BATERIAS

MANUAL DE CAPACITACION

RETROALIMENTACION DEL MANUAL DE CAPACITACION

NOMBRE DEL MANUAL: ________________________________________________________

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Todo material de capacitacion continuamente se esta mejorando. A fin de continuar de esta manera, nos es de gran ayuda cualquier sugerencia que nos pueda anotar y entregarla al instructor o al departamento de capacitacion tecnica

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A fin de corregir las erratas que hubiera encontrado en el manual, favor de ayudarnos marcandolas a cantinuacion:

Pagina

Errata

Pagina

Errata

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PAGINA INTENCIONALMENTE EN BLANCO

ADVENTENCIA

LA PRESENTE INFORMACION TECNICA SE HA PREPARADO CON FINES DE CAPACITACION Y NO DEBE SER USADA COMO REFERENCIA PARA EL DESARROLLO DE TRABAJOS DE LOS SISTEMAS DEL AVION, FUSELAJE, MOTORES O COMPONENTES

EN CASO DE EXISTIR DIFERENCIA ENTE ESTA INFORMACION Y AQUELLA PUBLICADA EN LOS MANUALES DE LOS FABRICANTES, ESTA ULTIMA TIENE PRIORIDAD

PAGINA INTENCIONALMENTE EN BLANCO

INTRODUCCION
1. General E. This manual contains the following: A. This manual is written to the ATA Specification 100 and the AECMA Simplified English standards. S.I. units of measure are used in this manual, with imperial units (U.S.) in parenthesis. B. This manual describes maintenance on components in a workshop. It does not describe maintenance on components when they are installed in the aircraft. C. Only approved technicians with the necessary skills should perform maintenance as described in this manual. D. Aircraft Maintenance Task Oriented Support System (AMTOSS) is not supported in this manual. Technical data for components

Maintenance components

and

repair

procedures

for

An Illustrated Parts List (IPL) with data for parts and components. Parts are identified in all sections of the manual by the IPL figure 1 item number. F. Verification of DISASSEMBLY, TESTING AND FAULT ISOLATION, and ASSEMBLY procedures is accomplished by performing the procedures in the manufacturing facility.

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INTRODUCCION
Definition Disposal Ni-Cd batteries contain: This paragraph describes the notations used in this manual. A. WARNINGS call attention to the use of materials, procedures, or limits that must be followed to avoid personal injury. Warnings will appear directly above the procedure they apply to. B. CAUTIONS call attention to procedures that must be followed to avoid damage to the equipment. C. NOTES call attention to procedures that make the job easier or include special information that pertains to the procedure. - Nickel - Cadmium - Potassium Hydroxide

Local legislation concerning disposal or recovery must be followed. For more information, contact your local Saft supplier.

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DESCRIPTION AND OPERATION 40176-4 / 40176-7

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DESCRIPTION AND OPERATION 40176-4 / 40176-7

1. A. Description General (1) Operational characteristics The alkaline battery has 20 vented nickelcadmium VP400KH cells with welded polyamide cases. The battery is connected to the aircraft system and can be used: To start the engine or the APU used in the aircraft system. On the ground, to supply electrical power to the aircraft. In flight, if a malfunction or a failure occurs in the onboard power supply system Operating temperature: -40C to +71C (40F to +160F) B. Characteristics

(2) Electrical characteristics Below is a listing of values used to service the battery:

Item 1 C1A 0.5 C1A 0.1 C1A

Value 36 A 18 A 3.6 A

Used For Charge / Discharge Charge Charge

NOTE: The 28 VDC electrical system charges the battery onboard aircraft

(3) Technical data

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CHARACTERISTICS 40176-4 / 40176-7

(3) Technical data

NOTE: Current values can be expressed in: 36 A = 1C1A, 18 A = 0.5C1A, and 3.6 A = 0.1C1A for this 36 C1Ah
battery.

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DESCRIPTION AND OPERATION 40176-4 / 40176-7 C. Detailed Description The battery has 20 VP400KH (13) cells housed in a stainless steel case (box) (1).

The case (box) (1) is lined with liners and spacers (kit (43)). The cells are kept upright by a molded silicone elastomer pad fastened to the cover that presses against the top of the cells. Cells are interconnected by rigid, nickel-plated copper links (22 thru 27).
The main power connector (28) connects the battery to the aircraft. The cover (2) that can be removed is attached to the case (1) by four latches.

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DESCRIPTION AND OPERATION 40176-4 / 40176-7

40176-4 / 40176-7 Battery Figure 1

Identification Plate (typical . may not be specific to this battery) Figure 2

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DESCRIPTION AND OPERATION 40176-4 / 40176-7

Overall Dimensions (drawing may not be representative of specific battery) Figure 3

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DESCRIPTION AND OPERATION 1756-1 and 1756-3

14

DESCRIPTION AND OPERATION 1756-1 and 1756-3 1. A. DESCRIPTION General Description B. Characteristics (1) Technical characteristics

The Saft alkaline battery has 20 semi-open, nickelcadmium VP170KH cells with welded polyamide cases. It is connected to the on-board systems of the aircraft, and is used: For starting the engines

-Nominal voltage: 24V -Rated capacity: 17Ah at 1-hour rate -Connector: MS 18093 -Electrolyte: Sol. KOH s.g. approximately 1.30 -Consumable volume of electrolyte 20cm3 per cell -Maximum dimensions of battery base:

On the ground before electrical ground power is applied to the aircraft on-board systems Airborne in case of malfunction or failure in the normal power supply The battery is charged on the aircraft by a dedicated charger.

