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10800 Mavinee Drive Tucson AZ 85737 USA

Tel: 1-520-297-0844 Fax 1-520-498-4924


CAGE Code: 0TMJ9

TRANSMITTAL SHEET

TO: HOLDERS OF XL2410-04 BACKUP BATTERY SYSTEM ABBREVIATED COMPONENT


MAINTENANCE MANUAL, ATA 24-32-24 DATED May 2/07, Revision 3.

REVISION NO. 4 DATED NOV 14, 2007

Pages which have been revised, added, or removed are shown below, with the reasons for the changes.
Please discard entire manual of previous issue(s) and replace with this complete manual.

HIGHLIGHTS

Subject/Page Description of Change

Title Page
Page TP1 Revised to reflect this revision.

Testing and Fault Isolation


Page 1006 Revised Figure 1001 and at Paragraph K. Capacity
Discharge Test, (1) added 2nd sentence “Connect the
2-wire bench charge harness to J1-A1 (+24 Vdc) and
J1-A4 (GND). See Figure 1001.”
Added Note after paragraph (6).

Storage (Including Transportation) Added paragraph (5) under 3.A.


Page 15002 “When shipping or storing the unit, always pull CB1
and CB2 and place a circuit breaker restraint around
the breakers.”

Page 1 of 1
24-32-24 Nov 14/07
10800 Mavinee Drive Tucson AZ 85737 USA
Tel: 1-520-297-0844 Fax 1-520-498-4924
CAGE Code: 0TMJ9

XL2410-04
BACKUP BATTERY SYSTEM

ABBREVIATED
COMPONENT MAINTENANCE MANUAL

PART NO.
100-2410-04

Page TP1
Initial Issue: Jun 27/03
Manual Part Number: MM-0070-01 24-32-24 Revision No. 4
Nov 14/07
ABBREVIATED COMPONENT MAINTENANCE MANUAL
100-2410-04

SAFETY ADVISORY

WARNING: BEFORE THE MATERIALS CALLED OUT IN THIS PUBLICATION ARE USED, KNOW
THE HANDLING, STORAGE AND DISPOSAL PRECAUTIONS RECOMMENDED BY THE
MANUFACTURER OR SUPPLIER. FAILURE TO COMPLY WITH THE
MANUFACTURERS' OR SUPPLIERS' RECOMMENDATIONS CAN RESULT IN
PERSONAL INJURY OR DISEASE.

WARRANTY/LIABILITY ADVISORY

SECURAPLANE ASSUMES NO RESPONSIBILITY FOR ANY SECURAPLANE EQUIPMENT WHICH IS


NOT MAINTAINED AND/OR REPAIRED IN ACCORDANCE WITH SECURAPLANE’S PUBLISHED
INSTRUCTIONS AND/OR SECURAPLANE’S REPAIR AUTHORIZATION. NEITHER DOES
SECURAPLANE ASSUME RESPONSIBILITY FOR SPECIAL TOOLS AND TEST EQUIPMENT
FABRICATED BY COMPANIES OTHER THAN SECURAPLANE.

INCORRECTLY REPAIRED COMPONENTS CAN AFFECT AIRWORTHINESS OR DECREASE THE LIFE


OF THE COMPONENTS. INCORRECTLY FABRICATED SPECIAL TOOLING OR TEST EQUIPMENT CAN
RESULT IN DAMAGE TO PRODUCT COMPONENTS OR GIVE UNSATISFACTORY RESULTS.

CONFIDENTIALITY NOTICE

This document contains confidential and proprietary information, which is proprietary to Securaplane® and
shall not be copied or reproduced, in whole or in part, or the contents divulged or used for manufacture,
without the specific written permission of Securaplane. Recipient, by acceptance, use, or retention of this
document, acknowledges and agrees to the foregoing and covenants to maintain the contents in confidence.

AIRCRAFT-ON-GROUND (AOG) SERVICE

For AOG service contact Securaplane at Tel: 1-520-297-0844 (US Toll Free: 1-800-279-7327). After
business hours, follow the AOG directions in the recorded message.

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TABLE OF CONTENTS

SECTION PAGE

INTRODUCTION .......................................................................................................................... INTRO-1


1. General Information.......................................................................................................... INTRO-1

DESCRIPTION AND OPERATION ........................................................................................................... 1


1. Description .................................................................................................................................... 1
2. Operation ...................................................................................................................................... 6
3. Leading Particulars .................................................................................................................... 14

TESTING AND FAULT ISOLATION .................................................................................................... 1001


1. General Information ................................................................................................................ 1001
2. Equipment and Materials ........................................................................................................ 1001
3. Test Procedures ..................................................................................................................... 1002

SCHEMATICS AND WIRING DIAGRAMS .......................................................................... Not Applicable

DISASSEMBLY .................................................................................................................... Not Applicable

CLEANING .......................................................................................................................................... 4001


1. General Information ................................................................................................................ 4001
2. Equipment and Materials ........................................................................................................ 4001
3. Cleaning Procedures .............................................................................................................. 4002

INSPECTION/CHECK ......................................................................................................................... 5001


1. General Check Information .................................................................................................... 5001
2. Equipment and Materials ........................................................................................................ 5001
3. Check Procedures .................................................................................................................. 5001

REPAIR ................................................................................................................................ Not Applicable

ASSEMBLY .......................................................................................................................... Not Applicable

FITS AND CLEARANCES ................................................................................................................... 8001


1. General Information ................................................................................................................ 8001

SPECIAL TOOLS, FIXTURES, EQUIPMENT AND CONSUMABLES ............................................... 9001


1. General Information ................................................................................................................ 9001

ILLUSTRATED PARTS LIST ............................................................................................... Not Applicable

SPECIAL PROCEDURES .................................................................................................... Not Applicable

REMOVAL ............................................................................................................................ Not Applicable

INSTALLATION .................................................................................................................... Not Applicable

SERVICING .......................................................................................................................... Not Applicable

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TABLE OF CONTENTS (Cont)

SECTION PAGE

STORAGE (INCLUDING TRANSPORTATION) ............................................................................... 15001


1. General Information .............................................................................................................. 15001
2. Equipment and Materials ...................................................................................................... 15001
3. Storage/Transportation Procedures ..................................................................................... 15002

REWORK ............................................................................................................................. Not Applicable

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ABBREVIATED COMPONENT MAINTENANCE MANUAL
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INTRODUCTION

1. General Information

A. Introduction

(1) This Abbreviated Component Maintenance Manual (ACMM) has the specifications,
description, cleaning and storage instructions for the XL2410-04 Backup Battery
System. Securaplane Technologies of Tucson, AZ, U.S.A. makes the XL2410-04
Backup Battery System.

