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TELEDYNE BATTERY PRODUCTS

1. G 6381E G 6381C G 6381E C Performance Data End Volts Capacity Weight H8 RE 160 35 EU NEN a ae 72 78 G 6381E C Performance at 24 10 Hours to 1 67 at 24 Q01 1120 Revision J 7 8 15 Page 51 of 62 Teledyne Battery Products G 639E C Gill DRY CHARGE MAINTENANCE MANUAL Since 1920 G 639E G 639E C Performance Data End Volts Per Cell G 639E C Performance at 24 C CUMD 10 Hours to 1 67 at 24 Q01 1120 Revision J 7 8 15 Page 52 of 62 Teledyne Battery Products G 638E C Gill DRY CHARGE MAINTENANCE MANUAL Since 1920
2. G 638E G 638C G 638E C Performance Data G 638E C Performance at 24 C a 10 Hours to 1 67 VPC at 24 C Q01 1120 Revision J 7 8 15 Page 53 of 62 Teledyne Battery Products G 640E C Gill DRY CHARGE MAINTENANCE MANUAL The Original Equipment Aircraft Battery Since 1920 10 200 MAX S VALUES IN ARE mm 259 1 9 400 MAX 8 781 238 8 CO 238 8 1 F a 4 L 1 7 687 7 625 195 3 8 193 7 End Volts Per Cell G 640E C Performance at 24 Hours to 1 67 VPC at 24 C Q01 1120 Revision J 7 8 15 Page 54 of 62 Teledyne Battery Products G 641 The Original Equipment Aircraft Battery Since 1920 a 6 625 t End Volts Per Cell G 641 Performance at 24 Hours
3. T G 88 Performance Data Capacity Energy Weight G 88 Performance at 24 Hours to 1 67 VPC at 24 C Q01 1120 Revision J 7 8 15 Page 42 of 62 Teledyne Battery Products G 240 Gill DRY CHARGE MAINTENANCE MANUAL The Original Equipment Aircraft Battery End Volts Per Cell Watts or Amperes Hours to 1 67 VPC at 24 C Q01 1120 Revision J 7 8 15 Page 43 of 62 Teledyne Battery Products G 241 The Original Equipment Aircraft Batt G 241 Performance Data Test e Electrolyte Run time Temperature ee ity gei Volume quarts Per Cell C 60 sec 1 2 18 t 2 42 30 min 6 5 1 67 24 8 G 241 Discharge at 2
4. 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 Q01 1120 Revision J 7 8 15 Page 12 of 62 Teledyne Battery Products Since 1920 Gill DRY CHARGE MAINTENANCE MANUAL The Original Equipment Aircraft Battery Table 4 INITIAL CONSTANT CURRENT CHARGE RATES Initial Gill Part Former Part Final Charge Number Number 9 Current Current 25 35 G 35M PS6 9 PS6 11 6GAA 13 PS12 9 PS12 9M PS12 11 PS12 11M PS12 24P9 PS12 24P9M PS12 24P11 PS12 24P11M MS18045 42 AN3150 MS18045 41 AN3154 AN3151 BB638 T E BB638 TI1 E BB639 T E BB640 T E G 41 G 240 G 241 G 242 G 243 G 244 G 245 G 246 G 247 GE 50E GE 50C GE 51E GE 54C GE 51C G 638E G 6381E G 639E G 640E G 641 6 25 ese 9 3 J 15 cas 3 is 3 J 15 co 88 3 2 1 esiz94 2 ezn 3 is 6 243 esiz iM 3 15 15 c 245 psiz z4PM 15 15 3 105 GE S0E Msi8045 42 15 c soc am3is0 3 15 518045 41 f 15 gE s4C
5. WARNING THE NATIONAL ELECTRIC CODE FORBIDS CHARGING BATTERIES INSTALLED IN AIRCRAFT OR WITHIN 10 FEET OF FUEL TANK AREAS Q01 1120 Revision J 7 8 15 Page 22 of 62 Teledyne Battery Products Since 1920 Gill DRY CHARGE MAINTENANCE MANUAL The Original Equipment Aircraft Battery 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 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 CI 7 8 7 1 These chargers must be capable of providing an output of around 33
6. 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 k Do not touch charger leads while the battery is on charge Q01 1120 Revision J 7 8 15 Page 27 of 62 Teledyne Battery Products Gill DRY CHARGE MAINTENANCE MANUAL The Original Equipment Aircraft Battery 7 11 JUMP STARTING AN ENGINE 7 11 1 Teledyne Gill batteries 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 J 7 8 15 Page 28 of 62 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 They can 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 colle
7. 35 volts and about 4 8 amperes with selector switch and provide a timer that can terminate charging when the charge is completed 7 8 7 2 The 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 Q01 1120 Revision J 7 8 15 Page 23 of 62 Teledyne Battery Products Since 1920 Gill DRY CHARGE MAINTENANCE MANUAL The Original Equipment Aircraft Battery approaches full charge As long as the charger timing is adequately controlled this charging regime will not damage the 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. 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 5 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 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 Q01 1120 Revision J 7 8 15 Page 24 of 62 Teledyne Battery Products Since 1920 Gill DRY CHARGE MAINTENANCE MANUAL The Original Equipment Aircraft Battery Gill Technical Support for any additional concerns with charging see Fig 5 for typical charge profile Figure 5 Standard Charging for a FULLY DISCHARGED BATTERY
