SartT (F6177) 26 quai C. Pasqua - 92300 Levallois-Perret - France Tél. +33 1 58 63 16 90 - Fax: +33 158 63 16 18 MAINTENANCE MANUAL WITH ILLUSTRATED PARTS LIST AIRCRAFT BATTERY 151CH1 date of creation: Nov 01/96 24-33-96 octzsn7sarTt Component Maintenance Manual 451CH1 This document and all information contained herein are the property of Saft. Its use is restricted solely to the maintenance of Saft batteries and may under no circumstances be used for any other manufacturer's prod- ucts. No person may, in whole or in part, duplicate, use or disclose this information for any other purpose without the prior written consent of Saft. 24-33-96 ocrzaitirsarTt Component Maintenance Manual 451CH1 RECORD OF REVISION Issue dato Issue dato 7 Feb 1572008 | Feb to/2008 | Saft 2 Sep 1272017 | Sep 1272017 | Saft 3 oct 2472017 | oct 242017 | sat 24-33-96 satansarTt Component Maintenance Manual 451CH1 PAGE INTENTIONALLY LEFT BLANK 24-33-96 oazuzorrsarTt Component Maintenance Manual 451CH1 RECORD OF TEMPORARY REVISION Tnserted Issue date Issue date Dato By 24-33-96 CladzorrsarTt Component Maintenance Manual 451CH1 PAGE INTENTIONALLY LEFT BLANK 24-33-96 ocrzuzotrService bulletin sarTt Component Maintenance Manual 451CH1 SERVICE BULLETIN LIST Thcorporation Into Number | Rev. Date Rev. Title 24-33-96 cifeazoirsarTt Component Maintenance Manual 451CH1 PAGE INTENTIONALLY LEFT BLANK 24-33-96 ocrzuzotrTITLE PAGE RECORD OF REVISIONS. RECORD OF TEMPO- RARY REVISIONS. SERVICE BULLETIN ust LIST OF EFFECTIVE PAGES TABLE OF CON- TENTS LIST OF ILLUSTRA- TIONS INTRODUCTION ROR ROR RTRA RTR2 sBL4 sBL2 LEP. LeP.2 Toca Toc.2 Toc3 Toc-4 Lom Lore Intro-t Intro-2 Intro-3 Intro-4 sarTt Component Maintenance Manual 451CH1 LIST OF EFFECTIVE PAGES Oct 24/2017 Oct 24/2017 Oct 24/2017 Blank Oct 24/2017 Blank Oct 24/2017 Oct 24/2017 Oct 24/2017 Oct 24/2017 DESCRIPTION AND OPERATION TESTING AND FAULT ISOLATION DISASSEMBLY CLEANING 24-33-96 1001 1002 1003 1004 3001 3002 4001 4002 Oct 24/2017 4/2017 Oct 24/2017 4/2017 4/2017 Oct 24/2017 Oct 24/2017 Blank 4/2017 Oct 24/2017 201 4/2017 Page LEP-1 Oct 24/2017INSPECTION/CHECK ASSEMBLY I FITS AND CLEA- RANCES SPECIAL TOOLS, FIXTURES, EQUIPMENT AND CONSUMABLE 5001 5002 5003, 5004 5005 5006 5007 5008 5009 5010 7001 7002 7003 7004 001 002 9001 9002 sarTt Component Maintenance Manual Oct 24/2017 Oct 24/2017 Oct 24/2017 Oct 24/2017 4/2017 ct 24/2017 Oct 24/2017 Oct 24/2017 Oct 24/2017 Oct 24/2017 Oct 24/2017 Oct 24/2017 Oct 24/2017 Oct 24/2017 Oct 24/2017 Blank Oct 24/2017 Oct 24/2017. 451CH1 ILLUSTRATED PARTS LIST STORAGE (INCLU- DING TRANSPORTA- TION) 24-33-96 10001 10002 10003 10004 10005 10008 15001 15002 15003 15004 Oct 2ai2017 Oct 24/2017 Oct 24/2017 Oct 24/2017 ct 24/2017 Oct 24/2017 Oct 24/2017 4/2017 Oct 24/2017 Oct 24/2017 Page LEP-2 Oct 24/2017sarTt Component Maintenance Manual 451CH1 TABLE OF CONTENTS RECORD OF REVISION - - RECORD OF TEMPORARY REVISION SERVICE BULLETIN LIST -- LIST OF EFFECTIVE PAGES --- TABLE OF CONTENTS ------------------- LIST OF ILLUSTRATIONS INTRODUCTION - 1. General === INTRO 2. Definitions INTRO-1 3. Safety ~ INTRO-1 ‘3-1. Physical === INTRO 3-2. Electrical INTRO-1 3-3. Chemical - INTRO-1 4. Aircraft Conversions. INTRO-2 5. Ground Applications INTRO-2 6. Placing a new battery in service - inital commissioning - INTRO-2 7. Battery Ratings INTRO-2 7-1. Capacity INTRO-2 8. Recycling - INTRO-2 9. End of life cells INTRO-2 40. Measurements - INTRO-3 410-1, Units of Measure - INTRO-3 10-2. Measurement Conversion Table - INTRO-3 10-3. Temperature Conversion Table INTRO-8 10-4. Abbreviations - INTRO-4 DESCRIPTION AND OPERATION 4. Description - 41-1. General 2. Technical data 2-4. Characteristics — 2.2. Overall dimensions 3, Description 4. Operation - 4-1, climatic requirement 4-2, Maintenance ~ 8, Charge - 5-1. Constant Current Charge - 5-2. Rapid Partial Charge 5-3. Constant Potential Charge 5-4. Other methods of charging TESTING AND FAULT ISOLATION - 4. Introduction ~~ 1-1. Battery electrical faults 4-2, Cell faults - 1-3. Physical faults DISASSEMBLY 4. Introduction 2. Safety = 24-33-96 alls!sarTt Component Maintenance Manual 451CH1 3. Equipment - 341, Standard tools - 3-2. Special tools 4, Disassembly procedures 4-1, Removing the cover (030) ----- 4-2. Removing the cells (160) 4-3. Removing the vent valves (210) 4-4, Removing the terminals (110) ~ 4-5. Removing the sensor (240) - 46. Disassembly of the battery - CLEANING 4. Introduction 2. Safety ~ 3. Equipment 3+4, Standard tools ~ 3-2. Special tools 3-3. Consumables - 4, Light Cleaning 4-1, Procedure - 6. Thorough Cleaning ---- 5-1, Procedure - 6. Lubrication - INSPECTION/CHECK - 4. Introduction 1-1, General 2. Maintenance intervals 2-4, Periodical check ~ 2-2. Regular check - 2:3. General overhaul - 5. Equipment 5-1, Standard tools - 5-2. Special tools 6. Periodical check - 6-1. Visual Inspection 6-2. Insulation check 6-3. Nuttightness - 6-4. Polarization test - 65. Residual discharge 6-6. Adjust electrolyte level 6-7. Supplementary test 7. Regular check =~ 7-4. Cell shorting 7-2. Capacity check 8. General overhaul 8-1. Component inspection 8-2. Replacement of faulty components. ~ 8-3. Sensor check ~ 8-4. Vent valve test - 9. Return to Service After Storage ASSEMBLY 4. Introduction 2. Safety - 3. Equipment 3+1, Standard tools ~ 3-2. Special tools, 4. Battery Assembly -- 24-33-96 als?sarTt Component Maintenance Manual 451CH1 4-4, Installation of the liner spacer kit (220) ~ 4-2. Installation of the cells (160) ~~ 4-3. Installation of the vent valve (210) 4-4, Installation of the sensor (240) - 4.5. Installation of the connector (110) ~~ 46. Recording - FITS AND CLEARANCES --- 4. Introduction 2. Torque table SPECIAL TOOLS, FIXTURES, EQUIPMENT AND CONSUMABLES 4. Introduction 2. Standard tools 3. Special tools 4. Consumables ILLUSTRATED PARTS LIST - 4. Introduction 4-4, General 4-2, Numerical Index ~ 4-3, Detailed Parts List 2. Alpha numerical index. 3, Detailed part list - STORAGE (INCLUDING TRANSPORTATION) -- 4. Introduction 1-4, General 4-2. Storage room = 4-3. Temperature conditions 2. Inactive long term storage - 3, Inactive stand-by storage 344, Definition - 3-2. Ambient temperature with ‘topping’ or refresh charge’ 3-3. Action atthe end of the standby period 4, Active stand-by mode (= use of a trickle charge) 5. Spares - 5-1. Spare Cells - 5:2. Spare O-rings, gaskets and vent valves 5:3. Other spares 6. Servicing after discharged storage 7. Transportation procedure - - 24-33-96 als?sarTt Component Maintenance Manual 451CH1 PAGE INTENTIONALLY LEFT BLANK 24-33-96 ocrzuzotrINTRO 1 2 5001 5002 5003, 5004 7001 7002 10001 15001 sarTt Component Maintenance Manual 451CH1 LIST OF ILLUSTRATIONS Universal Recycling Symbols, Overall dimensions 'S1CHt Nickel-Cadmium Aircraft Battery Periodical check Position of Syringe in Cell Vent Seat Regular check General overhaul Liner spacer kit installation Installation ofthe sensor |S1CH1 Nickel-Cadmium Aircraft Battery Short term storage INTRO-2 2 3 5002 5004 5008 5008 7002 7003, 10008 15002 24-33-96 Page LOI-4 Oct 24/2017sarTt Component Maintenance Manual 451CH1 PAGE INTENTIONALLY LEFT BLANK 24-33-96 ocrzuzotrsarTt Component Maintenance Manual 451CH1 INTRODUCTION 4. General ‘This manual provides the information necessary for an experienced shop technician to maintain Saft nickel-cadmium batteries. It describes construction of the battery, as well as techniques used to operate, maintain, repair, overhaul, and generally care for the battery. Following these instructions will enhance the abilty to obtain optimum performance and maximum lfe from Saft batteries, All aircraft batteries require checking and maintenance in order to make sure they are safe when installed and they perform their required functions especially In