CONCORDE BATTERY CORPORATION

2009 San Bernardino Road

West Covina, CA 91790
Phone: 626-813-1234
www.concordebattery.com

TO: HOLDERS OF COMPONENT MAINTENANCE MANUAL

FOR RG SERIES MAIN AIRCRAFT BATTERY (CMM 24-30-71)

DOCUMENT NO. 5-0171

REVISION H DATED AUG 06/2010

HIGHLIGHTS

Pages which have been revised, added, or removed are shown below with
a brief description of change. Add or remove these pages and record the
revision number and the date on the Record of Revisions page.

Page(s) Description of Change Effectivity

TP-1 Added RG-380E/40KH, RG-380E/40LH, RG-380E/44KH, All Models
RG-380E/44LH, RG-380E/60KH, RG-380E/60LH, RG-
390E/KH and RG-390E/LH. Deleted RG-380E/40H, RG-
RG-380E/44H, RG-380E/60H and RG-390E/H.
INTRO-1 Revised Paragraph 2.B to clarify intended use of CMM. All Models
101 Revised Paragraphs1.A.1, 1A.2, 1.B.1 and 1.B.2 to All Models
clarify capacity check intervals.
102 Revised Paragraph 2.B to include internal heating All Models
elements. Added “below 10 volts for more than 24 hours”
to Paragraph 3.A.
106 Revised Note under Paragraph 9. All Models
401 Corrected typo in Paragraph 3.A. All Models
1501 Revised Paragraph 5.D to clarify voltage thresholds. All Models
1502 Changed title of Paragraph 6 (Constant Potential Charge All Models
Procedure was Boost Charge Procedure).

24-30-71 Highlights
Page 1 of 1
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 CONCORDE BATTERY
CORPORATION
2009 San Bernardino Road
West Covina, CA 91790
Phone: 626-813-1234
www.concordebattery.com

RG SERIES MAIN AIRCRAFT BATTERY

COMPONENT MAINTENANCE MANUAL

Document Number 5-0171

Initial Issue Date Oct 10/2007
Current Revision Date Aug 06/2010 (Rev. H)

THIS CMM IS APPLICABLE TO THE FOLLOWING BATTERY TYPES

AUTHORIZED UNDER TSO-C173:
RG-47 RG-380E/40LS RG-380E/60LH
RG-49 RG-380E/44 RG-380E/60LS
RG-145-1 & RG-145-2 RG-380E/44K RG-390E
RG-206 RG-380E/44KH RG-390E/KH
RG-222 RG-380E/44KS RG-390E/L
RG-350 RG-380E/44L RG-390E/LH
RG-355 RG-380E/44LH RG-390E/LS
RG-380E/40B RG-380E/44LS RG-390ES
RG-380E/40K RG-380E/60B RG-400E/13
RG-380E/40KH RG-380E/60K RG-407
RG-380E/40KS RG-380E/60KH RG-442
RG-380E/40L RG-380E/60KS RG-500
RG-380E/40LH RG-380E/60L RG-600-1 & RG-600-2
* NOTE: This manual also applies to battery types not having authorization
under TSO-C173.

The data/information contained herein has been reviewed and approved for general
release on the basis that this document contains no export-controlled information.

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 CONCORDE BATTERY CORPORATION
COMPONENT MAINTENANCE MANUAL
RG SERIES MAIN AIRCRAFT BATTERY

RECORD OF REVISIONS

Revision No. Issue Date Date Inserted Inserted By

NC Oct 10/2007
A Jun 02/2008
B Oct 15/2008
C Jan 20/2009
D Mar 11/2009
E Jan 07/2010
F Apr 14/2010
G Jul 15/2010
H Aug 06/2010

NOTE: THE LATEST REVISION OF THIS CMM IS AVAILABLE FOR DOWNLOAD

FROM CONCORDE’S WEBSITE IN PDF FORMAT. IF YOU ARE UNABLE TO
ACCESS THE INTERNET, CONTACT CONCORDE AND A PRINTED COPY WILL BE
SENT TO YOU (SEE FRONT PAGE OF THIS CMM FOR WEBSITE AND COMPANY
CONTACT INFORMATION).