9. Since 1920 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 and negative plates International Air Transport Association International Civil Aviation Organization International Electro technical 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
10. amissa f 2 1 3 15 6 638 eBe38 T E 35 25 C 6381E eB638 TI E 35 25 c 639E sBeso T 15 G G40E BBe40 T E 15 csa den 43 4115 Note The Final Charge Current is initiated once the cells start gassing Q01 1120 Revision J 7 8 15 Page 13 of 62 Teledyne Battery Products SECTION 6 Gill DRY CHARGE MAINTENANCE MANUAL The Original Equipment Aircraft Battery Since 1920 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 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 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
11. 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 I filled all the cells with the electrolyte had received The electrolyte was not enough but topped off the low cells with water Can you help A During initial conditioning no water is to be added to the cells 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 Pleas
12. leak Q01 1120 Revision J 7 8 15 Page 9 of 62 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 p 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 Figure 2 Bottom of Vent Well Split Ring Approx 1 8 Top of Separators 1 ginal Equipment Satter g quip 001 1120 Revision J 7 8 1 5 10 of 62 Teledyne Battery Products Since 1920 Gill DRY CHARGE MAINTENANCE MANUAL The Original Equipment Aircraft Battery Table 3 ELECTROLYTE VOLUMES Fill Fill Gill Part Former Part ou Gill Part Former Part Number Number Number Number Quarts Quarts 2 G 247 50 MS18045 42 8 G 35M GE
13. shall be performed as follows 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 one hour 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 e The battery is considered airworthy if it meets 8096 of the one hour capacity rating 48 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 J 7 8 15 Page 21 of 62 Teledyne Battery Products Since 1920 Gill DRY CHARGE MAINTENANCE MANUAL The Original Equipment Aircra
14. 4 C Hours to 1 67 VPC at 24 C Q01 1120 Revision J 7 8 15 Page 44 of 62 Teledyne Battery Products G 242 The Original Equipment Aircraft Battery 3600 17 Hours to 1 67 VPC at 24 C Q01 1120 Revision J 7 8 15 Page 45 of 62 Teledyne Battery Products mm G 243 The Original Equipment Aircraft Battery G 243 Performance Data End Volts Per Cell 6osec 12 360 150 3 10 60 min 1 67 24 G 243 Performance at 24 Hours to 1 67 VPC at 24 Q01 1120 Revision J 7 8 15 Page 46 of 62 Teledyne Battery Products G 244 The Original Equipment Aircraft Battery Since 1920 Capacity Weight Ib 90 360 432 720 G 244 Performance at 24 C 10 Hours to 1 67 VPC at 24 C Q01 1120 Revi
15. 5 1 150 1 125 1 200 NX 4 4 LIFE EXPECTANCY 4 4 1 4 4 2 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 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 J 7 8 15 Page 6 of 62 Teledyne Battery Products Since 1920 Gill DRY CHARGE MAINTENANCE MANUAL The Original Equipment Aircraft Battery 4 4 2 3 Undercharging e Chronic undercharging will lead to extensive sulfation and underperformance These batteries will be difficult to recharge 4 4 3 High Very Low temperature operations 4 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 chlo
16. 8 15 Revised references to Appendixes Troubleshooting Section Q01 1120 Revision J 12 04 Page 1 of 62 Teledyne Battery Products SECTION 2 COMPONENT MAINTENANCE MANUAL 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 J 12 04 Page 2 of 62 Teledyne Battery Products SECTION 3 COMPONENT MAINTENANCE MANUAL 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 the 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 dem
