COMPONENT MAINTENANCE MANUAL LT-Valve
Contents
1. 5 09 lt 5 esf Q 9 lt ALIOVdVO 9 2 3104 Z HAL lt 2 ioedeo Lu esned 8 re E uc 2 09 lt JNOH XoJddy 82 5 amp LIONdVO 5 o g a lt gt 4025 uono s 12 v yoouD Jed gt is Ajpede woad a 9 e m 2 2 22 5 Jnou sey S 9 gt 2 3AO8V AS SZ NVH1 VINALINO SS390Nd BOVLIOA SJ 55 zi z Jed Q gt 00 0 WHOS en TEGULI NO LINDYID gt gt LAS SZ OL AF 3SV11OA 5 3 ONY Je21j29 3 Aueyeg ed18vL xeu Apodemio ANSLLVE uaH1O SNId NO mem WV3M Nid Jo ses 8l NOISOHSMWOO SHOVHO 5 Aseyeg paly NOILO3dSNI c Jo dVASIA d UON 196105 AuDeju AYSLLVE S n i y l COMPONENT MAINTENANCE MANUAL The Original Equipment Aircraft Battery 7 UNSCHEDULED REMOVALS 7 1 Unscheduled removals may be required when the battery has been inadvertently discharged or has a premature failure Recharging2. The Original Equipment Aircraft Battery 6 ROUTINE MAINTENANCE 6 1 INSPECTION SERVICE PERIOD After initial installation Gill requires a capacity check of the battery to be performed every 300 flight hours or 6 months whichever occurs first Please refer to aircraft manufacturer s guidelines for further clarification WARNING The battery must be removed from the installation and serviced in a well ventilated designated area During servicing the battery will generate oxygen and hydrogen gases which can be explosive under the right conditions 6 1 1 Battery Integrity Visually inspect the battery for any signs of cracks corrosion unusual terminal pin wear or discoloration on the pins WARNING ALL VRLA batteries contain sulfuric acid which is highly corrosive and which can cause serious physical injury if it comes in contact with skin or if inhaled It can also cause serious eye injury or blindness if it comes into contact with the eyes Caution must be exercised to avoid damage to the exterior case which could allow the contents to escape or come in physical contact with external materials or personnel If a battery case is found to be damaged handle the battery with care and avoid contact with the skin Inspect all areas adjacent to the battery for evidence of corrosion 6 2 CONTINUED AIRWORTHINESS REQUIREMENT CAPACITY TESTING Figure 4 Battery Maintenance Flow provides an overview of Battery Maintenance
3. l COMPONENT MAINTENANCE MANUAL The Original Equipment Aircraft Battery Battery Part Number 7639 27 Specifications Watts Amps Capacity Ah Energy Wh 7639 27 Performance at 23 C LLLI SLONGOUd 11 3NAQ3T3 L Ag s li 11eg 1Je124IV ply pea 11 u 1 _ j 1 10 10 Hours to 1 67VPC at 23 0 001 4000 24 28 Teledyne Battery Products Specifications Battery Weight Ib Watts Amps Capacity Ah Energy Wh SLONGOUd 11 8 3NAG3T3L py pes 11 Hours to 1 67 VPC at 23 C Q01 4000 RevE Page 25 of 28 Teledyne Battery Products Premium LT Valve Regulated Lead Acid Aircraft Batteries TELEDYNE BATTERY PRODUCTS Teledyne Battery Products E 2 411 L Ili l lu Q gt A 5 5 lt 9 S gt S 8 s s 5 8 5 gt Aircraft Battery Capacity Ah Energy Wh Specifications soJeduiy Battery Part Number 7639 34 Q01 40
4. 2g TELEDYNE BATTERY PRODUCTS A Teledyne Technologies Company COMPONENT MAINTENANCE MANUAL LT Valve Regulated Lead Acid Batteries Part Numbers Applicable to this CMM 7639 27 7639 30LT 7639 34 7638 36 7638 48P Rev E September 3 2014 BATERY Provucrs A Teledyne Technologies Company CONTENTS Section Description Page 1 ROVISIONS c M M 1 2 SCOPE 2 3 Description of Valve Regulated Lead Acid batteries 3 Definition of Battery Specifications 4 State of Charge Vs Voltage 5 4 Service Instructions 6 5 Charging Constant Potential 2 2 8 Charging Constant Current 1 9 Charging u deerat 10 Charging Wal uy tte reto de RO a RE e 11 6 Routine Maintenance 12 Continued Airworthiness Testing 0 12 Reconditioning Battery meme 13 Deep Discharge Recovery 13 Monitoring Batteries Long Term Storage 14 7 Unscheduled Removals 16 8 Troubl
