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TELEDYNE BATTERY PRODUCTS

1. 10 Hours to 1 67 at 24 Q01 1120 Revision B 6 05 Page 48 of 74 Teledyne Battery Products G 247 The Original Equipment Aircraft Battery Gill DRY CHARGE MAINTENANCE MANUAL End Volts Test Capacity Energy Weight Electrolyte Per Cell Ah Wh Ib Volume quarts G 247 Performance at 24 C Amperes 10 Hours to 1 67 VPC at 24 C Q01 1120 Revision B 6 05 Page 49 of 74 Teledyne Battery Products G 6381E C Gill DRY CHARGE MAINTENANCE MANUAL The Original Equipment Aircraft Battery G 6381E C Performance Data G 6381E G 6381C End Volts Capacity Energy Weight Per Cell Ah Wh Ib Gua G 6381E C Performance at 24 C 001 1120 10 Hours to 1 67 at 24 Revision B 6 05 Page 50 of 74 Teledyne Battery Products G 639E C Gill DRY CHARGE MAINTENANCE MANUAL The Original Equipment Aircraft Battery G 639E G 639E C Performance Data Test Electrolyte Een Temperature grt pes ous Volume quar
2. Wh Ib Volume quarts 60 sec sno 25 s 15 o 432 ELLE 2 do o as do o ao 7o G 641 Performance at 24 C Hours to 1 67 VPC at 24 C Q01 1120 Revision B 6 05 Page 54 of 74 Teledyne Battery Products GE 50C Gill DRY CHARGE MAINTENANCE MANUAL The Original Equipment Aircraft Battery GE 50C Performance Data End Volts Test Capacity Energy Weight Electrolyte Per Cell Venue Ah Wh Ib Volume quarts 1320 5 1 67 24 744 3 50 120 GE 50C Performance at 24 C 10 Hours to 1 67 at 24 Q01 1120 Revision B 6 05 Page 55 of 74 Teledyne Battery Products 5 The Original Equipment Aircraft Battery GE 51C Performance Data End Volts Test Capacity Energy Weight Electrolyte Per Cell Vets eue Ah Wh Ib Volume quarts sse p te po ae 8 LLL 8 Exec ci ec e GE 51C Performance at 24 C 10 Hours to 1 67 at 24 Q01 1120 Revision B 6 05 Page 56 of 74 Teledyne Battery Products GE 54C Gill DRY CHARGE MAINTENANCE MANUAL The Original Equipment Aircraft Battery
3. 044 4 das b nte 16 7 4 Sump Jar Maintenance 2 17 7 5 Managing Periods of Non Use _ 18 7 6 Shelf Life and Storage Conditions 18 7 7 Continued Airworthiness Determination 19 7 8 Charging 21 7 8 7 Constant Current CI 22 7 8 8 Constant Voltage CV 23 7 9 Recharging Deeply Discharged Batteries 24 7 10 Battery Safety 25 Revision B 6 05 iii Teledyne Battery Products Gill SERVICE MANUAL Gill SERVICE MANUAL The Original Equipment Aircraft Battery Section Page 7 11 Jump Starting an Engine 27 8 RECYCLING nube tabs 28 8 1 Material Safety Data 5 28 8 2 Recycler Locations 28 8 3 International Recycling Resources 29 9 eel 30 10 GLOSSARY 33 11 TROUBLESHOOTING 34 12 APPENDIX Battery Specifications 38 13 APPENDIX B Using a Hydrometer 2 nce retra neret 58 14 APPENDIX C MSDS CE 60
4. 1 20 625 GE 54C Performance Data End Volts Test Energy Weight Electrolyte Per Cell Vere Ah Wh Ib Volume quarts Sose 12 48 2 E 2 2 8L 60 min E20 20 hr 46 384 GE 54C Performance at 24 C 10 Hours to 1 67 at 24 Q01 1120 Revision B 6 05 Page 57 of 74 Teledyne Battery Products Section 13 Gill DRY CHARGE MAINTENANCE MANUAL The Original Equipment Aircraft Battery APPENDIX B Using a Hydrometer Hydrometers are used to determine specific gravity of liquids Specific gravity is a ratio of the density of the substance measured versus the density of pure water at the same temperature Thus specific gravity will vary with temperature Note Figure 5 A hydrometer consists of a small sealed glass tube weighted at one end to make it float in an upright position in the fluid being measured See Figure 4 FIGURE 4 HYDROMETER MENISCUS BARREL E The liquid being measured will be pulled in the barrel such that the hydrometer floats on the liquid without touching the stopper at the base of the rubber bulb The meniscus will be convex and the actua
5. gently rock the battery a few times to allow the entrapped air to escape The battery may heat up due to the reactions going on in the celis occasionally causing the electrolyte to react vigorously Please ensure vent caps are placed on correctly After the soak time check each cell for electrolyte levels Add electrolyte to the top of the separators DO NOT ADD ANY WATER AT THIS TIME WARNING Electrolyte contains sulfuric acid which is highly corrosive and can cause severe burns to exposed skin and permanent damage to eyes Avoid spilling or splashing Wear rubber gloves and safety goggles whenever you are handling electrolyte 10 Connect the charging cables and begin charging using our recommended methods Refer to the charging rates in Table 2 GILL BATTERY MODELS AND INITIAL CHARGE RATES Lx ee Emergency Emergency Rate Amp p Rate ea Lel 1 3 1 M 3 4o 45 2 t css e io csoc s ss c240 2 13 s ss g244 2 13 sec ss co gt 3 17 35 70 6 43 3 277 leesc 3 4o 3o 3 1550 Rev 7 14 05 Q01 1120 Revision B 6 05 Page 72 of 74 Teledyne Battery Products Gill DRY CHARGE MAINTENANCE MANUAL The Original Equipment Aircraft Battery 11 After the first hour of charge check the electrolyte level in each cell Make sure thal the level is just to the bottom of the split ring USE
6. p TABLE 3 ELECTROLYTE VOLUMES Fill Gill Part Former Part Gill Part Former Part Volume Number Number Number Number Quarts 2 G 247 GE SOE G 35M GE 50C 51 51 54 G 240 PS12 9 G 241 PS12 9M 3 3 8 3 3 3 G 638E C 3 4 4 4 5 2 5 INITIAL CHARGING INSTRUCTIONS G 6381E C G 639E C G 640E G 641 a Replace vent caps tightly and start charging per recommendations for your battery type Note Table 4 for Initial Charge Rates 001 1120 6 05 10 74 Teledyne Battery Products sar1ojjeg TAL iS 2 gt un WOSHE M AA A 0 009 lt 008 Gill DRY CHARGE MAINTENANCE MANUAL b Do not allow the battery to stand for more than 8 hours after the electrolyte has been added before you begin to charge The Original Equipment Aircraft Battery c After the first hour of charge check the electrolyte levels in each cell Make sure that the level is just to the bottom of the split ring Use hydrometer to remove excess If the electrolyte levels are low ADD ELECTROLYTE ONLY DO NOT ADD WATER AT THIS STAGE WARNING Wear safety goggles when looking into the cells and acid resistant gloves when handling batteries Electrolyte contains sulfuric acid which is highly corrosive and can cause severe burns to exposed skin and permanent damage to eyes e Maintain temperature of th
7. 7 8 CHARGING 7 8 1 Charging must be conducted in a well ventilated area at ambient conditions ranging from 65 F to 80 F Please review charging method constant current or constant voltage before commencing The preferred method is constant voltage WARNING If the battery room is air conditioned as part of a general building wide air conditioning system the exhaust air from the battery room should not be returned to the air distribution system The room should have its own exhaust system that vents directly outdoors Sufficient ventilation should be provided to prevent hydrogen gas build up Please make sure that there are no sources of sparks in the battery room 7 8 2 Personal safety is of prime importance Follow manufacturer s instruction at all times Note the safety precautions at the end of this section WARNING THE NATIONAL ELECTRIC CODE FORBIDS CHARGING BATTERIES INSTALLED IN AIRCRAFT OR WITHIN 10 FEET OF FUEL TANK AREAS Q01 1120 Revision B 6 05 Page 21 of 74 Teledyne Battery Products The Original Equipment Aircraft Battery Gill DRY CHARGE MAINTENANCE MANUAL 7 8 3 Correct charging is very important and will affect the overall life of the battery The charging process is not 100 efficient due to losses resulting from internal resistance and will typically be 10 to 20 higher than the amount of capacity removed during discharge 7 8 4 Undercharging a battery occurs when the required 105 to 115
8. refer to Table 3 Q01 1120 Revision B 6 05 Page 8 of 74 Teledyne Battery Products Gill DRY CHARGE MAINTENANCE MANUAL The Original Equipment Aircraft Battery e Gently shake the electrolyte bottles before removing the cap to ensure electrolyte is thoroughly mixed CAUTION When adding electrolyte to dry charged batteries ensure cleanliness at all times Electrolyte contains about 40 sulfuric acid and is very corrosive Metals chlorides or organic impurities in electrolyte will definitely impair performance Avoid contaminating the electrolyte Any plastic container except nylon may be used to contain the electrolyte f Carefully add electrolyte through the wax coated funnel provided ora plastic non nylon funnel to prevent spillage filling each cell to the top of the separators WARNING Wear safety goggles when looking into the cells and acid resistant gloves when handling batteries Electrolyte contains sulfuric acid which is highly corrosive and can cause severe burns to exposed skin and permanent damage to eyes g Install the vent caps with a quarter turn and let the battery sit for approximately 30 minutes soak time gently rock the battery a few times to allow the entrapped air to escape h The battery may heat up due to the reactions going on in the cells occasionally causing the electrolyte to react vigorously Please ensure vent caps are placed on correctly Use external cooling fan if nee
9. 0200 95 008 The Original Equipment Aircraft Battery Gill DRY CHARGE MAINTENANCE MANUAL 5 1 TOOLS NEEDED a Hydrometer To read 1 110 to 1 300 with zero at 80 F b 80 F Correction Thermometer a thermometer capable of reading up to 150 F may also be used Constant Current Charger d Wax coated funnel provided a plastic non nylon funnel may also be used 5 2 FILLING OR ACTIVATION 5 2 1 Always use the electrolyte that is supplied with the batteries For design performance do not use electrolyte with specific gravities other than those specified 5 2 2 Please refer to Activation and Service Instructions for Gill Dry Charged Lead Acid Aircraft Batteries TBP 1560 latest revision provided with your battery 5 2 3 If electrolyte is not available refer to Appendix D for preparation of electrolyte from concentrated acid WARNING Electrolyte contains sulfuric acid which is highly corrosive and can cause severe burns to exposed skin and permanent damage to eyes Avoid spilling or splashing Wear rubber gloves and safety goggles whenever you are handling electrolyte or examining batteries during charging 5 2 4 The activation process a Inspect the battery for any shipping damage prior to filling b Permanently mark the activation date Month and Year on the battery making sure that the battery is not damaged while doing so Remove storage caps d Make sure you have enough electrolyte
10. Q01 1120 Revision B 6 05 Page 45 of 74 Teledyne Battery Products G 244 Gill DRY CHARGE MAINTENANCE MANUAL The Original Equipment Aircraft Battery G 244 Performance Data Test n Electrolyte End Volts Capacity Energy Weight EE CES en C dans 5400 225 4 90 4 1 67 432 18 18 42 G 244 Performance at 24 C 10 Hours to 1 67 VPC at 24 Q01 1120 Revision B 6 05 Page 46 of 74 Teledyne Battery Products G 245 Gill DRY CHARGE MAINTENANCE MANUAL The Original Equipment Aircraft Battery G 245 Performance Data Test 1 Electrolyte ps Temperature geo beu Volume quarts 60 606 12 1 2 Bat 1 67 1 5 G 245 Performance at 24 C Amperes 10 Hours to 1 67 VPC at 24 Q01 1120 Revision B 6 05 Page 47 of 74 Teledyne Battery Products G 246 Gill DRY CHARGE MAINTENANCE MANUAL The Original Equipment Aircraft Battery G 246 Performance Data End Volts Capacity Energy Weight E Per Cell Temperature Ah Wh Ib olume quarts 60 sec 4 w 16 54 19 46 32 78 G 246 Performance at 24 C
