Increase in EMI
Increase in EMI
Increase in EMI
Increase in EMI
Increase in EMI
Increase in EMI
Increase in EMI
Increase in EMI
Increase in EMI
Increase in EMI
Increase in EMI
Increase in EMI
Increase in EMI
Increase in EMI
Increase in EMI
Increase in EMI
Increase in EMI
Increase in EMI
Increase in EMI
Increase in EMI
Increase in EMI
Increase in EMI
Increase in EMI
Increase in EMI
Increase in EMI
Increase in EMI
Increase in EMI
Increase in EMI
Mil-Std 461
Mil-Std 461
Mil-Std 461
Mil-Std 461
Mil-Std 461
Mil-Std 461
Mil-Std 461
Mil-Std 461
Mil-Std 461
Mil-Std 461
Mil-Std 461
Mil-Std 461
Mil-Std 461
Mil-Std 461
Mil-Std 461
Mil-Std 461
Mil-Std 461
Mil-Std 461
Mil-Std 461
Mil-Std 461
Mil-Std 461
Mil-Std 461
Mil-Std 461
Mil-Std 461
Mil-Std 461
Mil-Std 461
Mil-Std 461
Mil-Std 461
Mil-Std 461
Mil-Std 461
Mil-Std 461
Mil-Std 461
Mil-Std 461
Mil-Std 461
Increased EMI
Increased EMI
Increased EMI
Increased EMI
Increased EMI
Increased EMI
Increased EMI
Increased EMI
Increased EMI
Increased EMI
Increased EMI
Increased EMI
Increased EMI
Increased EMI
Increased EMI
Increased EMI
Increased EMI
Increased EMI
Increased EMI
Increased EMI
Increased EMI
Increased EMI
Increased EMI
Increased EMI
Increased EMI
Increased EMI
Increased EMI
Increased EMI
Increased EMI
Increased EMI
Increased EMI
Increased EMI
Increased EMI
Increased EMI
Minor
Minor
Minor
Minor
Minor
Minor
Minor
Minor
Minor
Minor
Minor
Minor
Minor
Minor
Minor
Minor
Minor
Minor
Minor
Minor
Minor
Minor
Minor
Minor
Minor
Minor
Minor
Minor
Minor
Minor
Minor
Minor
Minor
Minor

Record Ref.
#
Des.
35
C117
36
C117
FMECA Analysis
Description
Part Type
Part #
M39014/02-1310,.1uf,100V,10%
M39014/02-1310,.1uf,100V,10%
Capacitor
Capacitor
M39014/02-1310
M39014/02-1310
Failure
Mode
open
shorted
Local Effect
Next Higher Effect
End Effect
Severity
Increase in EMI
Increase in EMI
Loss of EMI
Filtering
Mil-Std 461
Mil-Std 461
Increased EMI
Increased EMI
Loss of EMI
Filtering
Minor
Minor
37
C122
M39014/02-1310,.1uf,100V,10%
Capacitor
M39014/02-1310
open
38
C122
M39014/02-1310,.1uf,100V,10%
Capacitor
M39014/02-1310
shorted
Loss of EMI
Filtering
39
40
C214
C214
M39014/02-1310,.1uf,100V,10%
M39014/02-1310,.1uf,100V,10%
Capacitor
Capacitor
M39014/02-1310
M39014/02-1310
open
shorted
Increased EMI
Increased EMI
41
C403
M39014/02-1310,.1uf,100V,10%
Capacitor
M39014/02-1310
open
42
C403
M39014/02-1310,.1uf,100V,10%
Capacitor
M39014/02-1310
shorted
43
C239
M39014/02-1310,.1uf,100V,10%
Capacitor
M39014/02-1310
open
44
C239
M39014/02-1310,.1uf,100V,10%
Capacitor
M39014/02-1310
shorted
45
C240
M39014/02-1310,.1uf,100V,10%
Capacitor
M39014/02-1310
open
46
C240
M39014/02-1310,.1uf,100V,10%
Capacitor
M39014/02-1310
shorted
47
C309
M39014/02-1310,.1uf,100V,10%
Capacitor
M39014/02-1310
open
48
C309
M39014/02-1310,.1uf,100V,10%
Capacitor
M39014/02-1310
shorted
49
C312
M39014/02-1310,.1uf,100V,10%
Capacitor
M39014/02-1310
open
Will put excessive

power in R104,
R104 will burn open
Loss of EMI
Filtering
Minor
Increased EMI
Increased EMI
Minor
Minor
Erratic operation of
Increased
Charger will not
U401, possible
Noise on VCC
operate
destruction of Q402,
for U401
Q403,
Charger will not
Loss of Driver
operate
Charger may
Increased
operate
noise on inhibit
U205
erratically
line
Charger will
never turn off,
Inhibit function
battery will be
disabled
overcharged
Increased
noise on the
False low battery
low battery
fault flickering
fault line
Low battery
Low battery fault
always on
fault always on
Possible
premature switch
Increased
into topping
Ripple on +10V
mode
Temperature
circuits will not
operate, charger
Loss of 10V
Loss of +10V
Reference Voltage may remain in
main mode
charge
Increased
Possible false
Minor
Marginal
Marginal
Marginal
Marginal
Minor
Minor
Marginal
Marginal
Minor

Record Ref.
#
Des.
Description
Part Type
FMECA Analysis
Failure
Mode
Part #
50
C312
M39014/02-1310,.1uf,100V,10%
Capacitor
M39014/02-1310
shorted
51
C315
M39014/02-1310,.1uf,100V,10%
Capacitor
M39014/02-1310
open
52
C315
M39014/02-1310,.1uf,100V,10%
Capacitor
M39014/02-1310
shorted
53
C321
M39014/02-1310,.1uf,100V,10%
Capacitor
M39014/02-1310
open
54
C321
M39014/02-1310,.1uf,100V,10%
Capacitor
M39014/02-1310
shorted
55
C313
M39014/02-1310,.1uf,100V,10%
Capacitor
M39014/02-1310
open
56
C313
M39014/02-1310,.1uf,100V,10%
Capacitor
M39014/02-1310
shorted
57
C307
M39014/02-1310,.1uf,100V,10%
Capacitor
M39014/02-1310
open
58
C307
M39014/02-1310,.1uf,100V,10%
Capacitor
M39014/02-1310
shorted
59
C118
CK61AW222M,2200pf,500V,20%
Capacitor
CK61AW222M
open
60
C118
CK61AW222M,2200pf,500V,20%
Capacitor
CK61AW222M
shorted
Local Effect
Next Higher Effect
End Effect
Severity
noise on fault
triggering of the
line
fault indicator
Gate of Q300
All fault signals
shorted to
Minor
will be disabled
ground
Clock input to
Battery may not
Charger Topping
U305 will not
receive a full Marginal
timer circuit not
function
charge
functioning properly
properly
Charger will
remain in topping
Clock input to
mode, battery Marginal
U305 will not
will be
function
overcharged
Possible false
Increased
Increased noise on
triggering of the Minor
noise on the
the fault output
fault indicator
drain of Q300
Fault output will
drain of Q300
always register a Minor
grounded
fault
Increased
Possible false
False triggering of
noise on
triggering of the Minor
the fault output
Battery tap
fault indicator
fault output
Battery tap
fault output
Battery tap fault
Minor
will not register
shorted to
ground
May come out of
Noise will get
main mode
Minor
into the temp
charge
circuit
prematurely
The charger will
U302A has the
Battery will be
remain in main
Marginal
input shorted to
overcharged
mode
ground
Loss of EMI
Loss of EMI
Filtering,
Minor
Filtering
Increased EMI
Loss of EMI Excessive power in
Loss of EMI
Minor

Record Ref.
#
Des.
Description
Part Type
FMECA Analysis
Failure
Mode
Part #
Local Effect
Next Higher Effect
End Effect
Filtering
R100, R100 will

open
Filtering,
Increased EMI
Loss of EMI
Filtering,
Increased EMI
Loss of EMI
Filtering,
Increased EMI
Loss of EMI
Filtering,
Increased EMI
Loss of EMI
Filtering,
Increased EMI
Loss of EMI
Filtering,
Increased EMI
61
C119
CK61AW222M,2200pf,500V,20%
Capacitor
CK61AW222M
open
Loss of EMI
Filtering
62
C119
CK61AW222M,2200pf,500V,20%
Capacitor
CK61AW222M
shorted
Loss of EMI
Filtering
63
C120
CK61AW222M,2200pf,500V,20%
Capacitor
CK61AW222M
open
Loss of EMI
Filtering
64
C120
CK61AW222M,2200pf,500V,20%
Capacitor
CK61AW222M
shorted
Loss of EMI
Filtering
65
C207
CK61AW222M,2200pf,500V,20%
Capacitor
CK61AW222M
open
Loss of EMI
Filtering
C207
CK61AW222M,2200pf,500V,20%
Capacitor
CK61AW222M
shorted
67
C208
CK61AW222M,2200pf,500V,20%
Capacitor
CK61AW222M
open
68
C208
CK61AW222M,2200pf,500V,20%
Capacitor
CK61AW222M
shorted
69
C266
CK61AW222M,2200pf,500V,20%
Capacitor
CK61AW222M
open
70
C266
CK61AW222M,2200pf,500V,20%
Capacitor
CK61AW222M
shorted
71
C121
M39014/01-1317,1000pf,200V,10%
Capacitor
M39014/01-1317
open
Loss of EMI
Filtering
72
C121
M39014/01-1317,1000pf,200V,10%
Capacitor
M39014/01-1317
shorted
Loss of EMI
Filtering
Excessive power in
R102, R102 will
open
Loss of Phase
B, phase B is
shorted to
chassis
Loss of EMI
Filtering
Loss of Phase
C, phase C is
shorted to the
chassis
Loss of EMI
Filtering
Loss of Phase
A, phase A is
shorted to
chassis
66
Excessive power in
R101, R101 will
open
Severity
Minor
Minor
Minor
Minor
Minor
Loss of Phase B,
aircraft circuit Marginal
breaker will trip
Loss of EMI
Filtering
Minor
Loss of Phase C,
aircraft circuit
breaker will trip
Minor
Loss of EMI
Filtering
Minor
Loss of Phase A,
aircraft circuit Marginal
breaker will trip
Will put excessive

power in R103,
R103 will burn open
Loss of EMI
Filtering,
Increased EMI
Loss of EMI
Filtering,
Increased EMI
Minor
Minor

Record Ref.
#
Des.
FMECA Analysis
Description
Part Type
Part #
Failure
Mode
Local Effect
Loss of PWM
Loss of Power
u203 switching transformer output
Loss of PWM
Loss of Power
Increase Noise
on input of
U301B
Reference on
U301B input is
grounded
Battery tap
fault timer may
not work
correctly
Battery tap
fault timer may
not work
correctly
73
C224
M39014/01-1317,1000pf,200V,10%
Capacitor
M39014/01-1317
open
74
C224
M39014/01-1317,1000pf,200V,10%
Capacitor
M39014/01-1317
shorted
75
C319
M39014/01-1317,1000pf,200V,10%
Capacitor
M39014/01-1317
open
76
C319
M39014/01-1317,1000pf,200V,10%
Capacitor
M39014/01-1317
shorted
77
C323
M39014/01-1317,1000pf,200V,10%
Capacitor
M39014/01-1317
open
78
C323
M39014/01-1317,1000pf,200V,10%
Capacitor
M39014/01-1317
shorted
79
C204
235BC815,.1uf, 600V,20%
Capacitor
235BC815-1B
open
Reduced EMI
filtering A-B
80
C204
235BC815,.1uf, 600V,20%
Capacitor
235BC815-1B
shorted
Reduced EMI
filtering A-B
81
C205
235BC815,.1uf, 600V,20%
Capacitor
235BC815-1B
open
Reduced EMI
filtering B-C
82
C205
235BC815,.1uf, 600V,20%
Capacitor
235BC815-1B
shorted
Reduced EMI
filtering B-C
83
C206
235BC815,.1uf, 600V,20%
Capacitor
235BC815-1B
open
Reduced EMI
filtering A-C
84
C206
235BC815,.1uf, 600V,20%
Capacitor
235BC815-1B
shorted
Reduced EMI
filtering A-C
85
C210
CFR06RNE473KP, .047uF, 400V, 1
Capacitor
CFR06RNE473KP
open
86
C210
CFR06RNE473KP, .047uF, 400V, 1
Capacitor
CFR06RNE473KP
shorted
Next Higher Effect
Loss of EMI
Filtering
Loss of EMI
End Effect
Severity
Charger will not

Marginal
operate
Charger will not
Marginal
operate
Possible false
heater blanket
Minor
fault
False heater
blanket over
Minor
temp fault
Battery tap fault
output may not
Minor
register the
failure
Battery tap fault
output may not
Minor
register the
failure
Reduced EMI
filtering A-B,
Minor
Increased EMI
Reduced EMI
Will put excessive
filtering A-B,
Minor
power in R204,
R204 will burn open Increased EMI
Reduced EMI
filtering B-C,
Minor
Increased EMI
Reduced EMI
Will put excessive
filtering B-C,
Minor
power in R205,
Reduced EMI
filtering A-C,
Minor
Increased EMI
Reduced EMI
Will put excessive
filtering A-C,
Minor
power in R206,
Loss of EMI
Minor
Filtering
capacitor would
Loss of EMI
Minor

Record Ref.
#
Des.
Description
Part Type
FMECA Analysis
Failure
Mode
Part #
87
C217
CFR06RNE473KP, .047uF, 400V, 2
Capacitor
CFR06RNE473KP
open
88
C217
CFR06RNE473KP, .047uF, 400V, 2
Capacitor
CFR06RNE473KP
shorted
89
C218
CFR06RNE473KP, .047uF, 400V, 3
Capacitor
CFR06RNE473KP
open
90
C218
CFR06RNE473KP, .047uF, 400V, 3
Capacitor
CFR06RNE473KP
shorted
91
C211
235BC834-1-, 68uF, 60V, 10%
Capacitor
235BC834-1-
open
92
C211
235BC834-1-, 68uF, 60V, 10%
Capacitor
235BC834-1-
shorted
93
C222
235BC834-1-, 68uF, 60V, 10%
Capacitor
235BC834-1-
open
94
C222
235BC834-1-, 68uF, 60V, 10%
Capacitor
235BC834-1-
shorted
95
C228
235BC834-1-, 68uF, 60V, 10%
Capacitor
235BC834-1-
open
96
C228
235BC834-1-, 68uF, 60V, 10%
Capacitor
235BC834-1-
shorted
97
C234
235BC834-1-, 68uF, 60V, 10%
Capacitor
235BC834-1-
open
98
C234
235BC834-1-, 68uF, 60V, 10%
Capacitor
235BC834-1-
shorted
99
C212
235BC833-1-, 150uF, 35V, 20%
Capacitor
235BC833-1-
open
100
C212
235BC833-1-, 150uF, 35V, 20%
Capacitor
235BC833-1-
shorted
10
Local Effect
Next Higher Effect
End Effect
Filtering
Loss of Bus
voltage filtering
Bus shorted to
chassis
Loss of Bus
voltage filtering
Bus shorted to
chassis
Reduced 24V
Filtering
quickly burn open
Filtering
Loss of 15V
Increased
noise on
current limit
circuit
Current limit
reference is
shifted
Severity
Increased EMI
Minor
Increased EMI
Minor
Increased EMI
Minor
Increased EMI
Minor
Reduced 15V
Minor
stability
Charger will not
Marginal
operate
Peak current
during charge is Marginal
erratic
Peak charging
current limit is
shifted
Minor
U401 and U400,
Increased
Charger will not
Marginal
possible destruction
noise on
operate
Mosfet Drivers of Q400, 401, 402,
403
Loss of Driver
Charger will not
Marginal
operate
signal
Increased EMI
Increased EMI
on charger
on charger
Minor
output
output
Increased EMI
Increased EMI
Capacitor will
on charger
Minor
on charger
quickly burn open
output
output
Reduced 12V
Reduced 12V
Minor
Filtering
Filtering
Temperature
circuits will not
Marginal
Loss of 12V
operate, charge
may remain in

Record Ref.
#
Des.
Description
Part Type
FMECA Analysis
Failure
Mode
Part #
Local Effect
101
C213 CKR05BX471KR,470pF,10%,200V,(R
Capacitor
CKR05BX471KR
open
Reduced 15V
stability
102
C213 CKR05BX471KR,470pF,10%,200V,(R
Capacitor
CKR05BX471KR
shorted
Loss of 15V
103
C215 U767D250VG47RM19X29LL,47uF,250 Capacitor U767D250VG47RM19X29LL
open
104
shorted
105
open
106
shorted
107
C219
M39014/02-1320,.47uf,50V,10%
Capacitor
M39014/02-1320
open
108
C219
M39014/02-1320,.47uf,50V,10%
Capacitor
M39014/02-1320
shorted
109
C311
M39014/02-1320,.47uf,50V,10%
Capacitor
M39014/02-1320
open
110
C311
M39014/02-1320,.47uf,50V,10%
Capacitor
M39014/02-1320
shorted
111
C401
CKR06BX473KM,.047uF,10%,100V,(
Capacitor
CKR06BX473KM
open
112
C401
CKR06BX473KM,.047uF,10%,100V,(
Capacitor
CKR06BX473KM
shorted
113
C225
CKR06BX473KM,.047uF,10%,100V,(
Capacitor
CKR06BX473KM
open
114
C225
CKR06BX473KM,.047uF,10%,100V,(
Capacitor
CKR06BX473KM
shorted
11
Increased
ripple on
170VDC BUSS
Increased
ripple on
170VDC BUSS
Increased
ripple on
170VDC BUSS
Increased
ripple on
170VDC BUSS
Reduced 15V
stability
Next Higher Effect
PWM can not

maintain control of
system
PWM can not
maintain control of
system
PWM can not
maintain control of
system
PWM can not
maintain control of
system
Loss of 15V
Increased
noise on fault
line
Gate of Q300
shorted to
ground
FET Drive
Reduced VS bus I/V
Signal Altered
Reduced VS bus V,
FET Drive
excessive current
Signal Altered
flow
PWM output
Loss of Power
signal does not
Transformer output
reach T203
Signal reaching
PWM output
MOSFET Drivers is
signal is altered
distorted
End Effect
main mode
charge
Reduced 15V
stability
Charger will not
operate
Charger
operates
erratically
Charger
operates
erratically
Charger
operates
erratically
Charger
operates
erratically
Reduced 15V
stability
Charger will not
operate
Possible false
triggering of the
fault indicator
Severity
Minor
Marginal
Marginal
Marginal
Marginal
Marginal
Minor
Marginal
Minor
All fault signals

will be disabled
Minor
reduced charger
efficiency
Minor
Charger may not

Marginal
operate
Charger will not
Marginal
operate
Charger may not
operate, or will Marginal
operate

Record Ref.
#
Des.
Description
Part Type
FMECA Analysis
Failure
Mode
Part #
115
C402
CKR06BX473KM,.047uF,10%,100V,(
Capacitor
CKR06BX473KM
open
116
C402
CKR06BX473KM,.047uF,10%,100V,(
Capacitor
CKR06BX473KM
shorted
117
C221
M39014/01-1522,.0018uf,100V,10
Capacitor
M39014/01-1522
open
118
C221
M39014/01-1522,.0018uf,100V,10
Capacitor
M39014/01-1522
shorted
119
C223
CKR06BX104KM,.1uF,10%,100V,(M)
Capacitor
CKR06BX104KM
open
120
C223
CKR06BX104KM,.1uF,10%,100V,(M)
Capacitor
CKR06BX104KM
shorted
121
C229
M39014/01-1529,4700pf,100V,10%
Capacitor
M39014/01-1529
open
122
C229
M39014/01-1529,4700pf,100V,10%
Capacitor
M39014/01-1529
shorted
123
C230
235BC835-1, 1200uF, 50V, 10%
Capacitor
235BC835-1
open
124
C230
235BC835-1, 1200uF, 50V, 10%
Capacitor
235BC835-1
shorted
125
C231
235BC835-1, 1200uF, 50V, 10%
Capacitor
235BC835-1
open
126
C231
235BC835-1, 1200uF, 50V, 10%
Capacitor
235BC835-1
shorted
12
Local Effect
Next Higher Effect
End Effect
erratically
reduced charger
FET Drive
Reduced VS bus I/V
Signal Altered
efficiency
Reduced VS bus V,
Charger may not
FET Drive
excessive current
operate
Signal Altered
flow
Increased
Increased noise
noise on
on charger
reference
output
Charger PWM
voltage
TL431 Anode
compensation is
Ref shorted
not working
PWM Charger
Charger may not
compensation
operate
is altered
PWM Charger
Charger may not
compensation
operate
is altered
Increased
Increased EMI
noise on
on charger
charger output
output
Increased
Increased EMI
noise on
on charger
charger output
output
Increased EMI
Increased EMI
on charger
on charger
output
output
Charger may not
operate, or
Charger output
Capacitor will
Increased EMI
shorted
quickly burn open
on charger
output
Increased EMI
Increased EMI
on charger
on charger
output
output
Charger may not
Charger output
Capacitor will
operate, or
shorted
quickly burn open
Increased EMI
Severity
Minor
Marginal
Minor
Marginal
Marginal
Marginal
Minor
Minor
Minor
Marginal
Minor
Marginal

Record Ref.
#
Des.
Description
Part Type
FMECA Analysis
Failure
Mode
Part #
Local Effect
Next Higher Effect
127
C232
M39014/02-1415,1uf,50V,10%
Capacitor
M39014/02-1415
open
Increased EMI
on charger
output
128
C232
M39014/02-1415,1uf,50V,10%
Capacitor
M39014/02-1415
shorted
Charger output
shorted
129
C233
M39014/02-1415,1uf,50V,10%
Capacitor
M39014/02-1415
open
130
C233
M39014/02-1415,1uf,50V,10%
Capacitor
M39014/02-1415
shorted
131
C235
M39014/02-1415,1uf,50V,10%
Capacitor
M39014/02-1415
open
132
C235
M39014/02-1415,1uf,50V,10%
Capacitor
M39014/02-1415
shorted
133
C236
M39014/02-1415,1uf,50V,10%
Capacitor
M39014/02-1415
open
134
C236
M39014/02-1415,1uf,50V,10%
Capacitor
M39014/02-1415
shorted
135
C302
M39014/02-1415,1uf,50V,10%
Capacitor
M39014/02-1415
open
Increased
noise on Temp
Sensor Voltage
False charger
temperature
functions
136
C302
M39014/02-1415,1uf,50V,10%
Capacitor
M39014/02-1415
shorted
Shifted sensor
voltage
Higher temp then

actual
137
C303
M39014/02-1415,1uf,50V,10%
Capacitor
M39014/02-1415
open
Increased
noise on Temp
Sensor Voltage
False charger
temperature
functions
138
C303
M39014/02-1415,1uf,50V,10%
Capacitor
M39014/02-1415
shorted
Shorted temp
False Hot battery
13
Increased EMI
on charger
output
Increased EMI
on charger
output
Increased EMI
on charger
output
Increased EMI
on charger
output
Increased EMI
on charger
output
Increased EMI
on charger
output
Capacitor will
quickly burn open
Capacitor will
quickly burn open
Capacitor will
quickly burn open
Capacitor will
quickly burn open
End Effect
Severity
on charger
output
Increased EMI
on charger
Minor
output
Charger may not
operate, or
Increased EMI Marginal
on charger
output
Increased EMI
on charger
Minor
output
Increased EMI
on charger
Minor
output
Increased EMI
on charger
Minor
output
Increased EMI
on charger
Minor
output
Increased EMI
on charger
Minor
output
Increased EMI
on charger
Minor
output
Charger may
end main charge
Minor
mode
prematurely
False Hot battery
Minor
fault
Charger may
end main charge
Minor
mode
prematurely
False Hot battery Minor