5. During this inspection process the following components must be reviewed SLONGOUd 11 8 ANAGITAL Ag YLW py pes 11 6 2 1 Measure and record the battery voltage 6 2 2 Charge the battery using Table 2 Q01 4000 RevE Page 12 of 28 Teledyne Battery Products l COMPONENT MAINTENANCE MANUAL The Original Equipment Aircraft Battery Table 2 CHARGING PROCESS Battery Voltage Open Circuit Voltage OCV Discharge the battery at the one hour rate to 20V Recharge at constant potential CP of 28 2 to 29 volts until the charge rate drops to 1A Then charge at constant current CC of 1A for 12 hours Discharge at one hour rate to 20V see Appendix A then 24V 25 5V recharge at constant potential of 28 2 volts to 29 volts until charge current drops equal to or less than 0 5A Charge at constant potential of 28 2 volts to 29 volts until gt 25 5V charge rate current is equal to or less than 0 5A 6 2 3 Allow the battery to rest for 1 hour before starting the discharge test 6 2 4 battery should be discharged at the one hour rate see Table 3 Appendix to an end voltage of 1 67 volts per cell or 20 volts per IEC 60952 1 Measure the time The battery must achieve at least 85 of the rated time or 51 minutes at the 1 hour rate If the first discharge time is less than 51 minutes condition charge the battery per Section
6. the battery using Constant Potential method described in Section 5 2 should be attempted Perform a capacity check as outlined in Section 6 2 If the battery fails to provide specified capacity as noted in Table 2 Appendix A it should be rejected SLONGOUd 11 8 ANAGITAL 1Je124IV pes 11 001 4000 17 28 Teledyne Battery Products Since 1920 COMPONENT MAINTENANCE MANUAL The Original Equipment Aircraft Battery 8 LT VRLA TROUBLE SHOOTING GUIDE PROBLEM CAUSE RECOMMENDATIONS Battery is at end of life Battery has low capacity Battery has not been charged correctly Refer to Section 5 for charging options Will not come up to full Aircraft charging voltage may be Contact Aircraft Technical Support for charge lower than required for application assistance Flight legs too short to charge the Remove the battery from the aircraft and battery sufficiently recharge when necessary temperatures required Equipment left on accidentally Recharge per Section 5 if deeply battery is discharged discharged follow Section 6 3 22272777 Clean neutralize connections tighten all d connections S Check Cannon or Elcon type connectors for e good contact see 7 2 with Teledyne Go NoGo gauge part number 3600 51 Will not hold charge cout se Perform airworthiness te
7. 00 i E T Premium LT Valve Regulated Lead Acid Aircraft Batteries TELEDYNE BATTERY PRODUCTS Teledyne Battery Products E 5 Lu gt 2 E gt gt 2 o va 5 2 S S lt 5 5 I d gt Specifications Battery Part Number 7638 36 Q01 4000 to to E E Ae T l COMPONENT MAINTENANCE MANUAL The Original Equipment Aircraft Battery Battery Part Number 7638 48P Specifications Watts Amps Capacity Ah Energy Wh 7638 48P Performance at 24 C SLONGOUd 11 8 3NAG3T3L 1Je124IV pee 11 10 Hours to 1 67 at 24 001 4000 28 28 Teledyne Battery Products
8. 6 3 and repeat the discharge test This conditioning charge may be repeated once more if needed to ensure capacity is better than 85 6 2 5 If the second discharge fails to deliver at least 51 minutes the battery should be rejected Call Gill Technical Support for further details 6 2 6 Once the battery has passed all required inspections and after it is fully recharged using constant voltage charging methods the battery is ready for installation 6 3 RECONDITIONING BATTERY 6 3 1 Discharge the battery at the one hour rate to the end voltage of 20V If the battery is already below this voltage skip this step 6 3 2 Charge the battery at constant potential of 28 6V 0 4V until the charge rate drops to 1A followed by a constant current charge at 1A for 12 hours SLONGOUd 11 8 ANAGITAL 5 YLW pes 11 6 3 3 Repeat the discharge test per Section 6 2 4 followed by a recharge per Section 6 3 2 001 4000 13 28 Teledyne Battery Products l COMPONENT MAINTENANCE MANUAL The Original Equipment Aircraft Battery 6 3 4 battery should achieve full capacity 2 cycles If it does not reject the battery 6 4 DEEP DISCHARGE RECOVERY 6 4 1 Deep discharge is usually indicated by battery voltage of less than 24 volts battery which has been deeply discharged can be recharged using constant current charging t
