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Battery CMM - (complete manual: format)

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1. A 3 3 lt lt D et D EE o gt e gt s w Uu ct ED un lt m m g lt 2 m I 22 lt 79 g Hours 1 67VPC at 23 001 1101 9 26 14 Page 27 of 33 Teledyne Battery Products 7638 36 ET md Specifications 1 260 EE 1 958 1 408 1 492 1 128 1 156 7638 36 Performance at 23 v A 3 3 lt lt A D fe gt eu gt s UJ gi ct S n Uu lt m m g lt 2 m UJ 5 22 lt 79 a E Hours to 1 67VPC at 23 001 1101 9 26 14 Page 28 of 33 Teledyne Battery Products 7638 44 pecifications Ratings Watts 1400 880 70 44 1857 1247 1677 1051 1411 Amps C NENNEN 7638 44 Performance at 230F SJONGOUd AYALLVE 3NAG3T3L YLI ploy pes 11 Hours to 1 67 at 23 C 001 1101 9 26 14 Page 29 of 33 Teledyne Battery Products 7641 20 pecifications Ratings Watts
2. Eh D UJ lt m rm U lt zZ m UJ 2 lt 9 U 001 1101 9 26 14 Page 24 of 33 Teledyne Battery Products MAINTENANCE MANUAL APPENDIX B VRLA Battery Specifications and Performance Curves 1 7639 27 2 7639 34 3 7638 36 4 7638 44 5 7641 20 6 7035 28 7 7243 16 8 7025 20 A D 3 3 E lt lt D et a E gt gt e gt w Uu ct ED un lt m m g lt 2 m 0 1 22 lt 79 g 001 1101 9 26 14 Page 25 of 33 Teledyne Battery Products 7639 27 25302 Specifications Watts Amps 1 503 1 002 1 104 734 793 596 900 7639 27 Performance at 23 C SJONGOUd AYALLVE 3NAG3T3L ploy pes 11 Hours to 1 67VPC at 23 C 001 1101 9 26 14 Page 26 of 33 Teledyne Battery Products 7639 34 Specifications Battery Weight Ib Watts Amps 1 636 1168 92 774 761 604 55 Capacity Ah Energy Wh 50 7639 34 Performance at 23 C
3. 001 1101 9 26 14 Page 1 of 33 Teledyne Battery Products SECTION 2 COMPONENT MAINTENANCE MANUAL 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 1006 for type certificated aircraft This manual has been written for the purpose of guidance only consult Teledyne Battery Products TBP Technical Support for further information The latest list of our PMA s can be obtained on our website at www gillbatteries com or by calling our Customer Support at 800 456 0070 A 3 3 E lt lt D et a E gt o gt e gt s w Uu ct ED un lt m m g lt 2 m ga 1 22 lt 79 g 001 1101 9 26 14 Page 2 of 33 Teledyne Battery Products SECTION 3 COMPONENT MAINTENANCE MANUAL 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 optimum electrodes to provide the best possible performance characteristics for valve regulated lead acid batteries 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 WARN
4. 5 3 4 Since these are designed to provide 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 shut off timer 5 4 FLOAT CHARGING 5 4 1 This method of charging is essentially accomplished using a charger that can provide a constant potential charge at a lower voltage typically around 26 4V 0 2V for 24V batteries or 13 5V 0 2V for 12V See Figure 4 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 Alternatively Gill offers the GC 012 for 12V batteries as well 5 4 3 The batteries may be kept on the float charger for up to six months at this voltage Figure 4 Float Charger Profile Model GC 024 Max Current 7 44 Amps Ah Input at Float Voltage we By 100 Return Max Voltage Float Voltage 27 89 V 26 33 Volts Charge Current 5 o gt o Current drop float charge starts at this point Time hr v A 3 3 j lt lt A D Tz gt eu gt UJ gi ct S n Uu lt m m g lt 2 m UJ 22 lt 79 E 5 5 INITIAL CHARGING 5 5 1 All gen
5. 2 m I 22 lt 79 g s 001 1101 9 26 14 Page 32 of 33 Teledyne Battery Products 7025 20 The Original Equipment Aircraft Battery Specifications 7025 20 23 A 3 3 E lt lt D et a ET o gt gt s w e Uu ct ED un lt m m g lt 2 m I 22 lt 79 g Hours to 1 67 VPC at 23 001 1101 9 26 14 Page 33 of 33 Teledyne Battery Products