emergency conditions on board the aircraft. Maintenance checks also permit any prob- lems to be identified and comected. The maintenance interval is the period for which correct operation is assured with a low probability of failure and allows high levels of MTBUR and MTBF to be achieved. Apart from the question of safety, the avoid- ance of failure on board the aircraft, with consequent costly impact on delays, reduces operational costs, Every effort has been made to provide complete and accurate instructions. If a situation should arise that is not adequately described in this manual, please contact Saft via the internet at www. saftbalteries.com or at one of the following addresses: ‘Saft America Ine. (V09052) Saft (F6177) 711 Gil Harbin Industrial Boulevard 26 qual C. Pasqua Valdosta, Georgia 31601 - USA 92900 Levallois-Perret - France Tel: +1 (229) 247-2331 Tel : +33 1 58 63 16.00 Fax: +1 (229) 247-8486 fax: +33 168 63 16 18 Website All Saft technical documentation, distributors and repair shops can be found at www saftbatteries.com. 2. Definitions Wamings call attention to use of materials, procedures, or limits, which must be followed precisely to avoid injury to persons, Cautions call attention to procedures which must be followed to avoid damage to equipment, Notes call attention to procedures which make the job easier. 3. Safety Caution: Except for those steps that require the battery to be charged, do all steps on discharged batteries (refer to Residual discharge paragraph) to avoid the possibility of electric shock. Tighten vent-valves (210) prior to be- ginning discharge. Battery cells deliver very high current when short-circuited. Exercise caution. Remove rings, watches, necklaces, metallic belts or other jewelry to avoid electric shock. Caution: Do not tilt the battery while doing maintenance, any contact of skin with olectrolyte can cause severe burns. Safety rules are diferent from one country to another. Always follow local safety regulations. ‘There are three types of risks. 3-4. Physical = Handling: the battery is heavy. When you lift it, bend your legs and not your back - Use protective shoes. 3-2. Electrical Do not wear rings, watches, chains, belt buckles, necklaces or any other metallic objects, = Use insulated tools, 3-3, Chemical For a complete listing of hazards, refer to the safety information sheet available on Saft's website at www. saftbatter- igs.com. Electrolyte is very corrosive and can damage the skin: use gloves and an apron. Ifit touches the skin, flush affected part with water and neutralize with an acetic solution, vinegar or lemon juice, or with @ boric acid solution at 10% con- ‘centration, Electrolyte is very dangerous for eyes, use protective goggles. I the electrolyte comes in contact with the eyes, flush them with water for at least 15 minutes and immediately call a doctor. - Electrolyte ingestion can cause damage to the throat and the respiratory tract. Do not ty to vomit. Calla doctor im- mediately. ~ Skin contact with nickel can cause chronic eczema, ~ Inhalation of cadmium oxide can cause dry throat, headaches, vomiting, chest pain. iTinhaled, remove to fresh air. If Not breathing, give artificial respiration. If breathing is dificult, give oxygen. Get medical attention immediately. 24-33-96 s.!NtRosarTt Component Maintenance Manual 451CH1 Potassium hydroxide in the electrolyte can cause eczema, 4, Aircraft Conversions Saft aircraft batteries come in a wide variety of configurations that are approved for installation on selected aircraft. When re- placing a lead-acid battery with a Saft nickel-cadmium aircraft battery, itis vitally important to clean all mounting and holding fixtures in the aircraft prior to installation. All traces of acid and salt should be removed by washing with a neutralizing agent such as sodium bicarbonate (baking soda) in water. Once the area has been fully cleaned and prepared, the surface should be painted with an alkaline resistant paint. This preparation should ensure that your new Saft battery will not be harmed by sulfuric acid residue. 5. Ground Applications Your Saft battery can be used in such ground applications as starting gas turbine generators, ground mobile equipment, or in shop testing equipment. The same principles used in fight operations apply when the battery is used in ground applications. entiation of the battery during ground use can be accomplished through a ventilation system or by simply removing the cover (only in a well-ventilated area). Check with your local authorities for regulations in effect for your area, 6. Placing a new battery in service - initial commissioning NOTE: Whether or not the battery has been subject to disassembly and reassembly, before its issue to service and installation, the tightness of all upper nuts / screws must be checked to verify that torque values correspond with those specified (refer to the Nut tightness chapter). Saft batteries are shipped discharged. A visual inspection, torque check, charge procedure, electrolyte check, and insulation test should be done prior to the battery being placed into the aircraft for service. Refer to the Inspection/check chapter. Ifthe battery has been stored for longer than 3 months, refer to Servicing after discharged storage. 7. Battery Ratings 7-4. Capacity Nickel-cadmium batteries are rated in terms of capacity in ampere-hours (Ah) (ated capacity). ‘American Standard AS8033 defines capacity as “the dischargeable ampere-hours (Ah) available from a fully charged cellbat- tery at any specified discharge rate/temperature condition’. Other definitions for battery ratings can be found in EN2570, IEC 60952 and RTCA DO 293. A battery rated for 1C; An indicates that the battery is rated at a value based upon a discharge time of 1 hour at 23°C + 3°C (34°F 1 5.4°F), 8. Recycling All batteries eventually lose their ability to perform and are eligible for scrap and recycling. Saft takes environmental matters seriously and advocates proper recycling of nickel-cadmium batteries and their components. To that end, Saft operates recy- cling facilities in both Europe and North America, Nickel-cadmium batteries contain nickel, cadmium, and potassium hydroxide and should be disposed of properly. In all cases, rely on local and national regulations for proper battery disposal andior shipping to an appropriate recycling location, Ni-Cd Figure INTRO-4 Universal Recycling Symbols You can find the nearest recycling collection point on our website at www saftbatteries.com. 9. End of life cells EASA regulations ‘Part 145%, require that end of life cells must be disposed of in a manner that does not allow them to be re- turned to service. The following procedure provides a means of complying with these regulations, 24-33-99 Ps. !NtR02sarTt Component Maintenance Manual 451CH1 While other authority requirements (such as FAA) may be less explicit, Saft recommends that the following procedures be ad- Copted_in order to ensure that end of ite cells cannot be re-used ~ Ensure that appropriate protective measures (refer to Safely paragraph and the Battery Information Sheet (BIS)) are tak- en - Ensure that the cells fll discharged (refer to Gell shorting paragraph) = Put one of the terminals from the cell between the two sides of a bench vice and bend until the terminal breaks. In the event of electrolyte leakage, ensure that appropriate clean up measures as described in the Battery Information Sheet are observed - Dispose of the cell in accordance with applicable transport, health and safety and recycling regulations (Refer to Recycling paragraph), 10. Measurements ‘The measurements which are given in this manual come from the original manufacturer drawings. ‘This CMM uses the “Systeme Internationa’ (S..) units for quantities and values. It also gives the imperial units in parentheses. 