(2) This ACMM has the off-aircraft procedures for the XL2410-04 Backup Battery
System. This ACMM is not for use by a mechanic working on a XL2410-04 Backup
Battery System installed on the aircraft. The XL2410-04 Backup Battery System
must be returned to Securaplane or a facility approved by Securaplane for
disassembly and repair.

B Equipment Identification

(1) The configuration of the equipment is shown by part number, dash number, series
number, and MOD number marked on the identification label.

NOTE: Incorporated MOD status is indicated on the XL2410-04 Backup Battery


System identification label by blackened MOD circle(s).

C. Applicable Documents

(1) The reference documents for the XL2410-04 Backup Battery System are listed in
Table Intro 1.

Table Intro 1. Applicable Documents

Securaplane Document Document Number

Outline Drawing, XL2410-04 Backup Battery 100-2410-04

D. Product Support Services

(1) Product support for the XL2410-04 Backup Battery System is available from
Securaplane at:

Securaplane CAGE Code: 0TMJ9


10800 Mavinee Drive Tel: 1-520-297-0844
Tucson AZ 85737 USA Fax 1-520-498-4924
Email: support@securaplane.com Web: www.securaplane.com

E. Verification Dates

(1) Not applicable.

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F. Revision Service

(1) This ACMM is written in agreement with the Air Transport Association of America
iSpec 2200 and AECMA Simplified English guidelines.

(2) A complete revision of this manual will be issued when necessary throughout the
service life of the unit.

(3) A change bar in the margin will identify the revised text. If the entire page has
changed, a change bar will appear in the lower right corner.

G. Electrostatic Discharge

(1) The items susceptible to electrostatic discharge are handled in agreement with
IPC-A-610. Refer to the IPC-A-610C specification Sections 3.2 and 3.3 for the
definition of the standards and conditions.

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H. Abbreviations

(1) Abbreviations which may be used in this manual are defined below.

Abbreviation Nomenclature Abbreviation Nomenclature


A Ampere LB Pound(s)
AC Alternating Current LED Light Emitting Diode
AOG Aircraft on Ground LRU Line Replaceable Unit
ASSY Assembly mA Milliamperes
ATA Air Transport Association MAX Maximum
BITE Built-in-Test Equipment MM Millimeter(s)
C Celsius and/or Centigrade MOD Modification
CAGE Commercial and NHA Next Higher Assembly
Government Entity
No. Number
CM Centimeter(s)
ORIG Original
CMM Component Maintenance
Manual OZ Ounce

CONT Continued PN Part Number

DC Direct Current PSIG Pounds (each) square inch


gage
EIA Electronic Industry
Association Qty Quantity

F Fahrenheit REF Reference

FAA Federal Aviation REV Revision


Administration SB Service Bulletin
FIG. Figure SI Standards International
FT Feet SMPTE Society of Motion Picture and
Hz Hertz Television Engineers

IEC International Electrotechnical ST Street


Commission TDB To Be Determined
IEEE Institute of Electrical and TR Temporary Revision
Electronics Engineers
TYP Typical
INC Incorporated
USA United States of America
INTRO Introduction
V Volt(s)
IPL Illustrated Parts List
VAC Volts Alternating Current
IRE Institute of Radio Engineers
VDC Volts Direct Current
KG Kilogram(s)
W Watt
KPA Kilopascal(s)

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DESCRIPTION AND OPERATION

1. Description

A. Introduction

(1) This section has the physical description and operation for the XL2410-04 Backup
Battery System.

B. XL2410-04 Backup Battery System Description

(1) The XL2410-04 is an emergency battery designed to provide a stable


alternate/standby power source for avionics equipment and systems during ground
and airborne operations. The chassis is a single line replaceable unit (LRU), capable
of providing a battery output of 18 – 25 Vdc at 3.5 Amps for 3 hours, plus a 5 volt
lighting output rated at 2 Amps for 3 hours. See Figure 1.

(2) The XL2410-04 consists of two 13 Ah lead acid batteries with charge control and
protection circuitry located in the assembly.

(3) The XL2410-04 unit performs three major functions as an emergency battery
system. The first function involves charging the self-contained sealed-lead acid
batteries. The second function provides an indication of the state of charge of the
batteries. The third function ensures the safe operation of the system. These
functions are all implemented in hardware and do not involve the use of a
microprocessor or associated software.

(4) The XL2410-04 includes a power diode that directs the aircraft 28 Vdc bus voltage
directly to the output load whenever bus voltage is available. When the 28 Vdc bus
drops below 23 – 25 Vdc, the battery output automatically supplies the output load.

(5) The charge management system consists of a dedicated internal battery charger
operating from a 28 Vdc source provided from the aircraft bus. Whenever aircraft
power is present, the batteries are charged from the aircraft bus through this
charger, which limits the peak charge current to approximately 8 Amps. The voltage
limit from this dedicated charger is set to 30.5 Vdc in bulk mode, and is temperature
compensated in trickle mode.

(6) The XL2410-04 series emergency batteries are designed for minimum maintenance.
The XL2410-04 does not need to be removed from the aircraft for any reason except
for an outright failure, or preventative maintenance battery replacement.

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XL2410-04 Backup Battery System Front View


Figure 1

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C. XL2410-04 Backup Battery System Interface

(1) The interface diagram for the XL2410-04 Backup Battery System is shown in
Figure 2.

XL2410-04 Backup Battery System Functional Interface


Figure 2

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D. XL2410-04 Backup Battery System Front Panel

(1) The XL2410-04 front panel contains LEVEL TEST, BITE TEST, and FAULT RESET
pushbutton switches, two circuit breakers, and LEDs that indicate Charger faults and
battery status. The front panel switches and indicators shown in Figure 3 are
described in Table 1.