11. of the removed capacity is not returned during recharge If this were to occur repeatedly residual lead sulfate will eventually increase in the plates making it very difficult to recover the battery In this case the battery will suffer a permanent loss of capacity 7 8 5 Overcharging generally occurs when constant current charging is used without adequate controls This is the main reason for the preference of constant voltage charging over constant current Overcharging a battery will corrode the positive grids and break the water component in the electrolyte down to hydrogen and oxygen electrolysis 7 8 6 Prolonged overcharging will lead to loss of water from the electrolyte and grid corrosion 7 8 7 CONSTANT CURRENT 7 8 7 1 These chargers must be capable of providing an output of 35 volts and 8 amperes with selector switch and provide a timer that can terminate charging when the charge is completed 7 8 7 2 ampere hours of energy restored is the product of rate of charge in amperes and the time in hours 7 8 7 3 Since these chargers are designed to provide a constant current throughout the charging period this method could lead to overcharging if not controlled In order to control the charge input these chargers must have a shut off timer On charge voltage could go as high as 33 volts for a 24 volt battery or 16 5 volts for a 12 volt battery as the battery approaches full charge As long as the
12. 4 3 1 Higher temperatures above 120 F will lead to quicker grid and active material deterioration 4 4 3 2 Very low temperature below 10 F operations could lead to chronically undercharged batteries 4 4 4 Improper electrolyte level adjustments 4 4 4 1 Adding contaminated water other liquids e Electrolyte must be free from organics chlorides and metals These impurities will affect performance significantly 4 4 4 2 Using a battery with low levels of electrolyte e A battery operated with low levels of electrolyte will only use the submerged portions of the battery plates causing irreversible damage to the exposed portion of the plates 4 4 4 3 Adding too much water in some cells e These cells will have electrolyte that could be considerably diluted affecting the essential chemical balance in the cell causing decrease in performance TABLE 2 RECOMMENDED VOLTAGE REGULATOR SETTINGS Operating 12 Volt Battery 24 Volt Battery Temperature Nominal Maximum Minimum Nominal Maximum 13 35 13 75 13 95 90 136 140 142 276 280 283 p 1s 145 1445 281 285 Sections 145 147 286 290 L 1 CONTINUOUS OPERATION ABOVE 120 F IS NOT RECOMMENDED PREPARING DRY CHARGED BATTERIES FOR USE Q01 1120 Revision B 6 05 Page 7 of 74 Teledyne Battery Products sar1ojjeg TAL SLONGOUd AYALLVA ANAGHA FOYE TTT MAL M
13. 74 Teledyne Battery Products Section 4 Gill DRY CHARGE MAINTENANCE MANUAL The Original Equipment Aircraft Battery DRY CHARGED LEAD ACID BATTERIES 4 1 DESCRIPTION 4 1 1 These batteries are assembled with electrodes plates that have been fully charged and dried The dried plates are quite stable over time allowing the batteries to be stored indefinitely 4 1 2 Each cell is tightly sealed prior to shipment These seals must not be tampered with during storage and should only be removed just prior to activation with electrolyte Battery life begins when the electrolyte is added 4 1 3 It is recommended that these batteries be stored in cool dry areas as high humidity and temperature will only serve to discharge the negative plates requiring considerable conditioning if the oxidation is severe 4 2 SPECIFICATION DEFINITIONS Gill aircraft batteries are defined by a series of specifications 4 2 1 The One Hour Rate This is the rate of discharge a battery can endure for one hour with the battery voltage at or above 1 67 volts per cell or 20 volts for a 24 volt lead acid battery or 10 volts for a 12 volt lead acid battery The One Hour Capacity measured in Ampere Hours or Ah is the product of the discharge rate and time in hours to the specified end voltage 4 2 2 The Emergency Rate This is the rate of discharge a battery can endure for thirty minutes with the battery voltage at or above 1 67 volts per cell or 20
14. Constant Current Charge Charge the battery at the rates listed in the table above for 10 12 hours At the end of charge the battery voltage will stabilize over three consecutive readings with slight voltage drop al the end Individual cell specific gravity temperature compensated will stabilize between 1 275 and 1 295 If not in use batteries should be placed in a cool dry area and boost charged at least once a month 1550 Rev 7 14 03 Q01 1120 Revision B 6 05 Page 73 of 74 Teledyne Battery Products Gill DRY CHARGE MAINTENANCE MANUAL The Original Equipment Aircraft Battery CONTINUED AIRWORTHINESS INSTRUCTIONS FOR DRY BATTERIES IMIT To ensure continued airworthiness the battery should be removed and capacity tested The recommended service period should initially be at 600 50 hours or 11 1 calendar month s whichever comes first After the initial service the next check should be at 400 25 flight hours or 6 1 calendar month s whichever comes first The capacity test shall be performed as follows CAPACITY TEST Check for proper battery installation per STC Installation Instructions when performing annual and 100 hour inspections and when replacing battery after capacity test Remove the battery from the aircraft and charge according to our recommended charging instructions Allow the battery to stand on open circuit for one hour Connect the fully charged battery to a capacity teste
15. ELECTROLYTE ONLY WARNING Electrolyte contains sulfuric acid which 15 highly corrosive and can cause severe burns to exposed skin and permanent damage to eyes Avoid spilling or splashing Wear rubber gloves and safety goggles whenever you are handling electrolyte or examining batteries during charging Replace vent caps finger tight to ensure electrolyte does not leak Make sure that battery temperature does not exceed 115 F Reduce the charge rate or use external cooling if it does Completion of charge is indicated by a stable specific gravity reading of 1 275 to 1 295 temperature compensated laken over three hours A stable on charge voltage reading could also be used The battery should typically be charged in about 8 12 hours WARNING Wear safety goggles when looking into the cells Electrolyte contains sulfuric acid which is highly corrosive and can cause severe burns to exposed skin and permanent damage to eyes 15 At the end of charge all cells should be gassing bubbling uniformly 16 After the battery is fully charged adjust the level of the electrolyte to the bottom of the split ring bottom of vent well with the charger still on CHARGING Constant Potential Charge Charge the battery at 14 1 to 14 3 volts 12 volt battery or 28 2 to 28 6 volts 24 volt battery for a period of 24 hours Inrush current could be as high as 100 amps provided the charge voltage does not exceed the limits mentioned above
16. TELSTAR 12 L640 L6100 L6100S L 1260 12860 12880 12B80H 12890 12B90H L60 STARPOWER 25 STARPOWER 35 CENT 350 CENT 3100 CENT 660 CENT 680 CENT 680H CENT 690 CENT 690H CHEMICAL FAMILY LEAD AND LEAD COMPONENTS FORMULA NOT APPLICABLE MSDS 1001 Page 1 of 5 Updated March 2003 Q01 1120 Revision B 6 05 Page 60 of 74 Teledyne Battery Products Gill DRY CHARGE MAINTENANCE MANUAL The Original Equipment Aircraft Battery TELEDYNE BATTERY PRODUCTS MATERIAL SAFETY DATA SHEET DRY CHARGED BATTERY DOT DESCRIPTION NOT SUBJECT TO DOT REQUIREMENTS INTENDED USE ELECTRIC STORAGE BATTERIES FOR AIRCRAFT EMERGENCY LIGHTING MARINE GROUND SUPPORT AND ENGINE STARTING EQUIPMENT CONTAINS NO ELECTROLYTE MATERIAL SAFETY DATA SHEET FOR LEAD ACID BATTERY APPLIES WHEN FILLED AND SERVICED WITH ELECTROLYTE SECTION HAZARDOUS INGREDIENTS MATERIAL OR CAS WEIGHT OSHA PEL ACGIH TLV OSHA ACTION COMPONENT LEVEL Lead and lead compounds 7439 92 1 lt 95 50 g m 0 15 mg m 30 ug m3 Antimony 7440 36 0 14 0 5 mg m 0 5 mg m Not Applicable Arsenic 7440 38 2 0 1 10 ug m 0 2 mg m 5 Barium sulfate 7721 431 0 2 5 mg m 10 mg m Not Applicable Calcium compounds 7440 70 2 lt 0 1 5 mg m 2 mgm Not Applicable Carbon black extracts 1333 86 4 lt 0 1 3 5 mg m 3 5 mg m Not Applicable Tin compounds 7440 31 5 0 3 2 mg m 2 mg m Not Applicable As CaO Respirable SECTION Ill PHYSICAL DATA BOILING POINT LE
17. VAPOR PRESSURE lt 1 mmHg 70 F VAPOR DENSITY gt 1 SOLUBILITY in Water 100 96 VOLATILES BY VOL EVAPORATION RATE lt 1 APPEARANCE AND ODOR CLEAR LIQUID NO ODOR SECTION IV HEALTH HAZARD INFORMATION ROUTES OF EXPOSURE INHALATION INHALATION OF ELECTROLYTE CAN CAUSE BURNS IN THE UPPER RESPIRATORY TRACT LUNG IRRITATION AND PULMONARY EDEMA MAY OCCUR SKIN CONTACT ELECTROLYTE MAY CAUSE BURNS OR LOCALIZED IRRITATION EYE CONTACT ELECTROLYTE MAY CAUSE IRRITATION CORNEAL BURNS AND CONJUNCTIVITIS BLINDNESS OR SEVERE OR PERMANENT INJURY MAY RESULT INGESTION ELECTROLYTE MAY CAUSE BURNS TO THE MOUTH ESOPHAGUS AND STOMACH EFFECTS OF OVEREXPOSURE ACUTE OVEREXPOSURE SULFURIC ACID MAY CAUSE IRRITATION TO THE EYES NOSE AND THROAT DIFFICULTY IN BREATHING MAY BE EXPERIENCED ACID SPLASHED IN THE EYES OR ON THE SKIN MAY CAUSE BURNS OR IRRITATION CHRONIC OVEREXPOSURE REPEATED PROLONGED EXPOSURE TO DILUTE SULFURIC ACID MAY CAUSE IRRITATION OF THE SKIN REPEATED OR PROLONGED EXPOSURE TO MIST OR VAPORS OF SULFURIC ACID MAY CAUSE EROSION OF THE TEETH CHRONIC IRRITATION OF THE EYES OR CHRONIC INFLAMMATION TO THE NOSE THROAT AND BRONCHIAL TUBES CARCINOGENICITY IARC NTP OSHA Sulfuric acid X EMERGENCY AND FIRST AID PROCEDURES EYES WASH IMMEDIATELY WITH LARGE AMOUNTS OF WATER LIFTING THE LOWER AND UPPER LIDS CONTINUOUSLY GET MEDICAL ATTENTION SKIN IMMEDIATELY FLUSH THE EXPOSED AREA OF THE SKIN WITH LARGE AMO
18. and negative plates International Air Transport Association International Civil Aviation Organization International Electrotechnical Commission Peak current in amperes at 0 3 seconds of a 15 second discharge while testing at a constant terminal voltage of 12V for 24V lead acid batteries Refers to the ability of the battery to retain the electrolyte when subjected to tests identified under US DOT Reg 49 CFR Part 173 159 paragraph d Open Circuit Voltage measured with no loads connected to the battery Refers to the oxidation of the negative electrode The process by which oxygen combines reacts with the negative active material Fully charged negative plates convert to a very porous pure lead material often referred as sponge lead since it resembles a sponge under high magnification The measure of charge level of a battery This measure is not the same as available capacity A spent battery could indicate a full state of charge voltage but has lower capacity than the battery started out with Sulfation The product of discharge lead sulfate formed on both positive and negative plates Venting Means for a battery to release the gases it generates during charging Q01 1120 Revision B 6 05 Page 33 of 74 Teledyne Battery Products Section 11 Gill DRY CHARGE MAINTENANCE MANUAL GILL TROUBLE SHOOTING GUIDE The Original Equipment Aircraft Battery PROBLEM CAUSE RECOMMENDATIONS Battery has low capacity Batter
19. the emergency rate use the appropriate performance curves for that battery to determine the expected run time The curve below indicates how the axes should be read Please call Teledyne Tech Support for any questions Reading a Performance Plot 3 5 7 Hours to 1 75 at 24 Q01 1120 Revision B 6 05 Page 30 of 74 Teledyne Battery Products Gill DRY CHARGE MAINTENANCE MANUAL The Original Equipment Aircraft Battery Q How can determine if a dry charged battery is fully charged without using hydrometer A Battery voltage will stabilize towards full charge and begin a slight dip During this time all cells should be gassing uniformly At this stage the battery is considered to be fully charged Q purchased a dry charged battery a few months ago and activated it can leave it on the shelf until am ready to use it A Batteries start to age as soon as electrolyte is added Once the batteries have electrolyte added to them they must be put in service If you are unable to do so condition the batteries every two to three months top off charge Q My battery voltage is very low filled all the cells with the electrolyte had received The electrolyte was not enough but I topped off the low cells with water Can you help A During initial conditioning no water is to be added to the c