6. 700 400 Amps 35 20 140 920 860 550 620 400 mon gt mm 7641 20 Performance 23 A 3 3 lt lt D et D EE o gt e gt s w Uu ct ED un lt m m g lt 2 m I 22 lt 79 g 1 Hours to 1 67 VPC at 23 001 1101 9 26 14 Page 30 of 33 Teledyne Battery Products 7035 28 The Original E Specifications Battery Ratings Weight Ib Watts 1080 a 7035 28 23 A 3 3 lt lt D et D EE o gt e gt s w Uu ct ED un lt m m g lt 2 m I 22 lt 79 2 g s 0 1 67 23 001 1101 9 26 14 Page 31 of 33 Teledyne Battery Products 7243 16 Specifications Ratings Watts 600 384 me gt 161 as 7 0 305 Capacity 1 36 Energy Wh 300 384 PP 1 1 PI 7243 16 Performance at 23 C Hours to 1 67 VPC at 23 C A 3 3 lt lt D et D EE o gt e gt s w e Uu ct ED un lt m m g lt
7. D et a fe o gt e gt s w Uu ct ED un lt m m g lt 2 m ga I 22 lt 79 g SECTION 11 COMPONENT MAINTENANCE MANUAL GLOSSARY Active material The formed charged material on the positive and negative electrodes plates AGM Absorptive Glass Mat a non woven fiberglass separator that holds the electrolyte Ah Ampere hour the standard designation of capacity units for batteries CFR Code of Federal Regulations Charge Balance Net amount of charge lost Electrolyte The liquid added to a battery that is capable of conducting ions between the two electrodes Electrolysis Decomposition of an electrolyte by the action of an electric current flowing through the electrodes positive and negative plates IATA International Air Transport Association ICAO International Civil Aviation Organization IEC International Electrotechnical Commission lpp Peak current delivered at 0 3 seconds into a 15 second controlled discharge at a constant terminal voltage of half the nominal battery voltage lpr Discharge current at the conclusion of a 15 second controlled discharge at a constant terminal voltage of half the nominal battery voltage Nonspillable 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 OCV Open
8. FOR LIMITATIONS PROCEDURES AND PERFORMANCE INFORMATION NOT CONTAINED IN THIS SUPPLEMENT CONSULT THE BASIC PILOTS OPERATING HANDBOOK AIRPLANE FLIGHT MANUAL THE SPECIFIC STC OR THE BATTERY CONTINUOUS AIRWORTHINESS INSTRUCTIONS FOR THE APPLICATION THIS SERVICE MANUAL SHOULD NOT BE CONSTRUED AS THE FINAL AUTHORITY IN MAINTAINING YOUR SPECIFIC BATTERY PLEASE CONSULT WITH TELEDYNE TECHNICAL SUPPORT FOR FURTHER INFORMATION ii MAINTENANCE MANUAL CONTENTS Section Page l REVISIONIPAGE rer 1 ES o ET 2 3 LT VALVE REGULATED LEAD ACID 3 3 1 Description 3 3 2 Specification Definition 00 4 4 4 SERVICE INSTRUCTIONS 6 4 1 Shipment of Batteries 6 4 2 Inspection for Shipping Damage 6 4 3 Storage Requirements 6 4 4 Initial Inspection 7 Be CHARGING vde piat UR 9 5 SEE Nnm 9 5 2 Constant Voltage 9 5 3 Constant Current 222220240425 11 5 4 12 5 5 Initial Charging 20000 13 6 ROUTINE MAINTENANCE 14 6 1 Inspection Service Period 14 6
9. 2 Continued Airworthiness Requirement Capacity Testing 14 6 3 Reconditioning Battery 15 6 4 Recovery from Deep Discharge 15 6 5 Monitoring Batteries Long Term Storage 17 6 6 Inspection of Connectors 0101 17 7 UNSCHEDULED REMOVAL ttn 18 8 LT VRLA TROUBLE SHOOTING eere 19 9 0 4 4 20 TO RECYCLING 21 VEST 23 12 APPENDIX A VRLA Battery Capacities _ 24 12 APPENDIX VRLA Battery Specifications 25 001 1101 Revision Teledyne Battery Products SECTION 1 COMPONENT MAINTENANCE MANUAL REVISIONS Revised charging instructions title Revised charging instructions added Initial Charge added new spec sheets Added table for Constant Current Charging troubleshooting guide revised SOC vs Voltage chart Battery JMR installation Float charging recommendation and Reconditioning procedure 79 3 3 lt A D D w et D D gt a gt s UJ D m D UJ lt rm m g lt Z m 2 2 lt 79
10. 3 5 Long term storage at low temperatures around 0 F 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 O 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 For the 7025 7035 and 7200 series of batteries the terminal connections can be developed in these two ways Figure 2 Stud Wing Nut Q01 1101 Rev G 9 26 14 Page 7 of 33 Teledyne Battery Products A D 3 3 E lt lt D et D EE gt e gt w Uu ct ET lt m m g lt 2 m ga 1 22 lt 79 g MAINTENANCE MANUAL Inspect the hardware and contact surfaces Ensure clean surfaces and satisfactory contact of all mating components Torque settings for the stud bolt are 50 inch pounds Call TBP Technical Support if you find any discrepa
