Battery ICA - Gill Battery
Contents
1. 1 3 CONSTANT CURRENT CHARGE 4 5 1 4 CAPACITY TEST 5 6 INSPECTION MAINTENANCE SCHEDULE 5 7 TROUBLESHOOTING 6 8 REPAIRS 7 9 SPECIAL TOOLS 7 10 CONFIGURATION CONTROL 7 11 STORAGE INSTRUCTIONS 7 12 AIRWORTHINESS LIMITATIONS 8 13 ICA REVISONS 8 Document Number Page Revision Teledyne Battery Products 840 W Brockton Ave Redlands CA 92374 TD14 8 01 iii A INTRODUCTION This manual provides Maintenance Procedures for TSO C173 C173a authorized TELEDYNE BATTERY PRODUCTS Gill 7000 Series Valve Regulated Lead Acid LT VRLA Aircraft Batteries to ensure continued airworthiness of the batteries The TSO C173 C173a authorized batteries are listed in Teledyne Battery Products Document No TD14 8 00 Revision NC or later FAA approved revisions TSO C173 DEVIATIONS TSO C173 authorized batteries were tested in accordance with DO 293A with the following exceptions e Altitude Tested to an altitude of 60 000 feet instead of 55 000 feet e Rapid Decompression Tested for Rapid Decompression to an altitude of 60 000 feet instead of 55 000 feet NOTE The deviations are not applicable to TSO C173a authorized batteries INSPECTION AND MAINTENANCE 3 1 Initial Inspection 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 3 2 Initial Maintenance Check the open circuit voltage Typical practice should2. ON MAINTENANCE SCHEDULE e Remove the battery from the aircraft and perform capacity test 5 1 4 initially at 1 800 50 flight hours or 18 1 calendar month s whichever comes first After the initial check perform the capacity test at 900 50 flight hours or 9 1 calendar month s whichever comes first e Check battery integrity by visually inspecting the battery for any signs of cracks corrosion unusual terminal pin wear or discoloration Document Number Page Revision Teledyne Battery Products k 840 W Brockton Ave Redlands CA 92374 TD14 8 01 5of8 A 7 TROUBLESHOOTING Trouble Shooting Chart TROUBLE POSSIBLE CAUSE REMEDY Battery under capacity Battery life is beyond warranty or worn out Replace with new fully charged battery Will not come up to charge will not hold charge Aircraft charging rate may be rated lower than required for application Check and correct the setting in accordance with instructions applying to regulating equipment Aircraft Maintenace Manual Flight legs too short to charge battery sufficiently Short circuit short to ground in wiring or other electrical component problem Remove battery from aircraft and charge Check wiring and rest of electrical system Correct problem Recharge battery Loose connections corrosion etc Tighten clean and neutralize connections Battery quick disconnect worn beyond tole
3. TELEDYNE BATTERY PRODUCTS INSTRUCTIONS FOR CONTINUED AIRWORTHINESS and COMPONENT MAINTENANCE MANUAL For TSO C173 C173a Authorized Teledyne Battery Products GILL 7000 Series LT Valve Regulated Lead Acid Aircraft Batteries REFER TO APPROPRIATE AIRCRAFT MAINTENANCE MANUAL FOR ACCESS TO BATTERY AND ASSOCIATED ELECTRICAL SERVICES GILL isa registered trademark of TELEDYNE BATTERY PRODUCTS List of Active Pages PAGE i ji jii 1 2 3 4 5 6 7 8 REV c c A B A NC A A NC A B Document Number Page Revision Teledyne Battery Products 840 W Brockton Ave Redlands CA 92374 TD14 8 01 i C REVISIONS Initial Release 3 15 11 Revised paragraph 12 10 28 11 JMR JMR JMR MR Added TSO C173a on pages i and 1 Added J 1 30 13 NOTE in paragraph 2 MR MR Revised to include 12V battery Deleted Tables 1 amp 3 and referenced TD14 8 00 11 3 11 Es instead Added paragraph 13 asa ie Document Number Page Revision Teledyne Battery Products 840 W Brockton Ave Redlands CA 92374 TD14 8 01 ji c TABLE OF CONTENTS Section Page 1 INTRODUCTION 1 2 TSO C173 DEVIATIONS 1 3 INSPECTION AND MAINTENANCE 1 3 1 Initial Inspection 1 3 2 Initial Maintenance 1 3 3 Periodical Maintenance 1 4 INSTALLATION DESCRIPTION 2 5 SERVICING 3 5 1 1 INITIAL CHARGE 4 5 1 2 CONSTANT POTENTIAL CHARGE 4 5
4. be to recharge the battery at constant potential before placing into service See section 5 for all charging instructions NOTE GILL 7000 Series LT valve regulated lead acid batteries are fully conditioned when they leave the factory Even so in order to meet the warranty requirements and improve the reliability and life of the battery it must be fully charged before placing in service 3 3 Periodical Maintenance After the battery has been in service for a period of time maintenance or recharging may become necessary Teledyne Battery Products 840 W Brockton Ave Redlands CA 92374 Document Number Page Revision TD14 8 01 1of 8 e Check battery capacity by disconnecting the battery from the aircraft electrical system and checking the battery open circuit voltage OCV If the voltage is below 13 15 volts for a 12 V battery or 26 3 volts for a 24V battery remove the battery and recharge in a well ventilated area To avoid water loss and possible overcharge the manufacturer recommends a Constant Potential Charge 5 1 2 e Test the resiliency of the mating surfaces terminal pins to connector sockets insert the larger diameter probe of the tool Teledyne Battery Products TBP part number 3600 51 Go No Go Gauge into each helix or socket of the Elcon connector to maximum depth The fit should be snug and require a removal force greater than one pound To depict a worn terminal pin insert the smal
