-6-

OBJECTIVES/ADVICE

When you have completed this booklet you will be able to:-

• explain the functions of an aircraft battery,

• describe the construction of an aircraft
battery,

• list the provisions of an aircraft battery

stowage compartment,

• explain the battery vent system on an aircraft,

• describe battery charging,

• explain battery discharge rates,

• explain a battery condition check.

I have assumed that you will have the knowledge contained in

the Basic Electrics Module (Module No.2, Study Plan No. 9)
this will give you a good lead into this booklet.

Attempt the activities in the order given and carry out the
essential reading at the end.

,
This booklet will take you about one hour to complete.

INTRODUCTION

All aircraft will have an electrical power system that is used

to provide power for an assortment of radio communication and
navigation systems, engine and flight control systems,
instruments, and lighting systems, together with miscellaneous
systems, such as galley and cargo handling. Electrical power
will be required during all phases of aircraft operation, i.e.,
both in flight and on the ground.

On any aircraft there will be two sources of electrical power.

1. The engine driven generator, providing a.c. or d.c.

power whenever the engine is operating.

2. The battery, providing a source of d.c. power

whenever the engine generator is not operating.
 -8-

COMMENTS ON ACTIVITY 1

Your diagrams should look something like this:-

1. ALTERNATING CORRENT 2• 0 IREC'I' CURRENT

frequency - cycles per second

+
d.c.
volts '-~ _
polarity
o positive or
neqative

o +--l.. ~.
ti.JDe
.• 1 cycle ---

If you had difficulty remembering these terms, refer back to

the Basic Electrics Booklets.

THE AIRCRAFT BAT'l'ERY

The principal functions of an aircraft battery are:-

• to assist in maintaining the aircraft's d.c.
voltage constant under varying operating
conditions, such as when turning on a d.c. fuel
, pump.
• to supply power for internal starting of an
engine, i.e., auxiliary power unit (APU) on a
jet transport or a piston engine on a Piper
Cherokee.

• to maintain a limited amount of lighting,

communication, and instrument systems under
emergency conditions, such as during an engine
failure.

Principle of Operation
The battery operates on the principle of conversion of chemical
energy into electrical energy. This is done by the exchange of
electrons (the atomic components that produce electricity), due
to the chemical reaction, between the electrodes and the
electrolyte.
 -9-

two types of aircraft battery in use. It is

for you to be aware of both types. They are
fferent and not normally interchangeable between aircraft.
are the:-
• lead acid battery, ( .

• nickel-c.admium battery (commonly known as the

Ni-Cad Battery). 'i
e battery type is derived from the plate material
ectrodes) and liquid (electrolyte) that is used during
nstruction.

1 shows the construction of a typical battery cell.

TERMINAL POSTS

INTERLEAVED
PLATES (ELECTRODES)

, ELECTROL YTE

CELL CONTAINER

SUPPORTING RIBS

Fig. 1 TYPICAL BATTERY CELL

 -10-

Table I shows the materials that are used to make a battery

cell.

Plates
Lead
NickelPeroxide
Lead Electrode
Potassium
CadmiumElectrolyte
Sulphuric
Hydroxide
Hydroxide
Negative
Acid
Cell Type

TABLE 1. BATTERY MATERIALS

CAUTION

It is important for you to note that the

electrolyte is either acid or alkali. They
react violently when brought into contact with
one another.

Whenever handling a battery, never allow the

electrolyte to spill onto the airframe or your
body, damage to both will occur.

Special cleaning and neutralizing procedures

apply. Read a Maintenance Manual to ensure you
, are aware of them.

BATTERY CONSTRUCTION

An aircraft battery consists of a number of individual cells

interconnected together, the terminal posts are connected by
cell straps and brought out to a main receptacle for connection
into the aircraft's main wiring.
 '~:'i.~~J,L.
~. ': r "
..nr
.
1I.)'L".nJ;iilil.'.I'·· r[ ..•,'JjJJJn;"'>'-.','
,_ .~_.~" ", ' __ '_

-11-

The cells are enclosed in an acid (alkali) resistant metal

container with a removable lid.

This forms the battery box and it affords both electrical

shielding and mechan~caI protection.

Fig. 2 shows a typical Ni-Cad battery box.