11. OCV Discharge the battery at the one hour rate to 20V Recharge at lt 24V or constant potential CP of 28 6V 0 4V or 14 25V 0 2V until the charge lt 12V rate drops to Then charge at constant current CC of 1A for 12 hours Discharge at one hour rate to 20V see Appendix A then recharge at constant potential of 28 6V 0 4V or 14 25V 0 2V until charge current 24V 25 5V or 12V 12 75V drops equal to or less than 0 5A gt 25 5V or Charge at constant potential of 28 6V 0 4V or 14 25V 0 2V until gt 12 75V 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 The battery should be discharged at the one hour rate see Table 3 Appendix A 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 80 of the rated time or 48 minutes at the 1 hour rate If the first discharge time is less than 48 minutes condition charge the battery per Section 6 3 and repeat the discharge test This conditioning charge may be repeated once more if needed to ensure capacity is better than 80 6 2 5 If the second discharge fails to deliver at least 48 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 fo
12. as the temperature drops This decline is primarily related to the state of the electrolyte and easily recoverable once the battery has warmed up sufficiently ES 3 3 lt lt 5 Q E gt gt EM a 5 UJ UJ lt m m g lt 22 rn UJ 5 lt 2 g 8 T Q01 1101 Rev G 9 26 14 Page 5 of 33 Teledyne Battery Products SECTION 4 COMPONENT MAINTENANCE MANUAL SERVICE INSTRUCTIONS 4 1 SHIPMENT OF BATTERIES 4 1 1 The batteries are shipped conditioned and fully charged 4 1 2 Each battery is identified with unique serial number label and manufacturing date laser etched on the side opposite the positive terminal Please use this manufacturing date for future reference 4 2 INSPECTION FOR SHIPPING DAMAGE 4 21 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 number label on the packaging against the accompanying FAA Form 8130 3 or Certificate of Compliance 4 3 STORAGE REQUIREMENTS 4 3 1 TBPs 7000 series LT VRLA batteries be stored between 200F and 1100F store ideally at 80 F Storage at temperatures other than these can lead to permanent damage Storage temperatures will determine inspection requ
13. 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 After a pause of about 1 hour discharge the battery at the one hour rate see Table 3 until the battery drops to 20V or 10V depending on battery nominal voltage Record the time to 20V 10V If it is greater than 8096 of specification see Appendix A recharge per Section 5 2 and return to use If not continue to Section 6 4 5 Charge the battery at constant potential of 28 6V 0 4V or 14 2V 0 3V until the charge rate drops to 1A followed by a constant current charge at 1A for 12 hours Discharge the battery at the one hour rate see Table 3 until the battery drops to 20V or 10V depending on nominal battery voltage The battery should be at least 80 of capacity If the battery is lower than 80 repeat step 6 4 6 one Q01 1101 Rev G 9 26 14 Page 16 of 33 Teledyne Battery Products v A 3 3 j lt lt A D fe gt eu gt s e 99 ct S n Uu lt m rm g lt 2 m UJ 5 22 lt 79 E MAINTENANCE MANUAL more time I