9. a 24 volt lead acid battery Capacity measured in Ampere Hours or Ah is the product of the discharge rate and time in hours to the specified end voltage 3 2 1 2 The Emergency Rate This is the rate of discharge a battery can endure for thirty minutes with the battery voltage at or above 1 67 volts per cell or 20 volts for a 24 volt lead acid battery The Emergency Rate is the total essential load measured in amperes required to support the essential bus for thirty minutes 3 2 1 3 1 Peak Power Current This is the discharge current delivered at 0 3 seconds while testing during a 15 second power discharge controlled to maintain a constant terminal voltage of half the nominal battery voltage lor Constant Voltage Current This is the discharge current at the conclusion of a 15 second power discharge controlled to maintain a constant terminal voltage of half the nominal battery voltage 3 2 2 State of charge using voltage measurements should be used as a guide only Figure 1 indicates the relationship between Battery Open Circuit Voltage OCV and 96 State of Charge SOC 3 2 3 valve regulated batteries operate best in controlled temperatures Excessive excursions above 100 F can shorten the life of lead acid batteries The optimum operating temperature is around 80 Available capacity declines as the temperature drops This decline is primarily related to the state of the electrolyte and easily recoverable once the batte
10. age or before installation on aircraft follow the guidelines below Refer to Section 4 3 SLONGOUd 3NAG3T3L 5 1Je124IV ploy pes 11 6 5 1 If the batteries are stored for two years at recommended temperatures the batteries can be recharged at constant current of 1A for 120 of the one hour Q01 4000 14 28 Teledyne Battery Products l COMPONENT MAINTENANCE MANUAL The Original Equipment Aircraft Battery capacity see Appendix for specifications If it is 27Ah battery recharge at 1A for 1 2x27 1A 32 4 hours 6 5 2 Conduct a capacity check per Section 6 2 Repeat cycle starting with recharge per 6 3 2 The battery should be at capacity by the end of the second cycle Call Teledyne Tech Support if is not at capacity 6 6 INSPECTION OF CONNECTORS 6 6 1 Before connecting battery to aircraft ensure the connector sockets have not worn or become loose Use go no go gauge part number 3600 51 obtained from Teledyne SLONGOUd 3NAQ3T3L Yessy ploy pes 11 001 4000 15 28 Teledyne Battery Products Premium LT Valve Regulated Lead Acid Aircraft Batteries TELEDYNE BATTERY PRODUCTS 09 lt ALIOvdVO S S310A9 Z YILI uonoes Jed Teledyne Battery Products
11. ant Potential charge regime except when situations require specific charging treatment When batteries are left on shelf for a longer period they will have to be reviewed using open circuit voltage OCV as the primary guide with the State of Charge Vs Voltage graph Figure 1 The requirement at initial installation is to ensure battery will provide 10096 capacity Inspect battery voltage and reference to Figure 1 to verify state of charge For various battery voltages Table 1 provides the necessary charging and or conditioning that would be required Please contact Teledyne Tech Support if there are any situations that are not clear Table 1 INITIAL CHARGING PROCESS Discharge the battery at the one hour rate to 20V Recharge at constant potential CP of 28 2 to 29 volts until the charge rate drops to 1A Then charge at constant current CC of 1A for 12 hours Discharge the battery at the one hour rate to 20V see Appendix A The battery must achieve at least 100 1 hr of this rating If the battery passes recharge it using CP and CC method f not repeat CP and CC charge followed by one more discharge If the battery fails to meet capacity call Teledyne Tech Support for further direction SLONGOUd 11 8 3NAQ3T3L 5 YL ploy pes 11 001 4000 11 28 Teledyne Battery Products COMPONENT MAINTENANCE MANUAL
12. charging is very important and will affect the overall life of the battery The charging process is not 100 efficient due to losses resulting from internal resistance and will typically require 10 to 20 more recharge than the amount of capacity removed during discharge 5 1 3 Undercharging occurs when the battery is repeatedly subjected to time limited charging allowing residual lead sulfate to eventually increase in the plates making it difficult to fully recharge the battery In this case the battery will suffer a permanent loss of capacity 5 1 4 Overcharging generally occurs when either constant current charging is used without adequate control of total time on charge or the voltage limit in constant voltage charge is higher than the recommended range see Section 5 2 4 Overcharging a