REMOVABLE LID

CELL STRAPS

INDIVIDUAL CELL

MAIN RBCBP'1'ACLE

CELL OUTPUT • 1.2 V

20 CELLS (TYPICAL)
BATTERY OUTPUT = 20 X 1.2
• 24 V

, Fig. 2 TYPICAL NI-eAD BA'M'ERY BOX

Fig. 3 shows a typical light aircraft lead acid battery with 6

cells enclosed in a light weight polystyrene case.
 -12-

TERMINAL
AND CAP

Piq. 3 TYPICAL LIGHT AIRCRAFT LEAD ACID BATTERY .

BAftBRY INSTALLATION

Batteries are installed in either individual compartments

specially designed and located to provide adequate heat
dissipation, ventilation and protection or they will be located
within the aircraft's main electrical equipment bay beneath the
passenger compartment. .

Fig. 4 shows a typical lead acid battery installed in large jet

transport aircraft.
 -13-

TEFLON
COVERED WIRES

ACID JAR

INLBT
VENT HOSE

OO'l'LET VENT HOSE

Pig. 4 BATTERY INSTALLATION - JET TRANSPORT

"During normal operation, the battery cells give off gas and
fumes wh~h are removed from the battery box by the vent hose
system. Before the fumes are deposited overboard, they are
~awn through an acid jar which contains an acid neutralizing
.gent, normally·~ica~bonAte of soda (baking power), this will
:preventairframe corrosion .0 .

It is important to remove, clean and inspect the acid jar at

the periods specified in the aircraft Maintenance Manual.

NOTE A Ni-Cad battery vent system will not include an

acid jar.
! -14-

BATTERY CONNECTION

To facilitate removal and installation of an aircraft battery,

a quick disconnect assembly is normally used to connect the
power leads to the battery.

Fig. 5 shows a typical Ni-Cad battery and quick disconnect

assembly.

goxa
DISCORNEC'l'

, Piq. 5 goxa DIScaarBC'l' ASSEMBLY

The quick-disconnect plug consists of a socket and a coarse

pitch handwheel, it is readily connected to the receptacle by
rotating the handwheel. After installation it is important to
lock the handwheel in place by use of an attached locking pin.
 -16-

COMMENTS ON ACTIVITY 2

Your statements should read:-

1. A lead-acid battery has SULPHURIC ACID as an

electrolyte, and LEAD and LEAD PEROXIDE as
electrodes.

2. A Ni-Cad battery has POTASSIUM HYDROXIDE as an

electrolyte, and NICKEL HYDROXIDE and CADMIUM
HYDROXIDE as electrodes.

If you experience difficulty here refer back to Table 1.

Let us now move on.

BATTERY CHARGING AND DISCHARGING

Whenever a battery is supplying power, it is said to be

DISCHARGING, i.e., the chemical reaction is taking place and
producing electrons. This action alters the nature of both
electrode and electrolyte material until such time that the
chemical reaction ceases, battery output will be zero, and the
battery is said to be flat!

It is important that the battery is not allowed to become

completely discharged under normal operating conditions.
Therefore, whenever the aircraft's engine driven generator is
operating or external power is applied from a ground power
cart, the battery will be CHARGING, i.e., the chemical reaction
is reversed, re-establishing normal electrode and electrolyte
'conditions .

Discharge Rates

An important term you must be aware of is BATTERY CAPACITY

which is measured in AMPERE-HOURS (AH) and is defined as:-

• The maximum current, in amperes, which the

battery will deliver for a known time period, in
HOURS, until the output voltage has fallen to
minimum value.

For example, a battery whi~h discharges 8 amperes for 5 hours

is rated at 40 ampere-':'hours(8 x 5 = 40 AH).

Fig. 6 shows typical discharge rates for lead acid and Ni-Cad
batteries.
 -17-

30

26

'l'uminal volts

Ampere-hours
4
22
...••. ,
20A.""" " " 820
24
12
SA16"
,
"

18

Fiq. 6 TYPICAL DISCHARGE RA'l'ES - LEAD ACID AIm NX-CAD BA'l"l'ERIES

NOTE Ni-Cad battery capacity is greater than lead

acid battery capacity, this is one of the major
advantages of Ni-Cad batteries.
ome
Ins. Now let's move on to consider battery charging.
is
)Wer Battery Charging
tion
lyte Battery charging is achieved by passing a direct current, of
higher voltage than battery output, through the battery in a
direeti~n opposite to that of normal discharge current. The
,two methods of battery charging are:-

ACITY • constant voltage,

• constant curr~nt.