L=322.6mm (12.70in) W=163.1mm (6.42in) H=199.9mm (7.87in) - Maximum weight: 18.1kg (40lb.) - One temperature sensor with: one thermistor 3k W 2% @ 25C (77F)

DESCRIPTION AND OPERATION 1756-1 and 1756-3

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DESCRIPTION AND OPERATION 1756-1 and 1756-3 (2) Operational characteristics Operation temperature: -40C to +70C (40F to +158F) This connector connects the battery to the aircraft. The box (010) is fitted with: a removable cover and pad assembly (030)

Maximum instantaneous power:

two vent tubes

two latches

- at +27C (+80.6F), 12V, 15s: 9.9Kw - at -18C (+05F), 12V, 15s: 6.1Kw C. Detailed Description The battery contains 20 VP170KH (220, IPL Fig 1) cells housed in a stainless steel box. The box (010) is lined with thin sheets of insulation and wedges (020). The cells are maintained upright by means of molded silicon elastomer part fastened to the box cover that presses against the top of the cells. Cells are interconnected by rigid nickel plated copper links (090, 120, 130). End cells are connected by output connections (100,110) to an electrical connector (40).

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DESCRIPTION AND OPERATION 4078-3, 4078-24, 40178-24, and 40178-26

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DESCRIPTION AND OPERATION 4078-3, 4078-24, 40178-24, and 40178-26 1. A. DESCRIPTION General Description B. Characteristics (1) For starting the engines On the ground before electrical ground power is applied to the aircraft on-board systems Airborne in case of malfunction or failure in the normal power supply Technical characteristics Nominal voltage: 24V Rated capacity: 43Ah at 1-hour rate Connector: NFL 56-205A or MS 3509 Electrolyte: Sol. KOH s.g. approximately 1.30 Consumable volume of electrolyte 25cm3 per cell Maximum dimensions of battery base:

The Saft alkaline battery has 20 semi-open, nickelcadmium VHP 430KH-3 cells with welded polyamide cases. It is connected to the on-board systems of the aircraft, and is used:

The battery is charged on the aircraft by a dedicated charger.

L=268.4mm (10.57in) W=305.5mm (12.03in) H=262.1mm (10.325in) - Maximum weight: 38.4kg (84.7lb.) - One temperature sensor with: one thermistor 3k W 2% @ 25C (77F)

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DESCRIPTION AND OPERATION 4078-3, 4078-24, 40178-24, and 40178-26

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DESCRIPTION AND OPERATION 4078-3, 4078-24, 40178-24, and 40178-26

(2) Operational characteristics Operation temperature: -40C to +70C (40F to +158F) Maximum instantaneous power: - at +23C (+77F), 12V, 15s: 16.9Kw - at -18C (+05F), 12V, 15s: 11.6Kw C. Detailed Description The battery contains 20 VHP 430KH-3 (220, IPL Fig1) cells housed in a stainless steel box. The box (010) is lined with thin sheets of insulation and wedges (020). The cells are maintained upright by means of molded silicon elastomer part fastened to the box cover that presses against the top of the cells. Cells are interconnected by rigid, nickel-plated copper links (090, 100, 120, and 130). End cells are connected by output connection (110) to an electrical connector (40).

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TESTING AND FAULT ISOLATION 40176-4 / 40176-7

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TESTING AND FAULT ISOLATION 40176-4 / 40176-7 1. General (2) Special tools When special tools are used in this chapter, a code number that can be found in SPECIAL TOOLS, FIXTURES AND EQUIPMENT, identifies them. - Discharge bench: constant current 0-50 A - Power supply: 0-45 V, range 0-50 A (3) Instruments

This chapter provides the tests and inspections required to determine the condition of a unit removed for maintenance (scheduled or unscheduled). The table in section 7 (Fault Isolation) can be used to assist in isolating and detecting faults noted during the maintenance process. 2. Testing A. Equipment (1) Standard tools

- A multimeter, range 2 V to 50 V, 1% accuracy - A megohmeter, range 0-50 M @250 VDC, 3% accuracy

(4) Environmental conditions for testing - Ambient temperature: 20C 15C (68F 27F) - Pressure: 85 to 106 Kpa (25.1 to 31.3 inHg) - Relative humidity < 85%

- Standard mechanics tools - Safety gloves - Protective goggles - Safety shoes - Compressed air with manometer (0.1 to 1 bar (1.45 to 14.5 psi))

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TESTING AND FAULT ISOLATION 40176-4 / 40176-7 B. Precautions Maintenance should be performed regularly per the aircraft manufacturer.s recommendations, or as specified in this manual. The following precautions should be observed to insure the proper operation of the battery: - Do not install the battery in an aircraft that is too hot (>60C (140F)). - Carefully follow aircraft installation instructions to ensure good airflow. - Verify the capacity of the battery at specified intervals. - Charge the battery in a battery shop. - Maintenance should be performed per instructions found in the CHECK chapter to verify: Level of electrolyte Torque on the connection nuts Correct onboard charging Battery capacity D. Testing procedures (1) Insulation test (a) Place the leads of the megohmeter as indicated below. Check from the outer case (1) to each cell terminal. See Figure 1002 for information regarding minimum v alues. Figure 1001

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TESTING AND FAULT ISOLATION 40176-4 / 40176-7

Insulation Test Figure 1001

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TESTING AND FAULT ISOLATION 40176-4 / 40176-7 (2) Polarization Test (Figure 1002)

(a)

Charge the battery at 3.6 A for 1.5 hours

(b) Keep the battery in open circuit condition for 1 hour (c) Measure the open circuit voltage of each cell (d) If the open circuit voltage of any cell is 0 V (or negative polarity), perform a Special Test (refer to paragraph (4)) and repair if necessary. (e) If every cell has an open circuit voltage that is greater than 0 volts, charge the battery (refer to section 3).