20. 15 APPENDIX D Mixing Electrolyte 69 16 APPENDIX E Activation and Service Instructions for Gill Dry Charged Lead Acid Aircraft Batteries TBP 1560 70 Q01 1120 Revision B 6 05 iv Teledyne Battery Products Section 1 Gill DRY CHARGE MAINTENANCE MANUAL REVISIONS Description of Change Approved By Added new load tester 8 31 04 The Original Equipment Aircraft Battery cM Corrected manual number J Rajpara 6 30 05 Q01 1120 Revision B 6 05 Page 1 of 74 Teledyne Battery Products Section 2 Gill DRY CHARGE MAINTENANCE MANUAL The Original Equipment Aircraft Battery SCOPE This manual provides Maintenance Procedures for Gill Dry Charged Lead Acid Aircraft Batteries manufactured under FAA Parts Manufacturer Approvals PMA This manual has been written for the purpose of guidance only consult Teledyne Battery Products Technical Support for further information The latest list of our PMA s can be obtained on our website at www gillbatteries com or by calling our Customer Support at 800 456 0070 Q01 1120 Revision B 6 05 Page 2 of 74 Teledyne Battery Products Section 3 Gill DRY CHARGE MAINTENANCE MANUAL The Original Equipment Aircraft Battery INTRODUCTION Teledyne Battery Products of today had a modest beginning in the early 1920 s under the stewardship of Mr Lawrence Gill Since inception Gill has been producing first rate batteries primarily for t
21. 1560 7 6 SHELF LIFE AND STORAGE CONDITIONS 7 6 1 Once activated with electrolyte the battery is constantly undergoing parasitic discharging which vary with types of battery chemistries Note Figure 3 Shelf Life of Flooded Products 7 6 2 A battery should not be allowed to remain in a discharged condition for any appreciable period of time If the battery is kept in such a state the active material will gradually discharge and convert to lead sulfate and over time become very difficult to convert to the original active material For every 18 F increase in temperature the discharge rate will double If the battery is severely discharged typically down to 1 9V cell it will sustain permanent damage Q01 1120 Revision B 6 05 Page 18 of 74 Teledyne Battery Products The Original Equipment Aircraft Battery Gill DRY CHARGE MAINTENANCE MANUAL 7 6 3 A simple example to illustrate the magnitude of a parasitic drain over time If the external load is 0 1A And non use period is 3 weeks Total discharge 3 weeks x 24 hours day x 7 days week 50 4Ah Comparing this loss to the capacity of the battery this small drain can be quite significant over time FIGURE 3 Shelf Life 24V Dry Charged Lead Acid Batteries 2 5 e gt 8 5 E oO 5 2 E E 2 b Shelf Life Days 7 7 CONTINUED AIRWORTHINESS DETERMINATION FOR GILL AIRCRAFT BATTERIES 7 7 1 To ensur
22. AD 3164 F 1740 C 760 mm Hg POLYPROPYLENE gt 320 F MELTING POINT LEAD 621 F 327 43 SPECIFIC GRAVITY LEAD 11 34 VAPOR PRESSURE mm Hg 20 LEAD NEGLIGIBLE VAPOR DENSITY LEAD SOLUBILITY LEAD INSOLUBLE IN WATER 96 VOLATILES BY VOL NEGLIGIBLE EVAPORATION RATE LEAD NIA APPEARANCE AND ODOR NO ODOR BATTERY CASE IS PINK WHITE OFF WHITE OR BLACK SECTION IV HEALTH HAZARD INFORMATION ROUTES OF EXPOSURE INHALATION LEAD DUST VAPOR OR FUME MAY BE ABSORBED BY THE RESPIRATORY SYSTEM AND CAN RESULT IN BOTH ACUTE AND CHRONIC OVEREXPOSURE AS WELL AS RESPIRATORY RRITATION SKIN CONTACT LEAD IS NOT READILY ABSORBED THROUGH THE SKIN EYE CONTACT LEAD DUST VAPOR OR FUME MAY CAUSE IRRITATION INGESTION LEAD DUST VAPOR OR FUME MAY BE ABSORBED BY THE RESPIRATORY SYSTEM AND CAN RESULT IN BOTH ACUTE AND CHRONIC OVEREXPOSURE MSDS 1001 Page 2 of 5 Updated March 2003 Q01 1120 Revision B 6 05 Page 61 of 74 Teledyne Battery Products Gill DRY CHARGE MAINTENANCE MANUAL The Original Equipment Aircraft Battery TELEDYNE BATTERY PRODUCTS MATERIAL SAFETY DATA SHEET DRY CHARGED BATTERY EFFECTS OF OVEREXPOSURE ACUTE OVEREXPOSURE ACUTE UNTREATED OVEREXPOSURE TO LEAD MAY LEAD TO WEAKNESS VOMITING LOSS OF APPETITE UN COORDINATED BODY MOVEMENTS CONVULSIONS STUPOR AND POSSIBLY COMA CHRONIC OVEREXPOSURE CHRONIC UNTREATED EXPOSURE TO LEAD MAY CAUSE WEAKNESS INSOMNIA HY
23. D ELECTROLYTE SHOULD BE ABSORBED WITH NON ORGANIC TYPE ABSORBENT SUCH AS DRY SAND OR EARTH AVOID DILUTION WITH WATER NEUTRALIZING CHEMICALS USE SODA ASH OR BAKING SODA TO NEUTRALIZE ELECTROLYTE WASTE DISPOSAL METHODS ELECTROLYTE SHOULD BE HAULED TO A PERMITTED TREATMENT FACILITY SECTION VIII SPECIAL PROTECTION INFORMATION VENTILATION REQUIREMENTS BAT CR VEI TERY CHARGING AREAS MUST BE ADEQUATELY VENTILATED TO KEEP VAPOR D MIST CONCENTRATIONS BELOW EXPOSURE LIMITS DESIGN TERIA FOR VENTILATION SYSTEMS ARE CONTAINED IN THE INDUSTRIAL TILATION MANUAL PUBLISHED BY THE ACGIH SPECIFIC PERSONAL PROTECTIVE EQUIPMENT RESPIRATORY U DER NORMAL CONDITIONS OF USE RESPIRATORY PROTECTION IS REQUIRED HOWEVER SHOULD CONDITIONS ARISE WHERE RESPIRATORS ARE NEEDED USE ONLY NIOSH MSHA RESPIRATORS APPROVED FOR DUST FUME CH D MIST EMICAL GOGGLES FULL FACE SHIELD GLOVES APPROVED FOR SULFURIC ACID ACI MSDS 1003 D RESISTANT APRON Page 3 of 4 Updated March 2003 Q01 1120 Revision B 6 05 Page 67 of 74 Teledyne Battery Products Gill DRY CHARGE MAINTENANCE MANUAL The Original Equipment Aircraft Battery TELEDYNE BATTERY PRODUCTS MATERIAL SAFETY DATA SHEET BATTERY ELECTROLYTE SECTION IX SPECIAL PRECAUTIONS PRECAUTIONARY STATEMENTS AVOID THE USE OF NON INSULATED TOOLS IF THEY ARE REQUIRED TAKE CARE NOT TO MAKE A CONNECTION BETWEEN THE TWO BATTERY TERMINALS AS SEVERE SPARKING
24. ELEDYNE BATTERY PRODUCTS MATERIAL SAFETY DATA SHEET DRY CHARGED BATTERY HAZARD RATING TELEDYNE BATTERY PRODUCTS MATERIAL SAFETY DATA SHEET DRY CHARGED BATTERY THE INFORMATION CONTAINED HEREIN 15 BASED ON DATA CONSIDERED ACCURATE HOWEVER NO WARRANTY IS EXPRESSED OR IMPLIED REGARDING THE ACCURACY OF THESE DATA OR THE RESULTS TO BE OBTAINED FROM THE USE THEREOF VENDOR ASSUMES NO RESPONSIBILITY FOR INJURY TO VENDEE OR THIRD PERSON PROXIMATELY CAUSED BY ABNORMAL USE OF THE MATERIAL EVEN IF REASONABLE SAFETY PROCEDURES ARE FOLLOWED FURTHERMORE VENDEE ASSUMES THE RISK IN THIS USE OF THE MATERIAL CONTRACT ORDER NO NATIONAL STOCK NO SPECIFICATION REFERENCE NO DATE PREPARED MARCH 2003 SECTION PRODUCT IDENTIFICATION MANUFACTURER S TELEDYNE BATTERY PRODUCTS ADDRESS 840 WEST BROCKTON AVENUE REDLANDS CA 92374 TELEPHONE 909 793 3131 24 HOUR EMERGENCY CONTACT INFOTRAC 1 800 535 5053 PRODUCT NAME BATTERY ELECTRIC STORAGE DRY TRADE NAME TELEDYNE BATTERY GILL AIRCRAFT BATTERY CENTURION BIG BEAM TELSTAR SILTRON AIR TRACTOR AND SCHWEIZER SYNONYMS GE 50 GE 51 GE 54 G 25 G 25M 6 35 G 35M G 88 G 240 G 241 G 242 G 243 G 243W G 244 G 245 G 246 G 246AT G 247 G 638 G 639 G 6381 G 640 G 641 M83769 1 1 M83769 2 1 M83769 3 1 M83769 4 1 M83769 5 1 M83769 6 1 PS 14 13 2HN MS35000 4HN MS5047 6TL MS52149 T 1100 T 1100L T 2200 T 2200L T 6200 T 6200L SUPER TELSTAR 12 TELSTAR 8
25. F THEY ARE REQUIRED TAKE CARE NOT TO MAKE A CONNECTION BETWEEN THE TWO BATTERY TERMINALS AS SEVERE SPARKING MAY OCCUR WHICH COULD RESULT IN AN EXPLOSION RINGS METAL WATCH BANDS NECKLACES AND OTHER JEWELRY SHOULD BE REMOVED WHILE SERVICING BATTERIES SUFFICIENT VENTILATION SHOULD BE PROVIDED IN ALL WORK AREAS TO PREVENT A BUILD UP OF DANGEROUS GASES IF THE BATTERY ROOM IS AIR CONDITIONED AS PART OF AN OVERALL BUILDING SYSTEM THE EXHAUST AIR FROM THE BATTERY ROOM SHOULD NOT BE RETURNED TO THE AIR DISTRIBUTION SYSTEM THE ROOM SHOULD HAVE ITS OWN EXHAUST SYSTEM CONNECTED DIRECTLY TO OUTSIDE AIR HYDROGEN AND OXY GEN GASES ARE PRODUCED DURING NORMAL BATTERY OPERATION ESPECIALLY DURING CHARGING HYDROGEN GAS IS LIGHTER THAN AIR COLORLESS ODORLESS AND TASTELESS THEREFORE IT IS DIFFICULT TO DETECT WITHOUT SPECIAL EQUIPMENT ALWAYS ASSUME THAT SMALL AMOUNTS OF GASES ARE PRESENT AND TAKE ALL NECESSARY PRECAUTIONS SECTION X OTHER WARNINGS PROPOSITION 65 WARNING BATTERY POSTS TERMINALS AND RELATED ACCESSORIES CONTAIN LEAD AND LEAD COMPOUNDS CHEMICALS KNOWN TO THE STATE OF CALIFORNIA TO CAUSE CANCER AND REPRODUCTIVE HARM WASH HANDS AFTER HANDLING SARA TITLE III THE CHEMICALS LISTED BELOW ARE TOXIC CHEMICALS SUBJECT TO THE REPORTING REQUIREMENTS OF SECTION 313 OF TITLE OF THE SUPERFUND AMENDMENTS AND REAUTHORIZATION ACT OF 1986 AND 40 CFR PART 372 MATERIAL OR COMPONENT CAS WEIGHT Lead and lead compounds 7439 92 1 95 Ant
26. L USE OF THE MATERIAL EVEN IF REASONABLE SAFETY PROCEDURES ARE FOLLOWED FURTHERMORE VENDEE ASSUMES THE RISK IN THIS USE OF THE MATERIAL CONTRACT ORDER HAZARD RATING NATIONAL STOCK NO TH 3 SPECIFICATION REFERENCE 0 DATE PREPARED March 2003 2 PERSONAL PROTECTION D SECTION I PRODUCT IDENTIFICATION MANUFACTURER S NAME TELEDYNE BATTERY PRODUCTS ADDRESS 840 WEST BROCKTON AVENUE REDLANDS CA 92374 TELEPHONE 909 793 3131 24 HOUR EMERGENCY CONTACT INFOTRAC 1 800 535 5053 TRADE NAME BATTERY ELECTROLYTE VARIOUS GRADES SYNONYMS SULFURIC ACID FORMULA H2504 DOT DESCRIPTION CONSUMER COMMODITY ORM D INTENDED USE ELECTROLYTE FOR LEAD ACID BATTERIES SECTION Il HAZARDOUS INGREDIENTS MATERIAL OR CAS WEIGHT PEL ACGIH TLV OSHA ACTION COMPONENT 96 LEVEL Sulfuric acid 7664 939 50 1 mg m 1 mg m Not Applicable MSDS 1003 Page 1 of 4 Updated March 2003 Q01 1120 Revision B 6 05 Page 65 of 74 Teledyne Battery Products Gill DRY CHARGE MAINTENANCE MANUAL The Original Equipment Aircraft Battery TELEDYNE BATTERY PRODUCTS MATERIAL SAFETY DATA SHEET BATTERY ELECTROLYTE SECTION Ill PHYSICAL DATA BOILING POINT 203 F 95 C MELTING POINT 760 mmHg SPECIFIC GRAVITY 1 22 to 1 40
27. MAY OCCUR WHICH COULD RESULT IN AN EXPLOSION RINGS METAL WATCH BANDS NECKLACES AND OTHER JEWELRY SHOULD BE REMOVED WHILE SERVICING BATTERIES SUFFICIENT VENTILATION SHOULD BE PROVIDED IN ALL WORK AREAS TO PREVENT A BUILD UP OF DANGEROUS GASES IF THE BATTERY ROOMIS AIR CONDITIONED AS PART OF AN OVERALL BUILDING SYSTEM THE EXHAUST AIR FROM THE BATTERY ROOM SHOULD NOT BE RETURNED TO THE AIR DISTRIBUTION SYSTEM THE ROOM SHOULD HAVE ITS OWN EXHAUST SYSTEM CONNECTED DIRECTLY TO OUTSIDE AIR HYDROGEN AND OXY GEN GASES ARE PRODUCED DURING NORMAL BATTERY OPERATION ESPECIALLY DURING CHARGING HYDROGEN GAS IS LIGHTER THAN AIR COLORLESS ODORLESS AND TASTELESS THEREFORE IT IS DIFFICULT TO DETECT WITHOUT SPECIAL EQUIPMENT ALWAYS ASSUME THAT SMALL AMOUNTS OF GASES ARE PRESENT AND TAKE ALL NECESSARY PRECAUTIONS SECTION X OTHER WARNINGS PROPOSITION 65 SARA TITLE III THE CHEMICALS LISTED BELOW ARE TOXIC CHEMICALS SUBJECT TO THE REPORTING REQUIREMENTS OF SECTION 313 OF TITLE Ill OF THE SUPERFUND AMENDMENTS AND REAUTHORIZATION OF 1986 AND 40 CFR PART 372 MATERIAL OR COMPONENT CAS WEIGHT Sulfuric acid 7664 93 9 lt 50 THIS INFORMATION SHOULD BE INCLUDED IN ALL MSDS THAT ARE COPIED AND DISTRIBUTED FOR THIS MATERIAL UPDATED BY JESUS BUENO LUNA ENVIRONMENTAL HEALTH AND SAFETY COORDINATOR DATE MARCH 2003 MSDS 1003 Page 4 of 4 Updated March 2003 Q01 1120 Revision B 6 05 Page 68 of 74 Teledyne Battery Products Sec
28. NE INCOMPATIBILITY CONTACT OF LEAD WITH STRONG OXIDIZERS MAY LIBERATE HYDROGEN GAS HAZARDOUS DECOMPOSITION PRODUCTS NONE CONDITIONS CONTRIBUTING TO HAZARDOUS POLYMERIZATION WILL NOT OCCUR MSDS 1001 Page 3 of 5 Updated March 2003 Q01 1120 Revision B 6 05 Page 62 of 74 Teledyne Battery Products Gill DRY CHARGE MAINTENANCE MANUAL The Original Equipment Aircraft Battery TELEDYNE BATTERY PRODUCTS MATERIAL SAFETY DATA SHEET DRY CHARGED BATTERY SECTION VII SPILL OR LEAK PROCEDURES STEPS TO BE TAKEN IF MATERIAL IS SPILLED OR RELEASED SHOULD A BATTERY BREAK OPEN ISOLATE THE AREA PICK UP AND CONTAINERIZE ALL BATTERY PARTS AND MATERIALS LIMIT PERSONAL EXPOSURE WITH GLOVES EYE AND FACE PROTECTION WHEN A BATTERY IS BEING FILLED WITH SULFURIC ACID ELECTROLYTE ISOLATE THE AREA SHOULD BATTERY BREAK OPEN ELECTROLYTE SHOULD BE ABSORBED WITH A NON ORGANIC TYPE ABSORBENT SUCH AS DRY SAND OR EARTH AVOID DILUTION WITH WATER LEAD SPILLED FROM THE BATTERY SHOULD BE HEPA VACUUMED OR WET MOPPED DO NOT DRY SWEEP OR USE COMPRESSED AIR WASTE DISPOSAL METHODS BATTERY PARTS MAY BE RECYCLED BY AN EPA PERMITTED SECONDARY LEAD SMELTING FACILITY OR DISPOSED OF AS HAZARDOUS WASTE PURSUANT TO RCRA REQUIREMENTS SECTION VIII SPECIAL PROTECTION INFORMATION HANDLING AND STORAGE EXERCISE CAUTION IN HANDLING AND STORAGE DUE TO WEIGHT OF UNITS OTHER PRECAUTIONS USE CAUTION WHEN FILLING UNITS WITH ELECTROLYTE BATTERY ACID DILUTE S