14. s UJ D m D UJ lt rm m g lt Z m 5 2 lt 79 3 1 4 battery consists of six or twelve cells connected in series internally for 12V or 24V batteries respectively These cells are not replaceable 001 1101 9 26 14 Page 3 of 33 Teledyne Battery Products MAINTENANCE MANUAL 3 1 5 Each cell is constructed of premium grade LT electrodes plates that are electrically isolated by AGM separators 3 2 SPECIFICATION DEFINITION 3 2 1 TBP battery ratings are defined by a series of specifications 3 2 1 1 The One Hour Rate This is the rate of discharge current battery can endure for one hour with the battery voltage at or above 1 67 volts per cell which is 10V for a 12V battery or 20V for 24V battery The One Hour Capacity measured in Ampere Hours or Ah is the product of the discharge rate A and time in hours to the specified end voltage 3 2 1 2 The Emergency Rate This is the rate of discharge current battery can endure for thirty minutes with the battery voltage at or above 1 67 volts per cell which is TOV for a 12V battery or 20V for a 24V 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 Peak Power Current This is the discharge current delivered at 0 3 seconds while testing d
15. CE MANUAL UNSCHEDULED REMOVALS 7 1 Unscheduled removals may be required when the battery has been inadvertently discharged or has premature failure Recharging the battery using Constant Potential method described 5 2 should be attempted Perform capacity check as outlined 6 2 If the battery fails to provide specified capacity as noted in Table 3 Appendix A it should be rejected 7 2 In lieu of the capacity test set forth above testing on an installed battery may be performed during the 400 hour maintenance check or the periodic maintenance interval performed by the service center This test entails a battery OCV check which is compared to the graph in Figure 1 If the voltage is below 75 state of charge the battery should be pulled out for servicing as outlined in Section 6 v A 3 3 j lt lt A D Tz gt eu gt s UJ gi ct S n Uu lt m rm g lt 2 m UJ 5 22 lt 79 E 001 1101 9 26 14 Page 18 of 33 Teledyne Battery Products SECTION 8 COMPONENT MAINTENANCE MANUAL www gilbatteries com 8 LT VRLA TROUBLE SHOOTING GUIDE PROBLEM CAUSE RECOMMENDATIONS Battery has low capacit Battery has not been charged D don pM 2 Refer to Section 5 for charging options Will not come up to full Aircraft charging voltage may be Contact Aircraft Techni
16. Circuit Voltage measured with no loads connected to the battery Passivation Refers to the oxidation of the negative electrode Recombination The process by which oxygen combines reacts with the negative active material 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 State of Charge The state of charge is the ratio between the difference of the rated capacity and the charge balance to the rated capacity Sulfation The product of discharge lead sulfate formed on both positive and negative plates RN D 3 3 E lt D D D et D D a gt a a gt s 9 D Eh D UJ lt m r m g lt 2 m 2 lt 9 U ty Venting Means for battery to release the gases it generates during charging 001 1101 9 26 14 Page 23 of 33 Teledyne Battery Products SECTION 12 COMPONENT MAINTENANCE MANUAL APPENDIX Table 3 VRLA Battery Capacities Type Battery Voltage 1 Hour Rate 30 Minute Rate e _ 763927 27 7639 34 _ 7638 36 24 36 63 7638 44 24 14 70 7641 20 24 35 72416 24 16 1 25 9 3 3 r lt D lt D et a gt a gt s e UJ
17. ETY DATA SHEETS 10 1 1 The MSDSs can be downloaded as needed from the Gill website www qillbatteries 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 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 Recyclers 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 A 3 3 E l
18. ING 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 3 1 2 TBP valve regulated lead acid batteries have vent caps with 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 in an absorptive glass mat AGM separator that retains and immobilizes the electrolyte These batteries can be operated in any orientation without spilling electrolyte 79 3 3 E lt D D D o et D Tes D gt a e gt
