Doc No: T.O.

AEW-2-34-4
Issue No: 16

CHAPTER 5

Battery Unit Servicing

5.5  MAINTENANCE INSTRUCTIONS

a. Organizational level maintenance of the battery unit is limited to inspection, cleaning,

reconditioning, and evaluating the performance of the battery pack. Batteries that are in
operation should be reconditioned every 12 months due to inherent loss of battery capacity
over time. Batteries brought out of storage should be serviced before put into use. Battery units
with fault indicators should be serviced to evaluate possible battery pack problems.

b. Servicing of batteries includes disassembly, inspection, cleaning, reassembly, reconditioning,

and troubleshooting.

5.5.1  Disassembly  Disassembly of the battery unit is limited to removing the battery pack for
inspection, cleaning, and reconditioning. See Figure 5-1.

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5.5.1.1  Battery Pack Removal  To remove battery pack from battery unit (Figure 5-1), perform the
following:

WARNING

Do not wear jewelry. Remove rings, watches and other metallic objects which may
cause shock or burn hazard.

CAUTION

Disconnect the battery pack assembly connector, P4 from the unit prior to any
disassembly. Electronic components will be destroyed if shorted to the system
chassis.

a. Loosen the captive dzus fastener stud at the rear of the unit cover (1/4 turn is usually
sufficient).

b. Remove the pan head screw, lock washer and flat washer from the top front of the cover.

c. Slide the cover backward from the battery unit.

d. Remove the battery pack connector, P4 from the bracket mounted connector, J4 on top of the
front battery pack assembly hold down bracket.

e. Loosen the eight captive screws that hold the two battery pack assembly hold down brackets on
top of the battery pack assembly.

f. Lift the battery pack assembly out of the case.

5.5.1.2  Battery Pack Disassembly  The battery pack is disassembled for visual inspection of the cells
and other battery pack components. To disassemble the battery pack (Figure 5-2), perform the
following:

a. Remove nylon chords holding battery pack assembly together.

b. Remove upper battery cover.

c. If necessary, remove heater blanket.

d. If necessary, remove lower battery cover.

5.5.2  Inspection  

CAUTION

Maintenance of the battery unit should not be accomplished in a lead-acid battery

shop. Water, tools, or hydrometers that have been contaminated by contact with
lead-acid batteries should not be used. Anything associated with a lead-acid battery
(acid fumes included) should never come in contact with the nickel-cadmium battery
or its electrolyte. Acid will damage plates of nickel-cadmium cells.

Prior to inspection of battery unit, clean tops of cells with a non-metallic brush to remove any
potassium carbonate deposits, then wipe clean with a clean cloth moistened with distilled water.
Inspect battery unit case for physical damage; wiring for loose connections, broken wires, or charred
insulation; electrical connector for bent or broken pins, damaged connector shell, or corrosion; circuit
breaker for loose connections or physical damage; individual cells for loose terminals, loose
connections with intercell connectors, and cracks in cell casing; and intercell connectors for corrosion
and loose connections with cell terminals. White deposits on components of battery unit may only be
potassium carbonate and should not be considered corrosion unless a thorough cleaning reveals
deterioration of component.

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5.5.3  Cleaning  Clean the battery unit as follows:

5.5.3.1  Cells  

WARNING

Battery electrolyte will burn eyes and skin. Wear safety glasses and rubber gloves
when cleaning battery unit or its components.

CAUTION

Use only non-metallic brushes when cleaning battery unit. Wire brushes will damage
cell casing and may short across cell terminals.

Cells are cleaned by loosening all white deposits (dryed electrolyte) from the cells with a non-metallic
brush. The cells are then washed off with distilled water and dried with either a clean cloth or cotton
swabs.

5.5.3.2  Connector  The connector is cleaned by removing it from the battery unit case and loosening
all white deposits from the connector pins and connector shell with a non-metallic brush. Loose
deposits are then wiped free with a clean dry cloth.