5. ery 90 days Always recharge the battery as directed in paragraph 5 1 2 of this manual after storage and before re installing in aircraft 12 AIRWORTHINESS LIMITATIONS No airworthiness limitations associated with GILL 7000 Series valve regulated lead acid batteries See Doc TD14 8 00 for the battery Part Numbers The Airworthiness Limitations section is FAA approved and specifies maintenance required under Sec 43 16 and 91 403 of the Federal Aviation Regulations unless an alternative program has been FAA approved 13 ICA REVISONS Review our website at www gillbatteries com for updates to this and other key documents These updates can be found under the following link Under the Company Info section select Documentation which leads to the Maintenance Center In the Maintenance Center page under Technical Guides link is available to review any document that has been changed Follow the instructions on that page in order to obtain the necessary change s Document Number Page Revision Teledyne Battery Products 840 W Brockton Ave Redlands CA 92374 TD14 8 01 8 of 8 B
6. hen handling batteries Batteries that have been discharged to the point where their available power is diminished should not be jumped with another power source The discharged battery IS NOT AIRWORTHY because it will not have the necessary capacity required to operate the aircraft electrical system and avionics required in the event of generator failure Always wear eye protection when working with batteries Keep sparks flames burning cigarettes or other ignition sources away at all times Batteries generate explosive gases and must be handled with care Always use insulated tools Follow charger manufacturers instructions e g Teledyne Battery Products TDMC 90 or TSC 01V 24 volt battery chargers Do not allow any untrained personnel to work on batteries Do not disconnect live charger cables at the terminals of a battery because sparks will occur at the terminals Always turn charger off before disconnecting charger leads Make certain the charger cables are clean and not frayed A poor connection could cause localized heating leading to terminal damage melting or possible arcing Make sure the battery maintenance room is well ventilated and isolated from the main air conditioning system Gases from batteries are explosive and should not be allowed to blend in with the main system Do not touch charger leads while the battery is on charge Document Number Page Revision Teledyne Battery Products 840 W B
7. l diameter end of the tool This should also provide a snug fit with a nominal removal force greater then one pound Replace the connector if it shows excessive wear or fails to meet the fit test Part number 3600 51 Go No Go Gauge can be obtained from TBP NOTE The GILL 7000 Series valve regulated lead acid batteries cannot be accessed or opened to add fluid However periodic maintenance is still required in the form of boost charging if the battery becomes discharged 4 INSTALLATION DESCRIPTION e See Teledyne Battery Products Document No TD14 7 01 for typical installation procedure for 7600 series battery e For detail battery installation instructions see Aircraft Maintenance Manual or STC NOTE The conditions and tests for this TSO approval of this battery are minimum performance standards Those installing this battery on or in a specific type or class of aircraft must determine that the aircraft installation conditions are within the TSO standards TSO articles must have separate approval for installation in an aircraft The article may be installed only according to 14 CFR Part 43 or the applicable airworthiness requirements Nickel cadmium and lead acid battery safety concerns include the possibility of fire and venting violently Document Number Page Revision Teledyne Battery Products 840 W Brockton Ave Redlands CA 92374 TD14 8 01 2 of 8 A 5 SERVICING PRECAUTIONS Basic safety precautions w