19. Since 1920 The Original Equipment Aircraft Battery 800 456 0070 www gillbatteries com TELEDYNE BATIERY PRODUCTS COMPONENT MAINTENANCE MANUAL LT Valve Regulated Lead Acid Batteries Part Numbers Applicable to this CMM 7639 27 7639 34 7638 36 7243 16 7638 44 7641 20 7035 28 7025 20 PROPOSITION 65 WARNING BATTERY POSTS TERMINALS AND RELATED AC C ESSO RIES CONTAIN LEAD AND LEAD COMPOUNDS CHEMICALS KNOWN TO THE STATE OF CALIFORNIA TO CAUSE CANCER AND REPRODUCTIVE HARM WASH HANDS AFTER HANDLING Receipt and use of this technical document by any receiving party is subject to compliance with all decrees statutes rules and regulations of the United States Government and of the Governments of the countries in which Teledyne Battery Products and the receiving party are doing business at the time of receipt by the receiving party in effect or which may be in effect hereafter which govern exports or otherwise pertains to export controls including without limitation the Export Administration Regulations and the International Traffic in Arms Regulations Document Number 001 1101 Revision G Sep 26 2014 WARNING THE SAFETY INSTRUCTIO NS PREC AUTIONS POSTED IN VARIOUS SECTIONS WITHIN THIS MANUAL MUST BE STRICTLY FOLLO WED ALWAYS WEAR SAFETY GLASSES AND AC ID RESISTANT GLOVES WHENEVER HANDLING BATTERIES ELECTROLYTE CONTAINS SULFURIC ACID WHICH CAN PERMANENTLY DAMAGE EYES AND CAUSE SEVERE BURNS TO EXPOSED SKIN
20. age at this point the charge current starts to drop and will terminate after it has reached 0 5A and satisfied charger requirements The Original Equipment Aircraft Battery 80 com Figure 4 TSC 01V Charge Profile Constant Current Period Constant Voltage Period KS On Charge Voltage V Rate of Charge A o o e 8 o co X N QN nnn Charge Time HH MM SS 5 3 STANDARD CONSTANT CURRENT CI 5 3 These chargers must be capable of providing an output of 33 35V for 24V batteries or 16 5 17 5V for 12V batteries and 4 8 amperes with selector switch and include a timer that can terminate charging when the required charge input is attained 5 3 2 ampere hours of energy restored is the product of charge current in amperes and the time in hours 9 D 3 3 E lt D lt D D w et D D a gt a a gt s UJ D m D UJ lt m m g lt Z m 2 lt 79 ty 5 3 3 During such charging the on charge battery voltage will reach 32V 33V for 24V batteries or 16 16 5V for 12V This is standard for such a charge method Please use charge rate and times as indicated in Sections 5 5 6 4 and 6 5 001 1101 9 26 14 Page 11 of 33 Teledyne Battery Products MAINTENANCE MANUAL
21. arge If the battery fails to meet capacity call Teledyne Tech Support for further direction Discharge at one hour rate to 20V see Appendix A then recharge at constant potential of 28 6V 0 4V or 14 25V 0 2V until charge current drops to 0 5A or less If the charge rate does not drop below required value generally within 10 12 hours conduct up to 2 additional capacity tests and verify that the charge rate drops to 0 5A or less Charge at constant potential of 28 6V 0 4V or 14 25V 0 2V until charge rate current is equal to or less than 0 5A Q01 1101 Rev G 9 26 14 Page 13 of 33 Teledyne Battery Products a 3 3 r lt D D o et Tes o gt a e gt s go UJ o c m UJ lt m m g lt Z m 2 2 lt 79 2 SECTION 6 COMPONENT MAINTENANCE MANUAL ROUTINE MAINTENANCE 6 1 INSPECTION SERVICE PERIOD After initial installation Gill requires a capacity check of the battery to be performed at 1 800 50 hours or 18 months whichever comes first with subsequent capacity checks performed every 900 50hours or 9 months Please refer to aircraft manufacturer s guidelines for further clarification WARNING The battery must be removed from the installation and serviced well ventilated designated area During servicing the battery will generate oxygen and hydrogen gases whi