Record Ref.
#
Des.
Description
Part Type
FMECA Analysis
Failure
Mode
Part #
Local Effect
Next Higher Effect
sensor
fault
139
C308
M39014/02-1415,1uf,50V,10%
Capacitor
M39014/02-1415
open
Increased
noise on
U302A
140
C308
M39014/02-1415,1uf,50V,10%
Capacitor
M39014/02-1415
shorted
U302A has the

input shorted to
ground
141
C310
M39014/02-1415,1uf,50V,10%
Capacitor
M39014/02-1415
open
Increased
Noise on VCC
142
C310
M39014/02-1415,1uf,50V,10%
Capacitor
M39014/02-1415
shorted
Loss of +10V
143
C314
M39014/02-1415,1uf,50V,10%
Capacitor
M39014/02-1415
open
Input to U305
will not be
filtered
144
C314
M39014/02-1415,1uf,50V,10%
Capacitor
M39014/02-1415
shorted
Input to U305
will be shorted,
208 always on
145
C320
M39014/02-1415,1uf,50V,10%
Capacitor
M39014/02-1415
open
Loss of filtering
on U305 output
146
C320
M39014/02-1415,1uf,50V,10%
Capacitor
M39014/02-1415
shorted
Clock input can

not be shut off
on U305
147
C324
M39014/02-1415,1uf,50V,10%
Capacitor
M39014/02-1415
open
Increased
noise on
U301C
148
C324
M39014/02-1415,1uf,50V,10%
Capacitor
M39014/02-1415
shorted
U301C shorted
14
End Effect
Severity
fault
Possible
premature switch
Marginal
into topping
mode
Charger will
Charger will stay in never turn off,
Marginal
battery will be
main mode
overcharged
Possible
premature switch
Minor
into topping
mode
Temperature
circuits will not
operate, charger
Loss of 10V
Marginal
Reference Voltage may remain in
main mode
charge
Possible false timer
Battery may not
counting resulting in
lower time in topping
charge
mode
Timer will always be
Battery may not
operating, resulting
in reduced time in
charge
topping mode
Charger may
Charger may have
operate
Marginal
excessive noise on
erratically
the disable line
Charger will
remain in topping Marginal
mode
Possible false
battery heater
Minor
blanket over
temp fault
Heater blanket
Minor

Record Ref.
#
Des.
Description
Part Type
FMECA Analysis
Failure
Mode
Part #
Local Effect
Next Higher Effect
to ground
149
C267
M39014/02-1415,1uf,50V,10%
Capacitor
M39014/02-1415
open
Increased
noise on the
battery heater
blanket output
150
C267
M39014/02-1415,1uf,50V,10%
Capacitor
M39014/02-1415
shorted
Resister R251
will burn open
151
C305
M39014/02-1415,1uf,50V,10%
Capacitor
M39014/02-1415
open
Noise will get

into the temp
circuit
152
C305
M39014/02-1415,1uf,50V,10%
Capacitor
M39014/02-1415
shorted
153
C237
M39014/01-1535,.01uf,100V,10%
Capacitor
M39014/01-1535
open
154
C237
M39014/01-1535,.01uf,100V,10%
Capacitor
M39014/01-1535
shorted
155
C238
M39014/01-1535,.01uf,100V,10%
Capacitor
M39014/01-1535
open
156
C238
M39014/01-1535,.01uf,100V,10%
Capacitor
M39014/01-1535
shorted
157
C300
M39014/01-1535,.01uf,100V,10%
Capacitor
M39014/01-1535
open
158
C300
M39014/01-1535,.01uf,100V,10%
Capacitor
M39014/01-1535
shorted
159
C301
M39014/01-1535,.01uf,100V,10%
Capacitor
M39014/01-1535
open
15
The temp
voltage will be
passed to the
input of U302A
Increased EMI
on charger
output
Increased EMI
on charger
output
Increased EMI
on charger
output
Increased EMI
on charger
output
Severity
over temp will

never turn on
Resister R251 will
burn open
Increased noise on
the battery heater
blanket output
The charger will

remain in main
mode
Capacitor will
quickly burn open
Capacitor will
quickly burn open
Increased
noise on Temp
Sensor Voltage
False charger
temperature
functions
Shorted temp
sensor
Increased
noise on Temp
Sensor Voltage
False Hot battery

fault
False charger
temperature
functions
End Effect
Increased EMI
on the heater
blanket output
Increased EMI
on the heater
blanket output
May come out of
main mode
charge
prematurely
Battery will be
overcharged
Increased EMI
on charger
output
Increased EMI
on charger
output
Increased EMI
on charger
output
Increased EMI
on charger
output
Charger may
end main charge
mode
prematurely
False Hot battery
fault
Charger may
end main charge
mode
Minor
Minor
Minor
Marginal
Minor
Minor
Minor
Minor
Minor
Minor
Minor

Record Ref.
#
Des.
160
C301
Description
M39014/01-1535,.01uf,100V,10%
Part Type
Capacitor
FMECA Analysis
Part #
M39014/01-1535
Failure
Mode
Local Effect
Next Higher Effect
shorted
Shorted temp
sensor
False Hot battery

fault
Increased
Noise on
main/topping
line
161
C317
M39014/01-1535,.01uf,100V,10%
Capacitor
M39014/01-1535
open
162
C317
M39014/01-1535,.01uf,100V,10%
Capacitor
M39014/01-1535
shorted
163
C322
M39014/01-1535,.01uf,100V,10%
Capacitor
M39014/01-1535
open
164
C322
M39014/01-1535,.01uf,100V,10%
Capacitor
M39014/01-1535
shorted
165
C326
M39014/01-1535,.01uf,100V,10%
Capacitor
M39014/01-1535
open
Increased
noise on
U301C
166
C326
M39014/01-1535,.01uf,100V,10%
Capacitor
M39014/01-1535
shorted
U301C shorted
to ground
167
C325
M39014/01-1535,.01uf,100V,10%
Capacitor
M39014/01-1535
open
Increased
noise on
U301C
168
C325
M39014/01-1535,.01uf,100V,10%
Capacitor
M39014/01-1535
shorted
U301C shorted
to ground
169
C316
M39014/01-1535,.01uf,100V,10%
Capacitor
M39014/01-1535
open
170
C316
M39014/01-1535,.01uf,100V,10%
Capacitor
M39014/01-1535
shorted
16
Low on main /
topping line
Battery tap
fault timer will
not work
correctly
Battery tap
fault timer will
not work
correctly
End Effect
Severity
prematurely
False Hot battery
Minor
fault
Possible
oscillations
between main Marginal
and topping
mode
Charger will stay
Marginal
in topping mode
Battery tap fault
output will not
Minor
register the
failure
Battery tap fault
output will not
Minor
register the
failure
Possible false
battery heater
Minor
blanket over
temp fault
Heater blanket
over temp will
Minor
never turn on
Possible false
battery heater
Minor
blanket over
temp fault
Heater blanket
over temp will
Minor
never turn on
Clock oscillator
Charger will
on U305 will Charger may stay in
overcharge the Marginal
topping mode
not work
battery
correctly
Clock oscillator Charger may stay in
Charger will
Marginal
on U305 will
topping mode
overcharge the

Record Ref.
#
Des.
Description
Part Type
FMECA Analysis
Failure
Mode
Part #
171
C253
CKR06BX105KR,1uF,10%,50V,(R)
Capacitor
CKR06BX105KR
open
172
C253
CKR06BX105KR,1uF,10%,50V,(R)
Capacitor
CKR06BX105KR
shorted
173
C318
M39014/01-1523,2200pf,100V,10%
Capacitor
M39014/01-1523
open
174
C318
M39014/01-1523,2200pf,100V,10%
Capacitor
M39014/01-1523
shorted
175
C400
40L3101, 1uF, 400V, 10%
Capacitor
40L3101
open
176
C400
40L3101, 1uF, 400V, 10%
Capacitor
40L3101
shorted
177
C306
M39014/01-1293,47pf,200V,10%
Capacitor
M39014/01-1293
open
178
C306
M39014/01-1293,47pf,200V,10%
Capacitor
M39014/01-1293
shorted
179
C304
FFB14D0336K, 33uF, 75V,10%
Capacitor
FFB14D0336K
open
180
C304
FFB14D0336K, 33uF, 75V,10%
Capacitor
FFB14D0336K
shorted
Diode
1N5552
open
181
CR200 1N5552, 600V, 5AMP,GLASS RECTI
17
Local Effect
not work
correctly
Increased
noise on
charger output
Increased
noise on
charger output
Increase Noise
on gate of
Q301
Gate of Q301
shorted to
ground
Loss of Driver
Next Higher Effect
End Effect
battery
Increased EMI
on charger
output
Increased EMI
on charger
output
Possible heater
blanket
oscillations
Minor
Heater blanket
will never turn on
Minor
Minor
Minor
Charger will not

Marginal
operate
U401 and U400,
Increased
Charger will not
noise on
operate
Mosfet Drivers of Q400, 401, 402,
403
May come out of
Noise will get
main mode
into the temp
charge
circuit
prematurely
The temp
The charger will
Battery will be
voltage will be
remain in main
overcharged
passed to the
mode
input of U302A
Delta temp/time
No stored
circuit will not work, Battery will be
voltage across
overcharged
charger will remain
C271
in main mode
The charger will
U302A has the
Battery will be
remain in main
input shorted to
overcharged
mode
ground
Loss of 1/2 of Increased ripple on Phase B and C
phase A
the C215
will draw higher
Severity
Marginal
Minor
Marginal
Marginal
Marginal
Marginal

Record Ref.
#
Des.
Description
Part Type
FMECA Analysis
Part #
Failure
Mode
Local Effect
Next Higher Effect
rectification
182
Diode
1N5552
shorted
183
Diode
1N5552
open
184
Diode
1N5552
shorted
185
Diode
1N5552
open
186
Diode
1N5552
shorted
187
Diode
1N5552
open
188
Diode
1N5552
shorted
189
Diode
1N5552
open
18
Diode will burn

Increased ripple on
open with
the C215
excessive
currents
Loss of 1/2 of
phase A
rectification
Increased ripple on
the C215
Diode will burn

Increased ripple on
open with
the C215
excessive
currents
Loss of 1/2 of
phase B
rectification
Increased ripple on
the C215
Diode will burn

Increased ripple on
open with
the C215
excessive
currents
Loss of 1/2 of
phase B
rectification
Increased ripple on
the C215
Diode will burn

Increased ripple on
open with
the C215
excessive
currents
Loss of 1/2 of
Increased ripple on
End Effect
current, this may
trip the aircraft
breaker
Phase B and C
will draw higher
current, this may
trip the aircraft
breaker
Phase B and C
will draw higher
current, this may
trip the aircraft
breaker
Phase B and C
will draw higher
current, this may
trip the aircraft
breaker
Phase A and C
will draw higher
current, this may
trip the aircraft
breaker
Phase A and C
will draw higher
current, this may
trip the aircraft
breaker
Phase A and C
will draw higher
current, this may
trip the aircraft
breaker
Phase A and C
will draw higher
current, this may
trip the aircraft
breaker
Phase A and B
Severity
Marginal
Marginal
Marginal
Marginal
Marginal
Marginal
Marginal
Marginal

Record Ref.
#
Des.
Description
Part Type
FMECA Analysis
Failure
Mode
Part #
190
Diode
1N5552
shorted
191
Diode
1N5552
open
Local Effect
Next Higher Effect
End Effect
phase C
rectification
the C215
will draw higher

current, this may
trip the aircraft
breaker
Phase A and B
will draw higher
current, this may
trip the aircraft
breaker
Phase A and B
will draw higher
current, this may
trip the aircraft
breaker
Phase A and B
will draw higher
current, this may
trip the aircraft
breaker
Charger may not
operate, or will
operate
erratically
Charger may not
operate, or will
operate
erratically
Charger may not
operate, or will
operate
erratically
Charger may not
operate, or will
operate
erratically
Charger may not
operate
Charger may not
operate
Diode will burn

Increased ripple on
open with
the C215
excessive
currents
Loss of 1/2 of
phase C
rectification
Diode will burn

Increased ripple on
open with
the C215
excessive
currents
192
Diode
1N5552
shorted
193
Diode
1N5552
open
Main output
rectifier is
disable
194
Diode
1N5552
shorted
Excessive
noise on
charger output
195
Diode
1N5552
open
Main output
rectifier is
disable
196
Diode
1N5552
shorted
Excessive
noise on
charger output
197
CR206
JANTX1N5614,1.0A,200V
Diode
JANTX1N5614
open
198
CR206
JANTX1N5614,1.0A,200V
Diode
JANTX1N5614
shorted
19
Increased ripple on
the C215
Reduction in
the 24V
24V will
oscillate
Excessive noise on
charger output
Excessive noise on
charger output
Reduction in the
15V supply
Oscillation in 15V
supply
Severity
Marginal
Marginal
Marginal
Marginal
Marginal
Marginal
Marginal
Marginal
Marginal

Record Ref.
#
Des.
FMECA Analysis
Description
Part Type
Part #
Failure
Mode
199
CR207
JANTX1N5614,1.0A,200V
Diode
JANTX1N5614
open
200
CR207
JANTX1N5614,1.0A,200V
Diode
JANTX1N5614
shorted
201
CR208
JANTX1N5614,1.0A,200V
Diode
JANTX1N5614
open
202
CR208
JANTX1N5614,1.0A,200V
Diode
JANTX1N5614
shorted
203
CR209
JANTX1N5614,1.0A,200V
Diode
JANTX1N5614
open
204
CR209
JANTX1N5614,1.0A,200V
Diode
JANTX1N5614
shorted
205
CR400
1N5809,6 AMP, RECTIFIER
Diode
1N5809
open
206
CR400
Diode
1N5809
shorted
207
CR405
Diode
1N5809
open
208
CR405
Diode
1N5809
shorted
209
CR402
1N6642,300ma, 2.5A, SWITCHING
Diode
1N6642
open
210
CR402
Diode
1N6642
shorted
211
CR401
Diode
1N6642
open
212
CR401
Diode
1N6642
shorted
213
CR404
Diode
1N6642
open
20
Local Effect
Next Higher Effect
End Effect
Reduction in
the 24V
24V will
oscillate
Reduction in
the 24V
24V will
oscillate
Reduction in
the 24V
24V will
oscillate
FET Drive
Signal Altered
FET Drive
Signal Altered
FET Drive
Signal Altered
FET Drive
Signal Altered
Reduction in the
15V supply
Oscillation in 15V
supply
Reduction in the
15V supply
Oscillation in 15V
supply
Reduction in the
15V supply
Oscillation in 15V
supply
Charger may not

operate
Charger may not
operate
Charger may not
operate
Charger may not
operate
Charger may not
operate
Charger may not
operate
Charger may not
operate
Charger may not
operate
Charger may not
operate
Charger may not
operate
Charger will be
overstressed and
may fail to
operate
Reduced VS bus I/V

Dramatically
Reduced VS bus I/V
Reduced VS bus I/V
Dramatically
Reduced VS bus I/V
Charger may
Current mode
of charger is operate at a higher
then normal current
altered
Excessive
ripple on the
current limit
circuit
Charger may fail

to operate at the
correct current
Severity
Marginal
Marginal
Marginal
Marginal
Marginal
Marginal
Marginal
Marginal
Marginal
Marginal
Marginal
Minor
Charger will be
Charger may
Current mode
overstressed and
Marginal
may fail to
then normal current
altered
operate
Excessive
Charger may fail
ripple on the
to operate at the Minor
current limit
correct current
circuit
Current mode
Charger may
Charger will be
Marginal
of charger is operate at a higher overstressed and

Record Ref.
#
Des.
214
CR404
Description
Part Type
Diode
FMECA Analysis
Part #
1N6642
Failure
Mode
shorted
215
CR403
Diode
1N6642
open
216
CR403
Diode
1N6642
shorted
217
CR218
Diode
1N6642
open
218
CR218
Diode
1N6642
shorted
219
CR219
Diode
1N6642
open
220
CR219
Diode
1N6642
shorted
221
CR220
Diode
1N6642
open
222
CR220
Diode
1N6642
shorted
21
Local Effect
Next Higher Effect
End Effect
altered
then normal current
may fail to
operate
Excessive
ripple on the
current limit
circuit
Charger may fail

to operate at the
correct current
Charger will be
Charger may
Current mode
overstressed and
may fail to
then normal current
altered
operate
Excessive
Charger may fail
ripple on the
to operate at the
current limit
correct current
circuit
Charger may not
Mosfet driver
Charger will operate operate, or will
will not receive
operate
erratically
signal
erratically
Charger may not
Mosfet driver
will receive
operate
erratically
altered signal
erratically
Charger may not
Mosfet driver
will not receive
operate
erratically
signal
erratically
Charger may not
Mosfet driver
will receive
operate
erratically
altered signal
erratically
Charger may not
Mosfet driver
will not receive
operate
erratically
signal
erratically
Charger may not
Mosfet driver
will receive
operate
erratically
altered signal
erratically
Severity
Minor
Marginal
Minor
Marginal
Marginal
Marginal
Marginal
Marginal
Marginal

Record Ref.
#
Des.
Description
Part Type
FMECA Analysis
Failure
Mode
Part #
223
CR221
Diode
1N6642
open
224
CR221
Diode
1N6642
shorted
225
CR222
JANTX1N4148-1,.2A,100V-DIODE
Diode
JANTX1N4148-1
open
226
CR222
Diode
JANTX1N4148-1
shorted
227
CR305
Diode
JANTX1N4148-1
open
228
CR305
Diode
JANTX1N4148-1
shorted
229
CR304
Diode
JANTX1N4148-1
open
230
CR304
Diode
JANTX1N4148-1
shorted
231
CR308
Diode
JANTX1N4148-1
open
232
CR308
Diode
JANTX1N4148-1
shorted
233
CR309
Diode
JANTX1N4148-1
open
22
Local Effect
Next Higher Effect
End Effect
Severity
Charger may not

operate, or will
Marginal
operate
erratically
Charger may not
Mosfet driver
Marginal
will receive
operate
erratically
altered signal
erratically
Inhibit function Charger can not be Battery will be
Marginal
disabled
shut off
overcharged
Excessive
Charger can not be Battery will be
current into
Marginal
shut off
overcharged
opamp U205
Battery will be
overcharged at
Not path for
Cold battery shut
Minor
cold
U300 output
down will not work
temperatures
Battery will be
overcharged at
Direct current
Will disable hot
Minor
high
path into U300 battery shut down
temperatures
Battery will be
overcharged at
No path for
Hot battery shut
Minor
high
U303 output
down will not work
temperatures
Battery will be
Possible high
overcharged at
Will disable cold
Minor
current input
cold
battery shut down
for U303
temperatures
Hot and open
Hot and open
sensor fault will
sensor fault will
Minor
not shut down
not shut down
unit
unit
Hot and open
Will disable hot
sensor fault will
and cold
Minor
not shut down
battery shut
unit
down
Signal out of
Hot battery fault Minor
Mosfet driver
Charger will operate
will not receive
erratically
signal

Record Ref.
#
Des.
234
CR309
Description
Part Type
Diode
FMECA Analysis
Failure
Mode
Part #
JANTX1N4148-1
shorted
235
CR310
Diode
JANTX1N4148-1
open
236
CR310
Diode
JANTX1N4148-1
shorted
237
CR311
Diode
JANTX1N4148-1
Output of U302
disabled
U306 input is
now a high
current path
into the IC
CR311
Diode
JANTX1N4148-1
shorted
239
CR312
Diode
JANTX1N4148-1
open
240
CR312
Diode
JANTX1N4148-1
shorted
241
CR314
Diode
JANTX1N4148-1
open
242
CR314
Diode
JANTX1N4148-1
shorted
243
CR315
Diode
JANTX1N4148-1
open
23
U301 will be
disabled
Direct current
path into U301
Hot bat fault,
open sensor
fault, and tap
fault are
disabled
Diode steering
of fault outputs
disabled
open
238
Local Effect
U301 output
will not register
the fault
Possible high
current input
into U301
Next Higher Effect
Severity
will not work

Will disable open
sensor fault
High current path

into U301
Battery will be
overcharged
Marginal
Hot bat fault,

open sensor
fault, and tap
fault are disabled
Minor
Faults will not

register
Minor
Battery tap fault

circuit will not
work, battery will
be charged in a
faulted condition
Battery tap fault
circuit will not
work, battery will
be charged in a
faulted condition
Minor
Minor
Open sensor fault

will not work
Battery will be
overcharged
Marginal
Hot battery fault

may not work
Battery will be
overcharged
Marginal
Battery will be
overcharged
Marginal
Battery will be
overcharged
Marginal
Battery will be
overcharged
Marginal
Unit will return to

Clock will not
topping mode after it
stop counting
should have shut off
Clock will not
Unit will remain in
function
topping mode
correctly
Will prevent
topping mode Charger will remain
in main mode
timer from
disabling the
End Effect

Record Ref.
#
Des.
Description
Part Type
FMECA Analysis
Failure
Mode
Part #
Local Effect
Next Higher Effect
End Effect
Severity
charger
244
CR315
Diode
JANTX1N4148-1
shorted
245
CR313
Diode
JANTX1N4148-1
open
246
CR313
Diode
JANTX1N4148-1
shorted
Charger will
remain in main
mode charge
during a faulted Marginal
condition, battery
will be
overcharged
High current
path into the
timer circuit,
may damage
U305
Clock on U306
battery tap fault will
will not be
become intermittent
disabled
Clock on U306 3 minute timer on
battery tap fault
may not
circuit may not
operate
operate correctly
correctly
247
CR235
Diode
JANTX1N4148-1
open
Hysteresis for
U205 is
inoperative
248
CR235
Diode
JANTX1N4148-1
shorted
Hysteresis for
U205 is shifted
or inoperative
Tap circuit will not

function correctly
249
CR236
Diode
JANTX1N4148-1
open
High cell
imbalance will
not work

function correctly
Oscillations in
battery tap circuit
250
CR236
Diode
JANTX1N4148-1
shorted
High current
path into the
U205, may
damage IC
251
CR237
Diode
JANTX1N4148-1
open
Hysteresis for
U205 is
inoperative
Oscillations in
battery tap circuit
252
CR237
Diode
JANTX1N4148-1
shorted
Hysteresis for
U205 is shifted
or inoperative

function correctly
24
Battery may be
Marginal
overcharged
Battery may be
Marginal
overcharged
Battery tap
circuit will fail,
battery may be
overcharged
Battery tap
circuit will fail,
battery may be
overcharged
Battery tap
circuit will fail,
battery may be
overcharged
Battery tap
circuit will fail,
battery may be
overcharged
Battery tap
circuit will fail,
battery may be
overcharged
Battery tap
circuit will fail,
battery may be
overcharged
Marginal
Marginal
Marginal
Marginal
Marginal
Marginal