XL2410-04 Backup Battery System Controls and Indicators


Figure 3

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Table 1. XL2410-04 Controls, Indicators, and Connectors

Reference
Function
Designator

ENERGY LEVEL

LEVEL TEST When pressed, this momentary pushbutton tests the battery
pushbutton energy level by temporarily turning off the charger and
placing an internal load (heater blanket) across the battery.
When the pushbutton is depressed, the LOW, MID, or FULL
LED illuminates indicating the battery energy level. A level
test is also initiated when CB1 is closed after the unit has
been stored with CB-1 open. Remote test, J1-18 at ground
also initiates a Battery Level Test.
LOW LED Red LED illuminates when the battery energy is low (0 to 50
percent) during the level test. The Level Test output on pin 14
is open drain.
MID LED Yellow LED illuminates when the battery energy is (50 to 75
percent) during the level test. The Level Test output on pin 14
is open drain.
FULL LED Green LED illuminates when the battery energy is full (75 to
100 percent) during the level test. The Level Test output on
pin 14 is held low.
FAULT

BITE TEST The BITE TEST pushbutton is used to start the built-in self
pushbutton test. Test faults are introduced to verify proper operation of
the fault detection circuits, LEDs, and discrete output. All four
FAULT LEDs initially illuminate when BITE TEST is first
pressed; they extinguish as the pushbutton is released.
Holding the BITE TEST pushbutton depressed causes the
BATT, CHGR, O TEMP, and HTR LEDs to flash on and off
when the unit is operating on battery power only.
BATT LED Red LED illuminates, and the BITE signal on pin 10 is held
low, when there is a 4.0 Vdc difference between the battery
center tap and either end of the battery. This measurement is
only performed when the charger is off.
CHGR LED Red LED illuminates, and the BITE signal on pin 10 is held
low, when the charge circuit has a fault.
The Charge Fault shall be active when any of the following
conditions are active:
Charger output voltage out of range
BITE test performed.
O TEMP LED Red LED illuminates, and the BITE signal on pin 10 is held
low, when a Batt Over Temperature (>75°C) is detected, or if
a BITE test is performed. The charger shuts down.

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Table 1. XL2410-04 Controls, Indicators, and Connectors (Continued)

Reference
Function
Designator

HTR LED Red LED illuminates, and the BITE signal on pin 10 is held
low, when the four 40 W battery heaters are commanded ON
and heater current is low, or when heater current is detected
and heaters were not commanded ON.
FAULT RESET Pressing FAULT RESET for five seconds clears the stored
BITE TEST faults, if the faults were removed.
CB1 Circuit Breaker 1 is 40 Amps. Pull out for storage.
CB2 Circuit Breaker 2 is 7.5 Amps.

2. Operation

A. The XL2410-04 performs three major functions as an emergency battery system:

(1) Manages the charge of the self-contained sealed lead-acid batteries,

(2) Provides an indication of the state of the charge of the batteries,

(3) Ensures safe operation of the system.

B. Charge Method

(1) The batteries are charged directly from the aircraft 28 Vdc bus, and are always
maintained at their fullest possible capacity. The charge function is automatic, and
turns on as soon as aircraft input power is available. Charge current is limited to 8
Amperes with a peak voltage to internal batteries of 30.5 V maximum. The charger
temperature is monitored. When it reaches 80°C (176°F), the charger is shut down
and allowed to cool before resuming charge. This is a charger over temperature
protection feature.

(2) The charger switches between bulk and trickle mode automatically. Figure 4
presents a typical charge curve for the XL2410-04. Charge time is typically 2 to 3
hours from full discharge to full charge (92 minutes from full discharge to 80%
charge) for a new battery at 25°C.

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Charge Curve
Figure 4

(3) The unit uses a three-stage method for charging as follows:

(a) The first stage is a “bulk” mode constant current charge limited to 8 Amps
and 30.5 Vdc.

(b) The second stage begins when the batteries reach the 30.5 Vdc voltage
limit. They will continue to charge at this fixed voltage until the charge
current drops below 0.3 Amp.

(c) When this occurs, the third stage begins and the batteries continue to float
charge at a constant voltage according to the battery temperature
compensation curve shown in Figure 5.

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Temperature Compensation
Figure 5

C. Battery Capacity

(1) The XL2410-04 battery is nominally rated at 10.5 Amps for a one-hour rate at 24 Vdc.
Figure 6 shows the output curve for a constant 10.0 Amp discharge of a fresh battery set
at 25°C. A battery set is considered at the end of its service life when it is unable to drive
a 4-Amp load for more than 2 hours 50 minutes.

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10 Amp Discharge Curve


Figure 6

D. Connector Pin Assignments

(1) The J1 pin out assignments are shown in Table 2.

Table 2. XL2410-04 Backup Battery System J1 Connector Pin-Outs

J1-Pin Contact Signal Name Description


Size

A1 6 OUTPUT POWER +24 VDC OUTPUT #1 (40A)

A2 6 +28 VDC INPUT Aircraft +28 VDC INPUT

A3 6 NO CONNECTION

A4 6 POWER GROUND (Return) Provides a return path for both the aircraft +28
VDC input and the XL2410-04 +24 VDC output

1-4 16 NO CONNECTION

5-9 20 NO CONNECTION

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Table 2. XL2410-04 Backup Battery System J1 Connector Pin-Outs (Continued)

J1-Pin Contact Signal Name Description


Size

10 20 FAULT OUTPUT The FAULT OUTPUT signal (held low) indicates


that the XL2410-04 had a BATT, CHGR, 0
TEMP, or HTR failure. Refer to Table 1 for
details.

11-13 20 NO CONNECTION

14 20 LEVEL TEST OUTPUT This output is grounded when the Battery


Energy Level Test indicates more than 75%
battery energy remaining during the 20-second
Battery Energy Level Test. The output is open
drain when the Battery Energy Level Test
indicates less than 75% battery energy
remaining.

15-17 20 NO CONNECTION

18 20 REMOTE LEVEL TEST INPUT When low, this input signal initiates a 20-second
Battery Energy Level Test. Pin 14 indicates the
result of the test.