22. cal Support for charge lower than required for application assistance battery sufficiently recharge when necessary temperatures required Equipment left on accidentally Recharge per Section 5 if deeply discharged battery is discharged follow Section 6 3 Clean neutralize connections tighten all Loose connections corrosion connections Check Cannon or Elcon type connectors for good contact see 7 2 with Teledyne Go NoGo gauge part number 3600 51 Quick disconnect worn beyond tolerance Battery could be shorting under Will not hold charge load Perform airworthiness test per Section 6 2 Battery could be self discharging due to low state of charge Sulfation can build up based on repeated undercharge situations or Recharge per Section 5 if deeply discharged Excessive sulfation build up caused follow Section 6 3 by leaving the battery in discharged state for an extended period of time Remove and recharge the battery reduce equipment load or use an approved higher capacity battery Ensure that battery selection is correct for the application 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
23. ch 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 During this inspection process the following components must be reviewed 79 EX D 3 3 lt D D D ct D Tes D gt c gt s UJ c D m D UJ lt rm m g lt Z m UJ 5 2 lt 79 g 6 2 1 Measure and record the battery voltage 6 2 2 Charge the battery using Table 2 Q01 1101 Rev G 9 26 14 Page 14 of 33 Teledyne Battery Products MAINTENANCE MANUAL Table 2 CHARGING PROCESS Battery Voltage Open Circuit Voltage
24. could be eliminated by inspecting and correcting charge voltages Possible excessive use of starter and other electrical equipment 79 x 3 3 r lt lt r gt m gt x A UJ gi ct 09 lt m rm g lt 2 rn UJ 5 22 lt 79 Charging variations such as overcharging or chronic undercharging brought about by Excessive undercharging very short flights short flights should be compensated by periodic charging of battery 001 1101 9 26 14 Page 19 of 33 Teledyne Battery Products SECTION 9 COMPONENT MAINTENANCE MANUAL TRANSPORTATION 9 1 Gill LT VRLA batteries are classified as Nonspillable and are exempted from all other requirements of 49 CFR Chapter 1 Subchapter C Parts 106 180 as determined in 05 Department of Transportation s 49CFR Chapter 1 Part 173 159 paragraph b IATA ICAO Packing Instructions 806 Provision A67 v A 3 3 j lt lt A D Tz gt eu gt s UJ gi ct S n Uu lt m rm g lt 2 m UJ 22 lt 79 E 001 1101 9 26 14 Page 20 of 33 Teledyne Battery Products SECTION 10 COMPONENT MAINTENANCE MANUAL RECYCLING 10 1 MATERIAL SAF
25. d Lead Acid Batteries a o o S o gt o 5 o 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 105 110 115 120 Temperature F 5 2 4 The battery must be connected to the charger with output voltage set between 28 6V 0 3V for 24V batteries or 14 25V 0 2V for 12V batteries and left on until the charge rate drops below 0 5 ampere At this point disconnect the charger from its power source first before disconnecting the battery from the charger to eliminate any sparks Note Unless the charger is of a type that turns off automatically you must disconnect the charger and battery once the charge rate drops below 0 5 amperes 9 D 3 3 E lt m lt D D o et D Tes D a gt a a gt s e UJ D m D UJ lt m m g lt Z m 2 lt 79 ty 5 2 5 Alternatively constant voltage charging can be temperature compensated for better control Note Figure 3 for Temperature Compensated Charge Voltages This figure can be used for all 7000 series batteries 001 1101 9 26 14 Page 10 of 33 Teledyne Battery Products MAINTENANCE MANUAL 5 2 6 Figure 4 represents the TSC OI V Charger profile for 24V batteries only This is a specialized charger that provides a constant current charge initially as the battery voltage approaches the charger output volt