Record Ref.
#
Des.
253
254
CR238
CR238
Description
Part Type
Diode
Diode
FMECA Analysis
Part #
JANTX1N4148-1
JANTX1N4148-1
Failure
Mode
Local Effect
Next Higher Effect
open
Low cell
imbalance will
not work

function correctly
shorted
255
CR303
FJT1100
Diode
FJT1100
open
256
CR303
FJT1100
Diode
FJT1100
shorted
257
CR302
FJT1100
Diode
FJT1100
open
258
CR302
FJT1100
Diode
FJT1100
shorted
259
CR300
FJT1100
Diode
FJT1100
open
260
CR300
FJT1100
Diode
FJT1100
shorted
261
CR301
FJT1100
Diode
FJT1100
open
25
High current
path into the
U205, may
damage IC
The heater
blanket may be
on when the
charger is in
main mode
Additional
current will leak
into delta T
circuit causing
false triggering
Will prevent
U302 from
latching on
delta T
Will push
U302A input
pin high,
causing
premature
delta T
C271 will not
be able to
discharge on
power down
Delta T circuit
will not work
C271 will not
have bulk
charge
End Effect
Severity
Battery tap
circuit will fail,
Marginal
battery may be
overcharged
Battery tap
circuit will fail,
Marginal
battery may be
overcharged
Battery will be
Heater blanket will
cause false delta T, undercharged, or
Marginal
causing premature aircraft breaker
may trip
switch to topping
Premature switching
to topping mode
Battery will be
undercharged
Minor
May cause charger

to return to main
mode charge
Battery will be
overcharged
Marginal
Cause charger to
exit main mode
prematurely
Battery will be
undercharged
Minor
Charger may
register a false
delta Temp when
Minor
power cycling,
battery may be
undercharged
Charger will remain Battery may be
Marginal
in main mode
overcharged
Charger may
Battery may be
terminate main
Minor
undercharged
mode prematurely

Record Ref.
#
Des.
FMECA Analysis
Description
Part Type
Part #
Failure
Mode
Local Effect
Next Higher Effect
End Effect
Charger will remain

in main mode
Battery may be
overcharged
Charger will not
operate
Charger will not
operate, aircraft
breaker will trip
Charger will not
operate
Charger will not
operate, aircraft
breaker will trip
Charger will not
operate, charger
will register a
fault
Charger will not
operate, charger
will register a
fault
Charger will not
operate, charger
will register a
fault
Charger will not
operate, charger
will register a
fault
Charger will not
operate
Charger will not
operate
262
CR301
FJT1100
Diode
FJT1100
shorted
Delta T circuit
will not work
263
J1
D38999-20WD15PN, CONNECTOR,
CI
Connector
D38999-20WD15PN
open
No input power
264
J1
CI
Connector
D38999-20WD15PN
shorted
Connector will
burn itself open
265
J103
WTB20SAD9SY342, STRAIGHT
CONNECTOR
Connector
WTB20SAD9SY342
open
No input power
266
J103
CONNECTOR
Connector
WTB20SAD9SY342
shorted
Connector will
burn itself open
267
J104
CONNECTOR
Connector
WTB24SAD9SY342
open
No battery
temp signals
268
J104
CONE
Connector
WTB24SAD9SY342
shorted
No battery
temp signals
269
J2
CI
Connector
D38999-20WD97PN
open
No battery
temp signals
270
J2
CI
Connector
D38999-20WD97PN
shorted
No battery
temp signals
271
J205
Connector
WT4SAD9
open
272
J205
Connector
WT4SAD9
shorted
273
J206
WT4SAD9, 4 POSITION
RECEPTACLE
Connector
WT4SAD9
open
274
J206
WT4SAD9, 4 POSITION
RECEPTACLE
Connector
WT4SAD9
shorted
WT4SAD9, 4 POSITION
RECEPTACLE
WT4SAD9, 4 POSITION
RECEPTACLE
26
Mosfet drivers
are disabled
Mosfet drivers
are disabled
Main
transformer is
disabled
Main
transformer is
shorted
Severity
Marginal
Marginal
Marginal
Marginal
Marginal
Marginal
Marginal
Marginal
Marginal
Marginal
Marginal
Charger will not

Marginal
operate
Charger will not
operate, aircraft Marginal
breaker will trip

Record Ref.
#
Des.
Description
WT4SAD9, 4 POSITION
RECEPTACLE
WT4SAD9, 4 POSITION
RECEPTACLE
275
J207
276
J207
277
L100
335BC105-1, COMMON MODE

CHOKE
278
L100

CHOKE
279
L101 335BC108-1, INDUCTOR ASSEMBLY
FMECA Analysis
Part Type
Part #
Failure
Mode
Connector
WT4SAD9
open
Connector
WT4SAD9
shorted
Inductor
335BC105-1
open
Lose of Phase
A, B or C
Local Effect
Mosfet drivers
are disabled
Mosfet drivers
are disabled
Inductor
335BC105-1
shorted
Unbalanced
Input V,
excessive
currents
Inductor
335BC108-1
open
Lose of Phase
A, B or C
Unbalanced
Input V,
excessive
currents
Loss of DC
buss voltage
280
Inductor
335BC108-1
shorted
281
L201
235BC103-1, INDUCTOR
Inductor
235BC103-1
open
282
L201
Inductor
235BC103-1
shorted
Increased EMI
on DC buss
283
L202
Inductor
235BC103-1
open
Loss of DC
buss voltage
284
L202
Inductor
235BC103-1
shorted
Increased EMI
on DC buss
285
Inductor
335BC106-1
open
286
Inductor
335BC106-1
shorted
287
Inductor
335BC106-1
open
288
Inductor
335BC106-1
shorted
27
Next Higher Effect
No charger
output
Increased EMI
on the charger
output
No charger
output
Increased EMI
End Effect
Severity
Charger will not

Marginal
operate
Charger will not
Marginal
operate
Increased current
on remaining
phases
Increased current
on remaining
phases
Blow aircraft
breaker
Marginal
Blow aircraft
breaker
Marginal
Blow aircraft
breaker
Marginal
Blow aircraft
breaker
Marginal
Charger will not

operate
Increased EMI
on the charger
output and input
power cables
Charger will not
operate
Increased EMI
on the charger
output and input
power cables
Charger will not
operate
Increased EMI
on the charger
output
Charger will not
operate
Increased EMI
Marginal
Minor
Marginal
Minor
Marginal
Minor
Marginal
Minor

Record Ref.
#
Des.
Description
Part Type
FMECA Analysis
Failure
Mode
Part #
Local Effect
on the charger
output
No charger
output
Increased EMI
on the charger
output
289
Inductor
335BC107-1
open
290
Inductor
335BC107-1
shorted
291
L206
BEAD, FERRITE, FAIRITE, 267301
Inductor
2673015301
open
Heater blanket
will not work
292
L206
Inductor
2673015301
shorted
Increased
noise on heater
blanket circuit
293
P203
WTB20PR9ST342, RIGHT ANGLE

CON
Connector
WTB20PR9SY342
open
Battery tap is
missing
294
P203

CON
Connector
WTB20PR9SY342
shorted
295
P204

CON
Connector
WTB20PR9SY342
open
296
P204

CON
Connector
WTB20PR9SY342
shorted
297
P205
Connector
WT4PRD8-Top
open
298
P205
Connector
WT4PRD8-Top
shorted
299
P206
WT4PRD8, 4 POSITION RIGHT

ANGLE
Connector
WT4PRD8-Top
open
300
P206

ANGLE
Connector
WT4PRD8-Top
shorted
301
P207
Connector
WT4PRD8-Top
open

ANGLE
ANGLE
28
Next Higher Effect
Several signal
are shorted
together
Charger output
is open
Charger output
is shorted
Mosfet drivers
are disabled
Mosfet drivers
are disabled
Main
transformer is
disabled
Main
transformer is
shorted
Mosfet drivers
Tap circuit will

register a fault
End Effect
Severity
on the charger
output
Charger will not
Marginal
operate
Increased EMI
on the charger
Minor
output
Charger will
remain in cold
hold off mode
Minor
and never
charge the
battery
Increased noise
on heater
Minor
blanket circuit
Charger will shut
down based on Marginal
the tap fault
Charger will not
Marginal
operate
Charger will not
operate
Charger will not
operate, aircraft
breaker will trip
Charger will not
operate
Charger will not
operate
Marginal
Marginal
Marginal
Marginal
Charger will not

Marginal
operate
Charger will not
operate, aircraft Marginal
breaker will trip
Charger will not Marginal

Record Ref.
#
Des.
302
P207
303
Q400
304
Description
ANGLE
ANGLE
Part Type
FMECA Analysis
Failure
Mode
Part #
Local Effect
are disabled
Mosfet drivers
are disabled
No Bridge to
Bus connection
Bus connected
to CS XFMR
No Bridge to
Ground
connection
Bridge Bus
Grounded
No Bridge to
Bus connection
Bus connected
to Power
XFMR
No Bridge to
Ground
connection
Bridge Bus
Grounded
Main/topping
mode is
disabled
Main/topping
mode is
disabled
Low battery
fault always off
Low battery
fault always on
Connector
WT4PRD8-Top
shorted
IRF450, HEXFET TRANSISTOR
Transistor
IRF450
openD
Q400
Transistor
IRF450
shortedVDS
305
Q401
Transistor
IRF450
openD
306
Q401
Transistor
IRF450
shortedVDS
307
Q402
Transistor
IRF450
openD
308
Q402
Transistor
IRF450
shortedVDS
309
Q403
Transistor
IRF450
openD
310
Q403
Transistor
IRF450
shortedVDS
311
Q202 2N2907AJANTX,TRANS,PNP,60VCE
Transistor
2N2907AJTX
open
312
Q202 2N2907AJANTX,TRANS,PNP,60VCE
Transistor
2N2907AJTX
shorted
313
Q205
2N6788JANTX,POWER-MOSFET
MOSFET
2N6788JTX
open
314
Q205
MOSFET
2N6788JTX
shorted
315
Q300
MOSFET
2N6788JTX
open
Fault output will

never register
316
Q300
MOSFET
2N6788JTX
shorted
Fault output is
always on
29
Next Higher Effect
End Effect
Severity
operate
Charger will not
Marginal
operate
Reduced Bridge bus Charger will not
Marginal
I/V
operate
Overvoltage/Current Charger will not
Marginal
on Bridge Bus
operate
Overvoltage on
Bridge Bus
Charger will not

Marginal
operate
Low voltage/High I
on Bridge Bus
Charger will not

Marginal
operate
Charger will not
Reduced VS bus I/V
Marginal
operate
Overvoltage/Current Charger will not
Marginal
on VS Bus
operate
Overvoltage on VS
Bus
Charger will not

Marginal
operate
Low voltage/High I
on Bridge Bus
Charger will not

Marginal
operate
Battery may be
Marginal
overcharged
Battery may be
Marginal
overcharged
Low battery fault
will not register
Low battery fault
always on
A fault condition
will never be
known
Fault output is
always on
Minor
Minor
Minor
Minor

Record Ref.
#
Des.
Description
Part Type
FMECA Analysis
Failure
Mode
Part #
Local Effect
317
Q301
2N6764JANTX,POWER-MOSFET,NCHA
MOSFET
2N6764JTX
open
Heater blanket
will not work
318
Q301
MOSFET
2N6764JTX
shorted
Heater blanket
always on
319
R100 RLR07C1780FS,178ohm,1%,1/4W (S
Resistor
RLR07C1780FS
open
320
R101 RLR07C1780FS,178ohm,1%,1/4W (S
Resistor
RLR07C1780FS
open
321
R102 RLR07C1780FS,178ohm,1%,1/4W (S
Resistor
RLR07C1780FS
open
322
R240 RLR07C1780FS,178ohm,1%,1/4W (S
Resistor
RLR07C1780FS
open
323
R313
RLR07C2741FS 2.74K 1% 1/4W (S)
Resistor
RLR07C2741FS
open
Open sensor
324
R214
RLR07C2741FS 2.74K 1% 1/4W (S)
Resistor
RLR07C2741FS
open
15V goes to
24V (Vin)
325
R358
RLR07C2741FS 2.74K 1% 1/4W (S)
Resistor
RLR07C2741FS
open
2nd thermistor
will lose bias
326
R103 RLR07C2870FS 287ohm 1% 1/4W (S
Resistor
RLR07C2870FS
open
327
R204 RLR20C1210FS 121ohm 1% 1/2W (S
Resistor
RLR20C1210FS
open
328
R205 RLR20C1210FS 121ohm 1% 1/2W (S
Resistor
RLR20C1210FS
open
329
R206 RLR20C1210FS 121ohm 1% 1/2W (S
Resistor
RLR20C1210FS
open
330
R104
Resistor
RCR07G2R7JS
open
RCR07C2R7JS,2.7ohm,5%,1/4W (S)
30
Loss of EMI
Filtering
Loss of EMI
Filtering
Loss of EMI
Filtering
Loss of EMI
filtering on
charger output
Loss of EMI
Filtering
Reduced EMI
filtering A-B
Reduced EMI
filtering B-C
Reduced EMI
filtering A-C
Loss of EMI
Next Higher Effect
End Effect
Severity
Charger will
never charge the
Battery will never
battery, a low
Minor
increase in
battery fault will
temperature
occur, only under
cold conditions
Charger will turn
Battery will over
off, a fault will
Minor
temp
register
Loss of EMI
Minor
Filtering
Loss of EMI
Minor
Filtering
Loss of EMI
Minor
Filtering
Increased EMI
on charger
Minor
output
Charger will turn
False open sensor
off, a fault will
Minor
fault
register
Charger PWM
may be
overstressed, Marginal
charger may not
operate
back up heater
circuit will not Marginal
function
Loss of EMI
Minor
Filtering
Reduced EMI
Minor
filtering A-B
Reduced EMI
Minor
filtering B-C
Reduced EMI
Minor
filtering A-C
Loss of EMI
Minor

Record Ref.
#
Des.
Description
Part Type
FMECA Analysis
Failure
Mode
Part #
Local Effect
Next Higher Effect
Filtering
Loss of EMI
Filtering
Loss of EMI
Filtering
Loss of EMI
Filtering
Loss of EMI
Filtering
Loss of EMI
Filtering
331
R208
RWR81S1001FR 1K 0.1% 1W (R)
Resistor
RWR81S1001FR
open
332
R212
RWR81S1001FR 1K 0.1% 1W (R)
Resistor
RWR81S1001FR
open
333
R209 RWR80S4R99FS 4.99ohm 0.1% 2W (
Resistor
RWR80S4R99FS
open
334
R211 RWR80S4R99FS 4.99ohm 0.1% 2W (
Resistor
RWR80S4R99FS
open
335
R210
RLR07C10R0FS,10ohm,1%,1/4W (S)
Resistor
RLR07C10R0FS
open
336
R400
Resistor
RLR07C10R0FS
open
FET off
Reduced VS bus V
337
R401
Resistor
RLR07C10R0FS
open
FET off
Reduced VS bus V
338
R403
Resistor
RLR07C10R0FS
open
FET off
Reduced VS bus V
339
R404
Resistor
RLR07C10R0FS
open
FET off
Reduced VS bus V
340
R238
Resistor
RLR07C10R0FS
open
Mosfet driver
signal is altered
Current limit for
C267
341
R251
Resistor
RLR07C10R0FS
open
342
R213 RLR07C2490FS,249ohm,1%,1/4W (S
Resistor
RLR07C2490FS
open
343
R215
RLR07C2613FS 261K 1% 1/4W (S)
Resistor
RLR07C2613FS
open
344
R216
RLR07C2613FS 261K 1% 1/4W (S)
Resistor
RLR07C2613FS
open
345
R332
RLR07C2613FS 261K 1% 1/4W (S)
Resistor
RLR07C2613FS
open
346
R217
RLR07C1003FS,100K,1%,1/4W (S)
Resistor
RLR07C1003FS
open
31
More noise on
heater blanket, or
coming in from
heater blanket
End Effect
Filtering
Loss of EMI
Filtering
Loss of EMI
Filtering
Loss of EMI
Filtering
Loss of EMI
Filtering
Loss of EMI
Filtering
Charger will not
operate
Charger will not
operate
Charger will not
operate
Charger will not
operate
Charger may not
operate
Loss of EMI
Filtering
Severity
Minor
Minor
Minor
Minor
Minor
Marginal
Marginal
Marginal
Marginal
Marginal
Minor
Loss of 15V,
Charger will not
15V drops
Marginal
operate
below 2V
Loss of EMI
Loss of EMI
Minor
Filtering
Filtering
Loss of EMI
Loss of EMI
Minor
Filtering
Filtering
Hot battery
Charger will shut off
Charger is
shut down
Marginal
on false hot battery
disabled
feedback
voltage loss
Loss of control
Charger may
Battery may be Marginal

Record Ref.
#
Des.
Description
Part Type
FMECA Analysis
Failure
Mode
Part #
Local Effect
Next Higher Effect
End Effect
of the voltage
of U202
operate at higher
then normal
voltages
overcharged
Loss of
reference on
U205 Input
Loss of inhibit
signal
Temp sensor
loses bias
Inhibit function will

always be on
Charger will not

Marginal
operate
False hot battery

fault
Battery heater
blanket never
comes on
Battery may be
Marginal
overcharged
Charger is
Marginal
disabled
Charger may not
operate under Marginal
cold conditions
347
R242
RLR07C1003FS,100K,1%,1/4W (S)
Resistor
RLR07C1003FS
open
348
R243
RLR07C1003FS,100K,1%,1/4W (S)
Resistor
RLR07C1003FS
open
349
R314
RLR07C1003FS,100K,1%,1/4W (S)
Resistor
RLR07C1003FS
open
350
R319
RLR07C1003FS,100K,1%,1/4W (S)
Resistor
RLR07C1003FS
open
Heater control
reference loss
351
R320
RLR07C1003FS,100K,1%,1/4W (S)
Resistor
RLR07C1003FS
open
Hot battery
Charger shuts off on
shut down
false hot battery
reference loss
Charger does not
shut off on cold
battery
352
R323
RLR07C1003FS,100K,1%,1/4W (S)
Resistor
RLR07C1003FS
open
Cold battery
shut down
reference loss
353
R324
RLR07C1003FS,100K,1%,1/4W (S)
Resistor
RLR07C1003FS
open
Hot battery
fault reference No hot battery fault
loss
354
R327
RLR07C1003FS,100K,1%,1/4W (S)
Resistor
RLR07C1003FS
open
355
R317
RLR07C1003FS,100K,1%,1/4W (S)
Resistor
RLR07C1003FS
open
356
R328
RLR07C1003FS,100K,1%,1/4W (S)
Resistor
RLR07C1003FS
open
357
R339
RLR07C1003FS,100K,1%,1/4W (S)
Resistor
RLR07C1003FS
open
358
R343
RLR07C1003FS,100K,1%,1/4W (S)
Resistor
RLR07C1003FS
open
32
Open sensor
No open sensor
reference loss
fault
Floating input Never terminating
to op-amp
main mode charge
Loss of temp
sensor input to Never terminating
main mode charge
delta Temp
circuit
Charger may be on
Inverter will not when battery heater
is on, causing false
function
DT
Inverter input
Severity
Hot battery shut
Charger is
disabled
Battery may be
overcharged
under cold
conditions
Battery may be
overcharged
under hot
conditions
Battery will be
overcharged
Battery will be
overcharged
Battery will be
overcharged
Battery may be
undercharged
during cold
temperature
operation
Battery will be
Marginal
Marginal
Marginal
Marginal
Marginal
Marginal
Minor
Minor

Record Ref.
#
Des.
Description
Part Type
FMECA Analysis
Failure
Mode
Part #
359
R344
RLR07C1003FS,100K,1%,1/4W (S)
Resistor
RLR07C1003FS
open
360
R252
RLR07C1003FS,100K,1%,1/4W (S)
Resistor
RLR07C1003FS
open
361
R255
RLR07C1003FS,100K,1%,1/4W (S)
Resistor
RLR07C1003FS
open
362
R311
RLR07C1003FS,100K,1%,1/4W (S)
Resistor
RLR07C1003FS
open
363
R218
RNC55H9091FS 9.09K 1% 1/8W (S)
Resistor
RNC55H9091FS
open
364
R219
RNC55H9091FS 9.09K 1% 1/8W (S)
Resistor
RNC55H9091FS
open
365
R220
RLR07C1002FS,10K,1%,1/4W (S)
Resistor
RLR07C1002FS
open
366
R221
RLR07C1002FS,10K,1%,1/4W (S)
Resistor
RLR07C1002FS
open
367
R228
RLR07C1002FS,10K,1%,1/4W (S)
Resistor
RLR07C1002FS
open
368
R233
RLR07C1002FS,10K,1%,1/4W (S)
Resistor
RLR07C1002FS
open
33
Local Effect
Next Higher Effect
End Effect
loss U303B
down will not

function
charged during
hot conditions,
reducing battery
life
Back up heater
turn off circuit will
not be able to
show a fault
U301 will not

be able to
output a fault
signal
Battery voltage Battery tap circuit
on U205 will be will register a false
tap failure
lost
tap failure
lost
False triggering of
Loss of temp
DT/DT circuit, no
sensor input to
main mode charge
op-amp
function
Charger may
operate at higher
U202 anode
then normal
floating
voltages
Charger may
Reduces the
operate at higher
12V supplied to
then normal
N+ on U203
voltages
Charger may
Loss of the 12V
operate at higher
supplied to
then normal
U203
voltages
Current limit circuit
Q202 will lose
will operate
base drive
erratically
Charger may
VREF output of operate at higher
then normal
the PWM is lost
voltages
PWM
Severity
Minor
Fault indicator is
always on
Minor
Fault indicator is
always on
Minor
Battery may be
undercharged
Minor
Battery may be
Marginal
overcharged
Battery may be
Marginal
overcharged
Battery may be
Marginal
overcharged
Battery may be
Marginal
overcharged
Battery may be
Marginal
overcharged
Charger may not Marginal