29. PERTENSION SLIGHT IRRITATION TO SKIN AND EYES METALLIC TASTE IN MOUTH ANEMIA CONSTIPATION HEADACHE MUSCLE AND JOINT PAINS NEUROMUSCULAR DYSFUNCTION POSSIBLE PARALYSIS ENCEPHALOPATHY AND PNEUMOCONIOSIS LEAD EXPOSURE CAN POSE RISK TO DEVELOPING FETUSES AND MAY ALSO IMPAIR THE REPRODUCTIVE SYSTEMS IN BOTH MEN AND WOMEN DAMAGE TO THE KIDNEYS HEMATOPOIETIC AND OR CENTRAL NERVOUS SYSTEM MAY OCCUR CARCINOGENICITY IARC NTP OSHA Lead X X Arsenic X X X EMERGENCY AND FIRST AID PROCEDURES EYES DRY OXIDE WASH IMMEDI ATELY WITH LARGE AMOUNTS OF WATER LIFTING THE LOWER AND UPPER LIDS CONTINUOUSLY GET MEDICAL ATTENTION SKIN NOT A DIRECT ROUT OF ENTRY INHALATION REMOVE EMPLOYEE FROM AREA OF EXPOSURE GET IMMEDIATE MEDICAL ATTENTION INGESTION GET IMMEDIATE MEDICAL ATTENTION SECTION V FIRE AND EXPLOSION DATA FLASH POINT N AFORLEAD 675 FOR POLYPROPYLENE CASE AUTO IGNITION TEMPERATURE FLAMMABLE LIMITS AIR BY VOL EXTINGUISHING MEDIA USE HALON DRY CHEMICAL EXTINGUISHER BATTERY CASE WILL BURN SPECIAL FIRE FIGHTING PROCEDURES USE OF WATER IN EXTINGUISHING BURNING BATTERIES MAY CAUSE SPATTERING DUE TO THE PRESENCE OF MOLTEN LEAD UNUSUAL FIRE AND EXPLOSION HAZARD WHILE BATTERY IS BEING CHARGED HYDROGEN GAS IS PRODUCED BATTERY MAY EXPLODE IF HYDROGEN GAS IS TRAPPED INSIDE THE BATTERY CASE KEEP IGNITION SOURCES AWAY SECTION VI REACTIVITY DATA CONDITIONS CONTRIBUTING TO INSTABILITY NO
30. Since 1920 The Original Equipment Aircraft Battery TELEDYNE BATIERY PRODUCTS DRY GHARGED LEAD AGCGID AIRGRAFT BATTERY SERVIGE MANUAL PROPOSITION 65 WARNING BATTERY POSTS TERMINALS AND RELATED ACCESSORIES CONTAIN LEAD AND LEAD COMPOUNDS CHEMICALS KNO WN TO THE STATE OF CALIFO RNIA TO CAUSE CANCER AND REPRODUCTIVE HARM WASH HANDS AFTER HANDLING Document Number Q01 1120 Revision B 6 30 05 Receipt and use of this technical document by any receiving party is subject to compliance with all decrees statutes rules and regulations of the United States Government and of the Governments of the countries in which Teledyne Battery Products and the receiving party are doing business at the time of receipt by the receiving party in effect or which may be in effect hereafter which govern exports or otherwise pertains to export controls including without limitation the Export Administration Regulations and the International Traffic in Arms Regulations WARNING THE SAFETY INSTRUCTIONS PRECAUTIONS POSTED IN VARIOUS SECTIONS WITHIN THIS MANUAL MUST BE STRICTLY FOLLOWED ALWAYS WEAR SAFETY GLASSES AND ACID RESISTANT GLOVES WHENEVER HANDLING BATTERIES ELECTROLYTE CONTAINS SULFURIC ACID WHICH CAN PERMANENTLY DAMAGE EYES AND CAUSE SEVERE BURNS TO EXPOSED SKIN FOR LIMITATIONS PROCEDURES AND PERFORMANCE INFORMATION NOT CONTAINED IN THIS SUPPLEMENT CONSULT THE BASIC PILOTS OPERATING HANDBOOK AIRPLANE FLIGHT MANUAL THE SPECIFIC S
31. TC OR THE BATTERY CONTINUOUS AIRWORTHINESS INSTRUCTIONS FOR THE APPLICATION THIS SERVICE MANUAL SHOULD NOT BE CONSTRUED AS THE FINAL AUTHORITY IN MAINTAINING YOUR SPECIFIC BATTERY PLEASE CONSULT WITH TELEDYNE TECHNICAL SUPPORT FOR FURTHER INFORMATION The Original Equipment Aircraft Battery Section 1 2 3 4 001 1120 5 REVISION PAGE use o atur nhu 1 SCOPE antes 2 INTRODUCTION 3 DRY CHARGED LEAD ACID BATTERIES _ 4 4 1 4 4 2 Specification Definitions 4 4 3 Temperature Effects 5 Zo lue EXDECLdbY redi 6 PREPARING DRY CHARGED BATTERIES FOR USE 8 5 B5 5 cage xr 8 5 2 Filling or Activation qusc ee taa 8 20 4 Sx aa So nE YE DIEM en 13 6 1 Battery Installation Pre Verification 13 6 2 Battery Ventilation iiec ee 13 6 3 SumpjJar Treatment __ 14 6 4 Ventilation System Requirements 14 SERVICING 15 7 1 Service Requirements 15 7 2 Connector Wiring Inspection 15 7 3 Electrolyte Levels
32. ULFURIC ACID WEAR ACID RESISTANT PLASTIC OR RUBBER GLOVES EYE PROTECTION APRON AND BOOTS MATERIAL SAFETY DATA SHEET FOR LEAD ACID BATTERY APPLIES WHEN FILLED WITH SULFURIC ACID ELECTROLYTE VENTILATION REQUIREMENTS BATTERY CHARGING AREAS MUST BE ADEQUATELY VENTILATED TO PREVENT HAZARDOUS CONCENTRATIONS OF FLAMMABLE GAS OR ACID MIST DESIGN CRITERIA FOR VENTILATION SYSTEMS ARE CONTAINED IN THE INDUSTRIAL VENTILATION MANUAL PUBLISHED BY THE ACGIH SPECIFIC PERSONAL PROTECTIVE EQUIPMENT RESPIRATORY UNDER NORMAL CONDITIONS OF USE RESPIRATORY PROTECTION IS NOT REQUIRED HOWEVER SHOULD CONDITIONS ARISE WHERE RESPIRATORS ARE NEEDED USE ONLY NIOSH MSHA RESPIRATORS APPROVED FOR DUST FUME AND MIST CHEMICAL GOGGLES FULL FACE SHIELD GLOVES APPROVED FOR SULFURIC ACID ACID RESISTANT APRON MSDS 1001 Page 4 of 5 Updated March 2003 Q01 1120 Revision B 6 05 Page 63 of 74 Teledyne Battery Products Gill DRY CHARGE MAINTENANCE MANUAL The Original Equipment Aircraft Battery TELEDYNE BATTERY PRODUCTS MATERIAL SAFETY DATA SHEET DRY CHARGED BATTERY SECTION IX SPECIAL PRECAUTIONS PRECAUTIONARY STATEMENTS SHOULD A BATTERY BREAK OPEN AND A LEAD SPILL OCCURS PRECAUTIONS SHOULD BE TAKEN TO PREVENT LEAD DUST FROM BECOMING AIR BORNE INDIVIDUALS SHOULD WEAR RESPIRATORY PROTECTION PROTECTIVE CLOTHING RUBBER GLOVES AND EYE PROTECTION IF CONDUCTING A LEAD SPILL CLEAN UP AVOID THE USE OF NON INSULATED TOOLS I
33. UNTS OF WATER REMOVE ANY CONTAMINATED CLOTHING AND SHOES THIS CAN BE DONE WHILE UNDER SHOWER GET MEDICAL ATTENTION INHALATION REMOVE EMPLOYEE FROM AREA OF EXPOSURE TO FRESH AIR IF PERSON IS NOT BREATHING AND HAS NO PULSE PERFORM CPR KEEP VICTIM WARM AND AT REST IF BREATHING IS DIFFICULT GIVE OXY GEN GET IMMEDIATE MEDICAL ATTENTION INGESTION GIVE EMPLOYEE LARGE AMOUNTS OF WATER IF CONSCIOUS DO NOT INDUCE VOMITING GET MEDICAL ATTENTION MSDS 1003 Page 2 of 4 Updated March 2003 Q01 1120 Revision B 6 05 Page 66 of 74 Teledyne Battery Products The Original Equipment Aircraft Battery Gill DRY CHARGE MAINTENANCE MANUAL TELEDYNE BATTERY PRODUCTS MATERIAL SAFETY DATA SHEET BATTERY ELECTROLYTE SECTION V FIRE AND EXPLOSION DATA FLASH POINT AUTO IGNITION TEMPERATURE NIA FLAMMABLE LIMITS IN AIR BY VOL N A EXTINGUISHING MEDIA USE DRY CHEMICAL OR CO2 EXTINGUISHER FOR SMALL FIRES WATER FOG FOR LARGE FIRES SPECIAL FIRE FIGHTING PROCEDURES N A SECTION VI REACTIVITY DATA CONDITIONS CONTRIBUTING TO INSTABILITY NONE INCOMPATIBILITY CONTACT OF ELECTROLYTE WITH ORGANIC MATERIAL HAZARDOUS DECOMPOSITION PRODUCTS SULFURIC ACID MIST SULFUR DIOXIDE AND CARBON MONOXIDE MAY BE RELEASED WHEN ELECTROLYTE DECOMPOSES CONDITIONS CONTRIBUTING TO HAZARDOUS POLYMERIZATION WILL NOT OCCUR SECTION VII SPILL OR LEAK PROCEDURES STEPS TO BE TAKEN IF MATERIAL IS SPILLED OR RELEASE
34. Y CHARGE MAINTENANCE MANUAL The Original Equipment Aircraft Battery temperatures Note Table 1 for electrolyte freezing points with varying electrolyte strength sulfuric acid concentration 4 3 3 Charge acceptance at low temperatures less than 30 F is generally low It is preferred to charge batteries at higher temperatures 30 F to 90 F TABLE 1 FREEZING POINT OF ELECTROLYTE Specific Gravity 4 4 LIFE EXPECTANCY 4 4 1 Typical battery failure mode should be complete non reversible utilization of active material A battery that is operated and maintained per manufacturers guidelines should deliver several years of useful service However actual service life varies due to several factors 4 4 2 Charging variations 4 4 2 1 Improper voltage settings e Note recommended voltage settings in Table 2 Make sure that the voltage regulators are correctly adjusted 4 4 2 2 Overcharging e Overcharging could result from leaving a battery on charge too long at voltages higher than recommended This will result in deterioration of the active material and accelerated grid corrosion Q01 1120 Revision B 6 05 Page 6 of 74 Teledyne Battery Products Gill DRY CHARGE MAINTENANCE MANUAL 4 4 2 3 Undercharging e Chronic undercharging will lead to extensive sulfation and underperformance These batteries will be difficult to recharge The Original Equipment Aircraft Battery 4 4 3 High Very Low temperature operations 4
35. ater 5 Wait for electrolyte to cool down to ambient conditions before using Q01 1120 Revision B 6 05 Page 69 of 74 Teledyne Battery Products Section 16 Gill DRY CHARGE MAINTENANCE MANUAL The Original Equipment Aircraft Battery APPENDIX E The Original Equipment Aircraft Battery ACTIVATION AND SERVICE INSTRUCTIONS For Gill Dry Charged Lead Acid Aircraft Batteries CALIFORNIA PROPOSITION 65 WARNING WARNING Battery posts terminals and related accessories contain lead and lead compounds chemicals known to the State of California to cause cancer and reproductive harm Wash hands after handling 1560 Rav A 7 14 03 001 1120 Revision B 6 05 Page 70 of 74 Teledyne Battery Products Gill DRY CHARGE MAINTENANCE MANUAL The Original Equipment Aircraft Battery Activation Instructions For Gill Dry Charged Aircraft ri This aircraft battery is manufactured with dry charged plates Do not remove vent plugs until ready to fill the battery with acid These batteries will be activated filled and charged with electrolyte of 1 285 specific gravity provided by the manufacturer If you do not have the appropriate electrolyte please refer to the Gill website for instructions on preparing the electrolyte PLEASE FOLLOW THE SAFETY REQUIREMENTS AS MENTIONED Inspect the battery for any shipping damage prior to filling Permanently mark the activation date Month and Year on the battery maki
36. ce Data Test 1 Electrolyte pe Mad Temperature peu Eu Volume quarts m o 2 60 min xs a p 20 hr 23 1 9 3 46 G 35 Performance at 24 C Hours to 1 67 at 24 Q01 1120 Revision B 6 05 Page 40 of 74 Teledyne Battery Products Gill DRY CHARGE MAINTENANCE MANUAL et 14 405 The Original Equipment Aircraft Battery d G 88 Performance Data Test Electrolyte Run time ENS DLE Temperature Watts Amps red ERO Volume Per Cell Wh Ib quarts 6 000 1 296 G 88 Performance at 24 10 Hours to 1 67 at 24 Q01 1120 Revision B 6 05 Page 41 of 74 Teledyne Battery Products G 240 The Original Equipment Aircraft Battery G 240 Performance Data Test Electrolyte End Volts Capacity Energy Weight m Per Cal 5 424 302 ERE GE m 1 67 12 8 w 36 067 134 321 6 G 240 Discharge at 24 o o 9 lt o o 5 Hours to 1 67 at 24 Q01 1120 Revision B 6 05 Page 42 of 74 Tele
37. charger timing is adequately controlled this charging regime will not damage the battery Q01 1120 Revision B 6 05 Page 22 of 74 Teledyne Battery Products Gill DRY CHARGE MAINTENANCE MANUAL The Original Equipment Aircraft Battery WARNING Electrolyte contains sulfuric acid which is highly corrosive and can cause severe burns to exposed skin and permanent damage to eyes Avoid spilling or splashing Wear rubber gloves and safety goggles whenever you are handling electrolyte 7 8 7 4 Electrolyte specific gravity should be measured and constant over three consecutive readings see 5 2 5 g or a stable battery voltage battery voltage should be the same as the charger output voltage over three hours could be used Avoid prolonged charging at this voltage 7 8 7 5 It is preferred to use low rates 0 5 5 amps when charging batteries using this technique in order to reduce heat and minimize corrosion Note example under Recharging Deeply Discharged Batteries for general outline on using constant current recharge 7 8 7 6 Review Figure 4 for a basic charging profile of charge current and battery voltage 7 8 8 CONSTANT VOLTAGE CV 7 8 8 1 These chargers are generally designed to provide a constant voltage source with selectable initial current rates Model variants may provide selectable charge voltage Higher output current will reduce recharge time 7 8 8 2 The current in any circuit is directly proportional
