EPU-301 BATTERY PACK

COMPONENT
MAINTENANCE MANUAL

MODEL

EPU-301

EPM BATTERY PACK

COMPONENT MAINTENANCE MANUAL

Initial Issue Nov 1/86

Revision 3 Mar 17/09

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RECORD OF REVISIONS

RE ISSUE INSERT REV. ISSUE INSERT REV. ISSUE INSERT

V. DATE DATE BY NO. DATE DATE BY NO. DATE DATE BY
NO.
1 Aug 1/99
2 Dec 1/99
3 Mar 17/09

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RECORD OF REVISIONS

REV. ISSUE INSERT REV. ISSUE INSERT REV. ISSUE INSERT

NO. DATE DATE BY NO. DATE DATE BY NO. DATE DATE BY

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RECORD OF TEMPORARY REVISIONS

TEMPORARY PAGE ISSUE DATE

REV. NO. NUMBER DATE BY REMOVED BY

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RECORD OF TEMPORARY REVISIONS

TEMPORARY PAGE ISSUE DATE

REV. NO. NUMBER DATE BY REMOVED BY

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SERVICE BULLETIN LIST

SERVICE BULLETIN REVISION DATE BULLETIN

NUMBER NUMBER INCORPORATED INTO AUTHORIZATION
MANUAL

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SERVICE BULLETIN LIST

SERVICE BULLETIN REVISION DATE BULLETIN

NUMBER NUMBER INCORPORATED INTO AUTHORIZATION
MANUAL

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LIST OF EFFECTIVE PAGES

SUBJECT/PAGE DATE

Record of Revisions 1 Mar 17/09

Record of Revisions 2 Mar 17/09

Record of Temporary Revisions 1 Mar 17/09

Record of Temporary Revisions 2 Mar 17/09

Service Bulletin List 1 Mar 17/09

Service Bulletin List 2 Mar 17/09

List of Effective Pages 1 Mar 17/09

List of Effective Pages 2 Mar 17/09

Table of Contents 1 Mar 17/09

Table of Contents 2 Mar 17/09

List of Figures 1 Mar 17/09

List of Figures 2 Mar 17/09

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TABLE OF CONTENTS

Emergency Escape Path Marking System

Subject Chapter Section Page Effectivity

Description and Operation

Description 33-50-14 1

Operation 8

Fault Isolation

General 101

Test Set-Up 101

Prewire the DB-9 Test 101

Connector

Deep Discharge 101

Deep Charge 104

10 Minute Discharge Test 104

40 Minute Discharge Test 104

Test Complete – Recharge 104

Storage 105

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LIST OF FIGURES

FIGURE NO. DESCRIPTION (TITLE) PAGE

1 EPU-301 Battery Pack 2

2 EPU-301 Battery Pack Self Discharge Rate 3

3 EPU-301 Battery Pack Low Temperature 5

Thermal Switch

4 EPU-301 Battery Pack Capacity VS Storage Timer 6

5 EPU-301 Battery Pack Memory Effect 7

6 EPU-301 Battery Pack Continuous Overcharge 9

7 EPU-301 Battery Pack Capacity Maintenance 10

101 EPU-301 Battery Pack Test Connector 102

102 EPU-301 Battery Pack Test Configuration 103

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FLOOR PROXIMITY EMERGENCY ESCAPE PATH MARKING (EPM) SYSTEM –

EPU-301 BATTERY PACK DESCRIPTION/OPERATION

1. DESCRIPTION

A. General

The Floor Proximity Emergency Escape Path Marking (EPM) System is a floor
mounted and bulkhead mounted illuminated markers system designed to aid
passengers during emergency evacuation of the aircraft.

The EPM System augments the overall Emergency Lighting System. Actuating the
emergency lighting simultaneously activates the EPM System.

The EPM System is comprised of lamp harness assemblies, illuminated exit marker
assemblies, interconnecting cabling control module and battery packs.