Record Ref.
#
Des.
Description
Part Type
FMECA Analysis
Failure
Mode
Part #
369
R237
RLR07C1002FS,10K,1%,1/4W (S)
Resistor
RLR07C1002FS
open
370
R239
RLR07C1002FS,10K,1%,1/4W (S)
Resistor
RLR07C1002FS
open
371
R331
RLR07C1002FS,10K,1%,1/4W (S)
Resistor
RLR07C1002FS
open
372
R333
RLR07C1002FS,10K,1%,1/4W (S)
Resistor
RLR07C1002FS
open
373
R336
RLR07C1002FS,10K,1%,1/4W (S)
Resistor
RLR07C1002FS
open
374
R338
RLR07C1002FS,10K,1%,1/4W (S)
Resistor
RLR07C1002FS
open
375
R347
RLR07C1002FS,10K,1%,1/4W (S)
Resistor
RLR07C1002FS
open
376
R222
RLR07C1693FS,169K,1%,1/4W (S)
Resistor
RLR07C1693FS
open
377
R330
RLR07C1693FS,169K,1%,1/4W (S)
Resistor
RLR07C1693FS
open
378
R402
RLR07C1001FS,1K,1%,1/4W (S)
Resistor
RLR07C1001FS
open
34
Local Effect
Next Higher Effect
erratically
Feedback
compensation
circuit is
disabled
Mosfet driver
signal is altered
Mosfet driver
signal is altered
Loss of temp
sensor input to Charger will not turn
hot battery shut off on hot battery
down
Loss of temp
off on cold battery
cold battery
shut down
End Effect
operate, or may
be overstressed
Charger may not

operate
Charger may not
operate
Battery may be
overcharged
under hot
conditions
Battery may be
overcharged
under cold
conditions
Battery may be
Loss of temp
overcharged
sensor input to No hot battery fault
under hot
hot battery fault
conditions
Loss of temp
No open sensor
Open sensor
sensor input to
fault
fault inoperative
open sensor
fault
Charger will not
U305 will lose
Battery will be
operate in topping
input trigger
overcharged
mode
(reset)
Charger may
PWM will lose
Battery may be
operate at higher
part of the
overcharged
then normal
reference
voltages
Battery may be
Heater control
Battery heater will heated extremely
feedback
high by the
stay on
voltage loss
heater blanked
Charger will not
Increased base
Reduced charger
operate, or
drive current
output current
operate at a
for Q202
Severity
Marginal
Marginal
Marginal
Marginal
Marginal
Minor
Marginal
Marginal
Marginal
Marginal

Record Ref.
#
Des.
Description
Part Type
FMECA Analysis
Failure
Mode
Part #
Local Effect
379
R226
RLR07C1001FS,1K,1%,1/4W (S)
Resistor
RLR07C1001FS
open
Increased
voltage on ILIM
of PWM
380
R227
RLR07C1001FS,1K,1%,1/4W (S)
Resistor
RLR07C1001FS
open
Increased
voltage on ILIM
of PWM
381
R229
RLR07C1001FS,1K,1%,1/4W (S)
Resistor
RLR07C1001FS
open
Increased
voltage on ILIM
of PWM
382
R230
RLR07C1001FS,1K,1%,1/4W (S)
Resistor
RLR07C1001FS
open
Current limiting
circuit is
disabled
383
R232
RLR07C1001FS,1K,1%,1/4W (S)
Resistor
RLR07C1001FS
open
384
R312
RLR07C1001FS,1K,1%,1/4W (S)
Resistor
RLR07C1001FS
open
385
R329
RLR07C1001FS,1K,1%,1/4W (S)
Resistor
RLR07C1001FS
open
386
R350
RLR07C1001FS,1K,1%,1/4W (S)
Resistor
RLR07C1001FS
open
387
R359
RLR07C1001FS,1K,1%,1/4W (S)
Resistor
RLR07C1001FS
open
388
R231
RNC55H5112FS 51.1K 1% 1/8W (S)
Resistor
RNC55H5112FS
open
35
Next Higher Effect
End Effect
lower current
Charger will
operate at a
higher then
normal current
Charger will
operate at a
higher then
normal current
Charger will
operate at a
higher then
normal current
Charger will
operate at a
higher then
normal current
PWM
Charger may not
Feedback
operate, or may
compensation
erratically
be overstressed
circuit is
disabled
False open sensor
Charger is
Open sensor
fault
disabled
Battery may
Loss of temp
never charge
Battery heater will
sensor input to
under cold
never turn on
heater control
conditions
Back up heater turn
Fault indicator is
U301 will lose
off will always show
always on
a reference
a fault
back up heater
2nd thermister
circuit will not
will lose bias
function
PWM
Charger may not
Feedback
operate, or may
erratically
compensation
be overstressed
circuit is
Severity
Minor
Minor
Minor
Minor
Marginal
Marginal
Marginal
Minor
Marginal
Marginal

Record Ref.
#
Des.
Description
Part Type
FMECA Analysis
Failure
Mode
Part #
389
R236
RLR07C2212FS,22.1K,1%,1/4W (S)
Resistor
RLR07C2212FS
open
390
R241
RLR07C35R7FS 35.7ohm 1% 1/4W (
Resistor
RLR07C35R7FS
open
391
R244
RLR07C1004FS,1Meg,1%,1/4W (S)
Resistor
RLR07C1004FS
open
392
R245
RLR07C1004FS,1Meg,1%,1/4W (S)
Resistor
RLR07C1004FS
open
393
R246
RLR07C1004FS,1Meg,1%,1/4W (S)
Resistor
RLR07C1004FS
open
394
R334
RLR07C1004FS,1Meg,1%,1/4W (S)
Resistor
RLR07C1004FS
open
395
R341
RLR07C1004FS,1Meg,1%,1/4W (S)
Resistor
RLR07C1004FS
open
396
R349
RLR07C1004FS,1Meg,1%,1/4W (S)
Resistor
RLR07C1004FS
open
397
R308
RLR07C1004FS,1Meg,1%,1/4W (S)
Resistor
RLR07C1004FS
open
398
R247 RLR07C1000FS,100ohm,1%,1/4W (S
Resistor
RLR07C1000FS
open
399
R360 RLR07C1000FS,100ohm,1%,1/4W (S
Resistor
RLR07C1000FS
open
400
R248 RJR24CW103R,VAR.-RES.,10K,10%,
Resistor
RJR24CW103R
open
401
R316 RLR07C4640FS 464ohm 1% 1/4W (S
Resistor
RLR07C4640FS
open
36
Local Effect
disabled
Loss of PWM
u203 switching
Loss of EMI
filtering on
charger output
Loss of inhibit
bias
Low battery
fault circuit is
disabled
Low battery
fault will always
be enabled
Cold battery
shut down
feedback
voltage loss
U301B will lose
a reference
Next Higher Effect
End Effect
Severity
Loss of Power
transformer output
Charger will not

Marginal
operate
Increased EMI
on charger
Minor
output
Inhibit function may Battery may be
Marginal
not work
overcharged

on false cold battery
Battery heater
blanket over temp
fault is inoperative
Low battery fault

will not work
Minor
Low battery fault

will always stay
on
Minor
Charger is
disabled
Marginal
Battery may be
excessively
Marginal
heated by the
heater blanket
Back up heater turn

Fault indicator is
off will not show a
Minor
always on
fault
Battery tap fault will
Clock on U306 not register, charger Battery may be
Marginal
overcharged
will not operate will not shut off on
fault
Low battery
Low battery fault
Minor
fault disabled
will not register
Battery fault
Battery fault
Fault indicator is
indicator will not
Minor
indicator signal
always off
function
path opened
Charger may go to a
Battery may be
Loss of U202
higher then normal
Marginal
overcharged
Ref control
voltage
Open sensor False open sensor
Charger is
Marginal
U301 will lose
a reference

Record Ref.
#
Des.
402
R315
Description
RLR07C4223FS 422K 1% 1/4W (S)
Part Type
Resistor
FMECA Analysis
Failure
Mode
Part #
RLR07C4223FS
open
Shifted sensor
voltage - colder
Heater control
reference loss
403
R318
RNC55H5902FS 59K 1% 1/8W (S)
Resistor
RNC55H5902FS
open
404
R321
RLR07C3832FS 38.3K 1% 1/4W (S)
Resistor
RLR07C3832FS
open
405
R322
RNC55H2742FS 27.4K 1% 1/8W (S)
Resistor
RNC55H2742FS
open
406
R325
RNC55H1742FS 17.4K 1% 1/8W (S)
Resistor
RNC55H1742FS
open
407
R326
RNC55H2612FS 26.1K 1% 1/8W (S)
Resistor
RNC55H2612FS
open
408
R335
RLR07C3483FS 348K 1% 1/4W (S)
Resistor
RLR07C3483FS
open
409
R356
RLR07C3483FS 348K 1% 1/4W (S)
Resistor
RLR07C3483FS
open
410
R337
RLR07C4754FS 4.75Meg 1% 1/4W (
Resistor
RLR07C4754FS
open
411
R351
RLR07C4754FS 4.75Meg 1% 1/4W (
Resistor
RLR07C4754FS
open
412
R346
RLR07C4754FS 4.75Meg 1% 1/4W (
Resistor
RLR07C4754FS
open
413
R297
RLR07C4754FS 4.75Meg 1% 1/4W (
Resistor
RLR07C4754FS
open
37
Local Effect
Next Higher Effect
End Effect
fault
False charger
temperature
functions
disabled
Battery heater
blanket stays on
Charger does not

Hot battery
shut off on hot
shut down
battery
reference loss
Cold battery
shut down
false cold battery
reference loss
Hot battery
False hot battery
fault reference
fault
loss
Open sensor False open sensor
reference loss
fault
Loss of hysteresis
Loss of voltage
on hot bat fault
shift on op-amp
indicator
U301C feed
back resister
hysteresis
Loss of voltage Loss of hysteresis
shift on op-amp on open sensor fault
Charger will not
U305 will lose
come out of topping
clock source
mode
Battery tap fault
timer may not
U306 clock
function, inoperative
reference
battery tap fault
U205B tap fault not register, charger
will not shut off on
will not latch
fault
Severity
Charger will not

Marginal
operate correctly
Battery may be
heated extremely
high by the
heater blanked
Minor
Battery may be
Marginal
overcharged
Charger is
disabled
Marginal
Charger is
disabled
Marginal
Charger is
disabled
Marginal
Fault indicator
may flicker
Minor
Back up heater
turn off circuit
may oscillate
Fault indicator
may flicker
Battery will be
overcharged
Minor
Minor
Marginal
Battery may be
Marginal
overcharged
Battery may be
Marginal
overcharged

Record Ref.
#
Des.
Description
Part Type
FMECA Analysis
Failure
Mode
Part #
414
R298
RLR07C4754FS 4.75Meg 1% 1/4W (
Resistor
RLR07C4754FS
open
415
R340
RLR07C4752FS 47.5K 1% 1/4W (S)
Resistor
RLR07C4752FS
open
416
R254
RLR07C4752FS 47.5K 1% 1/4W (S)
Resistor
RLR07C4752FS
open
417
R342
RLR07C4751FS 4.75K 1% 1/4W (S)
Resistor
RLR07C4751FS
open
418
R357
RLR07C4751FS 4.75K 1% 1/4W (S)
Resistor
RLR07C4751FS
open
419
R352
RLR07C6813FS 681K 1% 1/4W (S)
Resistor
RLR07C6813FS
open
420
R348
RLR07C2552FS,25.5K,1%,1/4W (S)
Resistor
RLR07C2552FS
open
421
R353
LVR2-0.01-3%,.01ohm,2W,3%
Resistor
LVR2-0.01-3%
open
422
R345
RLR07C2003FS,200K,1%,1/4W (S)
Resistor
RLR07C2003FS
open
423
R354
RNC55H3832FS 38.3K 1% 1/8W (S)
Resistor
RNC55H3832FS
open
424
R355
RNC55H1002FS 10K 1% 1/8W (S)
Resistor
RNC55H1002FS
open
425
R296 RLR07C1005GR,10Meg,2%,1/4W (R)
Resistor
RLR07C1005GR
open
38
Local Effect
Next Higher Effect

will not latch
fault
Battery heater will
Mosfet 208 will
not function, charger
not turn on
may never operate
tap failure
lost
Battery heater over
U301B will lose
temp fault will not
a reference
work
U301C will lose
a reference
End Effect
Severity
Battery may be
Marginal
overcharged
Charger will not
operate at cold
temperatures
Minor
Fault indicator is
always on
Minor
Fault indicator is
always on
Minor
Inoperative back
up heater turn off
circuit
Minor
Charger will not

Battery will be
U305 will lose
come out of topping
Marginal
overcharged
clock source
mode
Charger will not
Battery will be
Q202 will lose
come out of main
Marginal
overcharged
base drive
mode
Back up heater turn
Fault indicator is
U301 will lose
Minor
always on
a reference
a fault
Q300 may not be
Q300 gate
Fault indicator is
able to turn off,
Minor
discharge path
always on
Fault indicator
is lost
always on
Inoperative back
U301C will lose
up heater turn off Minor
a reference
circuit
Inoperative back
U301C will lose
up heater turn off Minor
a reference
circuit
U306 tap fault Battery tap fault will
Battery may be
Marginal
timer will not be not register, charger
overcharged
triggered

Record Ref.
#
Des.
Description
Part Type
FMECA Analysis
Failure
Mode
Part #
Local Effect
Next Higher Effect
End Effect
Severity
fault
426
R300
RNC55H3652FS 36.5K 1% 1/8W (S)
Resistor
RNC55H3652FS
open
427
R253
RNC55H1052FS 10.5K 1% 1/8W (S)
Resistor
RNC55H1052FS
open
428
R309
RLR07C5114FS 5.11Meg 1% 1/4W (
Resistor
RLR07C5114FS
open
429
R310
RLR07C1005FS,10Meg,1%,1/4W (S)
Resistor
RLR07C1005FS
open
430
T200
1.5R18CT,115VAC, 400Hz, 1 PHASE Transformer
1.5R18CT
open
431
T200
1.5R18CT,115VAC, 400Hz, 1 PHASE Transformer
1.5R18CT
shorted
432
T400
335BC109-1, CURRENT SENSE

TRAN
Transformer
335BC109-1
open
433
T400

TRAN
Transformer
335BC109-1
shorted
434
T202
Transformer
335BC115-1
open
435
T202
Transformer
335BC115-1
shorted
436
T203
Transformer
335BC116-1
open
437
T203
Transformer
335BC116-1
shorted
438
U400
Driver
IR2110
LO Hi
335BC115-1, PLANNAR
TRANSFORMER
335BC115-1, PLANNAR
TRANSFORMER
TRAN
TRAN
HIGH AND LOW SIDE DRIVER
39
2nd thermister
will lose bias
tap failure
lost
Loss of delta time
Cap 271 not
circuit function for
able to
DT/DT circuit
discharge
Loss of delta time
Cap 271 not
able to charge circuit function for
DT/DT circuit
fully
Loss of bias
voltages
Loss of bias
voltages,
transformer
may burn open
Charger may
Loss of current
operate at higher
feedback
then normal
voltage
currents
Charger may
Loss of current
operate at higher
feedback
then normal
voltage
currents
Loss of main
output current
Excessive
current in T202
Loss of gate
driver signal
Loss of gate
driver signal
Q401 will self
Bottom FET
destruct due to
On
excessive currents
back up heater
circuit will not Marginal
function
Fault indicator is
always on
Minor
Battery may be
undercharged
Minor
Battery may be
undercharged
Minor
Charger will not

Marginal
operate
Charger will not
Marginal
operate
Aircraft breakers
Marginal
may trip
Aircraft breakers
Marginal
may trip
Charger will not
operate
Aircraft breakers
may trip
Charger will not
operate
Charger will not
operate
Marginal
Marginal
Marginal
Marginal
Charger will not

Marginal
operate

Record Ref.
#
Des.
FMECA Analysis
Description
Part Type
Part #
Failure
Mode
Local Effect
439
U400
Driver
IR2110
HO Hi
Top FET On
440
U400
Driver
IR2110
VS Hi
Bridge Bus
Voltage Low
441
U401
Driver
IR2110
LO Hi
Bottom FET
On
442
U401
Driver
IR2110
HO Hi
Top FET On
443
U401
Driver
IR2110
VS Hi
444
U400
Driver
IR2110
LO Lo
445
U400
Driver
IR2110
HO Lo
446
U400
Driver
IR2110
VS Lo
447
U401
Driver
IR2110
LO Lo
448
U401
Driver
IR2110
HO Lo
449
U401
Driver
IR2110
VS Lo
450
U202 5962-8410901PX, ADJUSTABLE PRE
Driver
5962-8410901PX
short
451
Driver
5962-8410901PX
open
452
U203 UC1846,Current Mode PWM Controller Controller
UC1846
high
453
UC1846
low
40
Next Higher Effect

Q400 will self
destruct due to
excessive currents
Q400, Q401 will see
higher then normal
currents
Q403 will self
destruct due to
excessive currents
Q402 will self
destruct due to
excessive currents
Q402, Q403 will see
higher then normal
currents
End Effect
Charger will not

Marginal
operate
Charger may not
operate at rated
current
Minor
Charger will not

Marginal
operate
Charger will not
Marginal
operate
Charger may not

operate at rated
current
Bottom FET
Charger will not
operate
Off
Charger will not
Top FET Off
operate
Bridge Bus
Charger will not
operate
Grounded
Bottom FET
Charger will not
operate
Off
Charger will not
Top FET Off
operate
Bridge Bus
Charger will not
Grounded
operate
Charger may not
Voltage
Charger peak
charge battery
reference into
voltage is reduced
correctly
U203 is too low
Voltage
Charger may not
Charger peak
reference into
charge battery
U203 is too voltage is increased
correctly
high
Mosfet Drivers
Charger will not
operate
will not function
Mosfet Drivers
Charger will not
will not function
operate
Bridge Bus
Voltage Low
Severity
Minor
Marginal
Marginal
Marginal
Marginal
Marginal
Marginal
Minor
Minor
Marginal
Marginal

Record Ref.
#
Des.
FMECA Analysis
Description
Part Type
Part #
Failure
Mode
454
U205
LT1014MJ,LINEAR,QUAD,OP-AMP
Op-Amp
LT1014MJ
high
455
U205
Op-Amp
LT1014MJ
low
456
U300
Op-Amp
LT1014MJ
high
457
U300
Op-Amp
LT1014MJ
low
458
U301
Op-Amp
LT1014MJ
high
459
U301
Op-Amp
LT1014MJ
low
460
U305
MICROCIRCUIT,14-STAGETIMER,CD
Timer
CD4060BF
high
461
U305
Timer
CD4060BF
low
462
U306
Timer
CD4060BF
high
463
U306
Timer
CD4060BF
low
464
U303
M38510/05553,
BUFFER/CONVERTER
Converter
M38510/05553
high
465
U303
M38510/05553,
BUFFER/CONVERTER
Converter
M38510/05553
low
466
U304
REF01,10V-PRECISION-REF
voltage ref
REF01
high
467
U304
voltage ref
REF01
low
41
Local Effect
Next Higher Effect
Cold battery
Charger will shut
shut down will
down
be enabled
Hot battery
Charger will shut
shut down will
down
be enabled
Battery faults
Charger will shut
will be enabled
down
Battery faults
Charger will shut
will be enabled
down
Battery faults
Charger will shut
will be enabled
down
Battery hot and
open sensor Charger will not shut
faults will not down on these faults
be enabled
False end to
Charger will skip
the topping
topping mode
mode
Charger will
never complete
topping mode
False output of
battery cell
imbalance
Charger will
never register a
cell imbalance
false hot
battery fault
unable to
register a hot
battery fault
Reference is in All temp circuitry will
not function
an overvoltage
correctly
condition
All temp
circuitry will be
End Effect
Severity
Charger will not

Marginal
operate
Charger will not
Marginal
operate
Charger will not
Marginal
operate
Charger will not
Marginal
operate
Charger will not
Marginal
operate
Battery may be
Marginal
overcharged
Battery may be
undercharged
Minor
Battery may be
undercharged
Minor
Fault indicator is
always on
Minor
Battery may be
Marginal
overcharged
Fault indicator is
always on
Minor
Battery may be
Marginal
overcharged
Erratic charger
Marginal
behavior
Fault indicator is
always on
Minor

Record Ref.
#
Des.
468
469
Description
Part Type
LM117H,VOLTAGE-REGULATOR,TORegulator
39
LM117H,VOLTAGE-REGULATOR,TOU213
Regulator
39
U213
FMECA Analysis
Part #
Failure
Mode
LM117H
high
LM117H
low
470
U302
AD712, DUAL-PRECISION, HIGH SP
Op-Amp
AD712
high
471
U302
AD712, DUAL-PRECISION, HIGH SP
Op-Amp
AD712
low
42
Local Effect
in a faulted
condition
15V Over
voltage
Loss of 15V
Next Higher Effect
End Effect
Severity
Erratic charger
Marginal
behavior
Charger will not
Marginal
operate
Charger will
Charger will remain
Battery will be
never register a
Marginal
in main topping
overcharged
delta T
mode
condition
Charger will go
Charger will
always register directly to topping Battery may be
Minor
mode, skipping main undercharged
a delta T
mode
condition
FMECA Analysis
Table 1.3-3: Results sorted by Criticality

Record Ref.
#
Des.
Description
Part Type
Part #
Failure Mode
C403
M39014/02-1310,.1uf,100V,10%
Capacitor
M39014/02-1310
open
C403
M39014/02-1310,.1uf,100V,10%
Capacitor
M39014/02-1310
shorted
C239
M39014/02-1310,.1uf,100V,10%
Capacitor
M39014/02-1310
open
C239
M39014/02-1310,.1uf,100V,10%
Capacitor
M39014/02-1310
shorted
C246
M39014/02-1310,.1uf,100V,10%
Capacitor
M39014/02-1310
open
C246
M39014/02-1310,.1uf,100V,10%
Capacitor
M39014/02-1310
shorted
C252
M39014/02-1310,.1uf,100V,10%
Capacitor
M39014/02-1310
open
C252
M39014/02-1310,.1uf,100V,10%
Capacitor
M39014/02-1310
shorted
C268
M39014/02-1310,.1uf,100V,10%
Capacitor
M39014/02-1310
shorted
10
C207
CK61AW222M,2200pf,500V,20%
Capacitor
CK61AW222M
shorted
11
C266
CK61AW222M,2200pf,500V,20%
Capacitor
CK61AW222M
shorted
43
Local Effect
Next Higher Effect
U401, possible
Increased Noise
on VCC for U401 destruction of Q402,
Q403,
End Effect
Severity
Charger will not

operate
Marginal
Charger will not

operate
Increased noise Erratic operation of
Charger may
on inhibit line
U205
operate erratically
Charger will never
Inhibit function
turn off, battery will
disabled
be overcharged
Possible premature
Increased Ripple
switch into topping
on +10V
mode
Temperature
circuits will not
Loss of 10V
operate, charger
Loss of +10V
Reference Voltage
may remain in main
mode charge
Charger Topping
Clock input to
Battery may not
timer circuit not
U305 will not
receive a full charge
function properly functioning properly
Charger will remain
Clock input to
in topping mode,
U305 will not
battery will be
function
overcharged
U302A has the
The charger will
Battery will be
input shorted to
remain in main mode
overcharged
ground
Loss of Phase B,
Loss of Phase B,
phase B is
aircraft circuit
shorted to
breaker will trip
chassis
Loss of Phase A,
Loss of Phase A,
phase A is
aircraft circuit
shorted to
breaker will trip
Loss of Driver
Marginal
Marginal
Marginal
Marginal
Marginal
Marginal
Marginal
Marginal
Marginal
Marginal