26. eral charging will be accomplished using the Constant Potential charge regime except when situations require specific charging treatment Q01 1101 Rev G 9 26 14 Page 12 of 33 Teledyne Battery Products MAINTENANCE MANUAL 5 5 2 When batteries are left on shelf for 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 I 5 5 3 requirement at initial installation is to ensure battery will provide 100 capacity Inspect battery voltage and reference to Figure 1 to verify state of charge 5 5 4 For various battery voltages Table 1 provides the necessary charging and or conditioning that would be required 5 5 5 Please contact Teledyne Tech Support if there are any situations that are not clear Battery Voltage Open Circuit Voltage OCV lt 24V or lt 12V 24V 25 5V or 12V 12 75V gt 25 5V or gt 12 75 Table 1 INITIAL CHARGING PROCESS Discharge the battery at the one hour rate to 20V Recharge at constant potential CP of 28 6V 0 4V or 14 25V 0 2V 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 the battery passes recharge it using CP and CC method f not repeat CP and CC charge followed by one more disch
27. f the battery does not provide more than 80 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 MONITORING BATTERIES IN LONG TERM STORAGE After storage or before installation on aircraft follow the guidelines below Refer to Section 4 3 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 capacity see Appendix for specifications If it is a 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 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 6 6 2 For the 7035 and 7200 series review instructions in Section 4 4 1 Q01 1101 Rev G 9 26 14 Page 17 of 33 Teledyne Battery Products A 3 3 E lt lt D et a E gt o gt e gt s w Uu ct ED un lt m m g lt 2 m ga I 22 lt 79 g SECTION 7 COMPONENT MAINTENAN
28. irements 4 3 2 7000 series LT VRLA batteries have a maximum of 24 months of inspection free storage life IF stored at temperatures between 40 F to 80 F 4 3 3 If stored between 95 F 3500 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 1 10 F will reduce battery life A 3 3 E lt lt D et a E gt o gt e gt s w e Uu ct ED un lt m m g lt 2 m ga I 22 lt 79 g During these monthly inspections the battery must be recharged per Section 5 2 and returned to storage If stored at these temperatures longer than three months there is possibility of damaging the battery 001 1101 9 26 14 Page 6 of 33 Teledyne Battery Products MAINTENANCE MANUAL 4 3 4 All batteries returned from service after initial use must be stored fully charged per Section 5 2 and returned to storage The storage start date and battery voltage must be logged on the outer package or marked on the battery The inspection intervals for these batteries will be the same as outlined in this section See Figure 1 for state of charge at various voltages The Original Equipment 4
29. ive 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 VOLTAGE OR CONSTANT POTENTIAL OR CP 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 a D 3 3 lt D D D et D zx D a gt a a gt s UJ D Eh D n UJ lt m r m g lt 2 m 2 lt 9 U ty 5 2 2 CV charging will result in a high initial charging current which will start dropping off when the voltage gradient between the charger and battery begins Q01 1101 Rev G 9 26 14 Page 9 of 33 Teledyne Battery Products MAINTENANCE MANUAL to decrease because the current in any circuit is directly proportional to the voltage gradient across that circuit The Original Equipment Aircraft Battery 80 5 5 2 3 Typically the charger will regulate to around 28 6V for 24V batteries or 14 3V for 12V batteries As the battery approaches the charger output voltage charge current will drop below 0 5 amperes Figure 3 Temperature Compensated Charge Voltages Valve Regulate
30. ncy WARNING ALL VRLA batteries contain sulfuric acid which is highly corrosive and can cause serious physical injury if it comes in contact with skin or 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 4 4 2 Forthose batteries with lids DO NOT remove the lid The vents are sealed to the cover and cannot be removed for maintenance 4 4 3 Inspect the open circuit voltage Typical practice should be to recharge the battery at constant potential before placing into service Review section 5 for all charging instructions 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 5 3 and 5 4 If there are any concerns while recharging please call Tech Support at Teledyne Battery Products 4 4 4 Charging should be terminated when the charge current drops to less than 0 5 ampere may take up to 15 hours depending on the state of charge of the battery Q01 1101 Rev G 9 26 14 Page 8 of 33 Teledyne Battery Produc