battery will corrode the positive grids and break down the water component in the electrolyte to hydrogen and oxygen electrolysis This is quite detrimental to the life of VRLA batteries since the water cannot be replaced 5 2 STANDARD CONSTANT POTENTIAL OR CONSTANT VOLTAGE OR CV 5 2 1 These chargers are generally designed to provide a constant voltage source with selectable initial current rates Model variants provide selectable charge voltage and initial charge rates Higher output current will reduce recharge time 5 2 2 CV charging will result in high initial charging current which will start dropping off when the voltage gradient betwe
13. cyclers may be obtained by calling 916 324 2423 or writing to the California Waste Exchange Resource Recovery Unit Hazardous Waste Management Program Department of Toxic Substances Control P O Box 806 Sacramento CA 95812 0806 10 2 4 Nation wide Recycling Most retailers auto parts stores or service outlets that sell new lead acid batteries will accept a small number one or two of spent lead acid batteries for recycling If you have a larger quantity to be recycled call to verify that your chosen outlet can handle a larger quantity of old batteries Even in a state where there is no lead acid battery recycling law it is common for battery retailers everywhere in the U S to accept used lead acid batteries from customers The spent batteries collected by retailers are shipped to EPA licensed and regulated facilities for recycling For additional information please use the following web address to locate nation wide recycling facilities www batterycouncil org SLONGOUd 11 8 3NAQ3T3L YL ploy pes 11 001 4000 20 28 Teledyne Battery Products l COMPONENT MAINTENANCE MANUAL The Original Equipment Aircraft Battery 10 3 INTERNATIONAL RECYCLING RESOURCES 10 3 1 British Battery Manufacturers Association 26 Grosvenor Gardens London SW1W OGT Direct Tel 44 207 838 4800 Direct Fax 44 207 838 4801 10 3 2 SNAM Societ
14. e Nouvelle d Affinage des Metaux Rue de la Garenne St Quentin Sallavier 38297 La Verpilliere Cedex France Telephone 33 74 945 985 Battery re processing 10 3 3 You can also locate a recycling facility through the following Call2Recycle a program of Rechargeable Battery Recycling Corporation RBRC website http Awww call2recycle org SLONGOUd 11 8 ANAGITAL Ag YL ploy pes 11 001 4000 21 28 Teledyne Battery Products The Original Equipment Aircraft Battery Active material AGM Ah CFR Electrolyte Electrolysis IATA ICAO IEC lop lpr Nonspillable OCV Passivation Recombination COMPONENT MAINTENANCE MANUAL 11 GLOSSARY The formed charged material on the positive and negative electrodes plates Absorptive Glass Mat a non woven fiberglass separator that holds the electrolyte Ampere hour the standard designation of capacity units for batteries Code of Federal Regulations The liquid added to a battery that is capable of conducting ions between the two electrodes Decomposition of an electrolyte by the action of an electric current flowing through the electrodes positive and negative plates International Air Transport Association International Civil Aviation Organization International Electrotechnical Commission Peak current delivered at 0 3 seconds into a 15 second controlled discharg
15. e at a constant terminal voltage of half the nominal battery voltage Discharge current at the conclusion of a 15 second controlled discharge at a constant terminal voltage of half the nominal battery voltage Refers to the ability of the battery to retain the electrolyte when subjected to tests identified under US DOT Reg 49 CFR Part 173 159 paragraph d Open Circuit Voltage measured with no loads connected to the battery Refers to the oxidation of the negative electrode The process by which oxygen combines reacts with the negative active material SLONGOUd ANAGITAL YLW ploy pes 11 Sponge lead Fully charged negative plates convert to a very porous pure lead material often referred as sponge lead since it resembles a sponge under high magnification Sulfation The product of discharge lead sulfate formed on both positive and negative plates Venting Means for a battery to release the gases it generates during charging 001 4000 22 28 Teledyne Battery Products l COMPONENT MAINTENANCE MANUAL The Original Equipment Aircraft Battery APPENDIX A Type 1 Hour Rate A 30 Minute Rate A 7639 34 7638 36 7638 48P SLONGOUd 11 8 ANAGITAL 1Je124IV pes 11 001 4000 23 28 Teledyne Battery Products