19-20 20 NO CONNECTION

21 20 5 VOLT CONVERTER INPUT 28 VDC input power

22 20 REMOTE CHGR/HTR INHIBIT REMOTE CHGR/HTR INHIBIT INPUT is


INPUT activated by applying a continuous ground to
pin 22. When active, this signal inhibits both
charging and heater operation. The charger
inhibit function should not be used any more
than necessary, as it precludes recharging the
unit after discharge.

23 20 5 VOLT CONVERTER 5 VDC at 2A.


OUTPUT

24 20 OUTPUT POWER The +24 VDC OUTPUT #2 (7.5A) is connected


to the 28 VDC aircraft.

25-29 20 NO CONNECTION

NOTES: J1 interface connector is: DSXN1RS33C4P0001. Mating connector is: DSXN1PS33C4S0301.

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E. Block Diagram

(1) The following paragraphs describe the functional elements of the block diagram
shown in Figure 7.

(2) EMI/Transient Filter

(a) The unit is protected from electromagnetic interference and transient events
on its input bus by the transient filter.

(3) Battery Pack (13 Ah Cells)

(a) The XL2410-04 contains two 13 Ah lead acid batteries with temperature
sensors located in the assembly. The batteries are configured in a series
combination to yield a 24 VDC, 13 Ah battery.

(4) Battery Heater

(a) To maintain optimum battery performance, four 40-Watt heaters (two for
each battery) warm the batteries if the temperature drops below 25°C (77°F).

(b) The heaters are turned off when battery 1 temperature is above 70°C
(158°F) and allowed to cool before they are turned back on. A separate
thermal safety switch, in the heater ground path, opens when battery 2
temperature is greater than 70°C (158°F).

(5) Charger/Heater Inhibit

(a) The charger/heater function is inhibited when the remote CHGR/HTR inhibit
input (J1-22) is grounded.

(6) Bypass Diode

(a) Under normal operating conditions, a steering diode applies aircraft 28 Vdc
bus to the output load. If the input bus drops below 23-25 Vdc, the battery
automatically supplies the output load via a BILATERAL FET described in
the Battery Cut Off Switch (Output Steering) paragraph.

(7) Battery Cut Off Switch (Output Steering)

(a) A solid-state battery cut-off switch in the battery output line prevents deep
discharge of the battery. This FET switch removes the load from the battery
when the voltage drops below 18 Vdc for more than 60 seconds. It re-
applies the load to the battery when the aircraft input bus, greater than 26
Vdc, is re-applied. The battery cut-off switch also acts as a solid state circuit
breaker and turns off at loads greater than 40 Amps.

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XL2410-04 Backup Battery System Block Diagram


Figure 7

(b) The current-limit threshold is time dependent as shown in Table 3. The


battery cut-off switch opens under the following conditions:

1 Battery voltage drops below 18 Vdc for 60 seconds. The battery-cut


off switch turns back on when the input bus is re-applied. This
function prevents over-discharge of the battery.

2 Current exceeding the limits in Table 3.

3 Level Test is selected.

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Table 3. Current Limit Thresholds

lout (A) Shutdown Delay


40 Indefinite
50 2.4 seconds
60 1.2 seconds
70 0.6 seconds
80 10 milliseconds

(8) 5 Volt Converter

(a) The 5 Volt Converter converts 28 Vdc input power to 5 Vdc with a maximum
5A output.

(b) Several devices protect the battery system from over discharge, over
current, and over temperature conditions.

(9) Circuit Breakers

(a) The 40 Amp circuit breaker, in series with the battery, provides redundant
protection for the 40 Amp output on pin A1 of J1. The 7.5 Amp circuit
breaker, in series with the 24 Vdc output on pin A24 of J1 provides separate
protection and is also protected by the 40 Amp circuit breaker. The 40 Amp
circuit breaker is also used to shut down the XL2410-04 for long term
storage.

CAUTION: IMMEDIATELY FOLLOWING AN EMERGENCY POWER TOTAL


DISCHARGE, 28 VDC POWER MUST BE PROVIDED TO THE
XL2410-04 TO RECHARGE THE BATTERY. THE BATTERIES DO
NOT REQUIRE A COOL DOWN PERIOD PRIOR TO
RECHARGING (AS NICKEL-CADMIUM BATTERY TECHNOLOGY
MAY REQUIRE) AFTER USAGE.

NOTE: If the XL2410-04 battery will not take a charge after being left
discharged, the batteries may have become sulfided. The
indication of sulfiding is that the battery will not accept a full
charge. Securaplane does not warranty damage due to sulfiding.

(10) Current Sense

(a) The electronic current sense circuit cuts off the battery from the output pin
during an over-current fault on the +24 Vdc output line. The current limit
threshold is time dependent; to facilitate large inrush peaks such as might be
encountered when powering incandescent lights. The time delay for
shutdown is a function of the current after which the CHG LED lights. Refer
to Table 3 for shutdown delays. Reset is initiated by pressing the front panel
FAULT RESET switch for approximately five seconds.

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(11) Temperature Sensor

(a) A thermistor temperature sensor monitors battery temperature. The internal


level test load temperature is sensed by a PTC thermistor to ensure that the
test load is removed from the battery if the thermistor temperature exceeds
+70°C.

(12) LEVEL TEST Switch

(a) On command from the front panel LEVEL TEST switch, an internal test load
(battery heaters) is placed across the battery, and the battery is
disconnected from the output terminals for 5 seconds to check the battery
energy level.

(b) One of three front panel LEDs indicate the energy remaining in the battery.

1 An energy level above 75% is indicated as FULL (green LED).

2 An energy level between 50% and 75% is indicated as MID


(yellow LED).

3 An energy level at or below 50% is indicated as LOW (red LED).

(c) The level test function is performed automatically when the CB1 is first
closed after the unit has been stored with the breaker pulled.

(d) It is recommended that the battery energy level test be performed at least
once a year.

NOTE: The battery energy level test is more accurate when the
XL2410-04 has been off-of-charge for at least 2 hours. Test
accuracy increases with elapsed time off charge due to the
voltage level setting characteristic of sealed lead batteries that
have been charged above their normal 2 volt per cell voltage.