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 CONCORDE BATTERY CORPORATION
COMPONENT MAINTENANCE MANUAL
RG SERIES MAIN AIRCRAFT BATTERY

RECORD OF TEMPORARY REVISIONS

Temporary Page Date

Revision No. Number Issue Date By Removed By

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 CONCORDE BATTERY CORPORATION
COMPONENT MAINTENANCE MANUAL
RG SERIES MAIN AIRCRAFT BATTERY

SERVICE BULLETIN LIST

SB NUMBER DESCRIPTION DATE ISSUED

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COMPONENT MAINTENANCE MANUAL
RG SERIES MAIN AIRCRAFT BATTERY

LIST OF EFFECTIVE PAGES

SUBJECT PAGE(S) DATE OF

LATEST REVSION
Title Page TP-1 Aug 06/2010

Record of Revisions ROR-1 Aug 06/2010

Record of Temporary Revisions RTR-1 Aug 06/2010

Service Bulletin List SBL-1 Aug 06/2010

List of Effective Pages LOEP-1 Aug 06/2010

Table of Contents TOC-1 and TOC-2 Aug 06/2010

Introduction INTRO-1 thru INTRO-3 Aug 06/2010

Description and Operation 1 thru 3 Aug 06/2010

Testing and Fault Isolation 101 thru 107 Aug 06/2010

Schematic and Wiring Diagrams 201 Aug 06/2010

Disassembly 301 Aug 06/2010

Cleaning 401 Aug 06/2010

Check 501 Aug 06/2010

Repair and Disposal 601 Aug 06/2010

Assembly 701 Aug 06/2010

Fits and Clearances 801 Aug 06/2010

Special Tools, Fixtures, Equipment Aug 06/2010
901 and 902
and Consumables
Storage (Including Transportation) 1501 thru 1503 Aug 06/2010

Last Page LP-1 Aug 06/2010

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 CONCORDE BATTERY CORPORATION
COMPONENT MAINTENANCE MANUAL
RG SERIES MAIN AIRCRAFT BATTERY

TABLE OF CONTENTS

SECTION PAGE
INTRODUCTION INTRO-1
1. Scope and Purpose INTRO-1
2. Application INTRO-1
3. Definitions INTRO-1
4. Safety Precautions INTRO-2
5. Airworthiness Limitations INTRO-3
6. Deviations INTRO-3
7. Personnel INTRO-3
DESCRIPTION AND OPERATION 1
1. General 1
2. Characteristics of RG Series Main Aircraft Batteries 3
TEST AND FAULT ISOLATION 101
1. Capacity Checks 101
2. Externally Mounted Components 102
3. Testing Discharged Batteries 102
4. Test Facilities 102
5. Tools, Fixtures, Equipment and Consumables 102
6. Test Set Up 104
7. Capacity Test Procedure 105
8. Constant Potential Charge Procedure 105
9. Conditioning Charge Procedure 106
10. Fault Isolation Summary 107
SCHEMATIC AND WIRING DIAGRAMS 201
DISASSEMBLY 301
CLEANING 401
1. General 401
2. Tools, Fixtures, Equipment and Consumables 401
3. External Cleaning 401
4. Internal Cleaning 401
CHECK 501
1. General 501
2. Tools, Fixtures, Equipment and Consumables 501
3. External Checking 501
4. Internal Checking 501
REPAIR AND DISPOSAL 601
ASSEMBLY 701
FITS AND CLEARANCES 801

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 CONCORDE BATTERY CORPORATION
COMPONENT MAINTENANCE MANUAL
RG SERIES MAIN AIRCRAFT BATTERY