10-4. Units of Measure A ‘Ampere Ah ‘Ampere hours CA Rated current Gyan Rated capacity for an hour 9 Gram m Meter ‘min Minute N Newton Nm Newton meter Pa Pascal Voc Volt direct current “c Degree Celsius % Percent w ‘Ohm ft Foot in Inch ing Inch of mercury 'b Pound Ibf.in Pound force inch °F 104-3. Multiplying Prefixes u da k M Degree Fahrenheit Micro Mili Deca Kilo Mega 10-2. Measurement Conversion Table 1 kPa tom From U.S. Standard System to ILS. Measurement 0.1450 psi 0.3937 in 24-33-96 Page INTRO-3 Oct 24/2017sarTt Component Maintenance Manual 451CH1 tom* 0.1550 int 1N 0.2248 lot 19 0.0353 02 1k 2.2046 Ib 41mm. 0.0394 in 1Nm 8.8507 Ibfin From U.S. Standard System to 1.8. Measuroment 1 psi 6.8948 kPa tin 2.54 cm tin 254mm in 6.4516 om? 1ibF 4.4482 N toz 28,3495 g Tinkig 93,3864 kPa 1b 0.4536 kg 1 gal (US.) 3,7854 limi 4 Totin 0.1130 N.m Abt 1,3558 Num 10.3. Temperature Conversion Table |. SI MEASUREMENT Degrees Celsius (°C) Celsius = (Fahrenheit - 32) x 0.5555 10-3-2. U.S. STANDARD SYSTEM Degrees Fahrenh Fahrenheit = (Celsius x 1.8) + 32 10. cr) 10-4, Abbreviations ‘The abbreviations given below are used in this manual: AECMA European Association of Aerospace Industries ATA Air Transport Association of America dia. diameter EASA European Alr Safety Authority FAA Federal Aviation Authority fig figure IATA International Transport Air Association IMDG. International Maritime Dangerous Goods 'pl iustrated parts list max. maximum mfr manufacturer min ‘minimum, MTBF ‘Mean time between failure MTBUR ‘Mean time between unscheduled removal i number pin part number para, paragraph ret. refer to sa subassembly TBD to be defined v Voltage 24-33-96 Page INTRO-4 Oct 24/2017sarTt Component Maintenance Manual 451CH1 DESCRIPTION AND OPERATION 4. Description 41-4, General The batteries are connected to the aircraft system: ~ According to the aircraft manufacturer, to start the engine or the APU. = On the ground, to provide power before electrical power is supplied to the aircraft systems, - In fight, if a malfunction or a failure occurs in the power supply system. 2. Technical data 244. Characteristics ‘The most important characteristics are indicated in the table below. Technical data Values Electrolyte level (rim) | 20 mm (0.79 in) Consumable volume of electrolyte per cell End of charge voltage | 1.55 V/per cell 15 em (0.92 in 24-33-96 ccrzudoirsarTt Component Maintenance Manual 451CH1 2.2. Overall dimensions ap 210 max, 133 MAX Figure 1 Overall dimensions 3. Description NOTE: The item numbers are those of the detailed parts list chapter (Refer to Detailed part list). ‘The 151CHt Saft nickel-cadmium battery consists of a box (020), containing 20 individual cells CVHi50KH. These cells are conriected in series to obtain 24 V. nominal. Individual cells are enclosed in @ polyamide container that provides insulation, allowing them to be fitted side-by-side in the battery box. Interconnection of cells is via rigid, highly conductive, nickel-plated copper links (130 to 150). Each link is held in place by nickel-plated copper nuts (100) on the cells'terminals. Inside the battery box, individual cells are held in place by partitions, liners and spacers (220), and a cover (030) The terminals (110) connects the battery tothe aircraft DC power. 24-33-96 ccrzadoirsarTt Component Maintenance Manual 451CH1 The cover (030), which can be removed, is attached to the box (020) by four screws. et Or—~ Cover complete Filling instruction plat Connector Box Identication plate Connector, sensor Figure 2 Nickel-Cadmium Aircraft Battery 4, Operation 4.1. climatic requirement Unless otherwise stated, charge and discharge testing should be done when the battery temperature is between + 15 °C and +30°C. 4-2. Maintenance AAlmaintenance, including charging, dlscharging, should be done specifcaly in accordance withthe instructions contained in this manual 5. Charge 5-1. Constant Current Charge Starting with a discharged battery ~ Remove the cover complete (030). = Loosen, but do not remove, all vent-valves (210). 24-33-96 ccrzudoirsarTt Component Maintenance Manual 451CH1 ~ Charge using one of the methods shown in the table below. NOTE: Check cell voltage at the beginning of the charge. If any cell indicates an immediate voltage rise above 1.5 V, ‘add 5 cm? of distilled or deionized water to that cell. ~ During the last 15-30 minutes of the overcharge cycle, Adjust electrolyte level. Final charge Main charg a (overcharge) Minimum Current Current and duration Aa aren ‘Minimum voltage 15a time mini 10h 1.5 V [per cell BAfor4h 55. [per cal maxi 12h TSA time mini 2h 1.55 V/per cell 15 Atoranh 1.55VIper call ‘maxi 2 30 min, 1A time mini Th 1.57 V/ per call 15Atorah 155.V per call maxi 115 min Table 1 - Charge Rates 5-2. Rapid Partial Charge (One of the following twa procedures can be used in an emergency situation to charge the battery to approximately 80% ofits capacity. Do not use these procedures for charging the battery during normal maintenancé = Charge the battery at 7.5 A untl the battery reaches an average of 1.55 Vicell. Do not charge for more than 2 hours ‘and 30 minutes or ~ Charge the battery at 15.A untl the battery reaches an average voltage of 1.57 Vicell. Do not charge for more than 1 hour and 15 minutes. 5-3. Constant Potential Charge Caution: Constant potential charging should not be attempted if the open circuit battery voltage is below 1.0 V per cell In an emergency, a partially discharged battery may be recharged using a constant potential charging system such as exists, on the aircraft. Do not use this procedure for charging the battery during normal maintenance: With the use of a constant potential system, itis imperative thatthe charge rate be checked periodically for accuracy, and that, the charger be set according to the average ambient operating temperature. NOTE: A maintenance check of the battery should be done at the Connect the battery to the constant potential power source. Charge for a minimum of 1 hour at 1.425 Vicell to obtain approx- imately 90% of the rated capacity ofthe battery. NOTE: A maintenance check of the battery should be done at the earliest opportunity to verify battery performance. st opportunity to verify battery performance. 5-4, Other methods of charging In addition to the constant current method of charging, other methods that fully charge the battery can be used. However, in any case, individualcell voltage checks (U 21.55 V/ per cell) and electrolyte adjustments must be carried out using a final over- Charge sequence at constant current 1.5 during 4 hours. If specific instructions are not given inthe charger operating manual, you must frst contact Saft, 24-33-96 ccrzadoirsarTt Component Maintenance Manual 451CH1 TESTING AND FAULT ISOLATION 4. Introduction This chapter gives the tests and inspections required to find the cause of faulty condition ofthe unit either removed for unsched- Uuled maintenance or during scheduled maintenance. The test procedure is given in the tables below. For each test refer to the indicated procedures which specify all necessary information. 