(13) Remote Level Test Initiation

(a) When low, the REMOTE LEVEL TEST input signal initiates a 20-second
Battery Energy Level Test. If the remote test is deactivated before 20
seconds expires, the test is immediately discontinued. Pin 14 indicates the
result of the test.

3. Leading Particulars

A. XL2410-04 Backup Battery System Leading Particulars

(1) The leading particulars for the XL2410-04 Backup Battery System are shown in
Table 4.

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Table 4. Leading Particulars

Parameter Specification

Input Power:
Voltage 24-36 Vdc (28.5 Vdc nominal)

Current 17 Amps maximum (heaters and charger operating)

Connector, Interface DSXN1RS33C4P0001 polarized

Connector, Mating DSXN1PS33C4S0301

Output 1:

Voltage 24 Vdc
Capacity (pin A1) 10.5 Amps: 1 hour min. (@+25 to +60°C) (new unit)
Current Maximum (pin A1) 0 to 40 Amps continuous (less output 2 and 3 loads)
Output 2:

Voltage 24 Vdc
Current Maximum (pin 24) 0 to 7.5 Amps continuous protected by thermal breaker
Output 3:

Voltage 5 Vdc
Current Maximum (pin 23) 0.0 to 2.0 Amps continuous, overload protected
Charge Time: Approximately 2 to 3 hours from full discharge to full charge
Physical:
Height 7.63 in (19.38 cm) Maximum
Width 3.65 in (9.27 cm) Nominal
Length 15.03 in (38.18 cm) Maximum
Weight 29.0 ± 1.5 lbs (13.20 ± 0.68 kg)
Operating Temperature Normal operating temperature -55°C to +60°C
Range:

Cooling Convection (no forced air)

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TESTING AND FAULT ISOLATION

1. General Information

A. Introduction

WARNING: BEFORE MATERIALS CALLED OUT IN THIS PUBLICATION ARE USED,


KNOW THE HANDLING, STORAGE, AND DISPOSAL PRECAUTIONS
RECOMMENDED BY THE MANUFACTURER OR SUPPLIER. FAILURE
TO FOLLOW THE MANUFACTURERS’ OR SUPPLIERS’
RECOMMENDATIONS CAN RESULT IN PERSONAL INJURY OR
DISEASE.

CAUTION: THESE PROCEDURES MUST BE DONE AT A STATIC-FREE


WORKSTATION IN ORDER TO PREVENT DAMAGE TO
ELECTROSTATIC SENSITIVE COMPONENTS.

CAUTION: THIS UNIT HAS ASSEMBLIES THAT ARE SUSCEPTIBLE TO DAMAGE


FROM INCORRECT HANDLING. DO NOT DROP OR HIT THE UNIT
DURING THESE PROCEDURES.

CAUTION: THESE PROCEDURES MUST BE DONE IN A CLEAN ENVIRONMENT IN


ORDER TO PREVENT DAMAGE TO MECHANICAL COMPONENTS.

(1) This section has the testing and fault isolation information for the XL2410-04 Backup
Battery System.

2. Equipment and Materials

A. Consumable Materials

(1) No consumable materials are needed for Testing and Fault Isolation procedures.

B. Special Tools, Fixtures, and Test Equipment

(1) Special tools and test equipment used during the Testing and Fault Isolation
procedures are shown in Table 1001.

NOTE: Equivalent alternatives can be used.

Table 1001. Special Tools, Fixtures, and Test Equipment

Equipment Characteristics Accuracy Source or


(CAGE)
Bench charge harness This can be a simple two Commercially
wire (use wire size AWG 14) available
arrangement with female
mating pins to connect to
the XL2410 connector pins.
Digital voltmeter 1% accuracy or Commercially
better available

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Table 1001. Special Tools, Fixtures, and Test Equipment (Continued)

Equipment Characteristics Accuracy Source or


(CAGE)
Electronic load 0-30 V, 0-100 Amps Commercially
available
DC power source 0-40 V, 0-20 Amps Commercially
available

3. Test Procedures

A. Do all tests with the test unit at ambient pressure and temperature, unless otherwise
specified by an individual test procedure.

(1) Temperature: 60° to 100°F (15.5 to 37.8°C)

(2) DC Input Voltage: 28.5 ± 0.1 Vdc

B. Regularly examine and certify instrument accuracy/calibration in accordance with applicable


government and commercial specifications.

C. Visually inspect the unit for signs of missing, broken, bent or cracked parts. Damaged parts
must be replaced before the unit is tested.

D. The Securaplane XL2410-04 Backup Battery does not need to be removed from the aircraft
to perform testing or to check charger status. Battery level testing is integrated into the
BATTERY LEVEL TEST and LEDs.

E. Securaplane considers four years to be the maximum life span for the XL2410-04 internal
batteries. If the batteries remain fully discharged longer than 2 days, capacity may fall below
65 per cent and require a special recharge procedure only available from Securaplane.

F. It is in the customer’s best interest to replace the internal batteries in the fourth year as a
preventative maintenance activity, thus preventing possible unscheduled maintenance
activity as the probability of battery failure increases with time.

G. The XL2410-04 uses two lead acid batteries. Unlike Ni-Cad batteries, lead acid batteries can
exist in a float environment with no maintenance required, and no memory (voltage
depression) problems.

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H. On Aircraft Fault Isolation

(1) Use Table 1002 to isolate faults while the XL2410-04 is on the aircraft.