SPECIAL TOOLS, FIXTURES, EQUIPMENT AND 901

CONSUMABLES
1. Tools 901
2. Fixtures 901
3. Equipment 901
4. Consumables 901
ILLUSTRATED PARTS LIST NOT APPLICABLE
SPECIAL PROCEDURES NOT APPLICABLE
REMOVAL NOT APPLICABLE
INSTALLATION NOT APPLICABLE
SERVICING NOT APPLICABLE
STORAGE (INCLUDING TRANSPORTATION) 1501
1. Storage Conditions 1501
2. Storage Facilities 1501
3. Tools, Fixtures, Equipment and Consumables 1501
4. Test Set Up 1501
5. Preparation for Installation 1501
6. Boost Charge Procedure 1502
7. Capacity Test Procedure 1502
8. Conditioning Charge Procedure 1503
9. Transportation 1503
END OF MANUAL (LAST PAGE) LP-1

LIST OF FIGURES
FIGURE Page
Figure 101. Test Set Up for RG Series Main Batteries 104

LIST OF TABLES
TABLE Page
Table 101. List of Test Equipment for 12 Volt Batteries 103
Table 102. List of Test Equipment for 24 Volt Batteries 103
Table 103. List of Mating Connectors 104
Table 901. List of Test Equipment for 12 Volt Batteries 901
Table 902. List of Test Equipment for 24 Volt Batteries 902
Table 903. List of Mating Connectors 902

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 CONCORDE BATTERY CORPORATION
COMPONENT MAINTENANCE MANUAL
RG SERIES MAIN AIRCRAFT BATTERY
INTRODUCTION

1. Scope and Purpose

A. This Component Maintenance Manual (CMM) has been prepared in
accordance with Air Transportation of America (ATA) Specification 100. It
provides instructions for proper storage, servicing, replacement, repair, and
disposal of RG Series valve regulated lead-acid main aircraft batteries
manufactured by Concorde Battery Corporation.

2. Application
A. Batteries covered by this CMM are designed for engine starting applications
and may also be used as an emergency power supply.
B. The test procedures specified in this CMM apply to batteries that are in a
workshop environment. These test procedures are not intended to be
performed while batteries are installed in an aircraft.
C. Batteries covered by this CMM have no field-replaceable components.
Batteries with field-replaceable components will have a dedicated CMM with
an illustrated parts list.

3. Definitions
A. Valve regulated lead-acid (VRLA) battery - A lead-acid battery in which there
is no free electrolyte and the internal pressure is regulated by a pressure relief
valve. This battery requires no maintenance of the liquid level and
recombines the gases formed on charge within the battery to reform water.
The battery may be used in any attitude without danger of leakage or spilling
of electrolyte.
B. Rated C1 capacity - The nominal capacity, expressed in Ampere-hours (Ah),
obtained from a fully charged battery when discharged at the one hour rate to
the specified end point voltage at a temperature of 21 - 25EC (70 - 77EF).
C. C1 rate – The rate, in amperes, equal to the battery’s rated C1 capacity. For
example, the C1 rate of a battery rated at 3.5Ah is 3.5 amperes.
D. End Point Voltage (EPV) - The voltage at which the discharge current is
terminated when measuring battery capacity. Unless otherwise stated, the
EPV is equal to 20.0 volts (10.0 volts for 12 volt batteries).
E. Open Circuit Voltage (OCV) – The voltage of the battery at rest (no charging
or discharging current present). A stable OCV requires a rest of at least four
hours.