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TESTING AND FAULT ISOLATION 40176-4 / 40176-7

Insulation Test Parameters Figure 1002

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TESTING AND FAULT ISOLATION 40176-4 / 40176-7 (3) Vent-Valve (20) Test During charge, before putting the vent-valve (20) back onto the cells, verify proper operation. (d) Decrease the pressure slowly to 0.1 bar (1.45 psi) and note the pressure at which the bubbles stop. (e) Reject all vent-valves that have an opening pressure greater than 0.7 bar (10 psi) and/or remain open at a pressure less than 0.14 bar (2 psi). (f) Install the ASSEMBLY). vent-valve (20) (Refer to

(a) Install the vent-valve (20) with its O-ring (21) on the end of a testing apparatus (Refer to SPECIAL TOOLS, FIXTURES AND EQUIPMENT . Fig 9005).
(b) Connect the apparatus to a supply of compressed air through an adjustable reducing valv (c) Adjust the pressure to 0.5 bar (7.25 psi) and put the vent-valve into a container of water. Air bubbles will come out when the valve opens. If there are no bubbles, increase the pressure until you see bubbles and note the pressure.

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TESTING AND FAULT ISOLATION 40176-4 / 40176-7 (4) Special Test CAUTION: WHEN YOU CHARGE THE BATTERY
MORE THAN NECESSARY, YOU DECREASE THE LIFE OF THE CELLS. PERFORM THIS SPECIAL TEST ONLY WHEN SPECIFIED IN SECTION CHECK.

(d) With current still flowing, adjust the electrolyte in all cells. (e) Discharge the battery down to 0 V (Initial and Residual discharges) (Refer to section 5) (f) Replace any defective cells DISASSEMBLY and ASSEMBLY). (Refer to

(a) If the battery is discharged, charge the battery fully (refer to section 3) then continue to step (b). If already charged, continue to step (b). (b) Continue to charge the battery at 3.6 A for an additional 5 hours, regularly recording the voltage of each cell. NOTE: The temperature of cells that have damaged separators will increase significantly and continuously, and the voltage will continually decrease (over 0.1 V). (c) At the end of the additional 5-hour charge, mark any cell with a voltage less than 1.50 V for replacement.

(g) Charge the battery (Refer to section 3). 3. Charge A. Flight Charge The battery charge is normally maintained onboard by the electrical system or a dedicated onboard charger. NOTE: The decrease of water from the cells is in direct proportion to the overcharge the battery receives.

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TESTING AND FAULT ISOLATION 40176-4 / 40176-7 B. Ground Charge The following charging procedures are to be carried out in an appropriately equipped workshop.

CAUTION: REMOVE THE COVER TO CHARGE

THE BATTERY. THIS IS TO MAKE SURE THAT HYDROGEN GAS WILL NOT COLLECT IN THE BATTERY CASE.

CAUTION: WHEN THE BATTERY IS CHARGED IN

EXCESS OF THE TIMES AND RATES LISTED IN THE TABLE BELOW, THE LIFE OF THE CELLS IS DECREASED.

(1)

Constant current charge

(a) To charge a fully discharged battery, perform one of the Main Charge procedures listed in the table below followed by a corresponding Final Charge procedure.

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TESTING AND FAULT ISOLATION 40176-4 / 40176-7

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TESTING AND FAULT ISOLATION 40176-4 / 40176-7 NOTE: If during the Main Charge, the battery has not increased to the required voltage in the maximum charge time, proceed to the Final Charge. Do not continue to charge the battery at the high rate. If at the end of the Final Charge, all cells are not above the required voltage, refer to Fault Isolation. (b) For a battery not fully discharged or when the level of charge is unknown: 1. Discharge at 36 A (1C1A) down to 20 V (refer to section 5) 2. Charge: Refer to B (1)(a) for constant current charging instructions. (2) Other types of Charging: In addition to the constant current method of charging, other methods that fully charge the battery can be used. HOWEVER, IN EVERY CASE, CHECKS (V > 1.5 V) AND ADJUSTMENTS MUST BE USING A FINAL CHARGE CURRENT: 3.6 A AT 0.1C1A. CELL VOLTAGE ELECTROLYTE CARRIED OUT AT CONSTANT

If specific instructions are not given in the charger operating manual, Saft should be contacted before charging.

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CHARGE 1756-1 and 1756-3

33

TESTING AND FAULT ISOLATION 1756-1 and 1756-3

To charge a completely discharged battery, use one of the following procedures:

TESTING AND FAULT ISOLATION 1756-1 and 1756-3 NOTE: If the battery voltage has not risen sufficiently during this maximum charging time or if the battery voltage is exceeded before minimum charge time: refer to "TESTING AND FAULT ISOLATION". (3) Battery partially discharged and state of discharge unknown. TABLE 2 Discharge at 17Amps (1 C1A) down to 20 V. Charge: Refer to Table 1 above, Constant Current Charge. (4) The battery may also be charged at one of the constant current values given in section 2.A.(2) until the voltage at the battery terminals reaches the corresponding recommended voltage (30, 31 or 31.4V).