Table 1002. On Aircraft Fault Isolation

Symptom Cause Remedy

Output
A/C devices powered by XL2410-04 installation errors. Verify that XL2410-04 is
XL2410-04 not on. installed. Check electrical
connector for bent pins.
Check for power at device. Check A/C wiring.
If device switches off, after being Check for circuit overload or
on. wiring short. Reset XL2410-04
CBs.
A/C devices on one output circuit Check for open A/C wire.
are not on. Otherwise, send to repair shop.
No output voltage. The A/C circuit breaker is pulled. Reset the A/C circuit breaker.
The batteries are discharged. Recharge the batteries.
The output is cut off. Momentarily apply input voltage.
CB1 or CB2 on XL2410-04 A/C output circuit shorted. Troubleshoot respective output
front panel trips open. circuit and connected devices.
Output circuit within XL2410-04 Reset CB and retest. If fault
damaged. within XL2410-04, send to repair
shop.
CHRG LED is on. Charger output out of range. Press FAULT RESET for 5
seconds. Conduct BITE TEST. If
LED is still on, return to
Securaplane.
A charger related fault has Press FAULT RESET button for
occurred. 5 seconds. If still on, return to
Securaplane.
XL2410-04 will not charge. Aircraft input circuit breaker Close circuit breaker.
open.
Chgr/Htr Inhibit line is active. Reset Chgr/Htr Inhibit switch in
A/C.
No 28 Vdc power to connector Check for broken A/C wire.
P1-A2.
BATT LED is on. BATT related fault has occurred. Press FAULT RESET for 5
seconds. If still on, return to
Securaplane.
HTR LED is on. HTR related fault has occurred. Press FAULT RESET for 5
seconds. If still on, return to
Securaplane.

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Table 1002. On Aircraft Fault Isolation (Continued)

Symptom Cause Remedy

Level Test
The green ENERGY FULL The XL2410-04 circuit breaker is Reset the CB.
LED does not go on when pulled.
the LEVEL TEST switch is
pressed and released.
The batteries are discharged. Recharge the batteries.
The batteries are in a deep Return battery pack to
discharge state. Securaplane for service.
Energy Level Test – Yellow Battery not fully charged. Charge battery for 2 hours and
LED on. repeat level test. If same result,
schedule battery replacement at
next maintenance period.
Energy Level Test – Red Battery not charged or is Charge battery for 2 hours and
LED on. defective. repeat level test. If same result,
return battery pack to
Securaplane for service.
The BATT or ENERGY The problem is internal to the Return battery pack to
LEVEL LOW LED is always battery pack. Securaplane.
on.
The BATTERY LEVEL The battery temperature is Allow battery to cool. Perform
TEST does not work. greater than 70°C (158°F). Level Test; if test fails, return
battery pack to Securaplane for
service.
XL2410-04 fault reported to BATT, CHGR, 0 TEMP, or HTR Press FAULT RESET for 5
cockpit fault display. fault. seconds. Conduct BITE TEST. If
an LED is still on, return battery
pack to Securaplane for service.
A/C wiring fault. Check/fix A/C wiring.

I. Battery Energy Level Test Procedure

(1) Engage CB1 and CB2.

NOTE: The level test function is performed automatically when CB1 is first closed
after the unit has been stored with the breaker pulled. It is recommended
that the battery energy level test be performed at least once every 600
hours of operating time.

NOTE: The CHARGER ON LED illuminates for 5 seconds when CB1 is first
closed and both the charger and batteries are functional.

NOTE: The battery energy level test is more accurate when the XL2410-04 has
been off-of-charge for at least 2 hours. Test accuracy increases the
elapsed time off charge due to the voltage level settling characteristic of
sealed lead batteries that have been charged above their normal 2-volt
per cell voltage.

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(2) Depress the ENERGY LEVEL TEST switch on the front of the XL2410-04. At the end
of 10 seconds, a green FULL LED, or yellow MID LED, or red LOW LED will be
illuminated. The colors indicate:

(a) Green - above 75 percent of as new capacity remains

(b) Yellow - between 50 and 75 percent of as new capacity remains

(c) Red - below 50 percent of as new capacity remains

NOTE: On command from the front panel LEVEL TEST switch, an internal test
load (four 40 Watt heaters) is placed across the battery for 10 seconds to
check its energy level. The battery is disconnected from the output
terminals for 5 seconds to check the battery energy level.

NOTE: The internal load is thermally protected and will not allow a level test if the
load temperature exceeds 70°C (158°F).

NOTE: Ambient temperature, at the battery, affects the accuracy of the energy
level test circuit. Thus, if a unit has cold soaked for a long period and a
level test is performed, a reduction of 30 to 35% of true energy may be
erroneously indicated by the front panel amber LED. Conversely, a unit
soaked at a high temperature may indicate more energy than actually
exists. Optimum accuracy of the level test circuit is achieved when the
batteries are between 20°C and 30°C.

(3) If a red or yellow LED is illuminated, continue to the Charging Procedure.

(4) If a green LED is illuminated, no further tests are required.

J. Charging Procedure

(1) Connect the 2-wire bench charge harness to J1-A2 (+28 Vdc) and J1-A4 (GND).
See Figure 1001.

(2) Connect the other ends of the wires to the 28 Vdc supply, checking that the polarity
is correct. Do not turn the supply on at this time.

NOTE: If an ammeter is not included on the 28 Vdc supply, connect an ammeter


in series with the +28 Vdc lead (20 Amp capability).

(3) Adjust the power supply to 28.5 ± 0.5 Vdc.

(4) Turn the power supply on and note the input current. A low battery will cause up to
17-20 Amps to flow for a few seconds then settle at 15 Amps or below. Allow the
battery to charge until the input bus current is less than 300 mA.

(5) Turn the power supply OFF and disconnect the 2-wire bench charge harness.

(6) After charging the XL2410-04, pull CB1 and CB2 and allow it to sit for 8 to 24 hours.

(7) After 8 to 24 hours, engage CB1 and CB2 and perform a capacity check using the
ENERGY LEVEL TEST switch or for more accuracy proceed to the Capacity
Discharge Test.

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(8) If the unit does not successfully complete the Battery Energy Level Test, return the
XL2410-04 Backup Battery System to Securaplane Technologies.

Bench Charge Harness


Figure 1001

K. Capacity Discharge Test

(1) Once the batteries are fully charged, set the input voltage to zero and the output load
to 11.0 ± 0.1A. Connect the 2-wire bench charge harness to J1-A1 (+24 Vdc) and
J1-A4 (GND). See Figure 1001.

(2) Discharge the unit until it automatically shuts off the output load (cutoff). Verify the
discharge time is 55 minutes minimum.

(3) After discharge, set the input voltage to 28.5 ± 0.5 Vdc and the output load to zero.

(4) While monitoring the input current, continue charging until the input current drops to
less than 0.5A, indicating the batteries are fully charged.

(5) After charging is complete, turn the input voltage off.

(6) If the unit does not drive the load for the time listed above, return the XL2410-04
Backup Battery System to Securaplane Technologies.