4-4. Battery electrical faults (1) Zero battery oper-circut | (a) Defeciive electical connector (no | Check electical contacts, inks and tight voltage contact made) ness of nuts (refer to Inspection/check). (©) Link broken (2) Zero voltwith the battery | (a) Battery fully discharged Do an insulation check (refer to Inspec- set to “discharge” tion/check) (b) Battery circuit open or contacts | Examine the contacts and links, defective ‘Make sure the terminal nuts are tight, (refer to Inspection/check) Refer to related subsequent steps. (©) Cell completely dry Replace the cell (8) Low insulation | (@) Leakage of electrolyte Disassemble and clean the battery (refer to Disassembly and Cleaning). Do an electrolyte level check (refer to. Inspection/checto, Table 1 - Battery electrical faults 24-33-96 oitZizotr12. Cell faults Problem (1) Too much water decrease for all battery cells. (2) High water dispersion: water consumption in one or more cells) is very different {rom the other cells in the bet- tery. @)Acelihas a higher voltage atthe start of charge than is efined in para. Charge chap- ter Description and operation. sarTt Component Maintenance Manual 451CH1 Probable cause (a) Charge much more than the Imitor too much charge at high temperature (0) Previous maintenance has not been done. (@) more than 30% above the average value of added water in all cells: eak- ing celis), (0) less than 30% below the average value of added water in all cells: cell's) with damaged separator(s). (@) Dry cell ‘Correction Examine the cause of excessive charge Ifnecessary, adjust to normal operating temperature (refer to Description and oper. ation). Note the cell location and check the level of water consumption versus other cells at the next maintenance. Dissassemble the battery (refer to Disas- sembly). Clean the battery (refer to Clean- ing).. Replace the cell(s). Charge and do an electrolyte level check (refer to Inspec- tion/check). Do the Supplementary test (refer to Inspec: lonicheck). I necessary, replace the cells). When the defect occurs, add 5 em? (5 mi) Of distilled water to the cell. Do not adjust more accurately until the end of the charge. NOTE: if you charge a cell wi to increase too much. (@) A cel has a lower voltage at the end of charge than is defined in para. Charae chap- ‘er Description and operation (6) Low capacity cell ith a quantity of electrolyte which is not: (2) The cell was operated at tempera- tures and charge rates outside the lim: its, and the separator is damaged. (&) Usual wear after long operation (@) insufficient balancing () Usual wear after long operation. () Unusual operation, operation at high temperature or operation with low electrolyte. sufficient, this can cause the temperature Replace the cell (refer to Disassembly, Repeal Charae, discharge at 15 A and Gall shorting up to three times, Replace thecal eft Dissssamb Do the applicable procedure (refer to Inspection/check) (© Cell with a swollen case. (7) Cell with zero voltage when the battery circuit is (@) Cell operated with low electrolyte level; deterioration of separators and damaged plates. (@) Short-circulted cell Replace the cell (refer to Disassembly) Replace the cell (refer to Disassembly open. ‘Table 2 - Coll faults 24-33-96 Page 1002 Oct 24/201741-3. Physical faults Problem sarTt Component Maintenance Manual 451CH1 Probable cause Correction (1) Leakage of electrolyte. {a) Incorrect adjustment of electrolyte level (©) Cell polarity incorrect during high: rate discharge (for example, during the engine star) (¢) Too much charge at high tempera- ture or too much current. (2) The lower nut isnot correctly tight- ened, Disassemble and clean the battery (refer to Disassembly and Cleaning chapters). Do an electrolyte level check (refer to Inspection/checky) Disassemble and clean the battery (efer to Disassembly and Cleaning). Do an electrolyte level check (refer to Inspection/check). Investigate the cause of excessive charge. If necessary, adjust to normal operating temperature (refer to Disassemble and clean the battery (refer to Disassembly and Cleaning), Do an electrolyte level check (refer to Inspection/check). ‘Torque the lower nut (refer to Asses: by chapter) (2) Electrolyte found in the battery ox (3) Corrosion on the links, (4) The links are too hot. (a) Damaged cell case. (b) Leakage of electrolyte (@) Operation in acidic air (b) Mechanical damage to nicke! plat- ing, (2) Loose terminals nuts. Table 3 - Physical faults 24-33-96 | Make sure the battery test bench and | Make sure the nuts are torqued (refer Replace the cell ifnecessary and refer to related subsequent steps. Disassemble and clean the battery (efer to Inspection/check and Clean- ing). Do an electrolyte level check (refer to Inspection/check). the storage areas have no materials, which can give off acid fumes. Replace the damaged links (refer to. Disassembly, Assembly AND Storage including transportation to Inspection/check), Page 1003 Oct 24/2017sarTt Component Maintenance Manual 451CH1 PAGE INTENTIONALLY LEFT BLANK 24-33-96 ocrzuzotrsarTt Component Maintenance Manual 451CH1 DISASSEMBLY 4. Introduction NOTE: Refer to the Testing and fault isolation chapter to Identify the possible cause of a malfunction. This will give 1e necessary level of disassembly. ‘The instructions found in this section are designed to allow the maintenance person to completely disassemble the battery for the purpose of General Overhaul. However, some maintenance operations do not require complete disassembly. Disassemble only to the extent necessary to effect appropriate repair or replacement. 2. Safety Refer to chapter Standard tools in Special tools, fixtures. equipment and consumables, 3. Equipment 3-1, Standard tools Refer to chapter Standard tools in Special tools, fixtures, equipment and consumables, 3-2, Special tools, When special tools are used in this chapter, they are identified by a code number isted in Special ols, fxtures, equipment and consumables chapter. 4, Disassembly procedures NOTE: All () part identification numbers herein are IPL Fig. 1 item numbers and are using hypertext facility. 4-1, Removing the cover (030) Unscrew the srews (060) and the washer (070). Remove the cover taking care to avoid contact between the cover and the cell terminals or links. 4-2. Removing the cells (160) NOTE: Make note of the proper placement of the links (130 to 150) prior to removal. To facilitate ease of removal, remove the conter coll in each row first. Remove the nuts (080) and (090) Remove the nuts (100) and the washers (120) that attaches links to the cells. remove the connector (110) Remove all links (130 to 150) Fully screw the extractor tool (T04) onto a cell terminal then pull up to remove the cells (160) 4-3. Removing the vent valves (210) Unscrew the vent valve with the special tool (01). Remove the vent valve (210) with its O-ring 4-4, Removing the terminals (140) Unscrew the nuts (110) and the washer (100). ynsor (240) 4-5. Removing th: Remove the cable grip (230) Remove the nuts (260) and (270) withe the washer (290) attaching thermostat from the link Remove the sensor (240) 24-33-94 ittsarTt Component Maintenance Manual 451CH1 46, Disassembly of the battery Remove the cover (030) according to para. Removing the cover (030) Remove the connector (110) according to para. Removing the terminals (110). Remove the sensor (240) according to para. Removing the sensor (240). Remove the cells (160) according to para. Removing the calls (160). Remove the liner spacer kit (220). NOTE: Note placement prior to removal to ensure proper placement during re-assembly. 24-33-96 Page 3002 Oct 24/2017sarTt Component Maintenance Manual 451CH1 CLEANING 4. Introduction ‘The instructions in this chapter are for the general cleaning of your Saft aircraft battery. The instructions under “Light Cleaning” are to be done each time the battery is removed from the aircraft, and can be accomplished with no disassembly ofthe battery ‘The section “Thorough Cleaning” includes the instructions for the cleaning of a disassembled battery or the purpase of a Gen- eral Overhaul 2. Safety Refer to chapter Standard tools in Special tools, fixtures. equipment and consumables, 3. Equipment 344, Standard tools Refer to chapter Standard too's in Special tools. fixtures. equipment and consumables. 