TABLE 3 Charge at 30V at a temperature during 4 to 5 hour Adjusted charge voltage: for a +5C (+41F) battery temperature: 31V for a +35C (+95F) battery temperature: 31.4V

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CHARGE
4078-3, 4078-24, 40178-24, and 40178-26

36

TESTING AND FAULT ISOLATION 4078-3, 4078-24, 40178-24, and 40178-26 To charge a completely discharged battery, use one of the following procedures:

TESTING AND FAULT ISOLATION 4078-3, 4078-24, 40178-24, and 40178-26 NOTE: If the battery voltage has not risen sufficiently during this maximum charging time or if the battery voltage is exceeded before minimum charge time: refer to "TESTING AND FAULT ISOLATION". (3) Battery partially discharged and state of discharge unknown. TABLE 2 Discharge at 43 Amps (1 C1A) down to 20 V. Charge: Refer to Table 1 above, Constant Current Charge.

(4) The battery may also be charged at one of the constant current values given in section 2.A.(2) until the voltage at the battery terminals reaches the corresponding recommended voltage (30, 31 or 31.4V).

TABLE 3 Charge at 30V at a temperature during 4 to 5 hour Adjusted charge voltage: for a +5C (+41F) battery temperature: 31V for a +35C (+95F) battery temperature: 31.4V

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ELECTROLYTE CHECK AND ADJUSTMENT

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4. Electrolyte Check and Adjustment The easiest tool to use to adjust the level of the electrolyte is a plastic syringe (T02) with a plastic nozzle on the conical end. The length of the nozzle that goes into the cell must be 20 mm (0.79 in). This is the distance necessary between the seat of the vent-valve (20) and the electrolyte (refer to Figure 1003). NOTE: The maximum consumable amount of electrolyte for this battery is 25 cm3 (1.525 in3) per cell (refer to DESCRIPTION AND OPERATION).

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CAUTION: DO NOT USE ACID OR ACIDULATED WATER TO ADJUST THE ELECTROLYTE LEVEL IN NICKEL-CADMIUM BATTERIES. A VERY SMALL QUANTITY OF ACID IS SUFFICIENT TO CAUSE PERMANENT DAMAGE. USE ONLY DISTILLED OR DEIONIZED WATER (M01) (Refer to SPECIAL TOOLS, FIXTURES AND EQUIPMENT) A. Insert the nozzle into the cell until the nozzle rests on the seat of the vent-valve opening. Pull the syringe plunger up. If the level is not sufficient, the syringe tube stays empty when you pull the plunger up. If there is too much electrolyte, the electrolyte is removed by the syringe until the level aligns with the end of the nozzle. Discard any liquid drawn into the syringe when leveling, do not reuse the liquid in other cells.

B. If in check 4.A there is no liquid removed by the syringe, the level is not sufficient. Perform the following to adjust the electrolyte: (1) Add a measured amount (5 ml) of distilled or deionized water (M01) into the syringe and inject it into the cell. Keep record of how much distilled or deionized water (M01) is being injected into the cell during this procedure. NOTE: The amount of distilled or deionized water (M01) required to level the first cell will serve as a guide to the amount required for the remaining cells in the battery. However, each cell must be adjusted individually to ensure the correct level is achieved in each cell. (2) Repeat check 4.A to check for correct level.

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5. Discharge A. Initial Discharge and Capacity Test The initial discharge can also be used to determine the capacity of the battery. The battery should be discharged at a rate equal to its rated capacity. (1) For Initial Discharge (from aircraft or storage): (a) Discharge the battery at 1C1A down to 20 V, monitoring the time from the start of the discharge to the time the battery voltage (at the main terminals) reaches 20 V. The time should be greater than 30 minutes. If not, one of the following may be the cause:

- The aircraft charger may not be functioning properly - If the battery was left idle for a time, selfdischarge occurred - The battery cells may be imbalanced and need servicing (2) For Capacity Test (a) Discharge the battery at 1C1A, monitoring the time from the start of the discharge to the time any of the cells voltage falls below 1 V. Mark the time any cell in the battery reads below 1 V. Each cell in the battery should maintain a voltage higher or equal to 1 V for a full 60 minutes of discharge at 1C1A (refer to Discharge Table). If one or more cells should fall below 1 V in less than 60 minutes, refer to Section 7 (FAULT ISOLATION).

- There was a discharge performed after the last use of the battery onboard the aircraft

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NOTE: Repeating the charge and full discharge of a battery that does not pass capacity test may recover lost capacity. However, if the capacity continues to decline, refer to Section 7 (FAULT ISOLATION). B. Residual Discharge The Residual Discharge will clear the battery of all .residual. energy left in the battery after the Initial Discharge or the Capacity Test. This procedure is to be performed after the battery has been discharged to 1 V per cell. (1) As each cell is discharged to 1 V, connect a resistor approximately 1 3 W (T03) across the cell terminals and continue to discharge each cell in the battery. Keep these resistors in position for 12 to 16 hours, allowing the battery to cool.

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6. Temperature Sensor and Heater Control Thermostat Testing Testing of the temperature sensor and heater control thermostat may require the use of a climatic chamber or other device that will allow raising or lowering the temperature of components in the temperature sensor. Refer to the SCHEMATIC AND WIRING DIAGRAM section for information on the specific layout of the temperature sensor. A. Testing of the sensor (both 40176-4 & 40176-7) (1) Perform the following tests at the temperature specified. (2) This sensor is normally open at room temperature.

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Heater Control Thermostat Test (40176-7 only) (1) Perform the following tests at the temperature specified. (2) The heater control thermostat is normally open at room temperature.

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7. Fault Isolation

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C. Physical Faults

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C. Physical Faults

C. Physical Faults

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DISASSEMBLY

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1.