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COMPONENT MAINTENANCE MANUAL
RG SERIES MAIN AIRCRAFT BATTERY

4. Safety Precautions
A. WARNING: LOW CAPACITY HAZARD. Aircraft batteries are certified to
have a certain minimum capacity for emergency operations in the event of a
electrical generator system failure. Never use a battery that has less than
80% of rated capacity.
B. WARNING: ELECTRIC BURN HAZARD. Lead-acid batteries are capable of
delivering high currents if the terminals are shorted. The resulting heat can
cause severe burns and is a potential fire hazard. Take the following
precautions:
 Do not place tools or metal objects across battery terminals.
 Do not wear conductive rings, belt buckles, watches or other jewelry when
servicing batteries.
 Wear insulated gloves and use insulated tools when servicing batteries.
 Install battery terminal protectors whenever the battery is not connected in
the aircraft or to the test equipment.
C. WARNING: DANGER OF EXPLODING BATTERIES. Lead-acid batteries
can produce explosive mixtures of hydrogen and oxygen while on charge or
discharge, which can explode if ignited. Take the following precautions:
 Do not smoke, use an open flame, or cause sparking near a battery.
 Wear proper eye and face protection when servicing batteries.
 Make sure work area is well ventilated.
 Do not constant current charge a battery when installed in an aircraft.
 Connect cables securely to the battery terminals to avoid arcing.
D. WARNING: DANGER OF CHEMICAL BURNS. Lead-acid batteries contain
sulfuric acid which can cause severe burns to body tissue. Take the following
precautions:
 Never remove or damage vent valves.
 Avoid contact of the electrolyte with skin, eyes or clothing.
 Do not touch eyes after touching battery.
 In the event of acid in the eyes, flush thoroughly with clean cool water for
several minutes and get professional medical attention immediately.
 Refer to battery MSDS for additional information.
E. CAUTION: DANGER OF EQUIPMENT DAMAGE. To prevent damage to the
connector, arc burns, or explosion, batteries should never be connected or
disconnected while being charged or discharged. Batteries must be
connected or disconnected only when the circuit is open. Ensure the aircraft
battery switch, external power source, or the charger/analyzer is in the AOFF@
position before connecting or disconnecting the battery. Battery terminal
protectors should be installed whenever the battery is not connected in the
aircraft or to the test equipment.

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COMPONENT MAINTENANCE MANUAL
RG SERIES MAIN AIRCRAFT BATTERY

5. Airworthiness Limitations
A. For batteries covered by TSO-C173 the following limitation applies: The
conditions and tests for TSO approval of this battery are minimum
performance standards. Those installing this battery, on or in a specific type
or class of aircraft, must determine that the aircraft installation conditions are
within the TSO standards. TSO articles must have separate approval for
installation in an aircraft. The article may be installed only according to
14CFR part 43 or the applicable airworthiness requirements. Nickel-cadmium
and lead-acid battery safety concerns include the possibility of fire and
venting violently.
B. For batteries not covered by TSO-C173, there are no airworthiness limitations
associated with the installation of a Concorde valve-regulated lead-acid
battery in an aircraft.

NOTE: THE AIRWORTHINESS LIMITATIONS SECTION IS FAA APPROVED

AND SPECIFIES MAINTENANCE REQUIRED UNDER 14 CFR §§ 43.16 AND
91.403, UNLESS AN ALTERNATIVE PROGRAM HAS BEEN FAA
APPROVED.

6. Deviations
A. TSO-C173 dated May 2/2005 references RTCA/DO-293 dated Jul 29/2004.
Batteries covered by this CMM are approved based on Change 1 to
RTCA/DO-293 dated Dec 13/2006 or RTCA/DO-293A dated Dec2/2009.

7 Personnel
A. Only personnel authorized by the FAA to perform battery maintenance are
permitted to service Concorde aircraft batteries (see FAR 43.3).

8. Shop Verification
A. The following sections of this CMM were verified by actual performance:
 Testing and Fault Isolation – verified 5/14/10.
 Disassembly – not applicable.
 Assembly – not applicable.