38. contamination 7 2 INSPECTION 7 2 1 If the aircraft is equipped with a battery quick disconnect the mechanical integrity of the plug s must be checked for fit on the attaching screw to receptacle bayonet pins The resiliency of the female mating surfaces to the battery receptacle terminals must also be checked 7 2 2 Early discovery of defective connectors as well as battery receptacles is extremely important to prevent failure or possible fire hazard Check for the following a Excessively loose handle and locking assembly b Pitted or corroded mating surfaces Q01 1120 Revision B 6 05 Page 15 of 74 Teledyne Battery Products The Original Equipment Aircraft Battery Gill DRY CHARGE MAINTENANCE MANUAL 7 2 3 c Burn marks caused when battery is disconnected under load d To test for the resiliency of the mating surfaces to an oversized pin insert the larger diameter probe of the tool TBP 3600 51 Rev A GO NOGO Gauge into each helix or sleeve to maximum depth The fit should be snug and require a removal force greater than one pound e To be assured that the contact is adequate for a worn battery pin insert the small diameter end of the tool This must also provide a snug fit with a nominal removal force greater than one pound Replace the connector if it shows excessive wear or fails to meet the fit test f Battery contact pin must be inspected for corrosion pitting or b
39. ded i After the soak time check each cell for electrolyte levels Add electrolyte to the top of the separators DO NOT ADD ANY WATER AT THIS TIME j Connect the charging cables and begin charging using our recommended methods Refer to Initial Charging Rates in Table 4 k After the first hour of charge check the electrolyte level in each cell Make sure that the level is just to the bottom of the split ring USE ELECTROLYTE ONLY Replace vent caps finger tight to ensure electrolyte does not leak Q01 1120 Revision B 6 05 Page 9 of 74 Teledyne Battery Products Gill DRY CHARGE MAINTENANCE MANUAL m Make sure that battery temperature does not exceed 115 F Reduce the charge rate or use external cooling if it does The Original Equipment Aircraft Battery n Completion of charge is indicated by a stable specific gravity reading of 1 275 to 1 295 temperature compensated as described in Appendix B taken in three readings over three hours as described in paragraph 5 2 5 Initial Charging Instructions Use recommended hydrometer A stable on charge voltage reading may also be used The battery should typically be charged in about 8 12 hours using a constant current charger At the end of charge all cells should be gassing bubbling uniformly After the battery is fully charged adjust the level of the electrolyte to the bottom of the split ring bottom of vent well with the charger still on
40. department for additional instructions or review the discharge curves for the appropriate battery in Appendix A e The battery is considered airworthy if it meets 8096 of the 30 minute emergency capacity rating 24 minutes to the cut off voltage f If the battery fails to meet the minimum run time recharge using the constant current method until the specific gravity reading stabilizes over three consecutive readings Allow the battery to stand on open circuit for one hour WARNING Electrolyte contains sulfuric acid which is highly corrosive and can cause severe burns to exposed skin and permanent damage to eyes Avoid spilling or splashing Wear rubber gloves and safety goggles whenever you are handling electrolyte Q01 1120 Revision B 6 05 Page 20 of 74 Teledyne Battery Products Gill DRY CHARGE MAINTENANCE MANUAL g Repeat the discharge test as indicated If the failure persists replace the battery The Original Equipment Aircraft Battery h If the battery is found to be airworthy it must be recharged prior to re installing it in the aircraft 7 7 2 airworthiness limitations section noted 7 7 1 is FAA approved and specifies maintenance required under Sections 43 16 and 91 403 of the Federal Aviations Regulations unless an alternative program has been FAA approved 7 7 3 Proper installation charging and other maintenance records must be kept in case they are required for warranty adjustments
41. des two good chargers for 24V products Our TDMC 90 and the TSC 01V will provide the best charging capabilities Please review our web site for detailed specifications or call Gill Technical support for additional information Q How do process my warranty A Teledyne provides a Warranty Card with each battery it sells The customer should call the Warranty Helpline at 800 456 0070 ext 7 or 8 and discuss any warranty issues After obtaining a warranty authorization number the customer should send the completed form to any authorized Gill dealer for processing Q01 1120 Revision B 6 05 Page 32 of 74 Teledyne Battery Products The Original Equipment Aircraft Battery Section 10 Gill DRY CHARGE MAINTENANCE MANUAL Active material AGM Ah Corrosion CFR Electrolyte Electrolysis IATA ICAO IEC Ipp Nonspillable OCV Passivation Recombination Sponge lead State of Charge GLOSSARY The formed charged material on the positive and negative electrodes plates Absorptive Glass Mat a non woven fiberglass separator that holds the electrolyte Ampere hour the standard designation of capacity units for batteries Refers to oxidation generally excessive of the positive plate Code of Federal Regulations The liquid added to a battery that is capable of conducting ions between the two electrodes Decomposition of an electrolyte by the action of an electric current flowing through the electrodes positive
42. dyne Battery Products G 241 Gill DRY CHARGE MAINTENANCE MANUAL The Original Equipment Aircraft Battery c 241 Performance Data End Volts Test Capacity Energy Weight Electrolyte Per Cell Lepus Ah Wh Ib Volume quarts 24 3 G 241 Discharge at 24 Amperes 10 Hours to 1 67 VPC at 24 Q01 1120 Revision B 6 05 Page 43 of 74 Teledyne Battery Products G 242 The Original Equipment Aircraft Battery G 242 Performance Data Test Electrolyte End Volts Capacity Energy Weight E Ferca mtem CN yume 60 sec t 3600 3 6 40 17 T es 204 492 os 16 34 G 242 Performance at 24 C Hours to 1 67 at 24 Q01 1120 Revision B 6 05 Page 44 of 74 Teledyne Battery Products G 243 Gill DRY CHARGE MAINTENANCE MANUAL The Original Equipment Aircraft Battery G 243 Performance Data Test Electrolyte Temperature Volume C quarts End Volts Per Cell G 243 Performance at 24 C 10 Hours to 1 67 VPC at 24 C
43. e battery around 75 F to 110 F If it gets hotter reduce the charging rates and increase the charge time proportionally Note The charge time can be adjusted proportionally to compensate for chargers that may not be capable of delivering the recommended rate f It will take 8 to 12 hours to fully charge the battery using a constant current charger g The best indicator of full charge is a stable specific gravity reading Using the recommended hydrometer take three readings at approximately equal time intervals over three hours When fully charged the specific gravity should be greater than 1 275 Make sure that the readings are temperature compensated as described in Appendix B Appendix B has appropriate measurement techniques using a hydrometer Please call Teledyne Battery Products if there are any further questions h If itis not possible to measure specific gravity battery voltage may be used as an indicator ON CHARGE battery voltages will stabilize around 32 volts when charging at constant current for 24 volt batteries or 16 volts for 12 volt batteries i Atthe end of charge all cells will be gassing freely and the battery voltage will stabilize and start to drop slightly WARNING Electrolyte contains sulfuric acid which is highly corrosive and can cause severe burns to exposed skin and permanent damage to eyes Avoid spilling or splashing Wear rubber gloves and safety goggles whenever you are handling electrolyte or exam
44. e continued airworthiness the battery should be removed and capacity tested The recommended service period should initially be at 800 50 hours or 11 1 calendar month s whichever comes first After the initial service the Q01 1120 Revision B 6 05 Page 19 of 74 Teledyne Battery Products Gill DRY CHARGE MAINTENANCE MANUAL next check should be at 400 25 flight hours or 6 1 calendar month s whichever comes first The capacity test shall be performed as follows The Original Equipment Aircraft Battery a Check for proper battery installation per STC Installation Instructions when performing annual and 100 hour inspections and when replacing battery after capacity test b Remove the battery from the aircraft and charge it according to Teledyne Battery Products recommended charging instructions Allow the battery to stand on open circuit for one hour C Connect the fully charged battery to a capacity tester that incorporates a load resistance amp meter volt meter and a timer d Discharge the battery at the 30 minute capacity rate to 1 67 volts per cell 10 volts for a 12 volt battery and 20 volts for a 24 volt battery Record the discharge time Note There may be occasions when it will not be possible to conduct the discharge according to the rates required Teledyne Battery Products can provide the appropriate discharge curve for such occasions and suggest alternative rates Please call the Technical Service
45. echarge battery before process placing in service Quick disconnect worn beyond Check Cannon or Elcon type connectors tolerance for good contact see 7 2 with WOSHE MMM Teledyne Go NoGo gauge part number 3600 51 Battery could be shorting under The battery could be investigated as load follows 0 00 9 lt 008 i After a full charge verified by specific Q01 1120 Revision B 6 05 Page 34 of 74 Teledyne Battery Products The Original Equipment Aircraft Battery PROBLEM CAUSE RECOMMENDATIONS Will not hold charge gravities over 1 280 subject the cont d battery to the emergency rate of discharge Replace battery if it fails to support the load for at least 24 minutes ii Subject the battery to a short duration 30 90 seconds of a high rate of discharge over 150Amps measure battery voltage If the voltage drops below 9V 12V battery or 18V 24V battery replace battery Battery could be self Fully charge battery clean the top and discharging due to low state of place the battery in service If this charge Sulfation can build up repeats remove the battery from based on repeated undercharge service and monitor the drop in voltage situations over a week If it exceeds the rate shown in Figure 3 replace the battery NOTE If the electrolyte is contaminated with metals such as iron the battery will not hold a charge Please ensure electrolyte is kept clean at all times Excessive sulfa
46. ells Fill and adjust levels only with electrolyte Water is only added after the battery has been in service for some time and has lost water due to evaporation If you do not have enough electrolyte contact Teledyne Customer Service Q filled the battery with electrolyte and have been charging the battery on trickle charge for three days The specific gravities are around 1 245 and battery voltage is 14V Why is the gravity so low A This is a two part question The first concern is with the charger Trickle chargers are constant voltage chargers and will not charge the battery properly Teledyne recommends constant current charge when the battery is being charged for the first time Please note our description of constant current charging described in 7 8 7 Charging MUST be accomplished as Teledyne has recommended Do not use trickle chargers or constant voltage charging as these methods are not satisfactory for initial charge The other concern is how battery voltage is being measured Battery voltage must always measured two to three hours after charging has been stopped In this case a measure of 14V indicates that the user was determining battery voltage directly after charging was turned off Q01 1120 Revision B 6 05 Page 31 of 74 Teledyne Battery Products Gill DRY CHARGE MAINTENANCE MANUAL The Original Equipment Aircraft Battery Q Where can buy a good charger for 12V and 24V products A Teledyne Gill provi