The EPM 301 System utilizes the EPU 301 battery pack and the ECM 301 control
module for illumination power and system control.

B. EPU-301 Battery Pack

1. Physical Characteristics

The EPU-301 battery pack is a nickel-cadmium battery system consisting of

ten (10) selected and load matched nickel-cadmium cells. The cells are
connected in series configuration to provide a nominal 12.0 volt power
source.

The EPU-301 is packaged in a durable, sealed polycarbonate plastic case

(Ref. Figure 1). A 9 pin “D” connector provides the interface to the control
module.

2. Electrical Characteristics

(a) General

A nickel-cadmium battery is an efficient combination of active

materials which can be cycled (charged-discharged) repeatedly.

The open circuit voltage of a battery pack removed from charge may
be higher than 14.0 volts, but drops to approximately 13.5 volts after a
short period of time (Ref. Figure 2).

The EPU-301 delivers most of the power while the voltage is still
above 10 volts (Ref. Figure 2).

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Figure 1 EPU-301 Battery Pack

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Figure 2 EPU-301 Battery Pack Self Discharge Rate

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(b) Self Discharge

The self-discharge characteristics of the EPU-301 are shown at

ambient temperature (780F) in Figure 2. The self-discharge rates
increase at elevated temperatures. Storage is recommended below
700F to reduce self-discharge. Battery pack storage, for extended
periods of time, in a discharged state is not harmful to the battery
(Ref. Figure 4).

(c) Memory Effect

Nickel-cadmium batteries retain the characteristics of previous

cycling. After repeated partial discharges, the battery pack will fail to
provide a satisfactory full depth discharge. Figure 5 shows the initial,
first and second discharge curves after one-hundred 40% discharges.
Note that almost equal capacity is achieved from subsequent full
depth discharges but at a slightly lower voltage level.

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Figure 3 EPU-301 Battery Pack

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Figure 4 EPU-301 Battery Pack Capacity VS Storage Time

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INITIAL AND SUBSEQUENT CYCLES AFTER REPEATED SHALLOW DISCHARGES

Figure 5 EPU-301 Battery Pack Memory Effect

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2. OPERATION

A. General

The EPU-301 is installed by sliding it (connector first) into the control module chassis
to mate the battery pack and control module connector. The battery pack is secured
to the control module chassis with a retaining screw and flat washer.

Charging of the EPU-301 battery pack is provided through the control module from
the aircraft emergency lighting system. The control module regulates the charging
current at a nominal 60 milliamperes.

CAUTION: One (1) minute with the EPM system illuminated requires
approximately one (1) hour of charging time to return the battery pack
to its original state of charge.

B. Continuous Overcharging

Continuous overcharging for two years at a 60 milliamp rate without periodic

discharges initially decreases the available capacity to approximately 65% of the
original capacity on the first discharge. Cycling the battery pack again returns the
capacity to almost 90% of the original capacity (Ref. Figure 6).

C. Continuous Overcharging with Capacity Maintenance

Continuous overcharging has an initial detrimental effect on available capacity. A

capacity maintenance program consisting of a full discharge every three months
maintains battery pack capacity at approximately 90% of original capacity (Ref.
Figure 7).

CAUTION: It should be noted that charging the battery pack at a rate of 120
milliamps at a temperature equal to or less than 00C causes gassing
which can build to a high internal pressure within each cell. Venting
occurs when the internal pressure reaches a preset level. Both
gasses and electrolyte may be vented.