3-2. Special tools When special tools are used in this chapter, they are identiied by a code number listed in Special tools, fixtures, equipment ‘and consumables chapter 3-3, Consumables When consumables are used in this chapter, they are identified by a code number listed in Special tools, fixtures, equipment and consumables chapter. 4, Light Cleaning On an assembled battery Caution: Do not use solvent, petroleum spirits, trichloroethylone or other products contai the battery. The use of solvents may degrade the integrity of metal and plas NOTE: All () part identification numbers heroin are IPL Fig. 1 item numbers. ing chloride for cleaning 44. Procedure Caution: To prevent injury when using compressed air, direct air stream away from the body. Use safety goggles to prevent eye injury from airborne particles. = Remove the battery cover complete (030). ~ Check the battery vent tubes to ensure that they are clean and clear - Hand tighten the vent valves (210) withthe Universal vent wrench (L041) = Remove potassium carbonates (white deposits) from the top ofall cells (160) using a sti bristle, non-metal brush. - Disperse residual salts and dust particles from the battery using blasts of clean, dry compressed ar. Goat all nuts (100) and links (130 to 150) with MO2. 5. Thorough Cleaning On a disassembled battery 5-4. Procedure Fully disassemble the battery (refer to Disassembly chapter) 5-4-4, Cells (160) Make sure that the vent valve (210) is tight Caution: Do not soak the cells in water. To easily remove all the electrolyte and mineral salts from the terminals, the cover and the sides of the cell cases: clean in warm water with a soft brush Rub the cell with a cloth and let dry. 5-4-2. Box and cover (010) Clean with lightly soapy water, rub with a cloth and let dry. 24-33-9§ iesarTt Component Maintenance Manual 451CH1 544-3. Nuts, spring washers and links. Clean in lightly soapy water with a brush, rinse well with clean water and let dry. 5-1-4. Liner spacer kit (220) Clean in warm water and let dr. 5-4-5. Vent valve (210) Caution: The cleaning of the vent valve (210) must be done when the cells are assembled in the box. Remove the vent valve (210) (Refer to Disassembly chapter) Cover the cell holes to keep out unwanted materia ‘Soak the vent valve for some time (during the night, for example) in a container of distilled water to remove all salts from the vent hole, 6. Lubrication When the battery is clean (and after installation of the vent valve), coat all upper nuts (100), the washer (120) and links (130 to 150) with MO2. 24-33-96 oitZizetrsarTt Component Maintenance Manual 451CH1 INSPECTION/CHECK 4. Introduction 444. General This chapter includes the checks, the maintenance procedures and the functional ests that must be done to use Saftbatteries In fight and on the ground. NOTE: All() part identification numbers herein are IPL Fig. 1 item numbers. 2. Maintenance intervals The aircraft manufacturer is responsible for defining the usage and function, including maintenance intervals, for airraft bat- teries installed in its aircraft. Saft only provides recommendations that require the agreement ofthe aircraft manufacturer. NOTE: Maintenance stops must be completed in a battory shop. Saft distinguishes between three types of maintenance 244, Periodical check ‘The periodical check consists essentially of voltage and insulation checks, discharge of residual capacity and charge with elec- trolyte level adjustment. The main purpose of this periodical checks to replace water which is consumed by electrolysis during battery overcharge. It is normally applied between regular checks but can be omitted if the water consumption measured at the regular check is within allowable mits. 2-2. Regular check ‘The regular check is the same as the periodical check except that the battery is also deep discharged (‘balancing followed by a capacity check cycle. 2-3. General overhaul ‘The general overhaul is the same as the regular check except that the battery is also disassembled and thoroughly cleaned and inspected. 3. Recording {tis very important to record the battery check values (capacity, end of charge voltage, water consumption) for each cells as required in the battery logbook for each maintenance. It is recommended that an operator tracks these maintenance data in order to verify the interval is correct relative to that particular operation. This may also allow the interval to be extended if the data justifies it. 4. Safety Refer to chapter Standard tools in Special tools, fixtures. equipment and consumables, 5. Equipment 54. Standard tools Refer to chapter Standard tools in Special tools, fixtures. equipment and consumables. 5-2. Special tools When special tools are used in this chapter, they are identified by a code number listed in Special tools, fixtures. equipment ‘and consumables chapter. 24-33-96 itesarTt Component Maintenance Manual 451CH1 6. Periodical check PERIODICAL CHECK Visual Inspection OK? Insulation check U>21V ro cell wth reversed polarity Polarization test OK Battery accepted after Periodical check Figure 5001 Periodical check 24-33-96 oitfuzetrsarTt Component Maintenance Manual 451CH1 Consult the airframe manufacturer for specific maintenance intervals or special procedures to be followed. Otherwise, at spe- Gif intervals according to aircraft use, orif electrolyte consumption exceeds the approved consumption levels between 2 reg- lular checks, do this periodical check according to the above figure, NOTE: Time periods are given as a guideline. Modify in accordance with operational experience. Periodic and Regular maintenance checks may be combined if operating hours permit. 6-4. Visual Inspection Visual inspection should be done each time the battery is removed for maintenance. ~ Remove the cover complete (030). - Visually check each cell (160) for any evidence of electrolyte leakage. If there is salt or electrolyte traces doa General gverhaul. Excessive salts around a terminal post indicates possible leakage from the terminal O-ring. Verify the torque ofthe lower nut (refer to chapter Assembly). ~ Inspect the links (130 to 150) and all upper nuts (109), and washers (120). The hardware should be free of bends, tamish, corrosion, bums, or any loss of nickel plating. Minor tarnish can be polished off witha fine wire brush. Defec- tive hardware should be replaced. ~ Check the connector (110) for evidence of arcing, corrosion, cracks, or cross-threaded terminals. Replace the defec: tive connector. Caution: Worn aircraft terminals andior loose connections can greatly affect the performance of the battery. A defec- tive terminal (110) can cause battery self-discharge as wel as low voltage in servic ~ Inspect the electrical connector for bent or loose pins, corosion, cracks, faulty wire connections, evidence of arcing, ‘or cracked or loose potting material = Inspect the battery box (020) and cover assembly (030) for any damage. Minor dents may be repaired with a small rubber mallet. Ensure the cover gasket (050), if applicable, is undamaged and fully secured to the cover assembly (040) 6-2. Insulation check ‘A breakdown in electrical insulation between the cells (160) and the battery box (020) will result in a “leakage” current, which over time will discharge the battery. The most common cause for the loss of insulation is the leakage of electrolyte from the Cells (180) that acts as a conductor between the cells and the battery box (020). Because leakage current can affect battery performance, itis necessary that it be kept to a minimum. ‘Ona completely assembled battery, use a megohmmeter, set to 250 V DC, to mea- sure the insulation resistance between the positive terminal of each cell (160) and the battery box (020). Measure the insulation between pin A, B, C, D, E, F of the connector of the sensor (250) and the box(020), Measure the insulation between pin A, 8, C, D, E, F of the connector of the sensor (250) and the positive terminal (110) Refer to the table below for the acceptance criteria, 250 KQ 2MQ 10MQ Must be cleaned, Acceptable but | Acceptable for in ser- | Mandatory level of Do a General cleaning is recom- vice battery insulation for new or Overhaul mended in service battery ‘Check the cause after cleaning (overcharge...) 