Record Ref.
#
Des.
Description
Part Type
FMECA Analysis
Part #
Failure Mode
Local Effect
Next Higher Effect
End Effect
chassis
Loss of PWM
u203 switching
Loss of PWM
u203 switching
Loss of Power
transformer output
Loss of Power
transformer output
Charger will not

operate
Charger will not
operate
Charger will not
operate
12
C224
M39014/01-1317,1000pf,200V,10%
Capacitor
M39014/01-1317
open
13
C224
M39014/01-1317,1000pf,200V,10%
Capacitor
M39014/01-1317
shorted
14
C211
235BC834-1-, 68uF, 60V, 10%
Capacitor
235BC834-1-
shorted
Loss of 15V
15
C222
235BC834-1-, 68uF, 60V, 10%
Capacitor
235BC834-1-
open
Increased noise
on current limit
circuit
C228
235BC834-1-, 68uF, 60V, 10%
Capacitor
235BC834-1-
open
17
C228
235BC834-1-, 68uF, 60V, 10%
Capacitor
235BC834-1-
shorted
18
C212
235BC833-1-, 150uF, 35V, 20%
Capacitor
235BC833-1-
shorted
Loss of 12V
19
C213 CKR05BX471KR,470pF,10%,200V,(R Capacitor
CKR05BX471KR
shorted
Loss of 15V
20
C215 U767D250VG47RM19X29LL,47uF,250 Capacitor
U767D250VG47RM19X
29LL
open
21
U767D250VG47RM19X
29LL
shorted
22
U767D250VG47RM19X
29LL
open
23
U767D250VG47RM19X
29LL
shorted
24
C219
Capacitor
M39014/02-1320
shorted
25
C401 CKR06BX473KM,.047uF,10%,100V,(
Capacitor
CKR06BX473KM
shorted
M39014/02-1320,.47uf,50V,10%
44
Increased ripple
on 170VDC
BUSS
Increased ripple
on 170VDC
BUSS
Increased ripple
on 170VDC
BUSS
Increased ripple
on 170VDC
BUSS
PWM can not

maintain control of
system
PWM can not
maintain control of
system
PWM can not
maintain control of
system
PWM can not
maintain control of
system
Loss of 15V
FET Drive Signal Reduced VS bus V,
Marginal
Marginal
Marginal
Peak current during

Marginal
charge is erratic
U401 and U400,
Increased noise
on Mosfet Drivers
of Q400, 401, 402,
403
Loss of Driver
signal
16
Severity
Charger will not

operate
Marginal
Charger will not

Marginal
operate
Temperature
circuits will not
operate, charge Marginal
may remain in main
mode charge
Charger will not
Marginal
operate
Charger operates
Marginal
erratically
Charger operates
Marginal
erratically
Charger operates
Marginal
erratically
Charger operates
Marginal
erratically
Charger will not
operate
Charger may not
Marginal
Marginal

Record Ref.
#
Des.
Description
Part Type
FMECA Analysis
Part #
Failure Mode
26
C225 CKR06BX473KM,.047uF,10%,100V,(
Capacitor
CKR06BX473KM
open
27
C225 CKR06BX473KM,.047uF,10%,100V,(
Capacitor
CKR06BX473KM
shorted
28
C402 CKR06BX473KM,.047uF,10%,100V,(
Capacitor
CKR06BX473KM
shorted
29
C221
Capacitor
M39014/01-1522
shorted
30
C223 CKR06BX104KM,.1uF,10%,100V,(M)
Capacitor
CKR06BX104KM
open
31
C223 CKR06BX104KM,.1uF,10%,100V,(M)
Capacitor
CKR06BX104KM
shorted
32
C230
235BC835-1, 1200uF, 50V, 10%
Capacitor
235BC835-1
shorted
33
C231
235BC835-1, 1200uF, 50V, 10%
Capacitor
235BC835-1
shorted
34
C232
M39014/02-1415,1uf,50V,10%
Capacitor
M39014/02-1415
shorted
35
C308
M39014/02-1415,1uf,50V,10%
Capacitor
M39014/02-1415
open
36
C308
M39014/02-1415,1uf,50V,10%
Capacitor
M39014/02-1415
shorted
M39014/01-1522,.0018uf,100V,10
45
Local Effect
Next Higher Effect
End Effect
Altered
excessive current
flow
operate
Loss of Power
Transformer output
Charger will not

operate
PWM output
signal does not
reach T203
Charger may not

Signal reaching
PWM output
operate, or will
MOSFET Drivers is
signal is altered
operate erratically
distorted
Reduced VS bus V,
Charger may not
FET Drive Signal
excessive current
operate
Altered
flow
Charger PWM
voltage
TL431 Anode Ref
compensation is not
shorted
working
PWM Charger
Charger may not
compensation is
operate
altered
PWM Charger
Charger may not
compensation is
operate
altered
Charger may not
operate, or
Charger output Capacitor will quickly
Increased EMI on
shorted
burn open
charger output
Charger may not
operate, or
Increased EMI on
shorted
burn open
charger output
Charger may not
operate, or
Increased EMI on
shorted
burn open
charger output
Possible premature
Increased noise
switch into topping
on U302A
mode
Charger will never
U302A has the
Charger will stay in
turn off, battery will
input shorted to
main mode
be overcharged
ground
Severity
Marginal
Marginal
Marginal
Marginal
Marginal
Marginal
Marginal
Marginal
Marginal
Marginal
Marginal

Record Ref.
#
Des.
Description
Part Type
FMECA Analysis
Part #
Failure Mode
37
C310
M39014/02-1415,1uf,50V,10%
Capacitor
M39014/02-1415
shorted
38
C314
M39014/02-1415,1uf,50V,10%
Capacitor
M39014/02-1415
open
39
C314
M39014/02-1415,1uf,50V,10%
Capacitor
M39014/02-1415
shorted
40
C320
M39014/02-1415,1uf,50V,10%
Capacitor
M39014/02-1415
open
41
C320
M39014/02-1415,1uf,50V,10%
Capacitor
M39014/02-1415
shorted
42
C305
M39014/02-1415,1uf,50V,10%
Capacitor
M39014/02-1415
shorted
43
C317
M39014/01-1535,.01uf,100V,10%
Capacitor
M39014/01-1535
open
44
C317
M39014/01-1535,.01uf,100V,10%
Capacitor
M39014/01-1535
shorted
45
C316
M39014/01-1535,.01uf,100V,10%
Capacitor
M39014/01-1535
open
46
C316
M39014/01-1535,.01uf,100V,10%
Capacitor
M39014/01-1535
shorted
47
C400
40L3101, 1uF, 400V, 10%
Capacitor
40L3101
open
48
C400
40L3101, 1uF, 400V, 10%
Capacitor
40L3101
shorted
46
Local Effect
Next Higher Effect
End Effect
Severity
Temperature
circuits will not
Loss of 10V
operate, charger Marginal
Loss of +10V
Reference Voltage
may remain in main
mode charge
Possible false timer
Input to U305 will counting resulting in Battery may not
Marginal
not be filtered lower time in topping receive a full charge
mode
Timer will always be
Input to U305 will
Battery may not
operating, resulting
Marginal
be shorted, 208
in reduced time in receive a full charge
always on
topping mode
Charger may have
Charger may
Loss of filtering
excessive noise on
Marginal
operate erratically
on U305 output
the disable line
Clock input can
Charger will remain
not be shut off on
Marginal
in topping mode
U305
The temp voltage
Battery will be
will be passed to The charger will
Marginal
remain in main mode
overcharged
the input of
U302A
Increased Noise
Possible oscillations
on main/topping
between main and Marginal
line
topping mode
Low on main /
Charger will stay in
Marginal
topping mode
topping line
Charger will
Clock oscillator
Charger may stay in
on U305 will not
topping mode
battery
work correctly
Charger will
Clock oscillator
Charger may stay in
on U305 will not
topping mode
battery
work correctly
Charger will not
Loss of Driver
Marginal
operate
Charger will not
Increased noise
U401 and U400,
Marginal
operate
on Mosfet Drivers

Record Ref.
#
Des.
Description
Part Type
FMECA Analysis
Part #
Failure Mode
Local Effect
Next Higher Effect
End Effect
Severity
Battery will be
overcharged
Marginal
Battery will be
overcharged
Marginal
Battery will be
overcharged
Marginal
of Q400, 401, 402,

403
49
C306
M39014/01-1293,47pf,200V,10%
Capacitor
M39014/01-1293
shorted
50
C304
FFB14D0336K, 33uF, 75V,10%
Capacitor
FFB14D0336K
open
51
C304
FFB14D0336K, 33uF, 75V,10%
Capacitor
FFB14D0336K
shorted
52
Diode
1N5552
The temp voltage

will be passed to The charger will
remain in main mode
the input of
U302A
Delta temp/time
No stored voltage circuit will not work,
charger will remain
across C271
in main mode
U302A has the
The charger will
input shorted to
remain in main mode
ground
open
Loss of 1/2 of
phase A
rectification
53
Diode
1N5552
shorted
Diode will burn

open with
excessive
currents
54
Diode
1N5552
open
Loss of 1/2 of
phase A
rectification
55
Diode
1N5552
shorted
Diode will burn

open with
excessive
currents
56
Diode
1N5552
open
Loss of 1/2 of
phase B
rectification
57
Diode
1N5552
shorted
58
Diode
1N5552
open
47
Diode will burn

open with
excessive
currents
Loss of 1/2 of
phase B
Phase B and C will

Increased ripple on draw higher current,
this may trip the
the C215
aircraft breaker
Phase B and C will
this may trip the
the C215
aircraft breaker
Phase B and C will
this may trip the
the C215
aircraft breaker
Phase B and C will
this may trip the
the C215
aircraft breaker
Phase A and C will
this may trip the
the C215
aircraft breaker
Phase A and C will
this may trip the
the C215
aircraft breaker
Increased ripple on Phase A and C will
the C215
draw higher current,
Marginal
Marginal
Marginal
Marginal
Marginal
Marginal
Marginal

Record Ref.
#
Des.
Description
Part Type
FMECA Analysis
Part #
Failure Mode
Local Effect
Next Higher Effect
End Effect
rectification
59
Diode
1N5552
shorted
60
Diode
1N5552
open
61
Diode
1N5552
shorted
62
Diode
1N5552
open
63
Diode
1N5552
shorted
64
Diode
1N5552
open
65
Diode
1N5552
shorted
66
Diode
1N5552
open
67
Diode
1N5552
shorted
68
CR206
JANTX1N5614,1.0A,200V
Diode
JANTX1N5614
open
69
CR206
JANTX1N5614,1.0A,200V
Diode
JANTX1N5614
shorted
70
CR207
JANTX1N5614,1.0A,200V
Diode
JANTX1N5614
open
48
this may trip the

aircraft breaker
Phase A and C will
Diode will burn
open with
this may trip the
the C215
excessive
aircraft breaker
currents
Phase A and B will
Loss of 1/2 of
phase C
this may trip the
the C215
rectification
aircraft breaker
Phase A and B will
Diode will burn
open with
this may trip the
the C215
excessive
aircraft breaker
currents
Phase A and B will
Loss of 1/2 of
phase C
this may trip the
the C215
rectification
aircraft breaker
Phase A and B will
Diode will burn
open with
this may trip the
the C215
excessive
aircraft breaker
currents
Charger may not
Main output
Excessive noise on
operate, or will
rectifier is disable
charger output
operate erratically
Charger may not
Excessive noise
operate, or will
on charger output
operate erratically
Charger may not
Main output
Excessive noise on
operate, or will
rectifier is disable
charger output
operate erratically
Charger may not
Excessive noise
operate, or will
on charger output
operate erratically
Reduction in the Reduction in the 15V Charger may not
24V
supply
operate
Oscillation in 15V
Charger may not
24V will oscillate
supply
operate
Reduction in the Reduction in the 15V Charger may not
Severity
Marginal
Marginal
Marginal
Marginal
Marginal
Marginal
Marginal
Marginal
Marginal
Marginal
Marginal
Marginal

Record Ref.
#
Des.
Description
Part Type
FMECA Analysis
Part #
Failure Mode
Local Effect
Next Higher Effect
End Effect
24V
supply
Oscillation in 15V
supply
Reduction in the 15V
supply
Oscillation in 15V
supply
Reduction in the 15V
supply
Oscillation in 15V
supply
operate
Charger may not
operate
Charger may not
operate
Charger may not
operate
Charger may not
operate
Charger may not
operate
Charger may not
operate
Charger may not
operate
Charger may not
operate
Charger may not
operate
Charger will be
overstressed and
may fail to operate
Charger will be
overstressed and
may fail to operate
Charger will be
overstressed and
may fail to operate
Charger will be
overstressed and
may fail to operate
Charger may not
operate, or will
operate erratically
Charger may not
operate, or will
operate erratically
Charger may not
operate, or will
71
CR207
JANTX1N5614,1.0A,200V
Diode
JANTX1N5614
shorted
24V will oscillate
72
CR208
JANTX1N5614,1.0A,200V
Diode
JANTX1N5614
open
Reduction in the
24V
73
CR208
JANTX1N5614,1.0A,200V
Diode
JANTX1N5614
shorted
24V will oscillate
74
CR209
JANTX1N5614,1.0A,200V
Diode
JANTX1N5614
open
Reduction in the
24V
75
CR209
JANTX1N5614,1.0A,200V
Diode
JANTX1N5614
shorted
24V will oscillate
76
CR400
Diode
1N5809
open
77
CR400
Diode
1N5809
shorted
78
CR405
Diode
1N5809
open
79
CR405
Diode
1N5809
shorted
80
CR402 1N6642,300ma, 2.5A, SWITCHING
Diode
1N6642
open
Current mode of
charger is altered
81
Diode
1N6642
open
Current mode of
charger is altered
82
Diode
1N6642
open
Current mode of
charger is altered
83
Diode
1N6642
open
Current mode of
charger is altered
84
Diode
1N6642
open
Mosfet driver will Charger will operate

not receive signal
erratically
85
Diode
1N6642
shorted
86
Diode
1N6642
open
49
FET Drive Signal

Altered
FET Drive Signal
Altered
FET Drive Signal
Altered
FET Drive Signal
Altered
Reduced VS bus I/V

Dramatically
Reduced VS bus I/V
Reduced VS bus I/V
Dramatically
Reduced VS bus I/V
Charger may
operate at a higher
then normal current
Charger may
operate at a higher
then normal current
Charger may
operate at a higher
then normal current
Charger may
operate at a higher
then normal current
Mosfet driver will

receive altered
erratically
signal
not receive signal
erratically
Severity
Marginal
Marginal
Marginal
Marginal
Marginal
Marginal
Marginal
Marginal
Marginal
Marginal
Marginal
Marginal
Marginal
Marginal
Marginal
Marginal

Record Ref.
#
Des.
Description
Part Type
FMECA Analysis
Part #
Failure Mode
87
Diode
1N6642
shorted
88
Diode
1N6642
open
89
Diode
1N6642
shorted
90
Diode
1N6642
open
91
Diode
1N6642
shorted
92
CR222
Diode
JANTX1N4148-1
open
93
CR222
Diode
JANTX1N4148-1
shorted
94
CR309
Diode
JANTX1N4148-1
shorted
95
CR312
Diode
JANTX1N4148-1
open
96
CR312
Diode
JANTX1N4148-1
shorted
97
CR314
Diode
JANTX1N4148-1
open
98
CR314
Diode
JANTX1N4148-1
shorted
99
CR315
Diode
JANTX1N4148-1
open
50
Local Effect
Next Higher Effect
End Effect
operate erratically
Charger may not
Mosfet driver will
operate, or will
receive altered
erratically
operate erratically
signal
Charger may not
operate, or will
not receive signal
erratically
operate erratically
Charger may not
Mosfet driver will
operate, or will
receive altered
erratically
operate erratically
signal
Charger may not
operate, or will
not receive signal
erratically
operate erratically
Charger may not
Mosfet driver will
operate, or will
receive altered
erratically
operate erratically
signal
Inhibit function Charger can not be
Battery will be
disabled
shut off
overcharged
Excessive
Charger can not be
Battery will be
current into
shut off
overcharged
opamp U205
Direct current
Will disable open
Battery will be
path into U301
sensor fault
overcharged
U301 output will
Open sensor fault
Battery will be
not register the
will not work
overcharged
fault
Possible high
Hot battery fault may
Battery will be
current input into
not work
overcharged
U301
Unit will return to
Battery will be
Clock will not
topping mode after it
overcharged
stop counting
should have shut off
Clock will not
Unit will remain in
Battery will be
function correctly
topping mode
overcharged
Will prevent
topping mode
Charger will remain
Battery will be
timer from
in main mode
overcharged
disabling the
charger
Severity
Marginal
Marginal
Marginal
Marginal
Marginal
Marginal
Marginal
Marginal
Marginal
Marginal
Marginal
Marginal
Marginal

Record Ref.
#
Des.
Description
Part Type
FMECA Analysis
Part #
Failure Mode
Local Effect
Next Higher Effect
End Effect
Severity
Charger will remain

in main mode
charge during a
Marginal
faulted condition,
battery will be
overcharged
100
CR315
Diode
JANTX1N4148-1
shorted
High current path

into the timer
circuit, may
damage U305
101
CR313
Diode
JANTX1N4148-1
open
Clock on U306
will not be
disabled
battery tap fault will

become intermittent
Battery may be
overcharged
Marginal
Clock on U306
may not operate
correctly
3 minute timer on
battery tap fault
circuit may not
operate correctly
Battery may be
overcharged
Marginal
102
CR313
Diode
JANTX1N4148-1
shorted
103
CR235
Diode
JANTX1N4148-1
open
104
CR235
Diode
JANTX1N4148-1
shorted
105
CR236
Diode
JANTX1N4148-1
open
106
CR236
Diode
JANTX1N4148-1
shorted
107
CR237
Diode
JANTX1N4148-1
open
108
CR237
Diode
JANTX1N4148-1
shorted
109
CR238
Diode
JANTX1N4148-1
open
110
CR238
Diode
JANTX1N4148-1
shorted
111
CR303
FJT1100
Diode
FJT1100
open
51
Hysteresis for
U205 is
inoperative
Hysteresis for
U205 is shifted or
inoperative
High cell
imbalance will
not work
High current path
into the U205,
may damage IC
Hysteresis for
U205 is
inoperative
Hysteresis for
U205 is shifted or
inoperative
Low cell
imbalance will
not work
High current path
into the U205,
may damage IC
The heater
blanket may be
Oscillations in
battery tap circuit
function correctly
function correctly
Oscillations in
battery tap circuit
function correctly
function correctly
Heater blanket will

cause false delta T,
Battery tap circuit

will fail, battery may
be overcharged
Battery tap circuit
be overcharged
Battery tap circuit
be overcharged
Battery tap circuit
be overcharged
Battery tap circuit
be overcharged
Battery tap circuit
be overcharged
Battery tap circuit
be overcharged
Battery tap circuit
be overcharged
Battery will be
undercharged, or
Marginal
Marginal
Marginal
Marginal
Marginal
Marginal
Marginal
Marginal
Marginal

Record Ref.
#
Des.
Description
Part Type
FMECA Analysis
Part #
Failure Mode
Local Effect
on when the
charger is in
main mode
Will prevent
U302 from
latching on delta
T
Delta T circuit will
not work
Delta T circuit will
not work
112
CR302
FJT1100
Diode
FJT1100
open
113
CR300
FJT1100
Diode
FJT1100
shorted
114
CR301
FJT1100
Diode
FJT1100
shorted
115
J1
CI
Connector
D38999-20WD15PN
open
No input power
116
J1
CI
Connector
D38999-20WD15PN
shorted
Connector will
burn itself open
117
J103
CONNECTOR
Connector
WTB20SAD9SY342
open
No input power
118
J103
CONNECTOR
Connector
WTB20SAD9SY342
shorted
Connector will
burn itself open
119
J104
CONNECTOR
Connector
WTB24SAD9SY342
open
No battery temp
signals
120
J104
CONE
Connector
WTB24SAD9SY342
shorted
No battery temp
signals
121
J2
CI
Connector
D38999-20WD97PN
open
No battery temp
signals
122
J2
CI
Connector
D38999-20WD97PN
shorted
No battery temp
signals
123
J205
Connector
WT4SAD9
open
124
J205
Connector
WT4SAD9
shorted
125
J206
Connector
WT4SAD9
open
WT4SAD9, 4 POSITION
RECEPTACLE
WT4SAD9, 4 POSITION
RECEPTACLE
WT4SAD9, 4 POSITION
RECEPTACLE
52
Mosfet drivers
are disabled
Mosfet drivers
are disabled
Main transformer
is disabled
Next Higher Effect
End Effect
Severity
causing premature aircraft breaker may

switch to topping
trip
May cause charger
to return to main
mode charge
Charger will remain
in main mode
Charger will remain
in main mode
Battery will be
overcharged
Battery may be
overcharged
Battery may be
overcharged
Charger will not
operate
Charger will not
operate, aircraft
breaker will trip
Charger will not
operate
Charger will not
operate, aircraft
breaker will trip
Charger will not
operate, charger will
register a fault
Charger will not
register a fault
Charger will not
register a fault
Charger will not
register a fault
Charger will not
operate
Charger will not
operate
Charger will not
operate
Marginal
Marginal
Marginal
Marginal
Marginal
Marginal
Marginal
Marginal
Marginal
Marginal
Marginal
Marginal
Marginal
Marginal

Record Ref.
#
Des.
FMECA Analysis
Description
Part Type
Part #
Failure Mode
Local Effect
WT4SAD9, 4 POSITION
RECEPTACLE
Connector
WT4SAD9
shorted
Main transformer
is shorted
Connector
WT4SAD9
open
Connector
WT4SAD9
shorted
Inductor
335BC105-1
open
Inductor
335BC105-1
shorted
126
J206
127
J207
128
J207
129
L100
130
L100
131
Inductor
335BC108-1
open
132
Inductor
335BC108-1
shorted
133
L201
Inductor
235BC103-1
open
134
L202
Inductor
235BC103-1
open
135
Inductor
335BC106-1
open
136
Inductor
335BC106-1
open
137
Inductor
335BC107-1
open
138
P203