17. AIRPLANE FLIGHT MANUAL THE SPECIFIC STC OR THE BATTERY CONTINUOUS AIRWORTHINESS INSTRUCTIONS FOR THE APPLICATION THIS SERVICE MANUAL SHOULD NOT BE CONSTRUED AS THE FINAL AUTHORITY IN MAINTAINING YOUR SPECIFIC BATTERY PLEASE CONSULT WITH TELEDYNE TECHNICAL SUPPORT FOR FURTHER INFORMATION Gill DRY CHARGE SERVICE MANUAL The Original Equipment Aircraft Battery 800 456 0070 www gillbatteries com CONTENTS Section Page REVISION PAGE 2 2 3 INTRODUCTION au da vd see ru seda ocaeca ite do 3 4 DRY CHARGED LEAD ACID BATTERIES _ 4 4 Description nue c dus 4 4 2 Specification Definitions eere 4 4 3 Temperature Effects se saremo ioter ana skr 5 4 4 Life EXPE CUANCY ER RIS Md 6 5 PREPARING DRY CHARGED BATTERIES FOR USE 8 Bil Tools Needed os pur cix 8 5 2 Filling or Activation 8 6 INSTALLATION 14 6 1 Battery Installation Pre Verification 14 6 2 Battery Ventilation et 14 6 3 Sump Jar Treatment sex oi uda aver Exe pandx pd EARS 15 6 4 Ventilation System Requirements 15 7 SERVICING uiuiscisiaiascscuesucuzeds eid aazavisQadda De r3 e diae adds 16 7 1 Service Requirements ppp 16 7 2 Connector
18. COMPARTMENTS UNLESS ADEQUATE 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 order to reduce fire hazard and to eliminate corrosion of metal parts due to acid 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 Q01 1120 Revision J 7 8 15 Page 14 of 62 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 5 solution of sodium bicarbonate in water or about 38 of dry sodium bicarbonate The tube carrying fumes to the sump extends into the jar about 1 from the lid See Figure 3 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
19. SOC 8 GE 51C 5 54 3 638 9 G 6381E C BB638 TI E 9 C 639E C G 640E C 641 4 Note These are approximate volumes KR YR TR uo ou Ww w o JW 5 2 5 INITIAL CHARGING INSTRUCTIONS a Replace vent caps tightly and start charging per recommendations for your battery type Note Table 4 for Initial Charge Rates b Do not allow the battery to stand for more than 8 hours after the electrolyte has been added and before you begin to charge 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 Q01 1120 Revision J 7 8 15 Page 11 of 62 Teledyne Battery Products Since 1920 Gill DRY CHARGE MAINTENANCE MANUAL The Original Equipment Aircraft Battery d Replace the vent caps tightly then clean up any spilled electrolyte e Maintain temperature of the 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
20. Since 1920 The Original Equipment Aircraft Battery 800 456 0070 www gillbatteries com TELEDYNE BATTERY PRODUCTS DRY CHARGED LEAD ACID AIRCRAFT BATTERY SERVICE MANUAL PROPOSITION 65 WARNING BATTERY POSTS TERMINALS AND RELATED AC C ESSORIES CONTAIN LEAD AND LEAD COMPOUNDS CHEMIC ALS KNO WN TO THE STATE OF CALIFORNIA TO CAUSE CANCER AND REPRO DUCTIVE HARM WASH HANDS AFTER HANDLING Document Number 901 1120 Revision 7 8 15 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 INSTRUC TIONS PREC AUTIONS POSTED IN VARIOUS SECTIONS WITHIN THIS MANUAL MUST BE STRICTLY FOLLOWED ALWAYS WEAR SAFETY GLASSES AND ACID RESISTANTG LOVES WHENEVER HANDLING BATTERIES ELECTROLYTE CONTAINS SULFURIC ACID WHIC H 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
21. TO 20V ing A Battery Charges At Constant Current 75A To Constant Voltage Ch arging t 28V and Switches to Constant Voltage 28 25V 28 25V Charge Battery Voltage Profile On Discharge Z it Constant Voltage Battery Voltage Profile On Charge Charge Rate CHARGE RATE DECLINES DURING CONSTANT VOLTAGE CHARGE Discharge 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 techniques provided they have not been in the deep discharge state for more than 15 days at temperatures around 30 F to 80 F in which case the batteries should be replaced 7 9 2 The battery must be charged at a rate of 1 0A for 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 Q01 1120 Revision J 7 8 15 Page 25 of 62 Teledyne Battery Products Since 1920 Gill DRY CHARGE MAINTENANCE MANUAL The Original Equipment Aircraft Battery 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 7 9 3 Stable voltage measured 4 hours after charge termination should be over 26 3V for 24
22. V batteries and 13 1V for 12V batteries If not charging should be resumed using guidelines in 7 8 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 vent 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