47. ent caps Use the battery lifting strap or with hands placed at opposite corners Electrolyte can be stored indefinitely BEFORE opening and using the electrolyte shake the container gently EMERGENCY PROCEDURE FOR EXPOSURE TO ELECTROLYTE If electrolyte is splashed on the body wash it off immediately using large amounts of cool tap water or if it spilled out neutralize it with sodium bicarbonate solution followed by a clean water rinse Electrolyte splashed into eyes is extremely hazardous If this should happen force the eye open and flush it with cool clean water for about five minutes or longer if irritation persists A doctor should be called immediately and appropriate medical care should be applied Do not add any eye drops or other medication unless told to do so by the doctor If electrolyte is taken internally drink large quantities of water or milk followed with milk of magnesia beaten egg whites or vegetable oil See a doctor immediately Q01 1120 Revision B 6 05 Page 25 of 74 Teledyne Battery Products The Original Equipment Aircraft Battery Gill DRY CHARGE MAINTENANCE MANUAL 7 10 2 Maintain a safe charging area Always follow these safety precautions when handling batteries WARNING ALWAYS WEAR EYE PROTECTION WHEN WORKING WITH BATTERIES ELECTROLYTE CAN DAMAGE EYES PERMANENTLY a b Batteries You must be well aware of applicable OSHA guidelines for safety precautions note MSDS i
48. eries that have been discharged to the point where their cranking power has been diminished must NOT be jumped with another power source The discharged battery may not be airworthy because it does not have the necessary capacity required to operate the aircraft avionics and electrical system in the event of generator failure Q01 1120 Revision B 6 05 Page 27 of 74 Teledyne Battery Products Section 8 Gill DRY CHARGE MAINTENANCE MANUAL The Original Equipment Aircraft Battery RECYCLING BATTERIES 8 1 MATERIAL SAFETY DATA SHEETS 8 1 1 These have been included in Appendix C They be downloaded as needed from the Gill website www gillbatteries com 8 2 RECYCLER LOCATIONS 8 2 1 All parts of spent lead acid batteries are recyclable Generally batteries are collected by retailers and wholesalers who send large quantities to battery recyclers for reclamation Battery recyclers are permitted hazardous waste treatment recycling facilities If you have just a few batteries you should contact your local battery retailers or wholesalers 8 2 2 The following is a listing of recyclers in California GNB Inc Resource Recycling Division 2700 South Indiana Street Los Angeles CA 90023 213 262 1101 RSR Quemetco Inc 720 South 7th Avenue City of Industry CA 91745 800 527 9452 8 2 3 The California Department of Toxic Substances Control publishes an annual listing of commercial hazardous waste recyclers
49. ge to eyes Avoid spilling or splashing Wear rubber gloves and safety goggles whenever you are handling electrolyte or examining batteries during charging 7 3 3 Adjust electrolyte level just below the vent well at the end of the charge with the use of a hydrometer Remember the electrolyte will heat up and expand as the battery is being charged 7 3 4 Check the battery electrolyte level and the sump jar on a routine basis every 100 flight hours Do not allow the cells to run dry or be too full of electrolyte 7 3 5 Formation of whitish green deposits around terminals indicates a leakage of electrolyte Make sure that all vent caps are tight clean the deposits with a wire brush and carefully neutralize the terminals with a 5 solution of sodium bicarbonate in water WARNING Electrolyte contains sulfuric acid which is highly corrosive and can cause severe burns to exposed skin and permanent damage to eyes Avoid spilling or splashing Wear rubber gloves and safety goggles whenever you are handling electrolyte 7 3 6 The surface of the battery should be wiped clean and kept this way A film of electrolyte over the top of the battery may bridge across the terminals causing the battery to discharge 7 3 7 If the electrolyte is heavily discolored brown or black it represents an aged battery or one that has been subjected to severe vibration or overcharge Replace the battery 7 4 SUMP JAR MAINTENANCE 7 4 1 Inspect the elect
50. he aircraft industry In the 1960 s Gill Electric was sold to Teledyne acquiring the new name of Teledyne Battery Products Gill has introduced most of the innovations in the industry including 24 volt batteries for light aircraft and low impedance high power batteries for the turbine fleet Meeting the stringent weight requirements it was a Gill battery that powered the Voyager s electrical systems and avionics on its record breaking non stop around the world flight Given our demonstrated ability of building batteries that have predictable characteristics to narrow specifications we are chosen as original equipment by most airframe manufacturers and are the popular choice for replacement Many design innovations contribute to the value of a Gill aircraft battery such as Through the partition intercell welding e Enveloped plates e Improved case cover seal e Heavy duty internal post e Redesigned cell construction to provide better power delivery and charge acceptance Whether cranking a piston engine spooling a demanding jet turbine or high output applications in business jets turboprops and helicopters Teledyne Battery Products has the right power source for the job Teledyne Battery Products is committed to utilizing developing synergies within the Teledyne group of companies to continue providing unsurpassed product integration enabling customers ease of use and reliability Q01 1120 Revision B 6 05 Page 3 of
51. imony 7440 36 0 1 1 Arsenic 7440 38 2 0 1 THIS LEAD ACID BATTERY IS CLASSIFIED AS A MANUFACTURED ARTICLE 40 CFR 372 3 AND THE HAZARDOUS MATERIALS LEAD ARSENIC AND NICKEL COMPOUNDS CONTAINED WITHIN ARE NOT RELEASED UNDER NORMAL CONDITIONS OF USE SINCE THESE CHEMICALS ARE NOT RELEASED DURING NORMAL USE THEY ARE EXEMPT FROM THE REPORTING REQUIREMENTS CONTAINED IN 40 CFR PART 372 SUBPART B HOWEVER SULFURIC ACID MAY BE RELEASED INTO THE ENVIRONMENT IF A BATTERY BREAKS AND THEREFORE MAY NOT BE EXEMPT FROM THE REPORTING REQUIREMENTS OF SARA TITLE Ill SEE EXEMPTIONS 40 CFR 372 38 b THIS INFORMATION SHOULD BE INCLUDED IN ALL MSDS S THAT ARE COPIED AND DISTRIBUTED FOR THIS MATERIAL UPDATED BY JESUS BUENO LUNA ENVIRONMENTAL HEALTH AND SAFETY COORDINATOR DATE MARCH 2003 MSDS 1001 Page 5 of 5 Updated March 2003 Q01 1120 Revision B 6 05 Page 64 of 74 Teledyne Battery Products The Original Equipment Aircraft Battery Gill DRY CHARGE MAINTENANCE MANUAL TELEDYNE BATTERY PRODUCTS MATERIAL SAFETY DATA SHEET BATTERY ELECTROLYTE TELEDYNE BATTERY PRODUCTS MATERIAL SAFETY DATA SHEET BATTERY FLUID ELECTROLYTE THE INFORMATION CONTAINED HEREIN IS BASED ON DATA CONSIDERED ACCURATE HOWEVER NO WARRANTY IS EXPRESSED OR IMPLIED REGARDING THE ACCURACY OF THESE DATA OR THE RESULTS TO BE OBTAINED FROM THE USE THEREOF VENDOR ASSUMES NO RESPONSIBILITY FOR INJURY TO VENDEE OR THIRD PERSON PROXIMATELY CAUSED BY ABNORMA
52. ining batteries during charging Q01 1120 Revision B 6 05 Page 11 of 74 Teledyne Battery Products Gill DRY CHARGE MAINTENANCE MANUAL The Original Equipment Aircraft Battery j Once the battery has been charged and all cables disconnected clean residual electrolyte on the battery as follows Make sure the vent caps are on tight otherwise the solution of baking soda will enter the cells and partly neutralize the electrolyte then clean the battery with water and baking soda Wipe dry before installation TABLE 4 INITIAL CHARGE RATES Initial Gill Part Former Part Charme Final Charge Number Number A Current A Current A SIIYL J G 35M G 240 G 241 G 242 G 243 G 244 G 245 G 246 G 247 50 50 GE 51E GE 54C 51 G 638E G 6381E G 639E G 640E G 641 E 2 les gt 2 z un z G 25 3 1 5 S esm E uec JD wj G9 EN CENE NE NS G 24 EE GER G 242 G 243 G 244 G 245 6 246 G 247 GE SOE GE sOC GE S1E GE s4C NEN _ EN GE S C G 638E G 6381E G 639E L 30 30 9 3 G G40E csa lc 3 1 0 009 lt 008 001 1120 6 05 12 74 Teledyne Battery Products Section 6 Gill DRY CHARGE MAINTENANCE MANUAL The Original Equipment Aircraft Ba
53. l gravity reading will be taken at the base of the meniscus Q01 1120 Revision B 6 05 Page 58 of 74 Teledyne Battery Products Gill DRY CHARGE MAINTENANCE MANUAL The Original Equipment Aircraft Battery Verify the resolution value per increment on the bulb of the hydrometer on the hydrometer scale and use appropriate temperature correction as indicated on the scale Figure 5 FIGURE 5 TEMPERATURE CORRECTION SCALE TEMPERATURE CORRECTION USING A HYDROMETER CALIBRATED FOR ZERO CORRECTION AT 80 F 60 F 70 F 8 4 SUBTRACT FROM READING Temperature Correction When using an 80 80 hydrometer use the correction values indicated in Figure 5 As the electrolyte cools down the measured specific gravity will increase and vice versa when the electrolyte warms up The true specific gravity is subsequently determined by applying the appropriate correction for temperature This correction is calculated as follows If the measured hydrometer reading or specific gravity is 1 275 and the temperature of the electrolyte is 60 F then you would subtract 8 points to obtain the actual specific gravity 1 275 0 008 1 267 Similarly if the temperature were 1109F then you would add 12 points 1 275 0 012 1 287 001 1120 6 05 59 74 Teledyne Battery Products Section 14 Gill DRY CHARGE MAINTENANCE MANUAL The Original Equipment Aircraft Battery APPENDIX C T
54. n Appendix C Keep sparks flames burning cigarettes or other ignition sources away at all times WARNING generate explosive gases and must be handled with care C d e 9 h j k Always use insulated tools Leave vent caps on while charging removing them only when verifying electrolyte levels or checking for gassing This will prevent cells from bridging temporary shorting out between the cells because electrolyte could well out of the cells if left open Follow charger manufacturer s instructions Do not allow any untrained personnel to work on batteries Do not break live circuits at the terminals of a battery because sparks will occur at the terminals Make certain the charger cables are clean and not frayed A poor connection can cause localized heating leading to terminal damage melting or possible arcing Make sure the room is well ventilated and isolated from the main air conditioning system Gases from batteries are explosive and corrosive due to entrained sulfuric acid in the gases and must not be allowed to blend in with the main system ALWAYS TURN THE CHARGER OFF BEFORE DISCONNECTING THE BATTERY Do not touch charger leads while the battery is on charge Q01 1120 Revision B 6 05 Page 26 of 74 Teledyne Battery Products Gill DRY CHARGE MAINTENANCE MANUAL The Original Equipment Aircraft Battery 7 11 JUMP STARTING AN ENGINE 7 11 1 Teledyne Gill batt