16. echniques for best recovery 6 4 2 Discharge the battery at the one hour rate see Table 3 until the battery drops to 20V 6 4 3 Recharge the battery at a constant current charge rate of 1 0A for a total input in ampere hours of 12096 of the one hour capacity which is determined as follows For example for a one hour capacity of 27 Ah the charge time is determined as follows 1 2 120 input x 27Ah 32 4 Ah Ampere hours needed At the charge rate of 1 0 amperes the total charge time would be 32 4Ah 1 0A 32 4 hours 6 4 4 After a pause of about 1 hour discharge the battery at the one hour rate see Table 2 until the battery drops to 20V Record the time to 20V If it is greater than 8596 of specification see Appendix A recharge per Section 5 2 and return to use If not continue to Section 6 4 5 6 4 5 Charge the battery at constant potential of 28 6 0 4V until the charge rate drops to 1A followed by a constant current charge at 1A for 12 hours 6 4 6 Discharge the battery at the one hour rate see Table 2 until the battery drops to 20V The battery should be at least 85 of capacity If the battery is lower than 85 repeat step 6 4 6 one more time If the battery does not provide more than 85 of the rated specification it should be rejected 6 4 7 Avoid subjecting a battery to frequent deep discharges as this can reduce the useful life of the battery 6 5 MONITORING BATTERIES IN LONG TERM STORAGE After stor
17. en the charger and battery begins to decrease because the current in any circuit is directly proportional to the voltage gradient across that circuit 5 2 3 Typically the charger will regulate to around 28 6 volts As the battery approaches the charger output voltage charge current will drop below 0 5 ampere 5 2 4 battery must be connected to the charger with output voltage set between 28 2V up to 29 0V for 24V batteries and left on until the charge rate drops below 0 5 amperes At this point disconnect the charger from its power source first before disconnecting the battery from the charger to eliminate any sparks SLONGOUd AYALLVE 3NAG3T3L 5 YLW Ploy pes 11 Q01 4000 Rev E Page 8 of 28 Teledyne Battery Products COMPONENT MAINTENANCE MANUAL The Original Equipment Aircraft Battery Note Unless the charger is of a type that turns off automatically the charger and battery must be disconnected once the charge rate drops below 0 5 ampere 5 2 5 Alternatively constant voltage charging can be temperature compensated for better control Note Figure 3 for Temperature Compensated Charge Voltages 5 2 6 Figure 2 represents TSC O1V Charger profile This is a specialized charger that provides a fixed rate constant current charge initially as the battery voltage approaches the charger output voltage Once the battery has achieved the charger ou
18. eshooting Guide 0 17 9 Transportation iier 18 10 pie C dete 19 11 Glossary P Cn 21 22 001 4000 September 3 2014 i COMPONENT MAINTENANCE MANUAL The Original Equipment Aircraft Battery 1 REVISIONS Description of Change Approved By Revised to correct Maintenance Flow Chart and various directions in Service Manual per review with Embraer 2 temperature conversions Dec 19 2012 3 2012 July 23 2012 Revised charging processes Inspection service period and minimum capacity requirements for battery approval Added part number 7639 30LT Added part number 7638 48P Nov 6 2013 Apr 2 2014 Sep 3 2014 SLONGOUd 3NAG3T3L YLW ploy pes 11 001 4000 1 28 Teledyne Battery Products l COMPONENT MAINTENANCE MANUAL The Original Equipment Aircraft Battery 2 SCOPE This manual provides Maintenance Procedures for Gill 7000 Series LT Valve Regulated Lead Acid LT VRLA Aircraft Batteries manufactured under FAA Parts Manufacturer Approval number PQ1006NM This manual is applicable for the following batteries 7639 27 7639 30LT 7639 34 7638 36 and 7638 48P This manual has been written for the purpose of guidance only co