We will consider an important aspect of constant current

.charging. This.i,.s. the preferred ,metl1od for charging Ni-Cad·
batteries, as it ,_is ,more effective. Ho"fi!ver; has '-one it
hours
~awback
an
"'-.
extent
in tha~ ..
that ~t eouId destroy the ---_
i:. t_wi,11 &!!.creasebattery
_---, ..~.~
battery
te~peratu.~e
by thermal
to such
runaway.-~-------
Ni-cad
 -18-

Fig. 7 explains the closed loop situation leading to thermal

runaway and battery destruction•
..

To protect against thermal runaway, <constant current charg~ng

systems use'a battery--eemper~ture sens1fi- en~fhat w1.ll
,~
----------~
~rature off.,t e above
rises arg ng
a setcurrent
limit. whenever the battery

Fig_ 8 shows a typical Ni-Cad battery and battery charger unit

fitted to a large jet transport aircraft. Note the battery
temperature sensor.

Piq_ 8 NI-<:AD BA'l"l'DY ANI) CHARGER INS'l'ALLED IN JET TRANSPORT

 -19-

in
Fig. 9 shows
Fig. 8. the simplified block diagram for the system shown

BATTERY CHARGER

00'1'P0'J."
TO D.C. LOADS

ENGINE DRIVEN
...--._.--~_._---.
__
.. _~ --

A.C. GENBRA1"OR COH'l'ROL

.--~--_._._---~--- Jt1RC'l'Iat BOX

BATTERY --
Pig. 9 BI.OCX DIAGRAM OP IN SITO BAT'l'ERY AND CHARGER

The constant voltage_c~~r9in9 method is normally found on~gh~

aircrart;'"6rthose whi<:hhave E!ngin~ driv~n d.c L--genE:rators.
Fig. 10 is a simplified schematlc o~ this type of system.
 -20-

GENERATOR
VOLTAGE REGULATOR

-- +

JUNCTION BOX

REVERSE CURREN'l' LIGHTS

PROTECTION

. on- -
BATTERY
SWITCH
- RADIO
MISC •
BA'l'TERY

I / :~NO

F1q. 10 SCHEMATIC CHARGING SYSTEM FOR LIGHT AIRCRAFT

Consider Fig. 10, the:-

• •
one current-
current
reverse
direction
the to
battery
the
voltage
charging only.
the
circuit connects
ensures
-maintains
and
output enables

•
ower • , in protecti,on
regulatorswitch
generator -

..•... _- -.-._.~~~.,.--('.
..
 -22-

COMMENTS ON ACTIVITY 3

The answers are:-

1. (c)
2. (a)
If your answers were wrong, refer back to the preceding
section.

Finally, we must look at checks that can be carried out on an

aircraft battery to prove its serviceability.

BATTERY CONDITION

The easiest way to check battery condition is to measure its

output. Normally, this is achieved by an instrument mounted in
the electrical panel, visible to the pilot or engineer. You
will recall that the unit of potential electricity is the volt
and the instrument that measures volts, is the voltmeter. The
voltmeter is wired into a circuit to measure the output voltage
of the battery. In addition some aircraft may have an ammeter
fitted, this measures battery current. Battery discharge will
be indicated by a large negative reading, battery charging is
indicated by the reverse, i.e., a large positive reading. with
the aircraft's generators operating the battery ammeter should
read nearly zero.

Fig. 11 shows a typical electrical instrument panel fitted to a

jet ,ran sport aircraft. Note the d.c. meters are on the left.
 -23-

AMMETER

(Measures battery
current when
-.itch placed
to BAT)

VOL'1'HB'1'ER

SBLBC'l'ORswrrea TIt
APUGIN
(Position to BA'!'
to c:beck battery GND TlST
PWlI
output)
'= I~ATl2
STOI,.
PM TlST '12 S'I"
GlN@GIN2
'WI
GALLEY RESIO
VOLTS

BA'l"'l'ERY
(Guarded)
SWI'l'CH BOf'o
BAT
ON ::@J
-AC_
(g
Fig. 11 ELEC'1'RlCAL INS'l'RUKENT PANEL

"typical reading for a good battery would be a no'minal 24

Its, but check the relevant maintenance manual for correct-
gures.