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 CONCORDE BATTERY CORPORATION
COMPONENT MAINTENANCE MANUAL
RG SERIES MAIN AIRCRAFT BATTERY
DESCRIPTION AND OPERATION

1. General

A. Cell Construction:
Concorde aircraft batteries are valve-regulated, recombinant gas, absorbed
electrolyte, lead acid batteries. The cells are sealed with a pressure relief
valve that prevents gases within the battery from escaping. The positive and
negative plates are sandwiched between layers of glass mat consisting of
glass micro fibers of varying length and diameter. This blend features superior
wicking characteristics and promotes maximum retention of the electrolyte.
Electrolyte is absorbed and held in place by the capillary action between the
fluid and the absorptive glass mat (AGM) fibers. By design, the AGM
separator is only about 90-95% saturated with electrolyte. The void space
provides the channels by which oxygen travels from the positive to the
negative plates during charging. When the oxygen gas reaches the negative
plate, it reacts with lead to form lead oxide and water. This reaction at the
negative plate suppresses the generation of hydrogen that otherwise would
come off the negative plate. In this manner, virtually all of the gas is
recombined inside the cell, eliminating the need to add water, resulting in
Amaintenance free@ operation.

B. Grids and Plates:

Each cell of a storage battery has positive and negative plates arranged
alternately, insulated from each other by separators. Each plate consists of a
framework, called the grid, and a lead paste compound called active material.
The grid is cast from a lead alloy. A heavy outside frame adds strength to the
plate for good vibration and shock durability. The small horizontal and vertical
wires support the active material. These wires also act as conductors for the
current. The lead paste compound (active material) is applied to the grid in
much the same manner as plaster is applied to a lath wall. A different paste
formula is used for the positive and negative plates.

C. Plate Groups:
Plate groups are made by joining a number of similar plates to a common
terminal post by means of a plate strap. The capacity of a battery is
determined by the number and size of plates in a group. Each plate is made
with a lug at the top which is fused to the strap. A positive group consists of a
number of positive plates connected to a plate strap and a negative group
consists of a number of negative plates connected in the same manner. The
two groups meshed together with separators between the positive and
negative plates constitute a cell element.

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COMPONENT MAINTENANCE MANUAL
RG SERIES MAIN AIRCRAFT BATTERY
D. Separators:
The main separator material is made of glass microfibers and is commonly
called absorptive glass mat (AGM). This material is extremely porous so it
retains a high volume of electrolyte and provides a minimum of resistance to
the ions passing through it. It is also highly wettable and resists chemical
attack from the electrolyte. The AGM is wrapped around the positive plates to
insulate them from the negative plates. An extra layer of micro porous
polyethylene surrounds the AGM layer to impart extra puncture resistance
and improve battery durability. This dual AGM/polyethylene separator system
is a unique feature of Concorde’s RG Series batteries.

E. Cell Containers
After the cell elements are assembled, they are placed in a container made of
plastic. The plastic used is selected for its high resistance to sulfuric acid, low
gas permeability and high impact strength. In many battery models, the
container is comprised of a monoblock that houses multiple cells in a single
container (for example, 4, 6 and 12 cell monoblocks are common).

F. Cell Covers
The assembled cell or monoblock has a cover made of plastic material similar
to that of the cell container. The cell or monoblock cover has holes through
which the terminal posts extend and it also includes the pressure relief
valve(s). The cover is permanently sealed to the cell or monoblock container
after the plate groups are installed.

G. Electrolyte
The assembled cell or monoblock contains an electrolyte consisting of a
mixture of sulfuric acid and water. The electrolyte is absorbed within the pores
of the plates and AGM separator. Unlike flooded (vented) cells there is no
“free” electrolyte. Therefore, the battery is nonspillable even when turned
upside down.