19. n 5 2 and stored The storage start date and battery voltage must be Q01 4000 Rev E Page 6 of 28 Teledyne Battery Products l COMPONENT MAINTENANCE MANUAL The Original Equipment Aircraft Battery logged on the outer package or marked on the battery The inspection intervals for these batteries will be the same as outlined in section See Figure 1 for state of charge at various voltages 4 3 5 Long term storage at temperatures less than 0 18 C will not detrimentally affect the life of the battery provided the battery is at a reasonably high state of charge over 80 before placing in storage The battery may be stored at lower temperatures but will need to be warmed up to 0 F 18 C before use 4 3 6 Please call TBP technical support if there are any questions regarding shelf life and recharge periods 4 4 INITIAL INSPECTION 4 4 1 Visually inspect the battery to ensure there is no damage Remove the protective cap over the terminal pins and ensure that the pins are clean and there is no corrosion The pins have been installed with the correct torque at the factory and do not require any re seating Call TBP Technical Support if you find any discrepancy 4 4 2 DO NOT remove the lid The vents are sealed in the cover and cannot be removed for maintenance 4 4 3 Inspect the open circuit voltage and review handling requirements according to the measured voltage per Section 5 5 Before placing the batter
20. nsult Teledyne Battery Products TBP Technical Support for further information SLONGOUd 11 8 ANAGITAL Yessy prov pes 11 001 4000 2 28 Teledyne Battery Products COMPONENT MAINTENANCE MANUAL The Original Equipment Aircraft Battery 3 VALVE REGULATED LEAD ACID BATTERIES 3 1 DESCRIPTION 3 1 1 The 7000 series LT valve regulated lead acid LT VRLA batteries are designed with an optimum lead alloy with tin and copper to provide the best possible electrode characteristics necessary for performance These LT VRLA batteries contain electrolyte absorbed in glass mat separators with no free electrolyte and are sometimes referred to as sealed or recombinant gas batteries WARNING ALL VRLA batteries contain sulfuric acid which is highly corrosive and which can cause serious physical injury if it comes in contact with skin It can also cause serious eye injury or blindness if it comes into contact with the eyes Caution must be exercised to avoid damage to the exterior case which could allow the contents to escape or come in physical contact with external materials or personnel If a battery case is found to be damaged handle the battery with care and avoid contact with the skin Inspect all areas adjacent to the battery for evidence of corrosion 3 1 2 TBP valve regulated lead acid batteries have vent caps with
21. r label on the packaging against the accompanying FAA Form 8130 3 or Certificate of Compliance 4 3 STORAGE REQUIREMENTS 4 31 TBPs 7000 series LT VRLA batteries be stored between 20 F 29 C and 110 F 43 C Ideal battery storage temperature is 80 F 27 C Storage at temperatures other than these can lead to permanent damage Storage temperatures will determine inspection requirements These requirements are identified under this section 4 39 2 TBPs 7000 series LT VRLA batteries a maximum of 24 months of inspection free storage life IF stored at temperatures between 40 F 4 C to 80 F 27 F 4 3 3 If stored between 95 F 35 C to 110 F 43 C the battery must be inspected on a monthly basis It is not recommended to store any VRLA batteries at these temperatures for excessive periods of time maximum 3 months storage Prolonged storage at high temperatures over 110 F or 43 C will reduce battery life due to various deleterious reaction mechanisms at higher temperatures During these monthly inspections the battery must be recharged per Section 5 2 and returned to storage If the storage period has exceeded the time recommended in this section contact Teledyne Battery Products for disposition SLONGOUd 11 8 3NAG3T3L YLW py pes 11 434 All batteries returned from service after initial use must be fully charged per Sectio