31. r 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 a D 3 3 E lt m D D et D zx D a gt a a gt s UJ D Eh D n UJ lt m r m g lt 2 m 2 lt 9 U ty 6 3 2 Charge the battery at constant potential of 28 6V 0 4V or 14 2 0 3V depending on nominal battery voltage until the charge rate drops to followed by constant current charge at for 12 hours 001 1101 9 26 14 Page 15 of 33 Teledyne Battery Products MAINTENANCE MANUAL 6 3 4 Repeat the discharge test per Section 6 2 4 followed by a recharge per Section 6 3 2 The battery should achieve full capacity in 2 cycles If it does not reject the battery DEEP DISCHARGE RECOVERY 6 4 1 6 4 2 6 4 3 6 4 4 6 4 5 6 4 6 Deep discharge is usually indicated by a battery voltage of less than 24 volts or 12 volts depending on nominal battery voltage A battery which has been deeply discharged can be recharged using constant current charging techniques for best recovery Discharge the battery at the one hour rate see Table 3 until the battery drops to 20V 24V batteries or 10V 12V batteries Recharge the battery at a constant current charge rate of 1 0A
32. t lt D et a o gt e gt s w e Uu ct ED un lt m m g lt 2 m I 22 lt 79 g 001 1101 9 26 14 Page 21 of 33 Teledyne Battery Products MAINTENANCE MANUAL Even in a state where there is no lead acid battery recycling law it s 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 10 3 INTERNATIONAL RECYCLING RESOURCES 10 3 1 10 3 2 10 3 3 British Battery Manufacturers Association 26 Grosvenor Gardens London SW1W OGT Direct Tel 44 0 207 838 4800 Direct Fax 44 0 207 838 4801 SNAM Societe Nouvelle d Affinage des Metaux Rue de la Garenne St Quentin Sallavier 38297 La Verpilliere Cedex France Telephone 00 33 74 945 985 Battery re processing You can also locate a recycling facility through the following Call2Recycle a program of Rechargeable Battery Recycling Corporation RBRC website http www call2recycle org 001 1101 9 26 14 Page 22 of 33 Teledyne Battery Products A 3 3 E lt lt
33. ts RN D 3 3 E lt lt D D et D zx D a gt a a gt s UJ D z UJ lt m r m g lt 2 m 2 lt 9 U ty SECTION 5 COMPONENT MAINTENANCE MANUAL CHARGING RECOMMENDATION Charging should be conducted well ventilated area at ambient conditions ranging from 65 F to 80 F 5 1 OVERVIEW 5 1 1 Please review the charging method constant voltage or constant current before commencing The preferred method is constant voltage Refer to Section 5 2 and 5 3 5 1 2 Correct 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 5 2 4 Overcharging a battery will corrode the posit
34. uring a 15 second power discharge controlled to maintain constant terminal voltage of half the nominal battery voltage IEC 60952 1 lpr 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 IEC 60952 1 3 2 2 State of charge using voltage measurements should be used as a guide only Figure 1 for a 24V battery indicates the relationship between Battery Open Circuit Voltage and State of Charge SOC Please note that state of charge is not the same as available capacity see GLOSSARY Q01 1101 Rev G 9 26 14 Page 4 of 33 Teledyne Battery Products v A 3 3 j lt lt D gt eu gt s e 99 ct S n Uu lt m m g lt 2 m UJ 5 22 lt 79 E MAINTENANCE MANUAL Figure 1 State of Charge Vs Voltage Approximate Terminal Voltage V 40 50 60 80 90 Approximate State of Charge Note Approximate Terminal Voltages would be half these values for a 12V battery 3 2 3 All 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 F Available capacity declines

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