General

3. Risks There are three types of risks involved in nickelcadmium battery maintenance:

WARNING: DISASSEMBLY SHOULD ONLY BE PERFORMED ON A COMPLETELY DISCHARGED BATTERY (REFER TO TESTING AND FAULT ISOLATION) Refer to the TESTING AND FAULT ISOLATION chapter to determine the malfunction and necessary level of disassembly required. The figures and item numbers used in this chapter correspond to those of the ILLUSTRATED PARTS LIST (IPL). 2. Safety The safety regulations are different from one country to another. Check local regulations for those that apply

A. Physical - Handling: Lift with your legs and not your back - Wear protective shoes
B. Electrical - Don.t wear rings, watches, chains, or belt buckles - Use insulated tools C. Chemical - Electrolyte is very corrosive and may cause severe burn to the skin: wear gloves and apron. - Contact with the eyes is very dangerous; wear protective goggles.

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4. Safety Measures - The electrolyte is caustic and can cause severe burns. If electrolyte comes in contact with the skin, flush the affected area with water and neutralize the solution with acetic solution, vinegar, lemon juice, or with boric acid solution at 10% concentration. - If the electrolyte comes in contact with the eyes, flush with water for at least 15 minutes and contact a physician. - Electrolyte ingestion can damage the throat and the respiratory tract. Do not try to vomit. Dilute the solution with water or milk. Contact a physician immediately. - Contact with nickel can cause chronic eczema. - Inhalation of cadmium oxide can cause a dry throat, cough, headaches, vomiting, or pain in the chest. Persons having inhaled cadmium oxide fumes must get fresh air, take oxygen, or have artificial respiration. Contact a physician as soon as possible.

- Potash can cause eczema. 5. Disassembly A. Equipment (1) Standard tools - Standard mechanic.s tools. - Safety gloves. - Protective goggles. - Safety shoes. - Eyewash. - Protective apron (2) Special tools When special tools are used in this chapter, a code number that can be found in SPECIAL TOOLS, FIXTURES AND EQUIPMENT, identifies them.

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B. Disassembly procedure WARNING: DISASSEMBLY SHOULD ONLY BE PERFORMED ON A FULLY DISCHARGED BATTERY (TESTING AND FAULT ISOLATION). (1) Remove the cover (2)

CAUTION: IN ORDER TO AVOID SHORTCIRCUIT, REMOVE THE LINKS ATTACHED TO THE CELL AND ADJACENT CELLS. (3) Remove a cell (13) (a) Remove the nuts (11) and the belleville or spring washers (12) that attach the links to the cell. (b) Remove all links (22 thru 27)

(a) Remove the cover by pulling up the tab on the latches that attach the cover (2) to the case (1) and lifting the cover upward.

CAUTION: REMOVE THE VENT-VALVE (20) ONLY FOR CLEANING OR LEVELING ELECTROLYTE. OVEREXPOSURE TO ATMOSPHERE WILL CAUSE DETRIMENTAL CHEMICAL CHANGES IN THE ELECTROLYTE.
(2) Remove the vent-valve (20) (a) Unscrew the vent-valve (20) with the special tool (T01). (b) Remove the vent-valve (20) with its o-ring (21).

(c) Fully engage the end of the special threaded tool (T04) onto one of the cell terminals. Pull up to remove the cell.

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(4) Remove the main power connector (28) (a) Remove the nuts (11) and belleville or spring washers (12). (b) Remove the screws (29) and washers (if equipped) (30). (c) Remove the connector (28) with the gasket (not numbered). (5) Remove the temperature sensor (4, 5) (a) Remove the connector (28) (refer to section (4)) (b) Remove the attaching nut (8) and O-ring (9). (c) Remove the nuts (11), belleville or spring washers (12), and brackets that hold down any part of the temperature sensor. (d) Disconnect (cut) any tie straps (not shown) holding parts of the temperature sensor (if applicable). (e) Remove the sensor (4, 5) with the O-ring (9) from the inside of the case (1).

(6) Disassembly of a complete battery (a) Remove the cover (2) (refer to Section (1)). (b) Remove the cells (13) (refer to Section (3)). (c) Remove the liner-spacer kit (43) by pulling out the liners and spacers, making sure to mark them to ensure correct placement during assembly. (d) Remove the connector (28) (refer to Section (4)). (e) Remove the sensor (4, 5) and O-ring (9) (refer to Section (5)).

CLEANING

CLEANING

1. General This chapter provides instructions for the cleaning and preservation of the battery components. The figure and item numbers used in this chapter correspond to those of the ILLUSTRATED PARTS LIST (IPL). 2. Equipment - Safety gloves. - Protective goggles. - Safety shoes. - Eyewash. - Protective apron. - Compressed air 3. Materials CAUTION: DO NOT USE PETROL, TRICHLOROETHYLENE OR OTHER SOLVENTS. SOME CHEMICALS CAN DEGRADE METAL PARTS CAUSING PREMATURE FAILURE.

- Ordinary water. - Distilled or deionized water (M01). - Neutral soap (M02). - Non-fluffy swab. - Non-wire brush. Rubbing alcohol (isopropyl) 4. Cleaning Procedure WARNING: BE CAREFUL WHEN HANDLING ELECTROLYTE AND AVOID SPLASHING. ELECTROLYTE IS A STRONG CAUSTIC AGENT AND CAN CAUSE SEVERE BURN. ALWAYS WEAR FACE AND EYE PROTECTION (PREFERABLY A TRANSPARENT FACE MASK), RUBBER GLOVES AND LONGSLEEVED CLOTHING. IN CASE OF CONTACT WITH SKIN, FLUSH WITH WATER. IN CASE OF CONTACT WITH EYES, FLUSH WITH WATER FOR AT LEAST 15 MINUTES AND SEEK MEDICAL ATTENTION.