55. ng sure that the battery is not damaged while doing so Remove storage seals Make sure have enough electrolyte refer to Table 1 ELECTROLYTE 1 286 SPECIFIC GRAVITY VOLUME Former Part MS18045 42 MS18045 41 AN3ISI 3154 2512 512 24 9 BB640 T E PS12 24P11 2 8 1550 Rev 7 14 03 Q01 1120 Revision B 6 05 Page 71 of 74 Teledyne Battery Products Gill DRY CHARGE MAINTENANCE MANUAL The Original Equipment Aircraft Battery WARNING Electrolyte contains sulfuric acid which is highly corrosive and can cause severe burns to exposed skin and permanent damage to eyes Avoid spilling or splashing Wear rubber gloves and safety goggles whenever you are handling electrolyte Gently shake the electrolyte bottles before removing the cap to ensure electrolyte thoroughly mixed Carefully add electrolyte through a plastic funnel to prevent spillage filling each call to the top of the separators CAUTION When adding electrolyte to dry charged batteries ensure cleanliness at all times Electrolyte contains about 40 sulfuric acid and is very corrosive Metal or organic impurities in electrolyte will definitely impair performance Avoid contaminating the electrolyte Any plastic container except nylon may be used to contain the electrolyte Install the vent caps with a quarter turn and let the battery sit for approximately 30 minutes soak time
56. ntilation System 4 SODIUM BICARBONATE 001 1120 6 05 14 74 Teledyne Battery Products Section 7 Gill DRY CHARGE MAINTENANCE MANUAL SERVICING The Original Equipment Aircraft Battery 7 1 SERVICE REQUIREMENTS 7 1 1 Proper maintenance is essential if the battery is to achieve maximum life and performance To assure these goals periodic inspection in the aircraft is necessary Please review Activation and Service Instructions for Gill Dry Charged Lead Acid Aircraft Batteries TBP 1560 latest revision 7 1 2 The battery must be inspected and serviced at 800 50 flight hours or 11 1 calendar months after initial installation whichever occurs first Thereafter the battery must be inspected and serviced once every 400 25 flight hours or 6 1 calendar months whichever occurs first unless the hours per flight are significantly reduced less than one hour such that the battery cannot be adequately charged on board 7 1 3 For continuing limited less than one hour flying the battery should be removed from the aircraft at least once a month for top off charging The Constant Voltage charging method described in the Activation and Service Instructions must be used 7 1 4 The use of separate lead acid and nickel cadmium battery storage facilities are recommended to prevent electrolyte
57. order to reduce fire hazard and to eliminate corrosion of metal parts due to acid WOSHE M AA A 6 2 BATTERY VENTILATION Some Teledyne Gill batteries are designed with cover manifold vents single or double so air can flow over the top of the battery and through a sump jar where the fumes are neutralized by a sodium bicarbonate solution or dry sodium bicarbonate 0 009 lt 008 001 1120 6 05 Page 13 of 74 Teledyne Battery Products Gill DRY CHARGE MAINTENANCE MANUAL The Original Equipment Aircraft Battery 6 3 6 4 SUMP JAR TREATMENT The sump jar has a capacity of approximately one pint and is available through your Teledyne Gill battery distributor The jar should contain thick pad saturated with a 596 solution of sodium bicarbonate in water or about 3 of dry sodium bicarbonate The tube carrying fumes to the sump extends into the jar about 1 from the lid See Figure 2 for basic ventilation outline VENTILATION SYSTEM REQUIREMENTS An overboard discharge tube leads from the top of the jar to a point outside the aircraft The tube is designed so there is air flow from the inlet venting out of the plane with negative pressure at inlet whenever the aircraft is in flight This helps to ensure a continuous flow of air across the top of the battery through the sump and outside the aircraft See FAA 43 13 1B Chapter 11 Section 2 Battery Ventilating Systems FIGURE 2 Battery Ve
58. orrecting charge voltages Excessive undercharging very short flights should be compensated by periodic charging of battery Electrolyte level must be kept at the required levels Use clean water preferably distilled only Remove battery and inspect If no visual damage is noted charge and perform capacity check Replace battery if case is damaged Replace battery Frozen battery due to Addition of water in cold weather without charging the battery Low specific gravity caused by improper filling storing battery in an undercharged condition Electrolyte runs out of vent Battery is overfilled plugs Or Battery consumes Remove excess electrolyte to specified levels Ensure specific gravity is correct excessive water Q01 1120 Revision B 6 05 Page 36 of 74 Teledyne Battery Products Electrolyte runs out of vent plugs Or Battery consumes excessive water cont d Battery voltage is at 0 and will not accept charge Electrolyte in battery freezes Battery is chronically Check voltage regulator settings and overcharged adjust as required Shorted or grounded cable Repair short or ground in electrical causing direct full discharge of system and replace battery battery and irreparable damage Battery left in a discharged Replace battery state Electrolyte specific gravity too low Polarity reversed BEEN Replace battery NEW BATTERY is under capacity or uses excessive water during first 25 h
59. ours of use Remove battery from aircraft and charge completely If possible provide a few cycles to the battery Battery inadvertently charged in reverse Battery may not have received a full initial charge or full complement of electrolyte Q01 1120 Revision B 6 05 Page 37 of 74 Teledyne Battery Products Section 12 Gill DRY CHARGE MAINTENANCE MANUAL The Original Equipment Aircraft Battery APPENDIX A Battery Specifications and Performance Curves 1 G 25 2 G 35 3 G 88 4 G 240 5 G 241 6 G 242 7 G 243 8 G 244 9 G 245 10 G 246 11 G 247 12 G 6381E C 13 G 639E C 14 G 638E C 15 G 640E C 16 G 641 17 GE 50E C 18 GE 51E C 19 GE 54E C Q01 1120 Revision B 6 05 Page 38 of 74 Teledyne Battery Products 6 25 Gill DRY CHARGE MAINTENANCE MANUAL The Original Equipment Aircraft Battery G 25 Performance Data S Per Cell Ah _ Ib Bate NETT RENE EN NET NN EIE ES 1 67 26 38 15 30 50 G 25 Performance at 24 C Hours to 1 67 at 24 Q01 1120 Revision B 6 05 Page 39 of 74 Teledyne Battery Products Gill DRY CHARGE MAINTENANCE MANUAL The Original Equipment Aircraft Battery G 35 Performan
60. r thal incorporates a load resistance amp meter volt meter and a timer Discharge the battery at the 30 minute capacity rate to 1 75 volts per cell 10 volts for a 12 volt battery and 20 volts for a 24 volt battery Note the discharge time The battery is considered airworthy if it meets 8096 of the 30 minute emergency capacity rating 24 minutes to the cut off voltage Ifthe battery fails to meet the minimum run time recharge using the constant current method until the specific gravity reading stabilizes over three consecutive readings Allow the battery to stand on open circuit for one hour 7 Repeat the discharge test as indicaled If the failure persists replace the battery 8 Ifthe battery is found to be airworthy it must be recharged prior to re installing it in the aircraft The airworthiness limitations section is FAA approved and specifies maintenance required under Sections 43 16 and 91 403 of the Federal Aviations Regulations unless an alternative program has been FAA approved PLEASE CALL TECH SUPPORT AT TELEDYNE BATTERY PRODUCTS IF THERE ARE ANY CONCERNS OR QUESTIONS REGARDING THESE INSTRUCTIONS TELEDYNE BATTERY PRODUCTS 840 WEST BROCKTON AVENUE REDLANDS CA 92374 800 456 0070 www gillbatteries com 1550 Rev 7 14 03 Q01 1120 Revision B 6 05 Page 74 of 74 Teledyne Battery Products
61. rolyte levels and the sump jar at the specified battery maintenance intervals noted in 7 3 4 Q01 1120 Revision B 6 05 Page 17 of 74 Teledyne Battery Products Gill DRY CHARGE MAINTENANCE MANUAL The Original Equipment Aircraft Battery 7 4 2 If there is any flow of electrolyte the sump jar clean as follows a Wear goggles and rubber gloves b Slowly add sodium bicarbonate to the residual acid the sump jar until the reaction subsides shake jar side to side slowly c Wash jar and pad thoroughly 7 4 3 Once the jar has been cleaned recharge it with fresh sodium bicarbonate as follows a about 3 of dry sodium bicarbonate in the jar b Saturate a new pad with 5 solution of sodium bicarbonate and place pad over the sodium bicarbonate in the jar C Install jar to lid hand tighten be sure gasket is in place 7 5 MANAGING PERIODS OF NON USE 7 5 1 Periodically users will find that they have to curtail flying for any number of reasons During these times the batteries have to be correctly maintained for continued service 7 5 2 Teledyne Battery Products recommends that the battery be removed from the plane during such non use and either kept on trickle charge 13 5V to 13 8V for 12V batteries or 27V to 27 6V for 24V batteries recharged every 90 days or recharged prior to flight The recharge should be in accordance with Teledyne Battery Products Activation and Service Instructions TBP
62. tion 15 Gill DRY CHARGE MAINTENANCE MANUAL The Original Equipment Aircraft Battery APPENDIX D Mixing Electrolyte Sulfuric acid is a very strong mineral acid Safety precautions must be adhered to at ALL times Please do not deviate from these methods Raw Materials Concentrated sulfuric acid Specific Gravity 1 835 or 1 400 Clean water prefer distilled or de ionized Tools Equipment Plastic non nylon mixing tub tank with pour spout Stirring material plastic ladles Hydrometer to read 1 100 to 1 300 s g units Thermometer Wrap around safety goggles Acid resistant gloves Plastic NOT NYLON or Glass container for diluted electrolyte Procedure WARNING NEVER ADD WATER TO CONCENTRATED SULFURIC ACID ALWAYS ADD SULFURIC ACID TO WATER SINCE THIS ELIMINATES LOCALIZED REACTIONS BETWEEN THE ACID AND WATER SULFURIC ACID REACTS VERY VIGOROUSLY WITH WATER AND WILL GENERATE CONSIDERABLE HEAT 2 Slowly add one part by volume say one quart to 2 7 parts or 2 7 quarts of clean de ionized or distilled water Stir continuously with a plastic or glass stirrer One can mix any amount of electrolyte by varying the initial amounts of acid and water in the same ratio 1 part acid to 2 7 parts water 3 If you do not have concentrated sulfuric acid lower gravities of electrolyte such as 1 400 5 9 may also be used 4 For 1 400 s g electrolyte the mix ratio will be 1 part acid to 0 46 parts of w
63. tion build up Charge the battery at a constant current caused by leaving the battery in rate of 1 amp for a time equal to 1 5 a discharged state for an times the one hour capacity e g if the extended period of time battery is a 10Ah battery charge at 1A for 1 5 x 102 15 hours Occasionally one may need to cycle the battery a couple of times provide a discharge to the specified end voltage followed by a charge as identified above At the end of re conditioning specific gravity of the electrolyte must be at 1 275 or better for all cells Possible excessive use of starter Remove and recharge the battery and other electrical equipment reduce equipment load or use an approved higher capacity battery Battery life too short Application Ensure that battery selection is correct Q01 1120 Revision B 6 05 Page 35 of 74 Teledyne Battery Products Battery life too short cont d Charging variations such as overcharging or chronic undercharging brought about by short flights Using the battery with low electrolyte levels Hold down loose or too tight for the application Infrequent flying will lead to gradual discharge of battery especially if the breaks between flying are over three weeks Please review directions under Managing Periods of Non Use under SERVICE Ensure battery is not subjected to excessive vibration or high temperatures in service Overcharging could be eliminated by inspecting and c