23. Wiring Inspection pp 16 7 3 Electrolyte Levels ee 17 7 4 Sump jar Maintenance pp 19 7 5 Managing Periods of Non Use _ 19 7 6 Shelf Life and Storage Conditions 19 7 7 Continued Airworthiness Determination 21 7 8 CHarging 22 7 8 7 Constant Current CI eese 23 7 8 8 Constant Voltage _ 24 7 9 Recharging Deeply Discharged Batteries 25 7 10 Battery Safety scscedcsscsccstccccinsacesccesiadecisecsucssnnctewssdinenodens 26 Q01 1120 Revision 7 15 iii Teledyne Battery Products The Original Equipment Air Battery 800 456 0070 wwwg s com Section Page 7 11 Jump Starting an Engine Ne 28 8 RECYCLING 29 8 1 Material Safety Data Sheets 29 8 2 Retycler LOCSEIOTIS 29 8 3 International Recycling Resources _ 30 9 PRIS ereden reeeo 31 10 GLOSSARY ARUM Orc i DNE 34 11 TROUBLE SHOOTING Eas 35 12 APPENDIX Battery Specifications 39 13 APPENDIX B Using a Hydrometer _ 59 14 APPENDIX C Mixing Electrolyte eerte 61 15 APPENDIX D Activation and Service Instructions for Gi
24. abilizes over three hours Perform a capacity check per Continuous Airworthiness Instructions page 19 Replace if necessary Short circuit short to ground in 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 discharging battery in the thoroughly Recharge battery before process placing in service Quick disconnect worn beyond Check Cannon or Elcon type connectors tolerance for good contact see 7 2 with Teledyne Go NoGo gauge part number 3600 51 Battery could be shorting under The battery could be investigated as load follows i After a full charge verified by specific Electrolyte on top of cells and Remove battery from aircraft clean and 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 Q01 1120 Revision J 7 8 15 Page 35 of 62 Teledyne Battery Products Since 1920 Gill DRY CHARGE MAINTENANCE MANUAL The Original Equipment Aircraft Battery PROBLEM CAUSE Will not hold charge cont d Battery could be self discharging due to low state of charge Sulfation can build up based on repeated undercharge situations Excessive sulfati
25. ator 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 J 7 8 15 Page 17 of 62 Teledyne Battery Products Since 1920 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 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 596 solution of sodium bicarbonate in water WARNING Electrolyte contains sulfuric acid which is highly c
26. be adjusted proportionally to compensate for chargers that may not be capable of delivering the recommended rate f It may 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 around 1 275 to 1 295 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 it is 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 around 16 volts for 12 volt batteries i At the end of charge all cells will be gassing freely and the battery voltage will stabilize and start to drop slightly At this point the current rate must be switched to the Final Charge Current as indicated in Table 4 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
27. ble 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 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 Example below indicates that at 30A discharge the battery will run for 0 7 hours 42 minutes to the end point voltage READING A PERFORMANCE PLOT 1 2 5 10 Hours to 1 67 VPC at 24 Q01 1120 Revision J 7 8 15 Page 31 of 62 Teledyne Battery Products Since 1920 Gill DRY CHARGE MAINTENANCE MANUAL The Original Equipment Aircraft Battery Q How can determine if a dry charged battery is fully charged without using a hydrometer A Battery voltage will stabilize towards full
28. cted 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 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 Q01 1120 Revision J 7 8 15 Page 29 of 62 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 ha