5.5.3.3  Battery Unit Case  The battery unit case is cleaned by washing with water and drying with a
clean dry cloth.

5.5.4  Reconditioning  The battery pack is reconditioned, (deep cycled), charged and evaluated using
the Battery Charger Analyser 24-400T per the following:

NOTE
These guidelines are intended to assist a qualified technician to service the
nickel-cadmium battery pack contained in the AMPS 2000(A) series emergency power
supply.

a. Remove the battery pack assembly from the main AMPS 2000(A) unit and conduct a visual
inspection. Check for signs of heat, vented cells (white powder), integrity of spot welds and
condition of the wiring harness and connector.

b. Remove the insulating covers and check the open circuit voltage across each and every cell
(Figure 5-3) using a digital multimeter. Check for shorted cells which will read 0.00 volts. Any
cell which reads significantly lower than the average cell voltage (or under 1.20v) should be
identified and monitored very closely.

c. Insert 0-60°C thermometer between cells.

d. Connect to Battery Charger Analyser 24-400T. With reference to Figure 5-3, connect black lead
to negative (outer) post of cell #1 and connect the red lead to positive (centre) post of cell #20.

e. Set Battery Charger Analyser 24-400T switch selections to:

Function switch Analysis

Time Selector 1 hour
Voltage selector 20
Voltage scale 200

f. Select Battery Charger Analyser 24-400T power switch to ON.

g. Carry out residual capacity test and discharge fully at a rate of 7 amps for 1 hour, battery can
be considered fully discharged when voltage reaches 20 vdc for 54 minutes.

h. Select Battery Charger Analyser 24-400T power switch to OFF.

i. Allow battery to cool to within 5°C of the ambient temperature.

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j. Select Battery Charger Analyser 24-400T switch selections to:

Function switch Constant Current

Time selector 12 hours
Voltage selector 20
Voltage scale 200

k. Select Battery Charger Analyser 24-400T power switch to ON.

l. Select the required charge mode, turn the current selector to 700 mA and charge for 12 to 15
hours.

CAUTION

Battery cell temperature must not exceed the limit of 48.9°C during charging.

m. During charge, monitor temperature of cells. If the cell temperature limit is exceeded,
immediately cease charging and allow battery to cool within 5°C of ambient temperature.

n. During charge, the battery voltage will eventually start to decline whilst the temperature
continues to rise. If this occurs after 12 hours cease charging, otherwise continue to charge for
a maximum of 15 hours.

o. On completion of charge select battery Charger Analyser 24-400T power switch to OFF and
allow cells to cool.

5.5.5  Assembly  Assembly of the battery unit is limited to reassembling the battery pack and
installing the battery pack into the battery unit. See Figure 5-1.

5.5.5.1  Battery Pack Reassembly  To reassemble the battery pack (Figure 5-2), perform the following:

a. Install lower battery cover.

b. Install heater blanket.

c. Install upper battery cover.

d. Install nylon chord to hold battery pack assembly together.

5.5.5.2  Battery Pack Installation  To install battery pack into battery unit (Figure 5-1), perform the
following:

WARNING

Do not wear jewelry. Remove rings, watches and other metallic objects which may
cause shock or burn hazard.

CAUTION

Disconnect the battery pack assembly connector, P4 from the unit prior to any
disassembly. Electronic components will be destroyed if shorted to the system
chassis.

a. Place the battery pack assembly into the case.

b. Position the two battery pack assembly hold down brackets on top of the battery pack assembly
and tighten the eight captive screws that hold them in place.

c. Install the battery pack connector, P4 to the bracket mounted connector, J4 on top of the front
battery pack assembly hold down bracket.

d. Slide the cover forward onto the battery unit.

e. Install the pan head screw, lock washer and flat washer into the top front of the cover.

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f. Tighten the captive dzus fastener stud at the rear of the unit cover (1/4 turn is usually
sufficient).

5.5.6  Post Installation Battery Voltage Check  Carry out a Post Installation Battery Voltage Check as
detailed at Table 5-2.

End Of Data Module

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Non-configured print. Valid only on 2023-01-05 Figure 5-1. Battery Pack Removal

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Non-configured print. Valid only on 2023-01-05 Figure 5-2. Battery Pack Disassembly

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Non-configured print. Valid only on 2023-01-05 Figure 5-3. Battery Cell Test Sequence

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