NOTE: Always pull CB1 and CB2 and place a circuit breaker restraint around the
breakers.

Page 1006
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ABBREVIATED COMPONENT MAINTENANCE MANUAL
100-2410-04

CLEANING

1. General Information

A. Introduction

WARNING: BEFORE MATERIALS CALLED OUT IN THIS PUBLICATION ARE USED,


KNOW THE HANDLING, STORAGE, AND DISPOSAL PRECAUTIONS
RECOMMENDED BY THE MANUFACTURER OR SUPPLIER. FAILURE
TO FOLLOW THE MANUFACTURERS’ OR SUPPLIERS’
RECOMMENDATIONS CAN RESULT IN PERSONAL INJURY OR
DISEASE.

CAUTION: THESE PROCEDURES MUST BE DONE AT A STATIC-FREE


WORKSTATION IN ORDER TO PREVENT DAMAGE TO
ELECTROSTATIC SENSITIVE COMPONENTS.

CAUTION: THIS UNIT HAS ASSEMBLIES THAT ARE SUSCEPTIBLE TO DAMAGE


FROM INCORRECT HANDLING. DO NOT DROP OR HIT THE UNIT
DURING THESE PROCEDURES.

CAUTION: THESE PROCEDURES MUST BE DONE IN A CLEAN ENVIRONMENT IN


ORDER TO PREVENT DAMAGE TO MECHANICAL COMPONENTS.

(1) This section has general procedures recommended by Securaplane to clean the
XL2410-04 Backup Battery System. There is no disassembly required to clean the
unit.

2. Equipment and Materials

A. Consumable Materials

(1) Consumable materials used during the Cleaning procedures are shown in
Table 4001.

NOTE: Equivalent alternatives can be used.

Table 4001. Consumable Materials

Specification or Source or
Name
Part Number (CAGE) Code

Brush Soft bristle fibers Commercially available


Cloth Lint-free Commercially available
Solvent Micro Care Proclean (with Micro Care Chemical
solvent ESD safe brush, in Corp.
agreement with MIL 2000) 34 Ronzo Rd.
Bristol, CT 06010
Compressed Air 20 psig (138 kPa) maximum Commercially available
Isopropyl alcohol Federal Specification TT-I-735 Commercially available
Methyl-ethyl-ketone (MEK) Federal Specification TT-M-261 Commercially available

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B. Special Tools, Fixtures, and Test Equipment

(1) No special tools, fixtures, or test equipment are needed for Cleaning procedures.

3. Cleaning Procedures

A. Cleaning Practices

(1) Each part must be cleaned with the procedures in this section or the equivalent
procedures used by an approved overhaul facility.

(2) These procedures agree with good shop procedures as used by the Securaplane
facility. Clean parts are important to satisfactory operation.

(3) Use clean, dry, filtered, compressed air at a maximum of 20 psig (138 kPa) to dry
parts.

(4) Clean all metal parts to remove oil, grease, rust, and dirt.

B. External Cleaning

WARNING: USE APPROPRIATE PERSONAL PROTECTION. CHEMICAL


SOLUTIONS CAN CAUSE SKIN, EYE, AND LUNG DAMAGE. DANGER
AND HANDLING PRECAUTIONS FOR EACH CHEMICAL IS DIFFERENT.

NOTE: Cleaning is limited to external cleaning only.

(1) Clean the outside surfaces of the unit with a clean lint-free cloth, moistened with an
approved solvent (Micro Care Proclean, isopropyl alcohol, or MEK).

(2) The connectors shall be free of dirt or corrosion. Scrape off the corrosion and clean
the connectors with a soft bristle brush lightly moistened with the approved solvent
(Micro Care Proclean, isopropyl alcohol, or MEK). Remove solvent residue with a
clean, dry lint-free cloth.

(3) Use methyl-ethyl-ketone (MEK) to remove adhesive from parts.

NOTE: Use approved caps, plugs and barrier materials for part storage after
cleaning. Do not use tape, loose plastic, or rags to protect clean parts.

(4) Install a protective cap on the connector to protect against contamination and thread
damage.

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INSPECTION/CHECK

1. General Check Information

A. Introduction

CAUTION: THESE PROCEDURES MUST BE DONE AT A STATIC FREE WORK


STATION IN ORDER TO PREVENT DAMAGE TO ELECTROSTATIC
SENSITIVE COMPONENTS.

CAUTION: THIS UNIT CONTAINS AN ASSEMBLY THAT CAN BE DAMAGED BY


INCORRECT HANDLING. DO NOT DROP OR HIT UNIT DURING THESE
PROCEDURES.

CAUTION: THESE PROCEDURES MUST BE ACCOMPLISHED IN A CLEAN


ENVIRONMENT IN ORDER TO PREVENT DAMAGE TO MECHANICAL
COMPONENTS.

(1) This section has the general procedures to check the XL2410-04 Backup Battery
System. There is no disassembly required to check the XL2410-04 Backup Battery
System.

2. Equipment and Materials

A. Consumable Materials

(1) No consumable materials are needed for the Inspection/Check procedures.

B. Special Tools, Fixtures, and Test Equipment

(1) No special tools, fixtures, or test equipment are needed for the Inspection/Check
procedures.

3. Check Procedures

A. Internal Visual Checks

(1) There are no internal visual checks.

NOTE: Internal visual checks can only be done at an approved Securaplane


facility.

B. External Visual Checks

(1) Check the unit for nicks, cracks, scores, dents, scratches, corrosion, or broken welds
that may affect the unit’s operation.

(2) Check the exterior painted surfaces for cracked, chipped, blistered, or deteriorated
paint film.

(3) Check the identification, information, and instruction labels and make sure they are
legible and securely attached.

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(4) Check the connectors for broken, bent, or loose pins. Make sure the connectors are
mounted correctly.

(5) Check the chassis assembly for loose or missing fasteners.

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FITS AND CLEARANCES

1. General Information

A. Introduction

(1) This section has the Fits and Clearances for the XL2410-04 Backup Battery System.

(2) The XL2410-04 Backup Battery System dimensions are shown in Figure 8001.

(a) Dimensions are shown in inches.