CON
Connector
WTB20PR9SY342
open
139
P203

CON
Connector
WTB20PR9SY342
shorted
140
P204

CON
Connector
WTB20PR9SY342
open
141
P204

CON
Connector
WTB20PR9SY342
shorted
Charger output is
shorted
142
P205
Connector
WT4PRD8-Top
open
Mosfet drivers
WT4SAD9, 4 POSITION
RECEPTACLE
WT4SAD9, 4 POSITION
RECEPTACLE
CHOKE
CHOKE
53
Next Higher Effect
Mosfet drivers
are disabled
Mosfet drivers
are disabled
Lose of Phase A, Increased current on
B or C
remaining phases
Unbalanced Input
V, excessive
currents
Lose of Phase A, Increased current on
B or C
remaining phases
Unbalanced Input
V, excessive
currents
Loss of DC buss
voltage
Loss of DC buss
voltage
No charger
output
No charger
output
No charger
output
Battery tap is
missing
Several signal
are shorted
together
Charger output is
open
Tap circuit will

register a fault
End Effect
Charger will not
operate, aircraft
breaker will trip
Charger will not
operate
Charger will not
operate
Blow aircraft
breaker
Severity
Marginal
Marginal
Marginal
Marginal
Blow aircraft
breaker
Marginal
Blow aircraft
breaker
Marginal
Blow aircraft
breaker
Marginal
Charger will not

operate
Charger will not
operate
Charger will not
operate
Charger will not
operate
Charger will not
operate
Charger will shut
down based on the
tap fault
Charger will not
operate
Charger will not
operate
Charger will not
operate, aircraft
breaker will trip
Charger will not
Marginal
Marginal
Marginal
Marginal
Marginal
Marginal
Marginal
Marginal
Marginal
Marginal

Record Ref.
#
Des.
143
P205
144
P206
145
P206
146
P207
147
P207
148
Q400
149
Description
ANGLE
ANGLE
ANGLE
Part Type
FMECA Analysis
Part #
Failure Mode
Local Effect
are disabled
Mosfet drivers
are disabled
Main transformer
is disabled
Connector
WT4PRD8-Top
shorted
Connector
WT4PRD8-Top
open
Connector
WT4PRD8-Top
shorted
Connector
WT4PRD8-Top
open
Connector
WT4PRD8-Top
shorted
Transistor
IRF450
openD
Q400
Transistor
IRF450
shortedVDS
150
Q401
Transistor
IRF450
openD
151
Q401
Transistor
IRF450
shortedVDS
152
Q402
Transistor
IRF450
openD
153
Q402
Transistor
IRF450
shortedVDS
154
Q403
Transistor
IRF450
openD
155
Q403
Transistor
IRF450
shortedVDS
156
Q202 2N2907AJANTX,TRANS,PNP,60VCE Transistor
2N2907AJTX
open
157
Q202 2N2907AJANTX,TRANS,PNP,60VCE Transistor
2N2907AJTX
shorted
158
R214
RLR07C2741FS 2.74K 1% 1/4W (S)
Resistor
RLR07C2741FS
open
15V goes to 24V

(Vin)
159
R358
RLR07C2741FS 2.74K 1% 1/4W (S)
Resistor
RLR07C2741FS
open
2nd thermister

ANGLE
ANGLE
ANGLE
54
Next Higher Effect
Main transformer
is shorted
Mosfet drivers
are disabled
Mosfet drivers
are disabled
No Bridge to Bus Reduced Bridge bus
connection
I/V
Bus connected to Overvoltage/Current
CS XFMR
on Bridge Bus
No Bridge to
Overvoltage on
Ground
Bridge Bus
connection
Bridge Bus
Low voltage/High I
Grounded
on Bridge Bus
No Bridge to Bus
Reduced VS bus I/V
connection
Bus connected to Overvoltage/Current
Power XFMR
on VS Bus
No Bridge to
Overvoltage on VS
Ground
Bus
connection
Bridge Bus
Low voltage/High I
Grounded
on Bridge Bus
Main/topping
mode is disabled
Main/topping
mode is disabled
End Effect
operate
Charger will not
operate
Charger will not
operate
Charger will not
operate, aircraft
breaker will trip
Charger will not
operate
Charger will not
operate
Charger will not
operate
Charger will not
operate
Charger will not
operate
Severity
Marginal
Marginal
Marginal
Marginal
Marginal
Marginal
Marginal
Marginal
Charger will not

operate
Charger will not
operate
Charger will not
operate
Marginal
Charger will not

operate
Marginal
Charger will not

operate
Battery may be
overcharged
Battery may be
overcharged
Charger PWM may
be overstressed,
charger may not
operate
back up heater
Marginal
Marginal
Marginal
Marginal
Marginal
Marginal
Marginal

Record Ref.
#
Des.
Description
Part Type
FMECA Analysis
Part #
Failure Mode
Local Effect
Next Higher Effect
will lose bias

160
R400 RLR07C10R0FS,10ohm,1%,1/4W (S)
Resistor
RLR07C10R0FS
open
FET off
Reduced VS bus V
161
R401 RLR07C10R0FS,10ohm,1%,1/4W (S)
Resistor
RLR07C10R0FS
open
FET off
Reduced VS bus V
162
R403 RLR07C10R0FS,10ohm,1%,1/4W (S)
Resistor
RLR07C10R0FS
open
FET off
Reduced VS bus V
163
R404 RLR07C10R0FS,10ohm,1%,1/4W (S)
Resistor
RLR07C10R0FS
open
FET off
Reduced VS bus V
164
R238 RLR07C10R0FS,10ohm,1%,1/4W (S)
Resistor
RLR07C10R0FS
open
165
R213 RLR07C2490FS,249ohm,1%,1/4W (S
Resistor
RLR07C2490FS
open
166
R332
RLR07C2613FS 261K 1% 1/4W (S)
Resistor
RLR07C2613FS
open
167
R217
RLR07C1003FS,100K,1%,1/4W (S)
Resistor
RLR07C1003FS
open
168
R242
RLR07C1003FS,100K,1%,1/4W (S)
Resistor
RLR07C1003FS
open
169
R243
RLR07C1003FS,100K,1%,1/4W (S)
Resistor
RLR07C1003FS
open
170
R314
RLR07C1003FS,100K,1%,1/4W (S)
Resistor
RLR07C1003FS
open
171
R319
RLR07C1003FS,100K,1%,1/4W (S)
Resistor
RLR07C1003FS
open
172
R320
RLR07C1003FS,100K,1%,1/4W (S)
Resistor
RLR07C1003FS
open
173
R323
RLR07C1003FS,100K,1%,1/4W (S)
Resistor
RLR07C1003FS
open
174
R324
RLR07C1003FS,100K,1%,1/4W (S)
Resistor
RLR07C1003FS
open
55
Mosfet driver
signal is altered
Loss of 15V, 15V
drops below 2V
Hot battery shut
down feedback
on false hot battery
voltage loss
Charger may
Loss of control of
operate at higher
the voltage of
then normal voltages
U202
Loss of reference Inhibit function will
on U205 Input
always be on
Loss of inhibit
signal
Temp sensor
False hot battery
loses bias
fault
Battery heater
Heater control
blanket never comes
reference loss
on
Hot battery shut
down reference
false hot battery
loss
Cold battery shut Charger does not
shut off on cold
down reference
battery
loss
End Effect
circuit will not
function
Charger will not
operate
Charger will not
operate
Charger will not
operate
Charger will not
operate
Charger may not
operate
Charger will not
operate
Severity
Marginal
Marginal
Marginal
Marginal
Marginal
Marginal
Charger is disabled Marginal

Battery may be
overcharged
Charger will not
operate
Battery may be
overcharged
Marginal
Marginal
Marginal

Charger may not
operate under cold Marginal
conditions
Battery may be
overcharged under Marginal
cold conditions
Battery may be
Hot battery fault
No hot battery fault overcharged under Marginal
reference loss
hot conditions

Record Ref.
#
Des.
FMECA Analysis
Description
Part Type
Part #
Failure Mode
175
R327
RLR07C1003FS,100K,1%,1/4W (S)
Resistor
RLR07C1003FS
open
176
R317
RLR07C1003FS,100K,1%,1/4W (S)
Resistor
RLR07C1003FS
open
177
R328
RLR07C1003FS,100K,1%,1/4W (S)
Resistor
RLR07C1003FS
open
178
R218
RNC55H9091FS 9.09K 1% 1/8W (S)
Resistor
RNC55H9091FS
open
179
R219
RNC55H9091FS 9.09K 1% 1/8W (S)
Resistor
RNC55H9091FS
open
180
R220
RLR07C1002FS,10K,1%,1/4W (S)
Resistor
RLR07C1002FS
open
181
R221
RLR07C1002FS,10K,1%,1/4W (S)
Resistor
RLR07C1002FS
open
182
R228
RLR07C1002FS,10K,1%,1/4W (S)
Resistor
RLR07C1002FS
open
183
R233
RLR07C1002FS,10K,1%,1/4W (S)
Resistor
RLR07C1002FS
open
184
R237
RLR07C1002FS,10K,1%,1/4W (S)
Resistor
RLR07C1002FS
open
185
R239
RLR07C1002FS,10K,1%,1/4W (S)
Resistor
RLR07C1002FS
open
186
R331
RLR07C1002FS,10K,1%,1/4W (S)
Resistor
RLR07C1002FS
open
187
R333
RLR07C1002FS,10K,1%,1/4W (S)
Resistor
RLR07C1002FS
open
56
Local Effect
Next Higher Effect
Open sensor
No open sensor fault
reference loss
Floating input to Never terminating
op-amp
main mode charge
Loss of temp
sensor input to Never terminating
main mode charge
delta Temp
circuit
Charger may
U202 anode
operate at higher
floating
Charger may
Reduces the 12V
supplied to N+ on operate at higher
U203
Charger may
Loss of the 12V
operate at higher
supplied to U203
Current limit circuit
Q202 will lose
will operate
base drive
erratically
Charger may
VREF output of
operate at higher
the PWM is lost
PWM Feedback
compensation
erratically
circuit is disabled
Mosfet driver
signal is altered
Mosfet driver
signal is altered
Loss of temp
hot battery shut off on hot battery
down
Loss of temp
cold battery shut off on cold battery
down
End Effect
Battery will be
overcharged
Battery will be
overcharged
Severity
Marginal
Marginal
Battery will be
overcharged
Marginal
Battery may be
overcharged
Marginal
Battery may be
overcharged
Marginal
Battery may be
overcharged
Marginal
Battery may be
overcharged
Marginal
Battery may be
overcharged
Marginal
Charger may not

operate, or may be Marginal
overstressed
Charger may not
Marginal
operate
Charger may not
Marginal
operate
Battery may be
hot conditions
Battery may be
cold conditions

Record Ref.
#
Des.
FMECA Analysis
Description
Part Type
Part #
Failure Mode
188
R336
RLR07C1002FS,10K,1%,1/4W (S)
Resistor
RLR07C1002FS
open
189
R347
RLR07C1002FS,10K,1%,1/4W (S)
Resistor
RLR07C1002FS
open
190
R222
RLR07C1693FS,169K,1%,1/4W (S)
Resistor
RLR07C1693FS
open
191
R330
RLR07C1693FS,169K,1%,1/4W (S)
Resistor
RLR07C1693FS
open
192
R402
RLR07C1001FS,1K,1%,1/4W (S)
Resistor
RLR07C1001FS
open
193
R232
RLR07C1001FS,1K,1%,1/4W (S)
Resistor
RLR07C1001FS
open
194
R312
RLR07C1001FS,1K,1%,1/4W (S)
Resistor
RLR07C1001FS
open
195
R329
RLR07C1001FS,1K,1%,1/4W (S)
Resistor
RLR07C1001FS
open
196
R359
RLR07C1001FS,1K,1%,1/4W (S)
Resistor
RLR07C1001FS
open
197
R231
RNC55H5112FS 51.1K 1% 1/8W (S)
Resistor
RNC55H5112FS
open
198
R236
RLR07C2212FS,22.1K,1%,1/4W (S)
Resistor
RLR07C2212FS
open
199
R244
RLR07C1004FS,1Meg,1%,1/4W (S)
Resistor
RLR07C1004FS
open
200
R334
RLR07C1004FS,1Meg,1%,1/4W (S)
Resistor
RLR07C1004FS
open
201
R341
RLR07C1004FS,1Meg,1%,1/4W (S)
Resistor
RLR07C1004FS
open
57
Local Effect
Next Higher Effect
End Effect
Loss of temp
Battery may be
sensor input to No hot battery fault overcharged under
hot battery fault
hot conditions
Charger will not
U305 will lose
Battery will be
operate in topping
input trigger
overcharged
mode
(reset)
Charger may
PWM will lose
Battery may be
operate at higher
part of the
overcharged
reference
Battery may be
Heater control
heated extremely
Battery heater will
feedback voltage
high by the heater
stay on
loss
blanked
Charger will not
Increased base
Reduced charger
operate, or operate
drive current for
output current
at a lower current
Q202
Charger may not
PWM Feedback
operate, or may be
compensation
erratically
overstressed
circuit is disabled
False open sensor
Open sensor
Charger is disabled
fault
Battery may never
Loss of temp
Battery heater will
charge under cold
sensor input to
never turn on
conditions
heater control
back up heater
2nd thermister
circuit will not
will lose bias
function
Charger may not
PWM Feedback
operate, or may be
compensation
erratically
overstressed
circuit is disabled
Loss of PWM
Loss of Power
Charger will not
operate
Loss of inhibit Inhibit function may
Battery may be
bias
not work
overcharged
Cold battery shut
down feedback
Charger is disabled
on false cold battery
voltage loss
U301B will lose a
Battery heater
Battery may be
Severity
Marginal
Marginal
Marginal
Marginal
Marginal
Marginal
Marginal
Marginal
Marginal
Marginal
Marginal
Marginal
Marginal
Marginal

Record Ref.
#
Des.
202
R308
203
Description
RLR07C1004FS,1Meg,1%,1/4W (S)
Part Type
FMECA Analysis
Part #
Failure Mode
Resistor
RLR07C1004FS
open
R248 RJR24CW103R,VAR.-RES.,10K,10%,
Resistor
RJR24CW103R
open
204
R316 RLR07C4640FS 464ohm 1% 1/4W (S
Resistor
RLR07C4640FS
open
205
R315
RLR07C4223FS 422K 1% 1/4W (S)
Resistor
RLR07C4223FS
open
206
R321
RLR07C3832FS 38.3K 1% 1/4W (S)
Resistor
RLR07C3832FS
open
207
R322
RNC55H2742FS 27.4K 1% 1/8W (S)
Resistor
RNC55H2742FS
open
208
R325
RNC55H1742FS 17.4K 1% 1/8W (S)
Resistor
RNC55H1742FS
open
209
R326
RNC55H2612FS 26.1K 1% 1/8W (S)
Resistor
RNC55H2612FS
open
210
R351
RLR07C4754FS 4.75Meg 1% 1/4W (
Resistor
RLR07C4754FS
open
211
R346
RLR07C4754FS 4.75Meg 1% 1/4W (
Resistor
RLR07C4754FS
open
212
R297
RLR07C4754FS 4.75Meg 1% 1/4W (
Resistor
RLR07C4754FS
open
213
R298
RLR07C4754FS 4.75Meg 1% 1/4W (
Resistor
RLR07C4754FS
open
58
Local Effect
Next Higher Effect
End Effect
reference
blanket over temp

fault is inoperative
excessively heated
by the heater
blanket

Clock on U306 not register, charger
will not operate will not shut off on
fault
Charger may go to a
Loss of U202 Ref
higher then normal
control
voltage
False open sensor
Open sensor
fault
False charger
Shifted sensor
temperature
voltage - colder
functions
Hot battery shut Charger does not
shut off on hot
down reference
battery
loss
Cold battery shut
down reference
false cold battery
loss
Hot battery fault False hot battery
reference loss
fault
Open sensor
False open sensor
reference loss
fault
Charger will not
U305 will lose
come out of topping
clock source
mode
Battery tap fault
timer may not
U306 clock
function, inoperative
reference
battery tap fault
will not latch
fault
U205B tap fault Battery tap fault will
will not latch not register, charger
Severity
Battery may be
overcharged
Marginal
Battery may be
overcharged
Marginal

Charger will not
operate correctly
Marginal
Battery may be
overcharged
Marginal

Battery will be
overcharged
Marginal
Battery may be
overcharged
Marginal
Battery may be
overcharged
Marginal
Battery may be
overcharged
Marginal

Record Ref.
#
Des.
Description
Part Type
FMECA Analysis
Part #
Failure Mode
214
R352
RLR07C6813FS 681K 1% 1/4W (S)
Resistor
RLR07C6813FS
open
215
R348
RLR07C2552FS,25.5K,1%,1/4W (S)
Resistor
RLR07C2552FS
open
216
R296 RLR07C1005GR,10Meg,2%,1/4W (R)
Resistor
RLR07C1005GR
open
217
R300
Resistor
RNC55H3652FS
open
218
T200 1.5R18CT,115VAC, 400Hz, 1 PHASE Transformer
1.5R18CT
open
219
T200 1.5R18CT,115VAC, 400Hz, 1 PHASE Transformer
1.5R18CT
shorted
220
T400

TRAN
Transformer
335BC109-1
open
221
T400

TRAN
Transformer
335BC109-1
shorted
222
T202
Transformer
335BC115-1
open
223
T202
Transformer
335BC115-1
shorted
224
T203
Transformer
335BC116-1
open
225
T203
Transformer
335BC116-1
shorted
226
U400
Driver
IR2110
LO Hi
RNC55H3652FS 36.5K 1% 1/8W (S)
335BC115-1, PLANNAR
TRANSFORMER
335BC115-1, PLANNAR
TRANSFORMER
TRAN
TRAN
59
Local Effect
Next Higher Effect

fault
Charger will not
U305 will lose
come out of topping
clock source
mode
Charger will not
Q202 will lose
come out of main
base drive
mode
U306 tap fault
not register, charger
timer will not be
triggered
fault
2nd thermister
will lose bias
Loss of bias
voltages
Loss of bias
voltages,
transformer may
burn open
Charger may
operate at higher
then normal currents
Charger may
Loss of current
operate at higher
feedback voltage
then normal currents
Loss of main
output current
Excessive
current in T202
Loss of gate
driver signal
Loss of gate
driver signal
Q401 will self
Bottom FET On
destruct due to
excessive currents
Loss of current
feedback voltage
End Effect
Severity
Battery will be
overcharged
Marginal
Battery will be
overcharged
Marginal
Battery may be
overcharged
Marginal
back up heater
circuit will not
function
Charger will not
operate
Marginal
Marginal
Charger will not

operate
Marginal
Aircraft breakers
may trip
Marginal
Aircraft breakers
may trip
Marginal
Charger will not

operate
Aircraft breakers
may trip
Charger will not
operate
Charger will not
operate
Charger will not
operate
Marginal
Marginal
Marginal
Marginal
Marginal

Record Ref.
#
Des.
FMECA Analysis
Description
Part Type
Part #
Failure Mode
Local Effect
227
U400
Driver
IR2110
HO Hi
Top FET On
228
U401
Driver
IR2110
LO Hi
Bottom FET On
229
U401
Driver
IR2110
HO Hi
Top FET On
230
U400
Driver
IR2110
LO Lo
Bottom FET Off
231
U400
Driver
IR2110
HO Lo
Top FET Off
232
U400
Driver
IR2110
VS Lo
Bridge Bus
Grounded
233
U401
Driver
IR2110
LO Lo
Bottom FET Off
234
U401
Driver
IR2110
HO Lo
Top FET Off
235
U401
Driver
IR2110
VS Lo
236
UC1846
high
237
UC1846
low
238
U205
Op-Amp
LT1014MJ
high
239
U205
Op-Amp
LT1014MJ
low
240
U300
Op-Amp
LT1014MJ
high
241
U300
Op-Amp
LT1014MJ
low
242
U301
Op-Amp
LT1014MJ
high
60
Bridge Bus
Grounded
Mosfet Drivers
will not function
Mosfet Drivers
will not function
Cold battery shut
down will be
enabled
Hot battery shut
down will be
enabled
Battery faults will
be enabled
Battery faults will
be enabled
Battery faults will
be enabled
Next Higher Effect

Q400 will self
destruct due to
excessive currents
Q403 will self
destruct due to
excessive currents
Q402 will self
destruct due to
excessive currents
End Effect
Severity
Charger will not

operate
Marginal
Charger will not

operate
Marginal
Charger will not

operate
Marginal
Charger will not

operate
Charger will not
operate
Charger will not
operate
Charger will not
operate
Charger will not
operate
Charger will not
operate
Charger will not
operate
Charger will not
operate
Marginal
Marginal
Marginal
Marginal
Marginal
Marginal
Marginal
Marginal
Charger will shut

down
Charger will not

operate
Marginal
Charger will shut

down
Charger will not

operate
Marginal
Charger will shut

down
Charger will shut
down
Charger will shut
down
Charger will not

operate
Charger will not
operate
Charger will not
operate
Marginal
Marginal
Marginal

Record Ref.
#
Des.
Description
Part Type
FMECA Analysis
Part #
Failure Mode
Local Effect
Battery hot and

open sensor Charger will not shut
faults will not be down on these faults
enabled
Charger will
never register a
cell imbalance
unable to register
a hot battery fault
Reference is in
All temp circuitry will
an overvoltage
not function correctly
condition
243
U301
Op-Amp
LT1014MJ
low
244
U306
Timer
CD4060BF
low
245
U303
M38510/05553,
BUFFER/CONVERTER
Converter
M38510/05553
low
246
U304
voltage ref
REF01
high
247
U213
LM117H
high
15V Over voltage
LM117H
low
Loss of 15V
248
LM117H,VOLTAGE-REGULATOR,TORegulator
39
LM117H,VOLTAGE-REGULATOR,TOU213
Regulator
39
249
U302 AD712, DUAL-PRECISION, HIGH SP
Op-Amp
AD712
high
250
251
252
253
254
255
256
257
258
259
260
261
262
263
264
265
266
C100
C100
C101
C101
C102
C102
C103
C103
C104
C104
C105
C105
C106
C106
C107
C107
C108
Capacitor
Capacitor
Capacitor
Capacitor
Capacitor
Capacitor
Capacitor
Capacitor
Capacitor
Capacitor
Capacitor
Capacitor
Capacitor
Capacitor
Capacitor
Capacitor
Capacitor
235BC831-1B
235BC831-1B
235BC831-1B
235BC831-1B
235BC831-1B
235BC831-1B
M39014/02-1310
M39014/02-1310
M39014/02-1310
M39014/02-1310
M39014/02-1310
M39014/02-1310
M39014/02-1310
M39014/02-1310
M39014/02-1310
M39014/02-1310
M39014/02-1310
open
shorted
open
shorted
open
shorted
open
shorted
open
shorted
open
shorted
open
shorted
open
shorted
open
235BC831,2200pf,1000V
235BC831,2200pf,1000V
235BC831,2200pf,1000V
235BC831,2200pf,1000V
235BC831,2200pf,1000V
235BC831,2200pf,1000V
M39014/02-1310,.1uf,100V,10%
M39014/02-1310,.1uf,100V,10%
M39014/02-1310,.1uf,100V,10%
M39014/02-1310,.1uf,100V,10%
M39014/02-1310,.1uf,100V,10%
M39014/02-1310,.1uf,100V,10%
M39014/02-1310,.1uf,100V,10%
M39014/02-1310,.1uf,100V,10%
M39014/02-1310,.1uf,100V,10%
M39014/02-1310,.1uf,100V,10%
M39014/02-1310,.1uf,100V,10%
61
Next Higher Effect
Charger will remain