29. dry sodium bicarbonate the jar Saturate a new pad with a 5 solution of sodium bicarbonate and place pad over the sodium bicarbonate in the jar Install jar to lid hand tighten be sure gasket is in place MANAGING PERIODS OF NON USE 7 5 1 7 5 2 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 Teledyne Battery Products recommends that the battery be removed from the plane during such non use and maintained using any of the following methods a b Recharge every 90 days followed by a recharge per item below if needed Kept on trickle charge 13 5V to 13 8V for 12V batteries or 27V to 27 6V for 24V batteries Recharge prior to flight The recharge should be in accordance with Section 7 8 Alternatively the Activation and Service Instructions TBP 1560 can also be used for steps on recharging 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 Q01 1120 Revision J 7 8 15 Page 19 of 62 Teledyne Battery Products Since 1920 Gill DRY CHARGE MAINTENANCE MANUAL The Original Equipment Aircraft Battery Note Figure 4 Shelf Life of Flooded Products 7 6 2 A battery should not be allowed to remain in a discharged condition f
30. e 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 J 7 8 15 Page 32 of 62 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 provides 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 J 7 8 15 Page 33 of 62 Teledyne Battery Products The Original Equipment Aircraft Battery
31. 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 AC 43 13 1B Chapter 11 Section 2 Battery Ventilating Systems Figure 3 Battery Ventilation System Q lt lt J lt 7 gt BATTERY A 0 LJ Jo 5 A V A V SUMP 5 BICARBONATE V AIRCRAFT SKIN lt A m lt NEGATIVE POSITIVE VENT VENT Q01 1120 Revision J 7 8 15 Page 15 of 62 Teledyne Battery Products SECTION 7 Gill DRY CHARGE MAINTENANCE MANUAL The Original Equipment Aircraft Battery SERVICING 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 the latest revision of Activation and Service Instructions for Gill Dry Charged Lead Acid Aircraft Batteries TBP 1560 7 1 2 To ensure continued airworthiness remove the battery from the aircraft and perform capacity test 5 1 4 initially at 800 50 flight hours
32. ft Battery g Repeat the discharge test as indicated If the failure persists replace the 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 The airworthiness limitations section noted in 7 7 1 is FAA approved and specifies maintenance required under Sections 43 16 and 91 403 of the Federal Aviation 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 7 8 CHARGING 7 8 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 for batteries that have already been activated 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
33. he 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 actual gravity reading will be taken at the base of the meniscus 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 110 F then you would add 12 points 1 275 0 012 1 287 Q01 1120 Revision J 7 8 15 Page 60 of 62 Teledyne Battery Products SECTION 14 Gill DRY CHARGE MAINTENANCE MANUAL The Original Equipment Aircraft Ba
34. itely 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 or a 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 needed 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 D Replace vent caps finger tight to ensure electrolyte does not
35. itions before using Q01 1120 Revision J 7 8 15 Page 61 of 62 Teledyne Battery Products SECTION 15 Gill DRY CHARGE MAINTENANCE MANUAL The Original Equipment Aircraft Battery APPENDIX D Latest activation instructions are included with the battery A copy may be obtained from Teledyne Battery Products through the website www gillbatteries com Q01 1120 Revision J 7 8 15 Page 62 of 62 Teledyne Battery Products
36. ll Dry Charged Lead Acid Aircraft Batteries TBP 1560 __ 62 Q01 1120 Revision 7 15 iv Teledyne Battery Products The Original Equipment Air 800 456 0070 www g Battery s com Section Page 7 11 Jump Starting Engine pp 28 8 RECYCLING E S tad oss 29 8 1 Material Safety Data Sheets 29 8 2Recycler Locations 29 8 3International Recycling Resources 30 9 e TO 31 10 GLOSSARY ica 34 11 TROUBLE SHOOTING nb nana nas 35 12 APPENDIX Battery Specifications 39 13 APPENDIX B Using a Hydrometer _ 59 14 APPENDIX C Mixing Electrolyte acier annue 61 15 APPENDIX D Activation and Service Instructions for Gill Dry Charged Lead Acid Aircraft Batteries TBP 1560 _ 62 Q01 1120 Revision 7 15 iv Teledyne Battery Products SECTION 1 COMPONENT MAINTENANCE MANUAL REVISIONS Description of Change Approved By Completely Revised 7 15 03 Added new load tester Corrected manual number Revised load test conditions Revised Activation and Service JMR Instructions added other graphics Corrected service instruction language 7