22. rger that can provide a constant potential charge at a lower voltage typically around 26 4V 0 2V See Figure 3 for charger performance 5 4 2 Teledyne recommends using the GC 024 charger which is a constant potential charger that will revert to a float charger after the battery has been charged at 28 5V 0 3V 5 4 3 The batteries may be kept on float charge for up to six months at this voltage Figure 3 Float Charger Profile Model GC 024 Max Current 7 44 Amps Total Ah Input 48 19 Ah Ah Input at Float Voltage 1 16 Ah 100 Return of 47 03Ah 7 35 hours Max Voltage Float Voltage 27 89 V 26 33 Volts Charge Voltage Ah Charge Current Current at 0 0 amps 07 98 hrs Ah Input 48 02Ah SLONGOUd 11 8 ANAGITAL YLW py pes 11 Time hr Q01 4000 Rev E Page 10 of 28 Teledyne Battery Products COMPONENT MAINTENANCE MANUAL The Original Equipment Aircraft Battery 5 5 INITIAL CHARGING 5 5 1 5 5 2 5 9 3 5 5 4 5 5 5 Battery Voltage Open Circuit Voltage OCV Discharge at one hour rate to 20V see Appendix A then 24V 25 5V recharge at constant potential of 28 2 volts to 29 volts until charge current drops to 0 5A or less gt 25 5 Charge at constant potential of 28 2 volts to 29 volts until charge rate current is equal to or less than 0 5A All general charging will be at accomplished using the Const
23. ry has warmed up sufficiently SLONGOUd AYALLVE 3NAG3T3L 5 Yessy ploy pes 11 Q01 4000 Rev E Page 4 of 28 Teledyne Battery Products i COMPONENT MAINTENANCE MANUAL The Original Equipment Aircraft Battery Figure 1 Approximate State of Charge State of Charge Vs Voltage 2 A N e e lt us e N N N N N N N N N SLONGOUd 11 8 3NAG3T3L Yessy pee 11 A 001 4000 5 28 Teledyne Battery Products l COMPONENT MAINTENANCE MANUAL The Original Equipment Aircraft Battery 4 SERVICE INSTRUCTIONS 4 1 SHIPMENT OF BATTERIES 4 1 1 The batteries are shipped upright conditioned and fully charged 4 1 2 Each battery is identified with a unique serial number label and indelibly marked manufacturing date on the right side of the battery side adjacent to the positive terminal with the terminals facing forward Please use this manufacturing date for future reference 4 2 INSPECTION FOR SHIPPING DAMAGE 4 2 4 Upon receipt the packages must be examined for any shipping damage before they are placed in storage or use If any damage is noted contact the shipping company immediately 4 2 2 Type verification can be performed by checking the serial numbe
24. sified as Nonspillable and are exempted from all other requirements of 49 CFR Chapter 1 Subchapter C Parts 106 180 as determined in a US Department of Transportation s 49CFR Chapter 1 Part 173 159 paragraph d b IATA ICAO Packing Instructions 806 Provision A67 SLONGOUd 11 8 ANAGITAL 1Je134IV pee 11 001 4000 19 28 Teledyne Battery Products l COMPONENT MAINTENANCE MANUAL The Original Equipment Aircraft Battery 10 RECYCLING 10 1 MATERIAL SAFETY DATA SHEETS 10 1 1 The MSDSs can be downloaded as needed from the Gill website www gillbatteries com 10 2 RECYCLER LOCATIONS 10 2 1 All parts of spent lead acid batteries are recyclable Generally batteries are collected by retailers and wholesalers who send large quantities to battery recyclers for reclamation Battery recyclers are permitted hazardous waste treatment recycling facilities If you have just a few batteries you should contact your local battery retailers or wholesalers 10 2 2 Recycler in California RSR Quemetco Inc 720 South 7th Avenue City of Industry CA 91745 800 527 9452 10 2 3 The California Department of Toxic Substances Control publishes an annual listing of commercial hazardous waste recyclers which also includes facilities outside of California A copy of this publication the Directory of Industrial Re
25. st per Section 6 2 Battery could be self discharging due to low state of charge Sulfation can build up based on repeated undercharge situations Excessive sulfation build up caused by leaving the battery in a discharged state for an extended period of time Possible excessive use of starter d d and other electrical equipment 9 capacity battery Ensure that battery selection is correct for the application Recharge per Section 5 if deeply discharged follow Section 6 3 Infrequent flying will lead to gradual discharge of battery especially if the breaks Application between flying are over three weeks Please review directions under Managing Periods of Non Use under SERVICE Battery life too short Ensure battery is not subjected to excessive vibration or high temperatures in service Overcharging could be eliminated by Charging variations such as inspecting and correcting charge voltages overcharging or chronic undercharging brought about by Excessive undercharging very short flights short flights should be compensated by periodic charging of battery SLONGOUd 11 8 INAGITAL seueneg Yessy ploy pea payejnbay 11 001 4000 18 28 Teledyne Battery Products l COMPONENT MAINTENANCE MANUAL The Original Equipment Aircraft Battery 9 TRANSPORTATION 9 1 Gill LT VRLA batteries are clas