Charger will
in main topping
never register a
mode
delta T condition
Increase in EMI
Mil-Std 461
Increase in EMI
Mil-Std 461
Increase in EMI
Mil-Std 461
Increase in EMI
Mil-Std 461
Increase in EMI
Mil-Std 461
Increase in EMI
Mil-Std 461
Increase in EMI
Mil-Std 461
Increase in EMI
Mil-Std 461
Increase in EMI
Mil-Std 461
Increase in EMI
Mil-Std 461
Increase in EMI
Mil-Std 461
Increase in EMI
Mil-Std 461
Increase in EMI
Mil-Std 461
Increase in EMI
Mil-Std 461
Increase in EMI
Mil-Std 461
Increase in EMI
Mil-Std 461
Increase in EMI
Mil-Std 461
End Effect
Severity
Battery may be
overcharged
Marginal
Battery may be
overcharged
Marginal
Battery may be
overcharged
Marginal
Erratic charger
behavior
Marginal
Erratic charger
behavior
Charger will not
operate
Marginal
Marginal
Battery will be
overcharged
Marginal
Increased EMI
Increased EMI
Increased EMI
Increased EMI
Increased EMI
Increased EMI
Increased EMI
Increased EMI
Increased EMI
Increased EMI
Increased EMI
Increased EMI
Increased EMI
Increased EMI
Increased EMI
Increased EMI
Increased EMI
Minor
Minor
Minor
Minor
Minor
Minor
Minor
Minor
Minor
Minor
Minor
Minor
Minor
Minor
Minor
Minor
Minor
FMECA Analysis
Record
#
267
268
269
270
271
272
273
274
275
276
277
278
279
280
281
282
283
284
285
Ref.
Des.
C108
C109
C109
C110
C110
C111
C111
C112
C112
C113
C113
C114
C114
C115
C115
C116
C116
C117
C117
Description
Part Type
Part #
Failure Mode
Local Effect
Next Higher Effect
End Effect
Severity
M39014/02-1310,.1uf,100V,10%
M39014/02-1310,.1uf,100V,10%
M39014/02-1310,.1uf,100V,10%
M39014/02-1310,.1uf,100V,10%
M39014/02-1310,.1uf,100V,10%
M39014/02-1310,.1uf,100V,10%
M39014/02-1310,.1uf,100V,10%
M39014/02-1310,.1uf,100V,10%
M39014/02-1310,.1uf,100V,10%
M39014/02-1310,.1uf,100V,10%
M39014/02-1310,.1uf,100V,10%
M39014/02-1310,.1uf,100V,10%
M39014/02-1310,.1uf,100V,10%
M39014/02-1310,.1uf,100V,10%
M39014/02-1310,.1uf,100V,10%
M39014/02-1310,.1uf,100V,10%
M39014/02-1310,.1uf,100V,10%
M39014/02-1310,.1uf,100V,10%
M39014/02-1310,.1uf,100V,10%
Capacitor
Capacitor
Capacitor
Capacitor
Capacitor
Capacitor
Capacitor
Capacitor
Capacitor
Capacitor
Capacitor
Capacitor
Capacitor
Capacitor
Capacitor
Capacitor
Capacitor
Capacitor
Capacitor
M39014/02-1310
M39014/02-1310
M39014/02-1310
M39014/02-1310
M39014/02-1310
M39014/02-1310
M39014/02-1310
M39014/02-1310
M39014/02-1310
M39014/02-1310
M39014/02-1310
M39014/02-1310
M39014/02-1310
M39014/02-1310
M39014/02-1310
M39014/02-1310
M39014/02-1310
M39014/02-1310
M39014/02-1310
shorted
open
shorted
open
shorted
open
shorted
open
shorted
open
shorted
open
shorted
open
shorted
open
shorted
open
shorted
Mil-Std 461
Mil-Std 461
Mil-Std 461
Mil-Std 461
Mil-Std 461
Mil-Std 461
Mil-Std 461
Mil-Std 461
Mil-Std 461
Mil-Std 461
Mil-Std 461
Mil-Std 461
Mil-Std 461
Mil-Std 461
Mil-Std 461
Mil-Std 461
Mil-Std 461
Mil-Std 461
Mil-Std 461
C209
M39014/02-1310,.1uf,100V,10%
Capacitor
M39014/02-1310
open
Increased EMI
Increased EMI
Increased EMI
Increased EMI
Increased EMI
Increased EMI
Increased EMI
Increased EMI
Increased EMI
Increased EMI
Increased EMI
Increased EMI
Increased EMI
Increased EMI
Increased EMI
Increased EMI
Increased EMI
Increased EMI
Increased EMI
Loss of EMI
Filtering
Minor
Minor
Minor
Minor
Minor
Minor
Minor
Minor
Minor
Minor
Minor
Minor
Minor
Minor
Minor
Minor
Minor
Minor
Minor
286
Increase in EMI
Increase in EMI
Increase in EMI
Increase in EMI
Increase in EMI
Increase in EMI
Increase in EMI
Increase in EMI
Increase in EMI
Increase in EMI
Increase in EMI
Increase in EMI
Increase in EMI
Increase in EMI
Increase in EMI
Increase in EMI
Increase in EMI
Increase in EMI
Increase in EMI
Loss of EMI
Filtering
287
C209
M39014/02-1310,.1uf,100V,10%
Capacitor
M39014/02-1310
shorted
288
289
C214
C214
M39014/02-1310,.1uf,100V,10%
M39014/02-1310,.1uf,100V,10%
Capacitor
Capacitor
M39014/02-1310
M39014/02-1310
open
shorted
290
C240
M39014/02-1310,.1uf,100V,10%
Capacitor
M39014/02-1310
open
291
C240
M39014/02-1310,.1uf,100V,10%
Capacitor
M39014/02-1310
shorted
292
C250
M39014/02-1310,.1uf,100V,10%
Capacitor
M39014/02-1310
open
Increased noise
on fault line
293
C250
M39014/02-1310,.1uf,100V,10%
Capacitor
M39014/02-1310
shorted
Gate of Q300
shorted to ground
62
Loss of EMI
Filtering
Increased EMI
Increased EMI
Increased noise
on the low
battery fault line
Low battery fault
always on
Will put excessive

power in R104,
R104 will burn open
Minor
Loss of EMI
Filtering
Minor
Increased EMI
Increased EMI
Minor
Minor
False low battery

fault flickering
Minor
Low battery fault

always on
Possible false
triggering of the
fault indicator
All fault signals will
be disabled
Minor
Minor
Minor

Record Ref.
#
Des.
FMECA Analysis
Description
Part Type
Part #
Failure Mode
294
C257
M39014/02-1310,.1uf,100V,10%
Capacitor
M39014/02-1310
open
295
C257
M39014/02-1310,.1uf,100V,10%
Capacitor
M39014/02-1310
shorted
296
C259
M39014/02-1310,.1uf,100V,10%
Capacitor
M39014/02-1310
open
297
C259
M39014/02-1310,.1uf,100V,10%
Capacitor
M39014/02-1310
shorted
298
C268
M39014/02-1310,.1uf,100V,10%
Capacitor
M39014/02-1310
open
299
C118
CK61AW222M,2200pf,500V,20%
Capacitor
CK61AW222M
open
300
C118
CK61AW222M,2200pf,500V,20%
Capacitor
CK61AW222M
shorted
301
C119
CK61AW222M,2200pf,500V,20%
Capacitor
CK61AW222M
open
302
C119
CK61AW222M,2200pf,500V,20%
Capacitor
CK61AW222M
shorted
303
C120
CK61AW222M,2200pf,500V,20%
Capacitor
CK61AW222M
open
304
C120
CK61AW222M,2200pf,500V,20%
Capacitor
CK61AW222M
shorted
305
C207
CK61AW222M,2200pf,500V,20%
Capacitor
CK61AW222M
open
306
C208
CK61AW222M,2200pf,500V,20%
Capacitor
CK61AW222M
open
63
Local Effect
Next Higher Effect
Increased noise
Increased noise on
on the drain of
the fault output
Q300
drain of Q300
grounded
End Effect
Possible false
triggering of the
fault indicator
Fault output will
always register a
fault
Possible false
triggering of the
fault indicator
Increased noise
False triggering of
on Battery tap
the fault output
fault output
Battery tap fault
output shorted to
not register
ground
May come out of
Noise will get into
main mode charge
the temp circuit
prematurely
Loss of EMI
Loss of EMI
Filtering, Increased
Filtering
EMI
Loss of EMI
Loss of EMI
Excessive power in
Filtering
R100,R100 will open
EMI
Loss of EMI
Loss of EMI
Filtering
EMI
Loss of EMI
Loss of EMI
Excessive power in
Filtering
R101,R101 will open
EMI
Loss of EMI
Loss of EMI
Filtering
EMI
Loss of EMI
Excessive power in
Loss of EMI
R102, R102 will
Filtering
EMI
open
Loss of EMI
Loss of EMI
Filtering
EMI
Loss of EMI
Loss of EMI
Filtering
Filtering
Severity
Minor
Minor
Minor
Minor
Minor
Minor
Minor
Minor
Minor
Minor
Minor
Minor
Minor

Record Ref.
#
Des.
Description
Part Type
FMECA Analysis
Part #
Failure Mode
Local Effect
Loss of Phase C,
phase C is
shorted to the
chassis
Loss of EMI
Filtering
307
C208
CK61AW222M,2200pf,500V,20%
Capacitor
CK61AW222M
shorted
308
C266
CK61AW222M,2200pf,500V,20%
Capacitor
CK61AW222M
open
309
C203
M39014/01-1317,1000pf,200V,10%
Capacitor
M39014/01-1317
open
Loss of EMI
Filtering
310
C203
M39014/01-1317,1000pf,200V,10%
Capacitor
M39014/01-1317
shorted
Loss of EMI
Filtering
311
C256
M39014/01-1317,1000pf,200V,10%
Capacitor
M39014/01-1317
open
312
C256
M39014/01-1317,1000pf,200V,10%
Capacitor
M39014/01-1317
shorted
313
C260
M39014/01-1317,1000pf,200V,10%
Capacitor
M39014/01-1317
open
314
C260
M39014/01-1317,1000pf,200V,10%
Capacitor
M39014/01-1317
shorted
315
C204
235BC815,.1uf, 600V,20%
Capacitor
235BC815-1B
open
Reduced EMI
filtering A-B
316
C204
235BC815,.1uf, 600V,20%
Capacitor
235BC815-1B
shorted
Reduced EMI
filtering A-B
317
C205
235BC815,.1uf, 600V,20%
Capacitor
235BC815-1B
open
Reduced EMI
filtering B-C
318
C205
235BC815,.1uf, 600V,20%
Capacitor
235BC815-1B
shorted
Reduced EMI
filtering B-C
319
C206
235BC815,.1uf, 600V,20%
Capacitor
235BC815-1B
open
Reduced EMI
filtering A-C
64
Increase Noise
on input of
U301B
Reference on
U301B input is
grounded
Battery tap fault
timer may not
work correctly
Battery tap fault
timer may not
work correctly
Next Higher Effect
End Effect
Severity
Loss of Phase C,
aircraft circuit
breaker will trip
Minor
Loss of EMI
Filtering
Loss of EMI
EMI
Loss of EMI
Will put excessive
power in R103,
EMI
R103 will burn open
Possible false
heater blanket fault
Minor
Minor
Minor
Minor
False heater blanket

Minor
over temp fault
Battery tap fault
output may not
register the failure
Battery tap fault
output may not
Reduced EMI
filtering A-B,
Increased EMI
Reduced EMI
Will put excessive
filtering A-B,
power in R204,
Increased EMI
R204 will burn open
Reduced EMI
filtering B-C,
Increased EMI
Reduced EMI
Will put excessive
filtering B-C,
power in R205,
Increased EMI
R205 will burn open
Reduced EMI
filtering A-C,
Minor
Minor
Minor
Minor
Minor
Minor
Minor

Record Ref.
#
Des.
Description
Part Type
FMECA Analysis
Part #
Failure Mode
320
C206
235BC815,.1uf, 600V,20%
Capacitor
235BC815-1B
shorted
321
C210
CFR06RNE473KP, .047uF, 400V, 1
Capacitor
CFR06RNE473KP
open
322
C210
CFR06RNE473KP, .047uF, 400V, 1
Capacitor
CFR06RNE473KP
shorted
323
C217
CFR06RNE473KP, .047uF, 400V, 2
Capacitor
CFR06RNE473KP
open
324
C217
CFR06RNE473KP, .047uF, 400V, 2
Capacitor
CFR06RNE473KP
shorted
325
C218
CFR06RNE473KP, .047uF, 400V, 3
Capacitor
CFR06RNE473KP
open
326
C218
CFR06RNE473KP, .047uF, 400V, 3
Capacitor
CFR06RNE473KP
shorted
327
C211
235BC834-1-, 68uF, 60V, 10%
Capacitor
235BC834-1-
open
328
C222
235BC834-1-, 68uF, 60V, 10%
Capacitor
235BC834-1-
shorted
329
C234
235BC834-1-, 68uF, 60V, 10%
Capacitor
235BC834-1-
open
330
C234
235BC834-1-, 68uF, 60V, 10%
Capacitor
235BC834-1-
shorted
331
C212
235BC833-1-, 150uF, 35V, 20%
Capacitor
235BC833-1-
open
332
C213 CKR05BX471KR,470pF,10%,200V,(R Capacitor
CKR05BX471KR
open
333
C219
M39014/02-1320,.47uf,50V,10%
Capacitor
M39014/02-1320
open
334
C311
M39014/02-1320,.47uf,50V,10%
Capacitor
M39014/02-1320
open
335
C311
M39014/02-1320,.47uf,50V,10%
Capacitor
M39014/02-1320
shorted
336
C401 CKR06BX473KM,.047uF,10%,100V,(
Capacitor
CKR06BX473KM
open
65
Local Effect
Next Higher Effect
Reduced EMI
filtering A-C
Will put excessive

power in R206,
R206 will burn open
End Effect
Increased EMI
Reduced EMI
filtering A-C,
Increased EMI
Loss of EMI
Filtering
Loss of EMI
Filtering
Loss of EMI
Filtering
Loss of EMI
capacitor would
Filtering
quickly burn open
Loss of Bus
Increased EMI
voltage filtering
Bus shorted to
Increased EMI
chassis
Loss of Bus
Increased EMI
voltage filtering
Bus shorted to
Increased EMI
chassis
Reduced 24V
Reduced 15V
stability
Filtering
Current limit
Peak charging
reference is
current limit is
shifted
shifted
Increased EMI on
Increased EMI on
charger output
charger output
Increased EMI on Capacitor will quickly Increased EMI on
charger output
burn open
charger output
Reduced 12V
Reduced 12V
Filtering
Filtering
Reduced 15V
Reduced 15V
stability
stability
Reduced 15V
Reduced 15V
stability
stability
Possible false
Increased noise
triggering of the
on fault line
fault indicator
Gate of Q300
All fault signals will
shorted to ground
be disabled
FET Drive Signal Reduced VS bus I/V reduced charger
Severity
Minor
Minor
Minor
Minor
Minor
Minor
Minor
Minor
Minor
Minor
Minor
Minor
Minor
Minor
Minor
Minor
Minor

Record Ref.
#
Des.
Description
Part Type
FMECA Analysis
Part #
Failure Mode
337
C402 CKR06BX473KM,.047uF,10%,100V,(
Capacitor
CKR06BX473KM
open
338
C221
M39014/01-1522,.0018uf,100V,10
Capacitor
M39014/01-1522
open
339
C229
M39014/01-1529,4700pf,100V,10%
Capacitor
M39014/01-1529
open
340
C229
M39014/01-1529,4700pf,100V,10%
Capacitor
M39014/01-1529
shorted
341
C230
235BC835-1, 1200uF, 50V, 10%
Capacitor
235BC835-1
open
342
C231
235BC835-1, 1200uF, 50V, 10%
Capacitor
235BC835-1
open
343
C232
M39014/02-1415,1uf,50V,10%
Capacitor
M39014/02-1415
open
344
C233
M39014/02-1415,1uf,50V,10%
Capacitor
M39014/02-1415
open
345
C233
M39014/02-1415,1uf,50V,10%
Capacitor
M39014/02-1415
shorted
346
C235
M39014/02-1415,1uf,50V,10%
Capacitor
M39014/02-1415
open
347
C235
M39014/02-1415,1uf,50V,10%
Capacitor
M39014/02-1415
shorted
348
C236
M39014/02-1415,1uf,50V,10%
Capacitor
M39014/02-1415
open
349
C236
M39014/02-1415,1uf,50V,10%
Capacitor
M39014/02-1415
shorted
350
C302
M39014/02-1415,1uf,50V,10%
Capacitor
M39014/02-1415
open
351
C302
M39014/02-1415,1uf,50V,10%
Capacitor
M39014/02-1415
shorted
352
C303
M39014/02-1415,1uf,50V,10%
Capacitor
M39014/02-1415
open
353
C303
M39014/02-1415,1uf,50V,10%
Capacitor
M39014/02-1415
shorted
66
Local Effect
Next Higher Effect
Altered
FET Drive Signal
Reduced VS bus I/V
Altered
Increased noise
on reference
Increased noise
on charger output
Increased noise
on charger output
Increased EMI on
charger output
Increased EMI on
charger output
Increased EMI on
charger output
Increased EMI on
charger output
Increased EMI on Capacitor will quickly
charger output
burn open
Increased EMI on
charger output
charger output
burn open
Increased EMI on
charger output
charger output
burn open
False charger
Increased noise
temperature
on Temp Sensor
functions
Voltage
Shifted sensor
Higher temp then
voltage
actual
False charger
Increased noise
temperature
on Temp Sensor
functions
Voltage
Shorted temp
False Hot battery
sensor
fault
End Effect
efficiency
reduced charger
efficiency
Increased noise on
charger output
Increased EMI on
charger output
Increased EMI on
charger output
Increased EMI on
charger output
Increased EMI on
charger output
Increased EMI on
charger output
Increased EMI on
charger output
Increased EMI on
charger output
Increased EMI on
charger output
Increased EMI on
charger output
Increased EMI on
charger output
Increased EMI on
charger output
Charger may end
main charge mode
prematurely
False Hot battery
fault
Charger may end
main charge mode
prematurely
False Hot battery
fault
Severity
Minor
Minor
Minor
Minor
Minor
Minor
Minor
Minor
Minor
Minor
Minor
Minor
Minor
Minor
Minor
Minor
Minor

Record Ref.
#
Des.
FMECA Analysis
Description
Part Type
Part #
Failure Mode
Local Effect
354
C310
M39014/02-1415,1uf,50V,10%
Capacitor
M39014/02-1415
open
Increased Noise
on VCC
355
C324
M39014/02-1415,1uf,50V,10%
Capacitor
M39014/02-1415
open
Increased noise
on U301C
356
C324
M39014/02-1415,1uf,50V,10%
Capacitor
M39014/02-1415
shorted
U301C shorted to
ground
Increased noise
on the battery
heater blanket
output
357
C267
M39014/02-1415,1uf,50V,10%
Capacitor
M39014/02-1415
open
358
C267
M39014/02-1415,1uf,50V,10%
Capacitor
M39014/02-1415
shorted
359
C305
M39014/02-1415,1uf,50V,10%
Capacitor
M39014/02-1415
open
360
C237
M39014/01-1535,.01uf,100V,10%
Capacitor
M39014/01-1535
open
361
C237
M39014/01-1535,.01uf,100V,10%
Capacitor
M39014/01-1535
shorted
362
C238
M39014/01-1535,.01uf,100V,10%
Capacitor
M39014/01-1535
open
363
C238
M39014/01-1535,.01uf,100V,10%
Capacitor
M39014/01-1535
shorted
364
C300
M39014/01-1535,.01uf,100V,10%
Capacitor
M39014/01-1535
open
365
C300
M39014/01-1535,.01uf,100V,10%
Capacitor
M39014/01-1535
shorted
366
C301
M39014/01-1535,.01uf,100V,10%
Capacitor
M39014/01-1535
open
367
C301
M39014/01-1535,.01uf,100V,10%
Capacitor
M39014/01-1535
shorted
67
Next Higher Effect
End Effect
Possible premature
switch into topping
mode
Possible false
battery heater
blanket over temp
fault
Heater blanket over
temp will never turn
on
Resister R251 will

burn open
Increased EMI on
the heater blanket
output
Increased EMI on
the heater blanket
output
May come out of
Noise will get into
main mode charge
the temp circuit
prematurely
Increased EMI on
Increased EMI on
charger output
charger output
charger output
burn open
charger output
Increased EMI on
Increased EMI on
charger output
charger output
charger output
burn open
charger output
Charger may end
False charger
Increased noise
main charge mode
temperature
on Temp Sensor
prematurely
functions
Voltage
Shorted temp
False Hot battery
False Hot battery
sensor
fault
fault
Charger may end
False charger
Increased noise
main charge mode
temperature
on Temp Sensor
prematurely
functions
Voltage
Shorted temp
False Hot battery
False Hot battery
sensor
fault
fault
Resister R251
will burn open
Increased noise on
the battery heater
blanket output
Severity
Minor
Minor
Minor
Minor
Minor
Minor
Minor
Minor
Minor
Minor
Minor
Minor
Minor
Minor