64. to voltage gradient in that circuit Ohm s Law Using CV charging will result in a high initial charging current which will start dropping off when the voltage gradient between the charger and battery begins to decrease 7 8 8 3 Typically the charger will regulate to 28 4 volts 24 volt batteries or 14 2 volts 12 volt batteries As the battery approaches the charger output voltage charge current will drop below 1 ampere Please call Gill Technical Support for any additional concerns with charging see Fig 4 for typical charge profile Q01 1120 Revision B 6 05 Page 23 of 74 Teledyne Battery Products Gill DRY CHARGE MAINTENANCE MANUAL FIGURE 4 The Original Equipment Aircraft Battery V I Plot Standard Charging for a FULLY DISCHARGED BATTERY TO 1 75Volts per Cell OR 21V Constant Voltage Charging at 28 25V Charge pro i 15 Battery Voltage Charge Rate Voltage Current Constant Voltage Plateau 28 25V k Discharge 4 NOTE HOW THE CHARGE RATE DROPS OFF ONCE THE SET VOLTAGE IS REACHED IN CONSTANT CURRENT MODE THIS VOLTAGE WOULD BE AS HIGH AS 33V Time 7 9 RECHARGING DEEPLY DISCHARGED BATTERIES 7 9 1 Deep discharge is usually indicated by a battery voltage of less than 10 volts 12 volt battery or 20 volts 24 volt battery There is a possibility of recovering these batteries using constant current charging techniq
65. ts m EM AI NER m 28 2 90 G 639E C Performance at 24 C Hours to 1 67 at 24 Q01 1120 Revision B 6 05 Page 51 of 74 Teledyne Battery Products G 638E C Gill DRY CHARGE MAINTENANCE MANUAL The Original Equipment Aircraft Battery End Volts Test Capacity Energy Weight Electrolyte Per Cell Vera Ah Wh Ib Volume quarts 1 440 ff 1 67 24 888 G 638E C Performance at 24 10 Hours to 1 67 at 24 Q01 1120 Revision B 6 05 Page 52 of 74 Teledyne Battery Products Gill DRY CHARGE MAINTENANCE MANUAL G 640E C Q01 1120 End Volts Per Cell G 640E C Performance at 24 Test Electrolyte Temperature Volume C quarts 10 Hours to 1 67 at 24 Revision B 6 05 Page 53 of 74 Teledyne Battery Products G 641 The Original Equipment Aircraft Battery gt 1 L r m 700 Y M mM _ G 641 Performance Data End Volts Test Capacity Energy Weight Electrolyte Per Cell
66. ttery INSTALLATION WARNING When installing or removing a battery take special care to ensure that no sparks are created by tools and that the terminals are not shorted out by tools or loose jewelry ALWAYS REMOVE THE GROUND CABLE FIRST AND INSTALL IT LAST IF POSSIBLE ATTACH THE GROUND CABLE TO THE FRAME OF THE BATTERY COMPARTMENT Do not lift the battery by their vent tubes receptacles or terminals sar1ojjeg 3Jeo1ry 6 1 BATTERY INSTALLATION PRE VERIFICATION If the original equipment battery is of another type or manufacture the Teledyne Gill replacement should be accomplished with the proper FAA Approved Supplemental Type Certificated installation kit TAL WARNING The battery compartment must be coated with an acid resistant material to prevent corrosion due to accidental spills of electrolyte If possible the spilled electrolyte must be drained away from or contained such that it does not come into contact with the aircraft systems or structure WARNING BATTERIES MUST NOT BE LOCATED IN ENGINE COMPARTMENTS UNLESS ADEQUATE 2 gt un MEASURES ARE TAKEN TO GUARD AGAINST POSSIBLE FIRE HAZARDS DELETERIOUS EFFECTS OF HIGH TEMPERATURE ON BATTERIES AND PROVISION FOR ADEQUATE VENTILATION AROUND THE BATTERY WARNING Aircraft must be equipped with a leak proof battery ventilation system The system provides for the removal of gases and acid fumes from the airplane in
67. ues provided they have not been in the deep discharge state for more than 15 days at temperatures around 309F to 809F in which case the batteries should be replaced 7 9 2 The battery must be charged at a rate of 1 0A for a total input in ampere hours up to 200 of the one hour capacity which is determined as follows e g for a one hour capacity of 20 Ah the time is determined to be 2 x 20 Ah 40 Ah Ampere hours needed At the charge rate of 1 0 amperes the total time would be 40 Ah 1 0A 40 hours Q01 1120 Revision B 6 05 Page 24 of 74 Teledyne Battery Products Gill DRY CHARGE MAINTENANCE MANUAL 7 9 3 Stable voltage measured 4 hours after charge termination should be over 26 3V for 24V batteries and 13 1V for 12V batteries If not charging should be resumed using guidelines in 6 4 3 The Original Equipment Aircraft Battery 7 9 4 Avoid subjecting a battery to frequent deep discharge as this could affect the useful life of the battery 7 10 BATTERY SAFETY 7 10 1 Handling Battery Electrolyte WARNING WHEN WORKING WITH ELECTROLYTE ALWAYS WEAR SAFETY GOGGLES AND PROTECTIVE GLOVES AND CLOTHING USE EXTREME CARE TO AVOID SPILLING OR SPLASHING ELECTROLYTE 40 SULFURIC ACID AS IT IS VERY CORROSIVE AND WILL DESTROY CLOTHING BURN SKIN AND PERMANENTLY DAMAGE EYES a When handling plastic cased batteries do not exert pressure on the end walls as this could cause the electrolyte to spill out of the v
68. urn marks If any of these defects exist the surfaces should be cleaned If the cleaning process reduces the pin diameter below 0 370 the battery must be replaced In addition to inspecting the connector condition and type of wiring must be examined Excessive corrosion and use of aluminum wire can be detrimental to safe operation Please clean replace wiring Replacement wiring kits are available from the aircraft manufacturer 7 3 ELECTROLYTE LEVELS 7 3 1 Electrolyte levels must be maintained just over the plates at all times Lower levels will damage the battery Replenish electrolyte with clean water preferably distilled and NOT electrolyte unless electrolyte has been inadvertently spilled from the battery The frequency of water additions will depend on a Battery duty cycle b Battery operating temperature C Generator voltage regulator setting d Flight hours 7 3 2 Charge the battery when water is added This will mix the electrolyte and water to provide a homogeneous electrolyte Continue charging until the voltage and specific gravity readings are constant over three readings taken over three hours at approximately equal intervals Q01 1120 Revision B 6 05 Page 16 of 74 Teledyne Battery Products Gill DRY CHARGE MAINTENANCE MANUAL The Original Equipment Aircraft Battery WARNING Electrolyte contains sulfuric acid which is highly corrosive and can cause severe burns to exposed skin and permanent dama
69. volts for a 24 volt lead acid battery or 10 volts for a 12 volt lead acid battery The Emergency Rate is the total essential load measured in amperes required to support the essential bus for thirty minutes Q01 1120 Revision B 6 05 Page 4 of 74 Teledyne Battery Products Gill DRY CHARGE MAINTENANCE MANUAL 4 2 3 State of Charge State of Charge is a quick reference to the state of health of a battery These voltage measurements should be used as a guide only Note Figure 1 which indicates the relationship between Open Circuit Voltage No Load Voltage and State of Charge SOC for Dry Charged Products The Original Equipment Aircraft Battery Please note that state of charge is not the same as available capacity see GLOSSARY FIGURE 1 Battery Open Circuit Voltage Vs Approximate State of Charge 24 Volt Dry Charged Lead Acid Batteries o gt 5 o o S t State of Charge 4 3 TEMPERATURE EFFECTS 4 3 External temperatures will alter electrolyte viscosity in turn affecting the current developing characteristics of the battery Lower temperatures will generally result in reduced power performance 4 3 2 The freezing point of electrolyte is quite low However a discharged battery with lower specific gravity electrolyte will tend to freeze at higher Q01 1120 Revision B 6 05 Page 5 of 74 Teledyne Battery Products Gill DR
70. which also includes facilities outside of California A copy of this publication the Directory of Industrial Recyclers may be obtained by calling 916 324 2423 or writing to the California Waste Exchange Resource Recovery Unit Hazardous Waste Management Program Department of Toxic Substances Control P O Box 806 Sacramento CA 95812 0806 001 1120 6 05 28 74 Teledyne Battery Products Gill DRY CHARGE MAINTENANCE MANUAL The Original Equipment Aircraft Battery 8 2 4 Nation wide Recycling Most retailers auto parts stores or service outlets that sell new lead acid batteries will accept a small number one or two of spent lead acid batteries for recycling If you have a larger quantity to be recycled call to verify that your chosen outlet can handle a larger quantity of old batteries Even if you live in a state where there is no lead acid battery recycling law it s common for battery retailers everywhere in the U S to accept used lead acid batteries from customers The spent batteries collected by retailers are shipped to EPA licensed and regulated facilities for recycling For additional information please use the following web address to locate nation wide recycling facilities www batterycouncil org 8 3 INTERNATIONAL RECYCLING RESOURCES 8 3 1 British Battery Manufacturers Association 26 Grosvenor Gardens London SWIW Direct Tel 44 0 207 838 4800 Direct Fa
71. x 44 0 207 838 4801 8 3 2 SNAM Societe Nouvelle d Affinage des Metaux Rue de la Garenne St Quentin Sallavier 38297 La Verpilliere Cedex France Telephone 00 33 74 945 985 Battery re processing 8 3 3 For smaller batteries you may also contact the Rechargeable Battery Recycling Corporation RBRC at www rbrc com for directions Q01 1120 Revision B 6 05 Page 29 of 74 Teledyne Battery Products Section 9 Gill DRY CHARGE MAINTENANCE MANUAL The Original Equipment Aircraft Battery FREQUENTLY ASKED QUESTIONS Q How can 1 do the load test in compliance with the Continued Airworthiness requirements if do not have a tester It is preferable to perform the load test with an appropriate tester A 1 Teledyne now offers a brand new load tester The load tester will be available after September 2004 Please contact Teledyne Sales for further information 2 Aero Quality and Vencon provide affordable battery testers These companies can be contacted through their web site as follows www aeroquality com and www vencon com If no tester is available 3 The battery may be discharged with several components of known load on the plane the total load approximating as closely as possible to the emergency capacity of the battery Discharge the battery for 30 minutes The battery voltage should be at or above the minimum required 10V for a 12V battery and 20V for a 24V battery For known loads which are not the same as
72. y is at end of life Replace battery Will not come up to full Charging rate is insufficient Check and correct settings for charge appropriate battery in accordance with guidelines set in these instructions under SERVICING Will not hold charge Capacity of battery may be Confirm application requirements and Saito lower than required for replace battery application the battery sufficiently and recharge when necessary Standing too long hot climate replenish electrolyte and recharge Equipment left on accidentally After fully charging battery continue at battery is discharged reduced rate of one amp or less until charging voltage stabilizes over three hours Perform a capacity check per Continuous Airworthiness Instructions page 19 Replace if necessary Short circuit short to groundin Check wiring and rest of electrical wiring or other electrical system Correct problem recharge component problem battery Loose connections corrosion Clean and neutralize connections tighten all connections Electrolyte on top of cells and Remove battery from aircraft clean and z 2 les gt 2 z un battery box caused by neutralize the exterior of the battery overfilling high charge rates and inside battery box with a solution Could cause battery to bridge of sodium bicarbonate baking soda across the terminals Wash with clean water and dry discharging battery in the thoroughly R

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