37. ll cells Remove and recharge the battery reduce equipment load or use an approved higher capacity battery Teledyne Battery Products Since 1920 The Original Equipment Aircraft Battery Battery life too short Application 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 Gill DRY CHARGE MAINTENANCE MANUAL PROBLEM CAUSE RECOMMENDATIONS Ensure that battery selection is correct 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 correcting 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 Remove battery and inspect If no visual damage is noted charge and perform capacity check Replace battery if case 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 Elec
38. ly Note Figure 1 which indicates the relationship between Open Circuit Voltage No Load Voltage OCV and State of Charge SOC for Dry Charged Products 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 c o gt o a State of Charge 4 3 TEMPERATURE EFFECTS 4 3 1 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 J 7 8 15 Page 5 of 62 Teledyne Battery Products Since 1920 Gill DRY CHARGE MAINTENANCE MANUAL The Original Equipment Aircraft Battery 4 3 3 temperatures Note Table 1 for electrolyte freezing points with varying electrolyte strength sulfuric acid concentration Charge acceptance at low temperatures less than 309F is generally low It is preferred to charge batteries at higher temperatures 30 F to 90 F Table 1 FREEZING POINT OF ELECTROLYTE Freezing Point Specific Gravity T 1 285 1 250 1 225 1 o 1 1 NJN 1 17
39. n insert the larger diameter probe of the tool TBP 3600 51 Rev A or newer 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 burn marks If any of these defects exist the surfaces should be cleaned g If the cleaning process reduces the pin diameter below 0 370 the battery must be replaced 7 2 3 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 See Figure 2 for levels The frequency of water additions will depend on a Battery duty cycle b Battery operating temperature C Generator voltage regul
40. nd Volts andme Tarea 60 sec 1 2 18 2 42 30 min 8 1 67 24 10 240 16 384 GE 54C Performance at 24 C A LLL 4 T Hours to 1 67 VPC at 24 Q01 1120 Revision J 7 8 15 Page 58 of 62 Teledyne Battery Products The Original Equipment Aircraft Battery Gill DRY CHARGE MAINTENANCE MANUAL 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 STOPPER READ HERE MENISCUS BARREL E NSNNANNN i 774444 1100 1125 1150 1175 HHE 1225 1250 1275 1300 D ENLARGED VIEW GRADIENT SCALE No 1 Hydrometer Set Q01 1120 Revision J 7 8 15 Page 59 of 62 Teledyne Battery Products Since 1920 Gill DRY CHARGE MAINTENANCE MANUAL The Original Equipment Aircraft Battery T
41. ndle 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 SW1W OGT Direct Tel 44 0 207 838 4800 Direct Fax 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 http www rbrc com for directions Q01 1120 Revision J 7 8 15 Page 30 of 62 Teledyne Battery Products SECTION 9 Gill DRY CHARGE MAINTENANCE MANUAL The Original Equipment Aircraft Battery FREQUENTLY ASKED QUESTIONS Q How can 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 availa
42. on build up caused by leaving the battery in a discharged state for an extended period of time Possible excessive use of starter and other electrical equipment Q01 1120 Revision J 7 8 15 Page 36 of 62 RECOMMENDATIONS gravities over 1 280 subject the battery to the one hour rate of discharge Replace battery if it fails to support the load for at least 48 minutes 8096 of one hour capacity 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 Fully charge battery clean the top and place the battery in service If this repeats remove the battery from service and monitor the drop in voltage 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 Charge the battery at a constant current rate of 1 amp for a time equal to 1 5 times the one hour capacity e g if the battery is a 10Ah battery charge at 1A for 1 5 x 10 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 a
43. onstrated 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 e 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 J 12 04 Page 3 of 62 Teledyne Battery Products SECTION 4 COMPONENT MAINTENANCE MANUAL 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