6-3. Nut tightness. Tighten and check the torque ofall upper cell nuts (100) (refer to Fits and clearances) 24-33-96 Page 5003 Oct 24/2017sarTt Component Maintenance Manual 451CH1 6-4, Polarization test Charge the battery at 1.5 A for 1.5 hours. Leave the battery on open circuit for 1 hour. Measure the open circuit voltage of each cell. If any cell is zero (0) V or negative polarity, do a General overhaul. If all cells are above zero (0) V, continue with maintenance as specified. 6-5. Residual discharge Discharge the battery at the 15 A or 7.5A rate until each cell in the battery is discharged to 1.0 volt or below. 6-6. Adjust electrolyte level Caution: Using anything other than distilled or deionized water in nickel-cadmium cells will cause electrolyte contam- ination and damage. ‘Always take appropriate precautions to prevent any foreign substances from entering the cell. Anything other than distilled or deionized water that enters the cells will cause electrolyte contamination and will affect overall performance, ‘The amount of time that the vent-valves are removed from the cell for maintenance should be limited to prevent as much air as possible from entering the cell. Carbon dioxide inthe air will combine with the electrolyte to form potassium carbonate. Po- tassium carbonate will increase the internal resistance of the cells and thus decrease the performance at low temperatures and during high rate discharges. Always ensure that the vent-valves are properly secured while the battery is in use. Electrolyte level adjustment must be done during the last 15-30 minutes of the 4 hours overcharge at 1.5.4 rate of charge. Caution: Take care not to tilt cells while vent-valves are loosened or removed. Contact of electrolyte with skin can ‘cause burns. If contact occurs, flush area with large amounts of water. Electrolyte in the eyes is very serious. Flush with water and contact a doctor immediately. Caution: The battery must be fully charged before adjusting the electrolyte level. Use only distilled or deionized water (see chapter Spesial tons, Fixtures, equipment and consumables). Do not re-use water removed from cells. The quantity (in cm*) required to level the first cell will serve as a guide for requirements of the remaining cells but the amount of water required for each cell can vary, so carry out this check on a cell by cel basis. Each cell must be leveled individually. If the quantity of water added per call is above 80% of the electrolyte water volume ‘shown in the specification tables (refer to chapter Technical data), check the charging system. Ifitis functioning Properly, shorten the time period between servicing. Caution: The maximum amount of added water is 45 cm* (0,92 in’) per cell. Aajust the level of electroive, one cell at atime, using the folowing instructions: 1, Remove the vent-vaives (210) withthe vent-valve wrench (TO1) 2! Check the nozze length before fiting itto the syringe ~5 laser the syringe (T02) into the cell opening until the shoulder of the nozzle rests on the vent-valve seat 20.mm 0.79 in) N= \ | (Sa Figure 5002 Position of Syringe in Cell Vent Seat 24-33-96 octfuzetrsarTt Component Maintenance Manual 451CH1 ~ 4. Withdraw the plunger and check for any liquid in the syringe ‘Any excess liquid in the cell wil be drawn into the syringe until the electrolyte is level with the end of the nozzle. This isthe corect level for the electrolyte If the iquid level is to low, the syringe wll remain empl, indicating that the end ofthe syringe nozzle dd not reach the liquid in the cel. In this case, replenish low electrolyte: 5. Draw 5 cm” ofthe disiled water (M01) into the syringe and inject tint the cell =. With the syringe nozzle remaining on the vent-vaive (210) seat, slowiy withdraw the plunger in the syringe 7. the syringe remains empty, repeat steps § and 6, counting the number of 5 cm injections require to achieve the Correct level. Record the amount of water added to each cell on the maintenance record - 8. At the point in step 6 when some excess liquid is drawn into the syringe, the correct level for that call has been reached. Expel the excess liquid into a separate container for disposal. Do not re-use the iquid removed from cells. ‘Check wit local authorities for proper disposal of hazardous waste. 6-7. Supplementary test At the end of complete charge, continue to charge for 5 h at 1.5.4 (refer to PARA Charae) Measure the voltage ofthe individual cell voltages every 30 min. The individual cell voltages: must not decrease by more than 0.03 V during the 5 h test must be more than 1.55 V /per ca ~ Adjust the electrolyte level (refer to Adjust electrolyte level), 24-33-96 itesarTt Component Maintenance Manual 451CH1 7. Regular check no U> 1.08 Vieell ro cell with reversed polarity yes Vent valve cleaning (refer Cleaning) overhaul with Replacement of faulty compo- nents. Nut tightness Battery accepted after Regular check Consult the airframe manufacturer for specific maintenance intervals or special procedures to be followed. Otherwise, at spe- cific intervals according to aircraft use, or AFTER A MAXIMUM OF ONE YEAR, test the battery according to the above figure. Figure 5003 Regular check 24-33-96 Page 5006 Oct 24/2017sarTt Component Maintenance Manual 451CH1 NOTE: Time periods are given as a guideline. Modify in accordance with operational experience. Periodic and Regular ‘maintenance checks may be combined If operating hours permit. 7-4. Cell shorting ‘As each cel's voltage drops below 1.0 V, connect an equalizing resistor (T03) across each cell's terminals. Leave the resistors. In place for 12 to 16 hours to allow each cell to completely discharge and the battery to cool NOTE: As an altornative to the resistor a shorting clip can be applied when the voltage has dropped to 0.5 V. 7-2. Capacity check Discharge the battery at 15 A. Record the capacity when the first cell reaches 1.0 volt. Ths time must be greater than or equal to 1 hour. Continue to discharge to have 20 V at the batterie terminals and record the corresponding capacity. Note all the cells, reaching 1 V before 1 hour of discharge. For al theses cells, refer to page 1002 para (5)(a). 24-33-96 oitfuzetrsarTt Component Maintenance Manual 451CH1 8. General overhaul Scheduled GENERAL OVERHAUL U> 1.05 Vicell Polarization test ‘no cell wth reversed [ Sass] yes Component inspection Vent valve cleaning (refer to Cleaning) Battery accepted after general overhaul Figure 5004 General overhaul Consult the airframe manufacturer for specific maintenance intervals or special procedures to be followed. Otherwise, at spe- cific intervals according to aircraft use, or AFTER A MAXIMUM OF ONE YEAR, test the battery according to the above figure. 24-33-96 Page 5008 Oct 24/2017sarTt Component Maintenance Manual 451CH1 8-4. Component inspection 8-4-1. Colls Make sure that the lower terminal nuts are tight (refer to Fits and clearances chapter), Verify that cell boxes show no leakage. 8-4-2. Box “Make the sides of the box straight and remove dents. 8-4-3. Nuts, links and spring washers, Discard the components that show signs of corrosion or damage. 8-4-4. Packing parts Discard all defective components. 