A. (1)

Light Cleaning Remove the cover (2).

B. Thorough Cleaning WARNING: TO AVOID ELECTRIC SHOCK, DISASSEMBLY SHOULD ONLY BE PERFORMED ON A FULLY DISCHARGED BATTERY (REFER TO TESTING AND FAULT ISOLATION). (1) Disassemble the battery (refer to DISASSEMBLY) and then clean all components except the vent-valve (20) which must be cleaned while cells are in the case. Cells (13)

CAUTION: TO PREVENT SHORT-CIRCUIT, USE A RUBBER TUBE OR AN INSULATED NOZZLE TO DISPENSE COMPRESSED AIR. (2) Blow (with compressed air) across the tops of the cells to remove all dust and light traces of mineral salts from the battery. Using a clean cloth, wipe off all temperature sensor components. (3) Main Power Connector (28). (a) Clean connector pins with rubbing alcohol to clean off any accumulated grease and/or dirt. Inspect the pins for damage; pits, cracks, or scratches, that allow copper to show through the nickel plating. Replace connectors that are damaged with a Saft factory new unit.

(a)

1 Make sure the vent-valve (20) is tight. 2 Remove lower terminal nut (14), polarity washer (15,16), belleville or spring washers (17), flat washer (18), and clean in warm water if necessary. 3 Inspect the terminal o-ring (19) for cracks, breaks or leakage and clean in warm water. Replace if necessary.

4 Reassemble the dry hardware onto the cell and torque the lower terminal nut (14) per FITS AND CLEARANCES. CAUTION: DO NOT SOAK THE CELLS IN WATER. TAP WATER ENTERING CELL WILL CONTAMINATE ELECTROLYTE. 5 To easily remove all the electrolyte and mineral salts from the terminals, cover, and sides of the cell cases, clean in warm water with a soft brush. 6 Rub the cell with a cloth and let dry.

(d) Liner-spacer kit (43) 1 Clean in warm water with a soft brush and let dry. (e) Temperature Sensor (4, 5) 1 Wipe all parts with a damp cloth and let dry. CAUTION: CLEANING OF THE VENT-VALVE (20) MUST BE DONE WHEN THE CELLS ARE ASSEMBLED IN THE CASE (1). (f) Vent-valve (20) 1 Remove the vent-valve (20) (refer to DISASSEMBLY) during the Final Charge (refer to TESTING AND FAULT ISOLATION) at 0.1C1A. 2 Place a swab or soft cloth over the cell opening to keep out unwanted material. 3 Soak the vent-valve (20) for 1-2 hours in a container of distilled or deionized water to dissolve mineral salts from the vent-valve hole.

(b) Case (1) and handle (if equipped) 1 Clean with light soap (M02) and water, rub with a cloth and let dry. (c) Nuts, belleville or spring washers, flat washers, and links 1 Clean in warm water with a soft brush and let dry.

NOTE: To facilitate the cleaning process the water may be warmed to 50C (122F). (g) Main Power Connector (28)

1 Clean connector pins with rubbing alcohol to clean off any accumulated grease and/or dirt. Inspect the pins for damage; pits, cracks, or scratches, that allow copper to show through the nickel plating. Replace connectors that are damaged with a Saft factory new unit.
5. Lubrication When the battery is clean (with the vent-valve installed), put a thin layer of mineral vaseline (M04) or light oil on the terminals and on the links. Use of a paintbrush will make this procedure easier.

CHECK

CHECK 1. General - Standard mechanic.s tools. - Safety gloves. - Protective goggles. - Safety shoes. - Eyewash. - Protective apron. (2) Special tools - Periodic Check: adjustment of the electrolyte levels. - Regular Check: electrical functional testing, adjustment of electrolyte, and capacity test. - General Overhaul: disassembly, full cleaning, assembly and Regular Check. 2. Maintenance in workshop A. (1) Equipment Standard tools - Power supply 0-45 V, 0-50 A - Discharge bench, constant current 0-50 A - Multi-meter, range 2 V and 50 V, accuracy 1% - Megohmeter, range 0-50 M (voltage 250 VDC), accuracy 3% When special tools are used in this chapter, a code number that can be found in SPECIAL TOOLS, FIXTURES AND EQUIPMENT, identifies them. (3) Instruments

The checks in this chapter are necessary to use the batteries in flight and on the ground. The maintenance procedures in this chapter should be carried out in a battery shop. The three types of maintenance that will be detailed in this chapter are:

B. Conditions - Ambient temperature: 20C 15C (68F 27F) - Pressure: 85 to 106 Kpa (25.1 to 31.3 InHg) - Relative humidity < 85% C. Periodic Check If the electrolyte consumption exceeds the maximum consumable amount between two Regular Checks, this Period Check may be performed to adjust the electrolyte. Maintenance should be performed using Fig 5001 as a guide and will include the following steps: - Clean the battery. - Check the torque on nuts (11). - Perform an Insulation Test. - Measure the battery voltage. - Discharge the battery. - Charge the battery. - Clean the vent valves (20).