Record Ref.
#
Des.
FMECA Analysis
Description
Part Type
Part #
Failure Mode
Local Effect
Battery tap fault
timer will not
work correctly
Battery tap fault
timer will not
work correctly
368
C322
M39014/01-1535,.01uf,100V,10%
Capacitor
M39014/01-1535
open
369
C322
M39014/01-1535,.01uf,100V,10%
Capacitor
M39014/01-1535
shorted
370
C326
M39014/01-1535,.01uf,100V,10%
Capacitor
M39014/01-1535
open
Increased noise
on U301C
371
C326
M39014/01-1535,.01uf,100V,10%
Capacitor
M39014/01-1535
shorted
U301C shorted to
ground
372
C325
M39014/01-1535,.01uf,100V,10%
Capacitor
M39014/01-1535
open
Increased noise
on U301C
373
C325
M39014/01-1535,.01uf,100V,10%
Capacitor
M39014/01-1535
shorted
U301C shorted to
ground
374
C253
CKR06BX105KR,1uF,10%,50V,(R)
Capacitor
CKR06BX105KR
open
375
C253
CKR06BX105KR,1uF,10%,50V,(R)
Capacitor
CKR06BX105KR
shorted
376
C318
M39014/01-1523,2200pf,100V,10%
Capacitor
M39014/01-1523
open
377
C318
M39014/01-1523,2200pf,100V,10%
Capacitor
M39014/01-1523
shorted
378
C306
M39014/01-1293,47pf,200V,10%
Capacitor
M39014/01-1293
open
379
Diode
1N6642
shorted
380
Diode
1N6642
shorted
381
Diode
1N6642
shorted
68
Increased noise
on charger output
Increased noise
on charger output
Increase Noise
on gate of Q301
Gate of Q301
shorted to ground
Noise will get into
the temp circuit
Excessive ripple
on the current
limit circuit
Excessive ripple
on the current
limit circuit
Excessive ripple
Next Higher Effect
End Effect
Battery tap fault
output will not
Battery tap fault
output will not
Possible false
battery heater
blanket over temp
fault
Heater blanket over
on
Possible false
battery heater
blanket overtemp
fault
Heater blanket over
on
Increased EMI on
charger output
Increased EMI on
charger output
Possible heater
blanket oscillations
Heater blanket will
never turn on
May come out of
main mode charge
prematurely
Charger may fail to
operate at the
correct current
Charger may fail to
operate at the
correct current
Charger may fail to
Severity
Minor
Minor
Minor
Minor
Minor
Minor
Minor
Minor
Minor
Minor
Minor
Minor
Minor
Minor

Record Ref.
#
Des.
Description
Part Type
FMECA Analysis
Part #
Failure Mode
Local Effect
Next Higher Effect
on the current
limit circuit
Excessive ripple
on the current
limit circuit
382
Diode
1N6642
shorted
383
CR305
Diode
JANTX1N4148-1
open
Not path for

U300 output
Cold battery shut

down will not work
384
CR305
Diode
JANTX1N4148-1
shorted
Direct current
path into U300
Will disable hot

battery shut down
385
CR304
Diode
JANTX1N4148-1
open
386
CR304
Diode
JANTX1N4148-1
shorted
387
CR308
Diode
JANTX1N4148-1
open
388
CR308
Diode
JANTX1N4148-1
shorted
389
CR309
Diode
JANTX1N4148-1
open
390
CR310
Diode
JANTX1N4148-1
open
391
CR310
Diode
JANTX1N4148-1
shorted
392
CR311
Diode
69
JANTX1N4148-1
open
No path for U303 Hot battery shut

output
down will not work
Possible high
Will disable cold
current input for
battery shut down
U303
Hot and open
sensor fault will
not shut down
unit
Will disable hot
and cold battery
shut down
Signal out of
U301 will be
disabled
Hot bat fault,
open sensor
fault, and tap
fault are disabled
Diode steering of
High current path
fault outputs
into U301
disabled
Output of U302
disabled
End Effect
operate at the
correct current
Charger may fail to
operate at the
correct current
Battery will be
overcharged at cold
temperatures
Battery will be
overcharged at high
temperatures
Battery will be
overcharged at high
temperatures
Battery will be
overcharged at cold
temperatures
Severity
Minor
Minor
Minor
Minor
Minor
Hot and open

sensor fault will not
shut down unit
Minor
Hot and open

sensor fault will not
shut down unit
Minor
Hot battery fault will

not work
Minor
Hot bat fault, open

sensor fault, and
tap fault are
disabled
Minor
Faults will not

register
Minor
Battery tap fault

circuit will not work,
battery will be
charged in a faulted
Minor

Record Ref.
#
Des.
393
CR311
Description
Part Type
Diode
FMECA Analysis
Part #
JANTX1N4148-1
Failure Mode
shorted
394
CR303
FJT1100
Diode
FJT1100
shorted
395
CR302
FJT1100
Diode
FJT1100
shorted
Local Effect
Additional current
will leak into delta Premature switching
T circuit causing to topping mode
false triggering
Will push U302A
Cause charger to
input pin high,
exit main mode
causing
prematurely
premature delta
T
396
CR300
FJT1100
Diode
FJT1100
open
397
CR301
FJT1100
Diode
FJT1100
open
C271 will not

have bulk charge
398
L201
Inductor
235BC103-1
shorted
Increased EMI on
DC buss
399
L202
Inductor
235BC103-1
shorted
Increased EMI on
DC buss
400
Inductor
335BC106-1
shorted
401
Inductor
335BC106-1
shorted
402
Inductor
335BC107-1
shorted
70
Increased EMI on
the charger
output
Increased EMI on
the charger
output
Increased EMI on
End Effect
condition
Battery tap fault
circuit will not work,
battery will be
charged in a faulted
condition
U306 input is
now a high
current path into
the IC
C271 will not be

able to discharge
on power down
Next Higher Effect
Severity
Minor
Battery will be
undercharged
Minor
Battery will be
undercharged
Minor
Charger may
register a false delta
Temp when power Minor
cycling, battery may
be undercharged
Charger may
terminate main
mode prematurely
Battery may be
undercharged
Increased EMI on
the charger output
and input power
cables
Increased EMI on
the charger output
and input power
cables
Minor
Minor
Minor
Increased EMI on
the charger output
Minor
Increased EMI on
the charger output
Minor
Increased EMI on
Minor

Record Ref.
#
Des.
Description
Part Type
FMECA Analysis
Part #
Failure Mode
Local Effect
Next Higher Effect
the charger
output
L206
Inductor
2673015301
open
404
L206
Inductor
2673015301
shorted
405
Q205
MOSFET
2N6788JTX
open
406
Q205
MOSFET
2N6788JTX
shorted
407
Q300
MOSFET
2N6788JTX
open
408
Q300
MOSFET
2N6788JTX
shorted
409
Q301
MOSFET
2N6764JTX
open
410
Q301
MOSFET
2N6764JTX
shorted
411
R100 RLR07C1780FS,178ohm,1%,1/4W (S
Resistor
RLR07C1780FS
open
412
R101 RLR07C1780FS,178ohm,1%,1/4W (S
Resistor
RLR07C1780FS
open
413
R102 RLR07C1780FS,178ohm,1%,1/4W (S
Resistor
RLR07C1780FS
open
414
R240 RLR07C1780FS,178ohm,1%,1/4W (S
Resistor
RLR07C1780FS
open
415
R313
Resistor
RLR07C2741FS
open
Open sensor
416
R103 RLR07C2870FS 287ohm 1% 1/4W (S
Resistor
RLR07C2870FS
open
Loss of EMI
Filtering
RLR07C2741FS 2.74K 1% 1/4W (S)
71
Increased noise
on heater blanket
circuit
Low battery fault
always off
Low battery fault
always on
Fault output will
never register
Fault output is
always on
Heater blanket
will not work
Heater blanket
always on
Loss of EMI
Filtering
Loss of EMI
Filtering
Loss of EMI
Filtering
Loss of EMI
filtering on
charger output
Severity
the charger output
Heater blanket
will not work
403
End Effect
Battery will never

increase in
temperature
Battery will over
temp
Charger will remain

in cold hold off
mode and never
charge the battery
Increased noise on
heater blanket
circuit
Low battery fault will
not register
Low battery fault
always on
A fault condition will
never be known
Fault output is
always on
Charger will never
charge the battery,
a low battery fault
will occur, only
under cold
conditions
Charger will turn off,
a fault will register
Loss of EMI
Filtering
Loss of EMI
Filtering
Loss of EMI
Filtering
Increased EMI on
charger output
Minor
Minor
Minor
Minor
Minor
Minor
Minor
Minor
Minor
Minor
Minor
Minor
False open sensor Charger will turn off,

Minor
fault
a fault will register
Loss of EMI
Minor
Filtering

Record Ref.
#
Des.
Description
FMECA Analysis
Part Type
Part #
Failure Mode
417
R204 RLR20C1210FS 121ohm 1% 1/2W (S
Resistor
RLR20C1210FS
open
418
R205 RLR20C1210FS 121ohm 1% 1/2W (S
Resistor
RLR20C1210FS
open
419
R206 RLR20C1210FS 121ohm 1% 1/2W (S
Resistor
RLR20C1210FS
open
420
R104 RCR07C2R7JS,2.7ohm,5%,1/4W (S)
Resistor
RCR07G2R7JS
open
421
R208
RWR81S1001FR 1K 0.1% 1W (R)
Resistor
RWR81S1001FR
open
422
R212
RWR81S1001FR 1K 0.1% 1W (R)
Resistor
RWR81S1001FR
open
423
R209 RWR80S4R99FS 4.99ohm 0.1% 2W (
Resistor
RWR80S4R99FS
open
424
R211 RWR80S4R99FS 4.99ohm 0.1% 2W (
Resistor
RWR80S4R99FS
open
425
R210 RLR07C10R0FS,10ohm,1%,1/4W (S)
Resistor
RLR07C10R0FS
open
426
R251 RLR07C10R0FS,10ohm,1%,1/4W (S)
Resistor
RLR07C10R0FS
open
427
R215
RLR07C2613FS 261K 1% 1/4W (S)
Resistor
RLR07C2613FS
open
428
R216
RLR07C2613FS 261K 1% 1/4W (S)
Resistor
RLR07C2613FS
open
429
R339
RLR07C1003FS,100K,1%,1/4W (S)
Resistor
RLR07C1003FS
open
430
R343
RLR07C1003FS,100K,1%,1/4W (S)
Resistor
RLR07C1003FS
open
431
R344
RLR07C1003FS,100K,1%,1/4W (S)
Resistor
RLR07C1003FS
open
72
Local Effect
Next Higher Effect
Reduced EMI
filtering A-B
Reduced EMI
filtering B-C
Reduced EMI
filtering A-C
Loss of EMI
Filtering
Loss of EMI
Filtering
Loss of EMI
Filtering
Loss of EMI
Filtering
Loss of EMI
Filtering
Loss of EMI
Filtering
Reduced EMI
filtering A-B
Reduced EMI
filtering B-C
Reduced EMI
filtering A-C
Loss of EMI
Filtering
Loss of EMI
Filtering
Loss of EMI
Filtering
Loss of EMI
Filtering
Loss of EMI
Filtering
Loss of EMI
Filtering
Current limit for
C267
Loss of EMI
Filtering
Loss of EMI
Filtering
End Effect
More noise on
heater blanket, or
coming in from
heater blanket
Loss of EMI
Filtering
Loss of EMI
Filtering
Loss of EMI
Filtering
Battery may be
Charger may be on
undercharged
Inverter will not when battery heater
during cold
is on, causing false
function
temperature
DT
operation
Battery will be
Hot battery shut
charged during hot
Inverter input
down will not
conditions, reducing
loss U303B
function
battery life
U301 will not be
Back up heater turn
able to output a
off circuit will not be
fault signal
able to show a fault
Severity
Minor
Minor
Minor
Minor
Minor
Minor
Minor
Minor
Minor
Minor
Minor
Minor
Minor
Minor
Minor

Record Ref.
#
Des.
FMECA Analysis
Description
Part Type
Part #
Failure Mode
432
R252
RLR07C1003FS,100K,1%,1/4W (S)
Resistor
RLR07C1003FS
open
433
R255
RLR07C1003FS,100K,1%,1/4W (S)
Resistor
RLR07C1003FS
open
434
R311
RLR07C1003FS,100K,1%,1/4W (S)
Resistor
RLR07C1003FS
open
435
R338
RLR07C1002FS,10K,1%,1/4W (S)
Resistor
RLR07C1002FS
open
436
R226
RLR07C1001FS,1K,1%,1/4W (S)
Resistor
RLR07C1001FS
open
437
R227
RLR07C1001FS,1K,1%,1/4W (S)
Resistor
RLR07C1001FS
open
438
R229
RLR07C1001FS,1K,1%,1/4W (S)
Resistor
RLR07C1001FS
open
439
R230
RLR07C1001FS,1K,1%,1/4W (S)
Resistor
RLR07C1001FS
open
440
R350
RLR07C1001FS,1K,1%,1/4W (S)
Resistor
RLR07C1001FS
open
441
R241 RLR07C35R7FS 35.7ohm 1% 1/4W (
Resistor
RLR07C35R7FS
open
442
R245
RLR07C1004FS,1Meg,1%,1/4W (S)
Resistor
RLR07C1004FS
open
443
R246
RLR07C1004FS,1Meg,1%,1/4W (S)
Resistor
RLR07C1004FS
open
444
R349
RLR07C1004FS,1Meg,1%,1/4W (S)
Resistor
RLR07C1004FS
open
73
Local Effect
Next Higher Effect
Battery voltage
on U205 will be
lost
Battery voltage
on U205 will be
lost
Battery tap circuit

will register a false
tap failure
Battery tap circuit
tap failure
False triggering of
DT/DT circuit, no
main mode charge
function
Loss of temp
sensor input to
op-amp
End Effect
Severity
Fault indicator is
always on
Minor
Fault indicator is
always on
Minor
Battery may be
undercharged
Minor
Loss of temp
Open sensor fault
sensor input to No open sensor fault
inoperative
open sensor fault
Increased
voltage on ILIM
at a higher then
of PWM
normal current
Increased
voltage on ILIM
at a higher then
of PWM
normal current
Increased
voltage on ILIM
at a higher then
of PWM
normal current
Current limiting
at a higher then
circuit is disabled
normal current
Back up heater turn
Fault indicator is
U301 will lose a
always on
reference
a fault
Loss of EMI
Increased EMI on
filtering on
charger output
charger output
Low battery fault
circuit is disabled
not work
Low battery fault
will always be
always stay on
enabled
U301 will lose a Back up heater turn Fault indicator is
reference
off will not show a
always on
Minor
Minor
Minor
Minor
Minor
Minor
Minor
Minor
Minor
Minor

Record Ref.
#
Des.
Description
Part Type
FMECA Analysis
Part #
Failure Mode
Local Effect
Next Higher Effect
End Effect
Severity
fault
445
R247 RLR07C1000FS,100ohm,1%,1/4W (S
Resistor
RLR07C1000FS
open
446
R360 RLR07C1000FS,100ohm,1%,1/4W (S
Resistor
RLR07C1000FS
open
Low battery fault

disabled
Battery fault
indicator signal
path opened
Battery fault
indicator will not
function
Fault indicator is
always off
Minor
Battery heater
blanket stays on
Battery may be
heated extremely
high by the heater
blanked
Minor
Loss of hysteresis
on hot bat fault
indicator
Fault indicator may

flicker
Minor
447
R318
RNC55H5902FS 59K 1% 1/8W (S)
Resistor
RNC55H5902FS
open
Heater control
reference loss
448
R335
RLR07C3483FS 348K 1% 1/4W (S)
Resistor
RLR07C3483FS
open
Loss of voltage
shift on op-amp
449
R356
RLR07C3483FS 348K 1% 1/4W (S)
Resistor
RLR07C3483FS
open
450
R337
RLR07C4754FS 4.75Meg 1% 1/4W (
Resistor
RLR07C4754FS
open
451
R340
RLR07C4752FS 47.5K 1% 1/4W (S)
Resistor
RLR07C4752FS
open
452
R254
RLR07C4752FS 47.5K 1% 1/4W (S)
Resistor
RLR07C4752FS
open
453
R342
RLR07C4751FS 4.75K 1% 1/4W (S)
Resistor
RLR07C4751FS
open
454
R357
RLR07C4751FS 4.75K 1% 1/4W (S)
Resistor
RLR07C4751FS
open
455
R353
LVR2-0.01-3%,.01ohm,2W,3%
Resistor
LVR2-0.01-3%
open
456
R345
RLR07C2003FS,200K,1%,1/4W (S)
Resistor
RLR07C2003FS
open
457
R354
RNC55H3832FS 38.3K 1% 1/8W (S)
Resistor
RNC55H3832FS
open
74

Minor
not register
U301C feed back

Back up heater turn
resister
off circuit may
hysteresis
oscillate
Loss of voltage Loss of hysteresis Fault indicator may
shift on op-amp on open sensor fault
flicker
Charger will not
Battery heater will
Mosfet 208 will
not function, charger operate at cold
not turn on
temperatures
may never operate
Fault indicator is
always on
tap failure
lost
Battery heater over
Fault indicator is
U301B will lose a
temp fault will not
always on
reference
work
Inoperative back up
U301C will lose a
heater turn off
reference
circuit
Back up heater turn
Fault indicator is
U301 will lose a
always on
reference
a fault
Q300 may not be
Q300 gate
Fault indicator is
discharge path is able to turn off, Fault
always on
indicator always on
lost
U301C will lose a
Inoperative back up
reference
heater turn off
Minor
Minor
Minor
Minor
Minor
Minor
Minor
Minor
Minor

Record Ref.
#
Des.
Description
Part Type
FMECA Analysis
Part #
Failure Mode
458
R355
RNC55H1002FS 10K 1% 1/8W (S)
Resistor
RNC55H1002FS
open
459
R253
RNC55H1052FS 10.5K 1% 1/8W (S)
Resistor
RNC55H1052FS
open
460
R309
RLR07C5114FS 5.11Meg 1% 1/4W (
Resistor
RLR07C5114FS
open
461
R310 RLR07C1005FS,10Meg,1%,1/4W (S)
Resistor
RLR07C1005FS
open
462
U400
Driver
IR2110
VS Hi
463
U401
Driver
IR2110
VS Hi
464
Driver
5962-8410901PX
short
465
Driver
5962-8410901PX
open
466
U305
Timer
CD4060BF
high
467
U305
Timer
CD4060BF
low
468
U306
Timer
CD4060BF
high
469
U303
M38510/05553,
BUFFER/CONVERTER
Converter
M38510/05553
high
470
U304
voltage ref
REF01
low
75
Local Effect
Next Higher Effect
U301C will lose a

reference
Battery tap circuit
tap failure
Loss of delta time
Cap 271 not able
to discharge
DT/DT circuit
Loss of delta time
Cap 271 not able
to charge fully
DT/DT circuit
Q400, Q401 will see
Bridge Bus
higher then normal
Voltage Low
currents
Q402, Q403 will see
Bridge Bus
higher then normal
Voltage Low
currents
Voltage
Charger peak
reference into
voltage is reduced
U203 is too low
Voltage
Charger peak
reference into
voltage is increased
U203 is too high
False end to the Charger will skip
topping mode
topping mode
Charger will
never complete
topping mode
False output of
battery cell
imbalance
false hot battery
fault
All temp circuitry
will be in a
faulted condition
Battery voltage
on U205 will be
lost
End Effect
circuit
Inoperative back up
heater turn off
circuit
Severity
Minor
Fault indicator is
always on
Minor
Battery may be
undercharged
Minor
Battery may be
undercharged
Minor
Charger may not

operate at rated
current
Charger may not
operate at rated
current
Charger may not
charge battery
correctly
Charger may not
charge battery
correctly
Battery may be
undercharged
Minor
Minor
Minor
Minor
Minor
Battery may be
undercharged
Minor
Fault indicator is
always on
Minor
Fault indicator is
always on
Minor
Fault indicator is
always on
Minor

Record Ref.
#
Des.
471
Description
U302 AD712, DUAL-PRECISION, HIGH SP
Part Type
Op-Amp
76
FMECA Analysis
Part #
AD712
Failure Mode
low
Local Effect
Next Higher Effect
Charger will go
Charger will
directly to topping
always register a
mode, skipping main
delta T condition
mode
End Effect
Severity
Battery may be
undercharged
Minor
FMECA Analysis
FMEA Criticality Matrix

200
200
180
180
160
160
140
140
120
120
100
100
I. Catastrophic
II. Critical
III. Marginal
IV. Minor
80
80
60
60
40
40
20
20
0
A - Frequent
B - Reasonably Probable
C - Occasional
D - Remote
E - Extremely Unlikely
Occurrence
Figure 1.4-1: FMEA Mode Criticality Matrix. The specific failure modes are noted below and in
FMECA_Criticality_Risks.xls.
77
78
FMECA Analysis
79
FMECA Analysis
FMECA Analysis
Figure 1.4-2: FMEA Mode Criticality Matrix detailed listings. The numbers correspond to failure
modes in the FMECA_Criticality_Risks.xls file.
80
FMECA Analysis
Figure 1.4-3: FMEA Risk Levels Chart. Failure modes are ranked by severity level. Lines divide the
failure modes into low, medium and high risk levels with the failure modes shown as circles.
1.4
Conclusions and Recommendations
The battery charger board was not designed to be single point failure (items that would result in
failure of the system and are not compensated for by redundancy or alternative operational
procedure) proof. As this analysis suggests, there are several single point failure modes that can
inhibit or restrain operation of the board. They are documented in FMECA Modes List.xls.
However, there are no failures that are classified as severe or catastrophic.
A separate criticality/risk levels XLS file has also been included in a separate file entitled,
FMECA_Criticality_Risks.xls. It contains a relative measure of the consequences of each failure
mode and their frequency of occurrence including the failure mode criticality number and the
item criticality number (as defined by MIL-STD-1629A).
81

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Proprietary and Confidential

Battery Charger board

AEi Systems, LLC

September 27, 2006

Portions of this document may be proprietary to

Battery Charger board

Revision Date: 9/27/06

Proprietary and Confidential

Failure Modes, Effects, and Criticality Analysis (FMECA)

Last Rev Date:

FMECA Modes List.xls, FMECA_Criticality_Risks.xls

The following assumptions were made in order to complete this analysis.

Battery Charger board

Revision Date: 9/27/06

Proprietary and Confidential

This classification is assigned to provide a qualitative measure of the worst potential

Table 1.3-1: Severity Type Description

A failure which may cause converter and system loss

A failure which may cause converter loss

A failure which may cause degraded converter performance,

A failure not serious enough to significantly affect the system

Battery Charger board

Revision Date: 9/27/06

Proprietary and Confidential

The results of all mode criticalities are reported in FMECA_Criticality_Risks.xls.

Battery Charger board

Revision Date: 9/27/06

Proprietary and Confidential

Table 1.3-2: FMECA Analysis Results

Battery Charger board

Next Higher Effect

Revision Date: 9/27/06

Proprietary and Confidential

Next Higher Effect

Battery Charger board

Will put excessive

Revision Date: 9/27/06

Proprietary and Confidential

Battery Charger board

Next Higher Effect

Revision Date: 9/27/06

Proprietary and Confidential

Next Higher Effect

R100, R100 will

Battery Charger board

Revision Date: 9/27/06

Will put excessive

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CFR06RNE473KP, .047uF, 400V, 1

CFR06RNE473KP, .047uF, 400V, 1

Battery Charger board

Next Higher Effect

Revision Date: 9/27/06

Charger will not

Proprietary and Confidential

CFR06RNE473KP, .047uF, 400V, 2

CFR06RNE473KP, .047uF, 400V, 2

CFR06RNE473KP, .047uF, 400V, 3

CFR06RNE473KP, .047uF, 400V, 3

235BC834-1-, 68uF, 60V, 10%

235BC834-1-, 68uF, 60V, 10%

235BC834-1-, 68uF, 60V, 10%

235BC834-1-, 68uF, 60V, 10%

235BC834-1-, 68uF, 60V, 10%