H. Theory of Operation
A chemical reaction takes place when a battery is being charged or
discharged, as represented by the following equation:

Simplified lead acid electrochemical reaction

Discharge → ← Charge
PbO2 + Pb + 2H2 SO4 ] 2PbSO 4 + 2H2O

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COMPONENT MAINTENANCE MANUAL
RG SERIES MAIN AIRCRAFT BATTERY

On discharge, lead dioxide (PbO2) of the positive electrode and sponge lead
(Pb) of the negative electrode are both converted to lead sulfate (PbSO4)
freeing two electrons. On charge, the lead sulfate in the positive electrode is
converted to lead dioxide (PbO2) (with oxygen evolution on charge) and the
lead sulfate in the negative electrode is converted to sponge lead (with
hydrogen evolution on charge). The electrolyte, sulfuric acid (H2SO4), is an
active component in the reaction at both electrodes.

When flooded (vented) batteries are on charge, the oxygen generated at the
positive plates escapes from the cell. Concurrently, at the negative plates,
hydrogen is generated from water and escapes from the cell. The overall
result is the gassing of the cells and water loss. Therefore, flooded cells
require periodic water replenishment.

CAUTION: DO NOT REMOVE THE PRESSURE RELIEF VALVES ON AN

RG BATTERY AND DO NOT ADD WATER OR ELECTROLYTE. THE
RECOMBINANT GAS DESIGN ELIMINATES THE NEED TO REPLENISH
WATER AND ELECTROLYTE. REMOVING THE PRESSURE RELIEF
VALVE VOIDS THE WARRANTY.

When valve regulated batteries are on charge, oxygen combines chemically

with the lead at the negative plates in the presence of sulfuric acid to form
lead sulfate and water. This oxygen recombination suppresses the
generation of hydrogen at the negative plates. Overall, there is minimal water
loss during charging. A very small quantity of water may be lost as a result of
self discharge reactions. However, such loss is so small that no provision
need be made for water replenishment. The battery cells have a pressure
relief safety valve that may vent if the battery is overcharged.

2. Characteristics of RG Series Main Aircraft Batteries

A. The RG Series of main aircraft batteries consist of 6 or 12 cells connected in

series to make a nominal 12 VDC or 24VDC battery, respectively. The cells
are contained in a plastic or metallic container equipped with an electrical
receptacle for mating to the aircraft. In some models, temperature sensors are
present that interface to the aircraft charging and/or electrical system.
B. Technical characteristics of the various models are detailed on Concorde’s
website (see front page of this CMM).
C. If internet access is not available, contact Concorde for assistance (see front
page of this CMM).

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RG SERIES MAIN AIRCRAFT BATTERY

TESTING AND FAULT ISOLATION

1. Capacity Checks
A. Batteries Used to Start Turbine Engines:
1. Operating less than 1000 hours per year.
a. Initial check at 12 months after initial installation:
b. As long as the capacity is above 90%, subsequent capacity checks every 6
months in service.
c. If the capacity is between 85 and 90%, subsequent checks every 3 months
in service.
d. If the capacity is less than 85%, remove battery from service.
2. Operating 1000 hours per year or more:
a. Initial check at 1000 hours after initial installation:
b. As long as the capacity is above 90%, subsequent capacity checks every
500 hours in service.
c. If the capacity is between 85 and 90%, subsequent checks every 250 hours
in service.
d. If the capacity is less than 85%, remove battery from service.
B. All Other Batteries:
1. Operating less than 1000 hours per year:
a. Initial check at 12 months after initial installation.
b. As long as the capacity is above 90%, subsequent capacity checks every 12
months in service.
c. If the capacity is between 85 and 90%, subsequent checks every 6 months
in service.
d. If the capacity is less than 85%, remove battery from service.
2. Operating 1000 hours per year or more:
a. Initial check at 1000 hours after initial installation.
b. As long as the capacity is above 90%, subsequent capacity checks every
1000 hours in service.
c. If the capacity is between 85 and 90%, subsequent checks every 500 hours
in service.
d. If the capacity is less than 85%, remove battery from service.

NOTE: THE CAPACITY CHECK INTERVALS SPECIFIED ABOVE ARE GENERAL

RECOMMENDATIONS SUITABLE FOR MOST APPLICATIONS. THE INTERVALS MAY BE
ADJUSTED FOR A SPECIFIC AIRCRAFT OR FLEET ONCE THE AVERAGE BATTERY LIFE
IS ESTABLISHED.