- Adjust the electrolyte. - Check the torque on nuts (11). (1) Remove the cover (2). (2) Perform a Light Cleaning (refer to CLEANING). (3) Check the torque on all upper terminal nuts (11) (refer to FITS AND CLEARANCES). (4) Perform an Insulation Test (refer to TESTING AND FAULT ISOLATION). (5) Measure the voltage in open circuit at the battery terminals. If the battery voltage is less than 21 V, perform a polarization test (refer to TESTING AND FAULT ISOLATION). (6) Perform an Initial Discharge at 36 A down to 20 V at the battery terminals, and allow the battery to cool (refer to TESTING AND FAULT ISOLATION). (7) Charge the battery (refer to TESTING AND FAULT ISOLATION). (8) During the Final Charge (refer to TESTING AND FAULT ISOLATION), clean the ventvalves (20) (refer to CLEANING).

(9) Level the electrolyte (refer to TESTING AND FAULT ISOLATION). (10) Check the torque on all upper terminal nuts (11) (refer to FITS AND CLEARANCES).

D. Regular Check After six months, or according to aircraft manufacturer.s specifications, perform this check following the different procedures indicated in Figure 5002. - Perform a Light Cleaning. - Check the torque on all nuts (11). - Measure the voltage of the battery. - Perform an Initial Discharge. - Perform a Residual Discharge. - Perform an Insulation Test. - Test the temperature sensor. - Charge the battery. - Clean the vent-valves (20). - Adjust the electrolyte. - Perform a Capacity Test. - Charge the battery. - Check the torque on all nuts (11).

(1) Remove the cover (2). (2) Perform a Light Cleaning (refer to CLEANING). (3) Check the torque on all nuts (11) (refer to FITS AND CLEARANCES).

(4) Measure the voltage in open circuit at the battery terminals. If the battery voltage is less than 21 V, perform a polarization test. (5) Perform an Initial Discharge at 36 A down to a voltage of 20 V at the battery terminals. Monitor the time from the start of the discharge to the time the battery reaches 20 V (refer to TESTING AND FAULT ISOLATION). (6) Perform a Residual Discharge (refer to TESTING AND FAULT ISOLATION). (7) Perform an Insulation Test (refer to TESTING AND FAULT ISOLATION). (8) Test the temperature sensor (4, 5). This will likely require partial disassembly (refer to TESTING AND FAULT ISOLATION and DISASSEMBLY). (9) Charge the battery (refer to TESTING AND FAULT ISOLATION). (10) During the Final Charge (refer to TESTING AND FAULT ISOLATION), clean the vent-valves (20) (refer to CLEANING). (11) Adjust the electrolyte (refer to TESTING AND FAULT ISOLATION). (12) Perform a Capacity Test (Refer to TESTING AND FAULT ISOLATION). (13) Re-check the torque on all nuts (11) (refer to FITS AND CLEARANCES).

(14) Charge the battery and perform a final electrolyte adjustment (refer to TESTING AND FAULT ISOLATION).

E. General Overhaul The General Overhaul includes electrical tests contained in the Regular Check. It also includes disassembly and cleaning of all components. Perform the General Overhaul every 12 months, or according to aircraft manufacturer.s instructions following the procedures indicated in Figure 5003. - Check the torque on all nuts (11). - Measure the voltage of the battery in open circuit at the main terminals. - Perform an Initial Discharge. - Perform a Residual Discharge. - Disassemble the battery completely. - Perform a Thorough Cleaning. - Test the Temperature Sensor. - Check torque on lower nuts (14). - Assemble the battery. - Perform an Insulation Test. - Charge the battery. - Clean the vent-valves (20) and test. - Adjust the electrolyte.

- Perform a Capacity Test. - Check the torque on all nuts (11). - Charge the battery and perform a final electrolyte adjustment.

NOTE: If three cells are replaced during a single maintenance cycle, or five cells over the life of the battery, Saft recommends that all cells be changed or the battery be replaced.
(1) Check the torque on all nuts (11) (refer to TESTING AND FAULT ISOLATION). (2) Measure the voltage of the battery at the main terminals. If the voltage is less than 21 V, perform a polarization test (refer to TESTING AND FAULT ISOLATION). (3) Perform an Initial Discharge at 36 A down to 20 V (refer to TESTING AND FAULT ISOLATION). (4) Perform a Residual Discharge with resistor clips (T03) down to 0 V (refer to TESTING AND FAULT ISOLATION). (5) Disassemble the battery completely (refer to DISASSEMBLY).

(6) Perform a Thorough Cleaning (refer to CLEANING) and inspect components. (a) Verify the cells show no signs of leakage.

(11) During the Final Charge, clean and test the vent-valves (20) (refer to CLEANING and TESTING AND FAULT ISOLATION). (12) Adjust the electrolyte (refer to TESTING AND FAULT ISOLATION). (13) Perform a Capacity Test (refer to TESTING AND FAULT ISOLATION). (14) Check the torque on all nuts (11) (refer to FITS AND CLEARANCES). (15) Charge the battery and perform a final electrolyte adjustment (refer to TESTING AND FAULT ISOLATION).

(b) Remove any small dents from the case (1).

(7) Test the Temperature Sensor and Heater Control Thermostat (4, 5) (refer to TESTING AND FAULT ISOLATION). (8) Assemble the battery (refer to ASSEMBLY).

(9) Perform an Insulation Test (refer to TESTING AND FAULT ISOLATION). The value measured after a Thorough Cleaning should be at least 10 M.
(10) Charge the battery (refer to TESTING AND FAULT ISOLATION).

REPAIR

74

REPAIR
1. General 3. Repairs The only authorized repair(s) applicable to this unit:

Defective parts for which no repair instructions are given shall be rejected and replaced by Saft factory new parts only. The figure and item numbers used in this chapter correspond with those of the ILLUSTRATED PARTS LIST (IPL). 2. Equipment A. Special Tools When special tools are used in this chapter, a code number that can be found in SPECIAL TOOLS, FIXTURES AND EQUIPMENT, identifies them. B. Standard Tools Standard mechanics tools.