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ABBREVIATED COMPONENT MAINTENANCE MANUAL
100-2410-04

XL2410-04 Backup Battery System Fits and Clearances


Figure 8001

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ABBREVIATED COMPONENT MAINTENANCE MANUAL
100-2410-04

SPECIAL TOOLS, FIXTURES, EQUIPMENT AND CONSUMABLES

1. General Information

A. Consumable Materials

(1) Consumable materials used are shown in Table 9001.

NOTE: Equivalent alternatives can be used.

Table 9001. Consumable Materials

Specification or Source or
Name Use
Part Number (CAGE) Code

Brush Soft bristle fibers Commercially available Cleaning


Cloth Lint-free Commercially available Cleaning,
Storage
Solvent Micro Care Proclean (with Micro Care Chemical Cleaning
solvent ESD safe brush, in Corp.
agreement with MIL 2000) 34 Ronzo Rd.
Bristol, CT 06010
Compressed Air 20 psig (138 kPa) maximum Commercially available Cleaning

Isopropyl alcohol Federal Specification Commercially available Cleaning


TT-I-735
Methyl-ethyl- Federal Specification Commercially available Cleaning
ketone (MEK) TT-M-261
Barrier material MIL-B-131B Commercially available Storage
Dehydrating MIL-D-21576 Commercially available Storage
agent

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100-2410-04

B. Special Tools, Fixtures, and Test Equipment

(1) Special tools, fixtures, and test equipment used are shown in Table 9002.

NOTE: Equivalent alternatives can be used.

Table 9002. Special Tools, Fixtures, and Equipment

Specification or Source or
Name Use
Part Number CAGE Code
Bench Charge Harness This can be a simple two wire (use Commercially Testing
wire size AWG 14) arrangement with Available
female mating pins to connect to the
XL2410 connector pins.
Digital voltmeter Commercially Testing
Available
Electronic load 0-30 V, 0-100 amps Commercially Testing
Available
DC power source 0-40 V, 0-20 amps Commercially Testing
Available

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100-2410-04

STORAGE (INCLUDING TRANSPORTATION)

1. General Information

A. Introduction

WARNING: BEFORE MATERIALS CALLED OUT IN THIS PUBLICATION ARE USED,


KNOW THE HANDLING, STORAGE, AND DISPOSAL PRECAUTIONS
RECOMMENDED BY THE MANUFACTURER OR SUPPLIER. FAILURE
TO FOLLOW THE MANUFACTURERS’ OR SUPPLIERS’
RECOMMENDATIONS CAN RESULT IN PERSONAL INJURY OR
DISEASE.

CAUTION: THESE PROCEDURES MUST BE DONE AT A STATIC-FREE


WORKSTATION IN ORDER TO PREVENT DAMAGE TO
ELECTROSTATIC SENSITIVE COMPONENTS.

CAUTION: THIS UNIT HAS ASSEMBLIES THAT ARE SUSCEPTIBLE TO DAMAGE


FROM INCORRECT HANDLING. DO NOT DROP OR HIT THE UNIT
DURING THESE PROCEDURES.

CAUTION: THESE PROCEDURES MUST BE DONE IN A CLEAN ENVIRONMENT IN


ORDER TO PREVENT DAMAGE TO MECHANICAL COMPONENTS.

(1) This section has the storage and shipping procedures recommended by
Securaplane for the XL2410-04 Backup Battery System.

(2) Refer to the CLEANING section before storing the XL2410-04 Backup Battery
System.

2. Equipment and Materials

A. Consumable Materials

(1) Consumable materials used during the Storage procedures are shown in
Table 15001.

NOTE: Equivalent alternatives can be used.

Table 15001. Consumable Materials

Name Specification or Source or


Part Number (CAGE)
Barrier Material MIL-B-131B Commercially available
Dehydrating agent MIL-D-21576 Commercially available
Cloth Lint-free Commercially available

B. Special Tools, Fixtures, and Test Equipment

(1) No special tools, fixtures, or test equipment are needed for Storage procedures.

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3. Storage/Transportation Procedures

A. Prepare the XL2410-04 Backup Battery System for Storage or Transportation

(1) Clean the external surfaces with a clean, lint-free cloth.

(2) Put dust caps (supplied with unit) on the XL2410-04 Backup Battery System
J1 connector to protect against contamination.

(3) Wrap the unit in barrier paper.

(4) Put cushions at the sharp corners to prevent damage to the barrier material and
pack the container with the dehydrating agent (MIL-D-21576).

(5) When shipping or storing the unit, always pull CB1 and CB2 and place a circuit
breaker restraint around the breakers.

B. Storage Conditions

(1) The presence of certain environmental conditions during storage can cause damage
to parts. Some of these conditions are:

• Moisture
• High temperature (over 125°F) (52°C)
• Fuel or solvents
• Fumes that can cause corrosion
• Mechanical stresses
• Ultraviolet light
• Localized electromagnetic fields

NOTE: This is not a complete list of conditions that can inflict damage.

(2) Parts that have been stored where these conditions may be present must be
examined for damage and replaced as necessary.
NOTE: Refer to the INSPECTION/CHECK and CLEANING sections before
storing the XL2410-04.

(3) Store the unit in an area away from high temperatures, dust, moisture, and fumes
that could cause corrosion.

NOTE: To maintain battery energy level above 80%, the recommended storage
temperature should be 71 ± 5.0°F (25 ± 2.8°C).

(4) Control humidity (less than 70%) to prevent moisture contamination of the unit.

(5) Do not store the unit above 85°F (30°C) as it accelerates self discharge and reduces
battery life.

(6) While the battery is stored, perform a battery capacity check using the ENERGY
LEVEL TEST function at least every 6 months.

(7) If necessary recharge the battery using the Charging Test Procedure in the
TESTING AND FAULT ISOLATION section.

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C. Transportation Procedures

(1) Use the Securaplane shipping box or equivalent to transport the XL2410-04 Backup
Battery System.

(2) Before shipping the XL2410-04 Backup Battery System, call Securaplane Product
Support at 1-520-297-0844 for a Return Authorization Number and include it with the
unit.

(3) Include a failure report with the aircraft type and the XL2410-04 Backup Battery
System serial number.

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