8-4-5. Connector Check the connector (110) for evidence of arcing, corrosion, cracks, or cross-threaded terminals. Replace the defective con- rector. 8-2. Replacement of faulty components 8-2-1. Colls - 3/5 cells rule Saft strongly recommends to change all the cells or replace the complete battery if ‘one or more cells are found to be faulty and § of the original cells in the battery had previously been changed, or 3.or more cells 72 found to be faulty during the same maintenance. The 3/5 cells rule does not apply to the following failures: ~ technical fallure such as terminal thread damage, cell leakage, cell short-circuit. NOTE: All colls that are changed must be replaced by @ new Saft cell. 8-2-2. Other components Any other components that are to be changed must be replaced by a new Saft component. 8-3, Sensor check Check the sensor, if applicable, according to the table below: Thermostat T = 22 K-45 % at 25°C (77 “F) = dloses at 71 °C +2.8 °C (160 "F +5 °F) When temperature increase Thermistor co R= 300 KO 2 3k at 25°C (77 °F) ‘Shunt EF Continuity test Insulation Each pin of the connectorand | > 10 MO @ 250V DC each metallic parts of the sensor 8-4, Vent valve test NOTE: The Vent Valve Test is not necossary ifthe full sot of used vent valves is replaced by a brand new one each year during the General Overhaul. ~ This test should be done while the battery is on charge, just following the electrolyte leveling procedure. Check the ‘operation of the vent-valve assembly as follows: Place the vent valve (210) with its O-ring into the vent valve adapter (105) of the pressure test fixture. Immerse the vent-valve in water and slowly raise the air pressure 24-33-96 octfuzerrsarTt Component Maintenance Manual 451CH1 ~ Test according to the table below, and change all vent valves that do not pass the test. No distortion, spit or cracks Vent vaive is closed Vent valve opens Table 1 - Vent valve test 24-33-96 octfuzorrsarTt Component Maintenance Manual 451CH1 ASSEMBLY 4. Introduction This section covers basic battery assembly procedures. In al cases, when reassembling a battery, all components should be clean and dry. 2. Safety Refer to chapter Standard tools in Special tools, fixtures. equipment and consumables. 3. Equipment 344, Standard tools Refer to chapter Standard too's in Special tools, fixtures, equipment and consumables. 3-2. Special tools When special tools are used in this chapter, they are identified by a code number listed in Special tools. fixtures. equipment ‘and consumables. chapter. 4. Battery Assembly NOTE: All () part identification numbers herein are IPL Fig. 1 item numbers. 24-33-96 octZizetrsarTt Component Maintenance Manual 451CH1 4-4. Installation of the liner spacer kit (220) ES /-C (1 max) _-B (1 max) 220 — coe B(1 max) | Cc (1 max) —D Figure 7001 Liner spacer kit installation - Put the differents spacers in position (Ref. fig. 7001). 24-33-96 octfizorrsarTt Component Maintenance Manual 451CH1 = Install the cells Unit per assem- bly Description | Dimension (mm) Speer TSDORATE ‘Spacer O56 ‘Spacer TIS Spacer 0527S [Spacer ‘268x152 4-2 Installation of the cells (160) Pout cls (160) inthe side compartments Put four celis (160) in the middle of each compartment. Move the ast cell into poston (tis ifcult to put inthe last cel, remove one or two spacer). Caretully postion the cel (160) and push onto terminals with a piece of soft wood. Imake sure thatthe torque of the lower nuts (170) is correct according toils and clearances chapter. Install the links (130 thru 150). Install the washers (120) Install the upper nuts (100) and torque them according to Fits and clearances chapter. Lightly lubricate the terminals and the links with M02 (use a paintbrush). Install he cover complete (030) and attach it 43. Installation ofthe vent valve (210) Make sure the vent valves (210) are in good condition. Replace the vent valves (210) ifthe are worn, Install he vent valve (20) wth the universal vent wrench (TOt). 4-4. Installation of the sensor (240) thermistor Figure 7002 Installation of the sensor 24-33-96 octZizotrsarTt Component Maintenance Manual 451CH1 ‘Screw the thermostat on link (130) with the nut (260) ‘Screw on the links (130 to 150) on the cells with the washer (120) and nut (100). 4-5. Installation of the connector (110) ‘Screw the connector (110) with the washer (100). 46. Recording Fill out identification plate (210) i the box (020) has been changed Fill out the log book. 24-33-96 Page 7004 Oct 24/2017sarTt Component Maintenance Manual 451CH1 FITS AND CLEARANCES 1. Introduction ‘The torque values below are “lube torque" values. The thread of the terminals and attaching nuts (or screws) should be lightly ‘greased with (M02) prior to assembly and applying torque. 2. Torque table TPL TORQUE VALUE FIG ITEM 060 Nut 271029 2410256 ‘upper nut 100 Nut 7109 62 1080 Tower nut 170 Nut 451055 39210487 110 Terminal 708 62 080 260 Nut 09t011 791097 270 Nut 271029 2410 256 24-33-96 otfizotrsarTt Component Maintenance Manual 451CH1 PAGE INTENTIONALLY LEFT BLANK 24-33-96 ocrzuzotrsarTt Component Maintenance Manual 451CH1 SPECIAL TOOLS, FIXTURES, EQUIPMENT AND CONSUMABLES. 4. Introduction This chapter is divided into two parts: « The first part provides the list of special tools, fixtures and equipments needed to do the steps lsted in the other chapters + The second part provides the isting of consumable materiais used in this manual. Alllisted items are identified in this manual by a standard code number: = Tc for tools, fixtures and equipment, = Mxx for consumable materials. 2. Standard tools The folowing tems are recommended to do the procedures described inthis manuel. When necessary, equivalent substitutes may be used. ~ Constant current charger (DG current range 0-60A, minimum open DC voltage 40V) ~ Constant current load bank (OC current range 0-60 A, DC voltage range 1-40V) = Megohmmeter (0-50 MO @ 250 V continuous) = Precision Multimeter (Volt, 0, mA) 2000 points 1% or better ~ Torque Wrench (Fully insulated) 0-15 N.m (0-133 loin) ~ Standard mechanic's tools. = Satety gloves. - Protective goggles. = Safely shoes. Eye wash ~ Protective apron. = Sif bristle brush (non-metallic) = Small paintbrush (non-metalic) Dry, compressed air source (ess than 1.4 bar (20 psi) - Soft clean coth (atleast two required) 24-33-96 oitZizetrsarTt Component Maintenance Manual 451CH1 3. Special tools NOTE: Equivalent tools can be used. ‘A special tool kit (PIN 416161) Is avallablo from Saft containing all special tools T01, T02, T03, and T04. The tools are housed in a polypropylene box and each tool is insulated to ensure optimum safety for the technician. cove DESCRIPTION Farr 7 vosasz TH Urreravent wrench TaGTO | 005-000 TOE Synge assonbiy wih none Diam OTE Fea | ORT 06 Tu | 108 equaling resto reaaza Toa | Univers cel extecton toa 8 705 Ventvae adapter or Wa vane - Ta-300 4. Consumables NOTE: Equivalent alternatives can be used for list items. This paragraph describes the consumables used in the OMM, MANUFAG- DESIGNATION TURER PARTNUMBER OR SUPPLIER ‘AND (NAME, ‘SPECIFICATION ‘ADDRESS, CODE) Distiled or deionized water Local vendor Clear, coloriess, odorless while boiling, resistivity > 30 k2em 5 Sensor, assembly 105405 Nut, 6/32" 02077 NutMa 7102013 ‘Screw CL M&x10 vert Washer, spring 117026 Film, protector -ati108 Plate, identification “413609 Plate, SAFT label 413607 Plate, range label 24-33-96 SreesarTt Component Maintenance Manual 451CH1 Nomenclature Quantity per Nee | 1234567 Battery 340] 260088 Plate, reoycing 7 360 | 031282 Plate, filing instruction 2 ~ stem non ilustrated 24-33-96 ocfeazotrsarTt Component Maintenance Manual 451CH1 STORAGE (INCLUDING TRANSPORTATION) 4. Introduction 444. General Storage preparation and packaging makes sure that the equipment is protected against any attack by atmospheric agents. For a battery which has been cleaned and serviced and is not directly put ito service on board an aircraft, different methods ‘can be recommended depending on the purpose and the environment conditions of the *storage’. ‘The figure and item numbers are those ofthe llusrated pars lst chapter. 