44. or 11 1 calendar month s whichever comes first After the initial check perform the capacity test at 400 50 flight hours or 6 1 calendar month s whichever comes first 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 contamination 7 2 CONNECTOR WIRING 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 c Burn marks caused when battery is disconnected under load Q01 1120 Revision J 7 8 15 Page 16 of 62 Teledyne Battery Products Since 1920 Gill DRY CHARGE MAINTENANCE MANUAL The Original Equipment Aircraft Battery d To test for the resiliency of the mating surfaces to an oversized pi
45. or 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 7 6 3 Asimple 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 4 Shelf Life 24V Dry Charged Lead Acid Batteries Tested at 77 F Battery Open Circuit Voltage 60 80 Shelf Life Days Q01 1120 Revision J 7 8 15 Page 20 of 62 Teledyne Battery Products Since 1920 Gill DRY CHARGE MAINTENANCE MANUAL The Original Equipment Aircraft Battery 7 7 CONTINUED AIRWORTHINESS DETERMINATION FOR GILL AIRCRAFT BATTERIES 7 7 1 To ensure continued airworthiness remove the battery and perform capacity test as noted below initially at 800 50 flight hours or 11 1 calendar month s whichever comes first After the initial service perform the capacity test at 400 25 flight hours or 6 1 calendar month s whichever comes first The capacity test
46. orrosive 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 Note Excess electrolyte can be stored indefinitely in the containers they were shipped in Keep the caps on tightly to avoid spillage Q01 1120 Revision J 7 8 15 Page 18 of 62 Teledyne Battery Products The Original Equipment Aircraft Battery Since 1920 Gill DRY CHARGE MAINTENANCE MANUAL 7 4 7 5 7 6 SUMP JAR MAINTENANCE 7 4 1 7 4 2 7 4 3 Inspect the electrolyte levels and the sump jar at the specified battery maintenance intervals noted in 7 3 4 If there is any flow of electrolyte in the sump jar clean as follows a b C Wear goggles and rubber gloves Slowly add sodium bicarbonate to the residual acid in the sump jar until the reaction subsides shake jar side to side slowly Wash jar and pad thoroughly Once the jar has been cleaned recharge it with fresh sodium bicarbonate as follows a b Add about 3 of
47. rides 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 mE F Minimum Nominal Maximum Minimum Nominal Maximum 1335 13 75 1395 140 142 276 60 1385 1425 1445 281 CONTINUOUS OPERATION ABOVE 120 F IS NOT RECOMMENDED Q01 1120 Revision J 7 8 15 Page 7 of 62 Teledyne Battery Products SECTION 5 Gill DRY CHARGE MAINTENANCE MANUAL The Original Equipment Aircraft Battery PREPARING DRY CHARGED BATTERIES FOR USE 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 c 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
48. sion J 7 8 15 Page 47 of 62 Teledyne Battery Products 245 Capacity Weight Ah Ib G 245 Performance at 24 C Amperes 10 Hours to 1 67 VPC at 24 C Q01 1120 Revision J 7 8 15 Page 48 of 62 Teledyne Battery Products G 246 The Original Equipment Aircraft Battery Since 1920 End Volts Per Cell G 246 Performance at 24 C 10 Hours to 1 67 VPC at 24 C Q01 1120 Revision J 7 8 15 Page 49 of 62 Teledyne Battery Products G 247 The Original Equipment Aircraft Battery Since 1920 G 247 Performance at 24 C Amperes 10 Hours to 1 67 VPC at 24 C Q01 1120 Revision J 7 8 15 Page 50 of 62 Teledyne Battery Products y G 6381E C Gill DRY CHARGE MAINTENANCE MANUAL
49. tions 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 J 7 8 15 Page 39 of 62 Teledyne Battery Products Gill DRY CHARGE MAINTENANCE MANUAL The Original Equipment Aircraft Battery G 25 Performance Data Test i 2 End Volts Capacity Run time Per Cell Temperature Ah 60 sec 12 18 2 700 225 375 30 min 360 30 15 60min 167 4 216 18 18 20hr 18 15 30 Hours to 1 67 VPC at 24 C Q01 1120 Revision J 7 8 15 Page 40 of 62 Teledyne Battery Products Since 1920 Gill DRY CHARGE MAINTENANCE MANUAL The Original Equipment Aircraft Battery Hours to 1 67 VPC at 24 C Q01 1120 Revision J 7 8 15 Page 41 of 62 Teledyne Battery Products Gill DRY CHARGE MAINTENANCE MANUAL The Original Equipment Aircraft Battery Since 1920