26. tput voltage the charge current starts to drop down to less than 0 5 amperes Figure 2 TSC 01V Charge Profile Constant Current Constant Voltage Period On Charge Voltage V Rate of Charge A 21 00 00 22 02 00 23 00 00 24 00 00 25 13 59 Charge Time HH MM SS 5 3 STANDARD CONSTANT CURRENT 5 3 1 These chargers must be capable of providing an output of 35 volts and 8 amperes with selector switch and include a timer that can terminate charging when the required charge input is attained SLONGOUd 11 8 ANAGITAL YLW ploy pes 11 5 3 2 The ampere hours of energy restored is the product of charge current in amperes and the time in hours Q01 4000 Rev E Page 9 of 28 Teledyne Battery Products l COMPONENT MAINTENANCE MANUAL The Original Equipment Aircraft Battery 5 3 3 During such charging the on charge battery voltage will reach 32V 33V This is standard for such a charge method Please use charge rate and times as indicated in Sections 5 5 6 4 and 6 5 5 3 4 Since these chargers are designed to provide a constant current throughout the charging period this method can lead to overcharging if not controlled In order to control the charge input these chargers must have a shut off timer 5 4 FLOAT CHARGING 5 4 1 This method of charging is essentially accomplished using a cha
27. valves enclosed that are sealed in place and cannot be accessed for maintenance At no time must these vent caps be removed WARNING During normal operation the batteries will vent very small amounts of gases that must be vented away from the battery and aircraft The venting mechanisms consist of nozzles in the battery cover and vent tubes that are designed to exhaust the battery compartment Ensure that the vent tubes are not restricted or disabled in any way 3 1 3 The electrolyte is contained an absorptive glass mat AGM separator that retains and immobilizes the electrolyte These batteries can be operated in any orientation without spilling electrolyte SLONGOUd AYALLVE ANAGITAL 5 YLW pes 11 3 1 4 The battery consists of twelve cells connected in series internally making up a 24V battery These cells are not replaceable Q01 4000 RevE Page 3 of 28 Teledyne Battery Products l COMPONENT MAINTENANCE MANUAL The Original Equipment Aircraft Battery 3 1 5 Each cell is constructed of premium grade LT electrodes plates that are electrically isolated by AGM separators 3 2 DEFINITION OF BATTERY SPECIFICATIONS 3 2 1 TBP battery ratings are defined by the following 3 2 1 1 The One Hour Rate This is the rate of discharge a battery can endure for one hour with the battery voltage at or above 1 67 volts per cell or 20 volts for
28. y in service it must be fully charged Review Section 5 as needed For basic charging constant potential is the preferred charging method Deep discharge recovery will usually require application of Constant Current and or Constant Potential charging see Sections 6 3 and 6 4 If there are any concerns with recharging please contact Tech Support at Teledyne Battery Products WARNING ALL VRLA batteries contain sulfuric acid which is highly corrosive and which can cause serious physical injury if it comes in contact with skin or if inhaled It can also cause serious eye injury or blindness if it comes into contact with the eyes Caution must be exercised to avoid damage to the exterior case which could allow the contents to escape or come in physical contact with external materials or personnel If a battery case is found to be damaged handle the battery with care and avoid contact with the skin Inspect all areas adjacent to the battery for evidence of corrosion Q01 4000 Rev E Page 7 of 28 Teledyne Battery Products SLONGOUd AYALLVE ANAGITAL YLW py pes 11 l COMPONENT MAINTENANCE MANUAL The Original Equipment Aircraft Battery 5 CHARGING 5 1 OVERVIEW 5 1 1 Please review the charging method Constant Current or Constant Voltage before commencing The preferred method is Constant Voltage Refer to Section 5 2 and Section 5 3 5 1 2 Correct
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