4-2, Storage room Keep the batteries and spares in a dry and clean room. 4-3. Temperature conditions ‘The recommended temperature range is + 20 °C +15 °C (68 “F +27 °F). However, occasional excursion into the range of -60 °C to +60 °C (-76 °F to +140 °F) is permitted. 2. Inactive long term storage NOTE: There is no need of maintenance operation during the storage period. ‘The battery should be stored filed and discharged. Itis not necessary that itbe short circuited. No revalidation is required during storage. The storage life is 10 years, if using the following conditions: ~ sealed packaging, - temperature: +20 °C (68 °F) 415 °C (427 “F), humidity < 70 %, normal vertical position = Isolated from detrimental agents: ie. dirt, dust, dampness, vibration, corrosive atmosphere, Lead batteries must not be stored in the same room. Saft Ni-Cd batteries may be stored in temperatures ranging from -55 °C to +60 °C (-67 °F to +140 °F) for short periods of time without harming the battery. The standard cardboard packaging is considered unsealed and allows 2 years of storage under the above conditions. 24-33-96 SorsarTt Component Maintenance Manual 451CH1 3. Inactive stand-by storage 344, Definition the battery is charged afer being serviced then stored fully charged in a dedicated room in such a way that it can be installed inthe aircraft without further check. The battery may be kept in stand-by forthe period corresponding to 80% available capacity on figure 15001 (for example 24 days at 30 °C) with a maximum of 90 days. AVAILABLE CAPACITY (%C1Ah) CHARGE RETENTION Aircraft Ni-Cd battery Do not let the battery state of charge going into this area 10 20 #30 40 #50 60 70 80 9 REST TIME (days) Figure 15001 inactive stand by storage 3-2. Ambient temperature with ‘topping’ or ‘refresh charge" ‘The stand-by period defined in para. Inactive stand-by storage can be prolonged by applying a topping’ or ‘refresh’ charge, at the end ofthe period. The charge is defined as a short charge a 0.1 C1A, 0.5 C1Aor 1 C1A until the vollage reaches the values given in the table below VOLTAGE nd of "refresh " charge) 0.1 CA ‘30 V for 20 cells CHARGE ri 24-33-99 SreesarTt Component Maintenance Manual 451CH1 The battery can be ‘refreshed up to two (2) times (for example 24 days at +30°C can be prolonged to 72 days at +30°C) CAUTION: The time necessary to reach the required voltage should be very short. Do not do the the 4 hours overcharge at 0.1 C1A (refer to PARA Charge) during this ‘refresh’ charge op- eration. 3-3. Action at the end of the standby period At the end ofthe stand-by period, i the battery is not immediately installed inthe aircraft, do one of the following procedures: Ifthe battery has been subject to one period, or two successive periods of stand-by, it must be discharged and recharged (refer to Periodical check) after which it can be subject to another period of up to 3 months stand-by. If itis to be put into long term storage to para. Inactive long term storage. If the battery has been subject to three successive periods of stand-by, it must undergo electrical treatment (refer to Regular ‘chack) after which it can be subject to another sequence of three stand-by periods of up to 3 months itis to be put into long term storage refer to para. Inactive long term storage. CAUTION: If the above conditions are not mot, there is a risk of placing a battery on board the aircraft that doos not ‘meet the emergency requirements. If the battery has proviously been stored at a temperature below that of the ambient, condensation may ‘occur. Before installing, verify the insulation resistance. 4. Active stand-by mode CAUTION: water consumption. Principle: the battery is continuously charged, in an overcharge condition. Saft does not recommend this method, however some operators take responsibility forts use. This method is not reliable due to quantity and inaccuracy of water consumption. Example: if 40 Ah battery remains on a continuous trickle charge of 3 mA/An for one month, the total consumption of water | 35 cma/cell, ‘The operator must adjust the electrolyte level before placing the battery onboard the aircraft. Otherwise the risk of a battery Incident exists (cells dried out before the normal end of the interval maintenance). This creates the conditions for a thermal runaway with alts consequences (unscheduled removal with the possibilty ofthe total loss of the battery and a delayed ifnot cancelled fight). 5. Spares 5-4. Spare Cells, Spare cells must be stored filed and discharged (in a discharged cell, the electrolyte level is not visible). It is not necessary that they be short circuited. The vent valves must not be removed. The storage conditions are the same as those given in para. Inactive long term storage. No maintenance operation is needed during storage. Before installation in a battery, cells must be visually inspected for damage or leakage and cleaned and repaired as necessary in accordance with the battery maintenance documentation, ise of a trickle charge) 5-2, Spare O-rings, gaskets and vent valves 5-2-4, O-rings and gaskets 6 years of storage with storage conditions from date of manufacture unless otherwise specified on the packaging. They must be protected from exposure of air, ight and high humicity (< 70%). Storage life depends on temperature so itis recommended to store in a cool area (<25 °C / 77 °F). At #35 °C / 95 °F, storage life is reduced to 5 years. Before use, O-rings must be in- spected and any showing visible signs of damage, distortion or deterioration must be discarded. 5-2-2. Vent valves with O-rings 6 years of storage with storage conditions from date of manufacture unless otherwise specified on the packaging (the limitation Is due to the O-ring). Protected from exposure of ai, ight and high humidity (< 70%). Storage life depends on temperature so itis recommended to store in a sealed container (non-PVC) in a cool area (<25°C /77 °F). At #35 °C. / 95 °F, storage lie is reduced to 5 years. Before use, O-rings must be inspected and any showing visible signs of damage, distortion or deterioration must be discarded. 8-3, Other spares Other spares, protected from external contamination (i. dir, dust, dampness, vibration, corrosive atmosphere) and high hu- rmidity (+70 %), may be stored for unlimited periods. Before use, they must be inspected and any showing visible signs of darn- ‘age, distortion or deterioration must be discarded. 24-33-99 reesarTt Component Maintenance Manual 451CH1 ig after discharged storage Storage time Servicing procedure fess than 3 months sual Inspection Insulation check Nut tightness Charge Adjust electrolyte level [5 months to 1 year Charge followed by Periodical check ore than 1 year Charge followed by Regular check. 7. Transportation procedure The battery is normally discharged before packing. It is necessary to transport a charged battery, make sure that the output terminals are protected against short circu. The battery should then be packed vertically in its original container. If the original container is not available, the international andlor local packaging regulations applicable to the mode of transport and destination must be followed. ‘According to the IATA / IMDG dangerous goods regulations, Saft ships all existing nickel-cadmium batteries or cells for aircraft Under the classification UN2795 (wet, filed with alkali) according to packing instruction 800. 24-33-96 ocfeazotr