- Re-affixing the Cover Gasket (not shown).

A. Cover Gasket The Cover Gasket (3) can only be re-glued one time. (1) Remove the Cover Gasket (3) completely. (2) Clean all traces of glue from the cover (2). (3) Apply the glue (M03) to the flat side of the cover (2). (4) Let dry for 2 hours in a dry place (or as specified by manufacturer.s instructions). (5) Place Cover Gasket (3) on the bottom of the cover (2) and press firmly to seat.

C. Materials Neoprene glue (M03)

ASSEMBLY

76

ASSEMBLY
1. General (2) Standard Tools - Standard mechanic.s tools - Safety gloves - Protective goggles - Safety shoes - Eyewash - Protective apron B. Installation of the Temperature Sensor (4, 5) (1) Insert the sensor (4, 5) with the O-ring (9) and attach with nut (8). NOTE: Lay the remaining portion of the sensor to the side of the case, these components will be attached either during or after the cells are installed.

Battery assembly is to be performed in a clean, dry room where all parts are protected from any impact from other parts or tools. Any protective layers applied to replacement parts must be removed prior to assembly. The figure and item numbers used in this chapter correspond with those of the ILLUSTRATED PARTS LIST (IPL). 2. Assembly Procedures A. Equipment (1) Special Tools When special tools are used in this chapter, a code number that can be found in SPECIAL TOOLS, FIXTURES AND EQUIPMENT, identifies them.

C. Installation of the Main Power Connector (28) (1) Insert the main power connector (28) with the gasket (not numbered) into position in the battery case (1) and attach with screws (29) and washers (if equipped)(30). D. Installation of the liner spacer kit (43) (1) Insert the bottom liner into the bottom of the case (1). (2) Follow the assembly shown in Fig 7001, inserting liners and spacers in each position.

(3)

(4) NOTE: Additional liners and spacers may be necessary to keep cells (13) tight in the case (1). (5) E. Installation of Cells (13) (1) Torque all lower terminal nuts (14) (refer to FITS AND CLEARANCES). (2) Cells should be installed in rows. Install all but the center cell in each row according to their polarity as found in Fig. 7002. (6)

Make sure to install any liners and spacers (refer to Fig 7001) and/or temperature sensor plates (as applicable) that are needed in between the cells at this time. Carefully position the last cell (13) in each row and insert the cell (13) by pressing on the terminals with a piece of soft wood. This cell should be difficult to insert, requiring 25-30 lbft of pressure to seat. If the cell is too loose, install additional liners and spacers (43). If the cell is too difficult to insert, remove a liner or spacer (43) as needed. Never lubricate the cells to facilitate assembly. Lightly lubricate all links (22-27), belleville or spring washers (12), nuts (11), and cell terminals with a mineral vaseline (M04) or light oil using a paintbrush. Install the links (22-27), belleville or spring washers (12), and nuts (11). Torque all nuts (11) (refer to FITS AND CLEARANCES).

FITS AND CLEARANCES

FITS AND CLEARANCES

1. General

The FITS AND CLEARANCES section provides torque specifications for any components requiring a specific torque value, or clearance values for moving parts that require specific clearance distance. 2. Torque Specifications IMPORTANT: The values provided in the torque table (Fig 8001) are .lube torque. values. All threads should be lightly lubricated with mineral vaseline (M04) or light oil prior to installation and applying torque.

SPECIAL TOOLS, FIXTURES AND EQUIPMENT

SPECIAL TOOLS, FIXTURES AND EQUIPMENT 1 General This chapter provides pertinent specifications for any special tools that may be needed during battery maintenance. It also supplies a listing of consumable items that may be useful during normal servicing, repair, and use. 2. Special Tools, Fixtures and Equipment

3. Consumables NOTE: Equivalent alternatives may be used.

CARGADOR

87

THESUPERSEDER III, BATTERY CHARGER/ANALYZER The Superseder III is characterized by simple to set controls plus the condensed operating procedure found on the front panel that make it a very easy to operate CHARGER/ANALYZER, which combined with easy to read CURRENT, VOLTAGE, TIME and STATUS indicators, makes it also a very simple unit to monitor. The Superseder III is also designed for speed, for it can charge two batteries, (actually, any number of batteries where the total number of cells is 50 or less), at maximum currents, and it can also discharge two batteries at reduced currents, or one battery (25 cells or less) at maximum current. The Superseder III also provides a Voltage Control enhancement that allows the Charger- Analyzer, originally designed for Constant Current operation on Nickel-Cadmium batteries to also be able to handle Lead-Acid and other type of rechargeable batteries, where the end voltage is a more reliable indicator of the state of charge (as opposed to Nickel-Cadmium batteries). This instrument is also protected against certain internal performance deviations and programming errors, plus it is also designed to sense certain battery abnormalities to protect the instrument and battery from possible damage. In the event that any malfunction takes place, VISUAL and AUDIBLE indicators will turn on, alerting the operator and preventing any further operation of the unit. The Charger/Analyzer is basically a precision programmable constant current source (for charge) and a programmable constant current sink (for discharge) combined with voltage and temperature sensing circuits for total battery monitoring. The specially designed circuitry provides a performance not achieved by any of the older conventional battery charging methods. The Superseder III will deliver current into a short circuit or a battery or combination of batteries totaling 50 cells, within 1% of the programmed value, independent of line voltage variations (within 10% of the nominal line voltage).