8. rance Check battery quick disconnect and replace as needed Recharge battery Battery may be shorting under load Perform airworthy test on battery see section 5 1 4 Battery may be self discharging due to sulfation trace build up Charge battery as directed in section 5 Battery life too short less than battery warranty period Overcharge Check and correct adjustment in with instructions in aircraft service manual New battery under Capacity Battery may not have received a full initial charge Charge battery as directed in section 5 Call Teledyne Battery Products Technical Support at 1 800 456 0070 for additional assistance Teledyne Battery Products 840 W Brockton Ave Redlands CA 92374 Document Number Page Revision TD14 8 01 6 of 8 NC Disposal All parts of spent lead acid batteries are recyclable Generally batteries are collected by retailers and wholesalers who send large quantities to battery brokers for reclamation Battery brokers are permitted hazardous waste treatment recycling facilities Contact your local battery retailers or wholesalers for proper disposal of batteries in your area 8 REPAIRS Any repair to the battery must be accomplished at Teledyne Battery Products approved battery facility 9 SPECIAL TOOLS e Go No Go Gauge Part Number 3600 51 e Battery Charge Part Number TDMC 90 e Battery Charge Par
9. rockton Ave Redlands CA 92374 TD14 8 01 3 of 8 NC 5 1 1 INITIAL CHARGE All general charging will be accomplished using the Constant Potential Charge Based on the voltage the battery should be handled as shown in Table 1 for 12V battery and Table 2 for 24V battery Table 1 12V Battery Battery Voltage Call Tech Support at Teledyne Battery Products Discharge at one hour rate to 10 V Recharge at 12V 12 9V constant potential of 14 25 V to 14 5 V until charge rate drops lt 0 5A Charge at constant potential of 14 1 V to ney ees 14 5V until current drops lt 0 5A Table 2 24V Battery Battery Voltage Call Tech Support at Teledyne Battery Products Discharge at one hour rate to 20 V Recharge at 24V 25 8V constant potential of 28 5 V to 29 V until charge rate drops lt 0 5 A Charge at constant potential of 28 2 V to er apes 29 V until current drops lt 0 5 A 5 1 2 CONSTANT POTENTIAL CHARGE Charge the battery for a period of 24 hours at 14 1 to 14 5 volts for a 12V battery or at 28 2 to 29 0 volts for a 24V battery Inrush current can be as high as 100 Amps 5 1 3 CONSTANT CURRENT CHARGE Charge the battery at the rates listed in Teledyne Battery Products Document No TD14 8 00 Table 1 for 10 13 hours unless otherwise stated or until the battery voltage stabilizes for three 3 consecutive hours or drops NOTE DO NOT EXCEED THIRTEEN 13 HOURS Document Number Page Revision Teledyne Bat
10. t Number TSC 01V e Capacity Tester Part Number TCT 1000 10 CONFIGURATION CONTROL The battery configuration is controlled by its serial number Teledyne Battery Products have records including the configuration of each of the battery that is shipped from our facility 11 STORAGE INSTRUCTIONS e Teledyne s 7000 series valve regulated lead acid batteries can be stored between 20 F and 110 F store ideally at 80 F Storage at temperatures outside these temperatures can lead to permanent damage Storage temperatures will determine inspection requirements e Teledyne s 7000 series valve regulated lead acid batteries have a maximum of 24 months of inspection free storage life if stored at temperatures between 40 F and 80 F e Storage of batteries at high temperatures will only serve to discharge the battery faster For every 18 F increase in temperature the discharge rate will double If the battery is severely discharged typically 1 9 volts per cell 11 4 volts for 12V battery or 22 8 volts for 24 V battery it will sustain permanent damage Document Number Page Revision Teledyne Battery Products 840 W Brockton Ave Redlands CA 92374 TD14 8 01 7 of 8 A e If the aircraft is not going to be used for a period of time the battery will need to be correctly maintained for continued service The battery should be removed from the aircraft and either e Kept on trickle charge e Or recharged ev
11. tery Products 840 W Brockton Ave Redlands CA 92374 TD14 8 01 4of8 A ALWAYS CHARGE BATTERIES IN A WELL VENTILATED AREA The GILL 7000 Series valve regulated lead acid batteries cannot be accessed or opened to add fluid There is no battery electrolyte maintenance required for this battery 5 1 4 CAPACITY TEST e Connect battery to a capacity tester that incorporates a load resistance amp meter voltmeter and a time clock timer e Discharge the battery at the one hour capacity rate see NOTE below to 1 67 volts per cell 10 volts for 12V battery or 20 0 volts for 24V battery Note the discharge time to end voltage NOTE The one hour capacity rate Ah for the battery is listed in Table 1 of TSO C173 AUTHORIZED 7000 SERIES BATTERIES Document No TD14 8 00 Revision NC or later FAA approved revisions e The battery is considered airworthy if it meets 80 of the one hour capacity rating minimum of 48 minutes to the cut off voltage e If the battery fails to meet the minimum run time recharge using the constant potential method until charge current stabilizes this could take 10 to 24 hours Allow the battery to stand on open circuit for one hour after recharging Repeat the above capacity test If the failure persists replace the battery e If the battery is found to be airworthy as noted above recharge the battery using Constant Potential Charge prior to re installing it in the aircraft 6 INSPECTI
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