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Figure 6 EPU-301 Battery Pack Continuous Overcharge

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Figure 7 EPU-301 Battery Pack Capacity Maintenance

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FAULT ISOLATION – EPU-301

1. GENERAL

Testing of the EPU-301 battery pack requires that:

A. The battery pack must be tested with a load.

B. Testing must be in an ambient temperature of 00C or higher.

C. Battery pack must be deep discharge/charge cycled.

2. TEST SET-UP

Prepare power supply as follows:

A. Energize power supply and set the power supply to 18 VDC (open terminal voltage).

B. Set the power supply current limiting to minimum current.

C. Short output terminals of power supply and adjust current limiting for one (1) amp.

D. Turn off power supply and remove short from power supply.

3. PREWIRE THE DB-9 TEST CONNECTOR (Ref. Figure 101) as follows:

A. Connect pins 1, 2, and 3 together, attach one (1) inch of bus wire to pin 1.

B. Connect pins 4, 5, and 9 together, attach one (1) inch of bus wire to pin 4.

C. Connect pins 6, 7, and 8 together, attach one (1) inch of bus wire to pin 6.

4. DEEP DISCHARGE

Deep discharge battery pack as follows:

A. Configure EPM battery pack, test connector, switch (SW1), resistor, and voltmeter as
shown in Figure 102-A (NOTE: Ensure switch is OPEN prior to connecting test
connector to battery pack).

B. Close switch (SW1) discharging battery pack through resistor. Allow battery pack to
discharge until voltmeter reads 4 volts. At 4 volts open switch (SW1).

C. Remove resistor and voltmeter.

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Figure 101 EPU-301 Battery Pack Test Connector

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Figure 102 EPU-301 Battery Pack Test Configuration

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5. DEEP CHARGE
A. Configure EPM battery pack test connector, switch (SW1) and power supply as
shown in Figure 102-B. (NOTE: Ensure switch is open and power supply is
de-energized prior to connecting Test connector to battery pack.
B. Energize power supply. Close switch (SW1). Battery pack should be charging at 1
amp.

C. Charge battery pack for a minimum of sixty (60) ± 2 minutes.

D. Open switch (SW1) after 60 ± 2 minutes.

6. 10 MINUTE DISCHARGE TEST
A. Configure battery pack, switch, resistor and voltmeter as shown in figure 102-A.
B. Close switch (SW1) and discharge battery pack for ten (10) minutes. After 10
minutes open switch (SW1).
C. If battery pack voltage (voltmeter reading) is less than 12 volts, then battery pack
requires a second deep discharge/charge (Repeat steps 4A through 6C). If voltage is
less than 12 volts after second deep discharge/charge, then battery pack is
defective.

7. 40 MINUTE DISCHARGE TEST

A. Test configuration unchanged (Ref. Figure 102-A).

B. Close switch (SW1) and battery pack for forty (40) minutes. After 40 minutes open
switch (SW1).
C. If battery pack voltage (voltmeter reading) is less than 10 volts, then battery pack
requires a second deep discharge/charge (Repeat steps 4A through 7C). If voltage is
less than 10 volts after second deep discharge/charge, then battery pack is defective

8. TEST COMPLETE – RECHARGE

A. Reconfigure battery pack as shown in Figure 102-B.

B. Close switch (SW1).

C. Re-charge battery pack for a minimum of sixty (60) ± 2 minutes at 1 amp.

D. After 60 ± 2 minutes open switch (SW1).

E. De-energize power supply.
F. Disconnect battery pack from test connector.

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9. STORAGE

The Model EPU-301 battery pack, P/N P4-01-0049 should be stored at below 70° F to
reduce self-discharge. Battery pack storage, for extended periods of time, in a discharged
state is not harmful to the battery. (Ref. Figure 4)

The Model BC-501 Battery Charger, P/N P6-01-0006-001 is no longer available for
procurement after January 2009, but may still be used for Model EPU-301 battery pack, P/N
P4-01-0049 storage using the following procedures.

A. The Model EPU-301 battery pack, P/N P4-01-0049, may be stored in the charge
slots of a Model BC-501 Battery Charger, P/N P6-01-0006-001, in the following
manner:

(1) At room temperature of 20 +/- 5 degrees Celsius.

(2) For a minimum of 16 hours prior to installation. Batteries that have been
stored in a Model BC-501 battery charger for 12 months or more should be
deep cycled discharged and charged per the applicable paragraphs of this
manual. Batteries in storage for more than five years should be discarded
and replaced.

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