50. to 1 67 VPC at 24 Q01 1120 Revision J 7 8 15 Page 55 of 62 Teledyne Battery Products y GE 50C Gill DRY CHARGE MAINTENANCE MANUAL The Original Equipment Aircra 0 320 E GE 50C Performance at 24 10 Hours to 1 67 at 24 Q01 1120 Revision J 7 8 15 Page 56 of 62 Teledyne Battery Products GE 51C Gill DRY CHARGE MAINTENANCE MANUAL The Original Equipment Aircraft Battery Since 1920 GE 51C Performance Data End Volts Capacity FI 24 GE 51C Performance at 24 10 Hours to 1 67 at 24 Q01 1120 Revision J 7 8 15 Page 57 of 62 Teledyne Battery Products 54 Gill DRY CHARGE MAINTENANCE MANUAL The Original Equipment Aircraft Battery 9 400 MAX lol ZF GE 54C Performance Data Test n Electrolyte Temperature SEY pru Volume w quarts E
51. trolyte 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 J 7 8 15 Page 37 of 62 Teledyne Battery Products Since 1920 Gill DRY CHARGE MAINTENANCE MANUAL The Original Equipment Aircraft Battery PROBLEM CAUSE RECOMMENDATIONS Electrolyte runs out of vent Battery is chronically Check voltage regulator settings and plugs Or overcharged adjust as required Battery consumes excessive water cont d Battery voltage is at O and Shorted or grounded cable Repair short or ground in electrical will not accept charge causing direct full discharge of system and replace battery battery and irreparable damage Electrolyte in battery Battery left in a discharged Replace battery freezes state Electrolyte specific gravity too low Polarity reversed Battery inadvertently charged in Replace battery reverse NEW BATTERY is under Battery may not have received a Remove battery from aircraft and capacity or uses excessive full initial charge or full charge completely If possible provide water during first 25 hours complement of electrolyte a few cycles to the battery of use Q01 1120 Revision J 7 8 15 Page 38 of 62 Teledyne Battery Products SECTION 12 Gill DRY CHARGE MAINTENANCE MANUAL The Original Equipment Aircraft Battery APPENDIX A Battery Specifica
52. ttery APPENDIX C 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 s g may also be used 4 For 1 400 s g electrolyte the mix ratio will be 1 part acid to 0 46 parts of water 5 Wait for electrolyte to cool down to ambient cond
53. 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 J 7 8 15 Page 26 of 62 Teledyne Battery Products Since 1920 Gill DRY CHARGE MAINTENANCE MANUAL The Original Equipment Aircraft Battery 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 Review all applicable OSHA guidelines for safety precautions note MSDS in Appendix C b Keep sparks flames burning cigarettes or other ignition sources away at all times WARNING Batteries generate explosive gases and must be handled with care C Always use insulated tools d Leave vent caps on while charging removing them only when verifying e 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 g Do not break live circuits at the terminals of a battery because sparks will occur at the terminals h Make certain the charger cables are clean and not frayed A poor j
54. 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 f electrolyte is not available refer to Appendix C 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 c Remove storage caps d Make sure you have enough electrolyte refer to Table 3 Q01 1120 Revision J 7 8 15 Page 8 of 62 Teledyne Battery Products Since 1920 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 defin
55. 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 J 7 8 15 Page 34 of 62 Teledyne Battery Products SECTION 11 Gill DRY CHARGE MAINTENANCE MANUAL GILL TROUBLE SHOOTING GUIDE PROBLEM CAUSE RECOMMENDATIONS 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 lower than required for replace battery application LI Remove the battery from the aircraft the battery sufficiently and recharge when necessary ie too long hot climate Remove battery from aircraft check and electrolyte and recharge Since 1920 The Original Equipment Aircraft Battery pf left on accidentally After fully charging battery continue at battery is discharged reduced rate of one amp or less until charging voltage st
56. 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 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 J 12204 Page 4 of 62 Teledyne Battery Products Since 1920 Gill DRY CHARGE MAINTENANCE MANUAL The Original Equipment Aircraft Battery 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 on

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