WARNING: CAPACITY CHECKS PROVIDE ASSURANCE OF CONTINUED

AIRWORTHINESS OF THE BATTERY. ADJUSTMENTS TO THE FREQUENCY OF
CAPACITY CHECKS SHOULD BE BASED ON CAREFUL CONSIDERATION OF FACTORS
THAT AFFECT BATTERY LIFE. THESE FACTORS INCLUDE OPERATING PATTERNS,
ENVIRONMENTAL CONDITIONS, AND CONFIGURATION OF THE AIRCRAFT
ELECTRICAL SYSTEM. IF ANY OF THESE FACTORS CHANGE, THE BATTERY LIFE
SHOULD BE RE-ESTABLISED USING THE ORIGINAL CAPACITY CHECK SCHEDULE.

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RG SERIES MAIN AIRCRAFT BATTERY

2. Externally Mounted Components

A. Temperature Sensors: Some battery models are equipped with externally
mounted temperature sensors. Instructions for inspection and testing of
Concorde temperature sensors are contained in separate maintenance
manual supplements for each type of temperature sensor. These
maintenance manual supplements are available on Concorde’s website (see
front page of this CMM). If internet access is not available, contact Concorde
for assistance.
B. Heater Control Units: Some battery models are equipped with externally
mounted heater control units (HCUs). Instructions for inspection and testing
of Concorde HCUs and the associated heating element within the battery are
contained in separate maintenance manual supplements. These
supplements are available on Concorde’s website (see front page of this
CMM). If internet access is not available, contact Concorde for assistance.

3. Testing Discharged Batteries

A. If a battery is inadvertently discharged below 10 volts for more than 24 hours
while installed, it should be removed from the aircraft and subjected to a
capacity test as detailed in this Section.
B. After the battery is re-installed, the capacity test schedule may be adjusted
using this new date and equipment flight hours as the starting point for the
next capacity test interval.

4. Test Facilities
A. Concorde valve regulated lead-acid (VRLA) batteries may be serviced in any
battery facility, including nickel-cadmium service facilities. VRLA batteries are
sealed to prevent cross contamination of the electrolyte.

WARNING: LEAD-ACID BATTERIES CAN PRODUCE EXPLOSIVE MIXTURES

OF HYDROGEN AND OXYGEN WHILE BEING CHARGED OR DISCHARGED.
NEVER SERVICE BATTERIES IN AN AIRTIGHT OR SEALED ENCLOSURE
AND MAKE SURE WORK AREA IS WELL VENTILATED.

5. Tools, Fixtures, Equipment and Consumables

A. Refer to Table 101 for required test equipment for 12 volt batteries.
B. Refer to Table 102 for required test equipment for 24 volt batteries.
C. Refer to Table 103 for mating connectors.

NOTE: EQUIVALENT SUBSTITUTES MAY BE USED FOR THESE ITEMS.

CAUTION: CONTACT CONCORDE FOR ASSISTANCE WITH SELECTION OF

BATTERY CHARGING EQUIPMENT. SOME BRANDS OF BATTERY
CHARGERS WILL DESTROY THE BATTERY.

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RG SERIES MAIN AIRCRAFT BATTERY

Table 101. List of Test Equipment for 12 Volt Batteries

Description Source Part Purpose

Number

Electronic Load, capable of constant Commercially N/A Capacity Testing

current at C1 ADC and 10-14 VDC Available
with EPV termination at 10 VDC.

Constant Voltage Power Supply, Commercially N/A Constant Potential

capable of 14.00 – 14.25 VDC and at Available Charging
least C1 ADC output.

Constant Current Power Supply, Commercially N/A Constant Current

capable of C1/10 ADC and at least 17 Available Charging
VDC output.

Digital Multimeter (DMM), capable 9- Commercially N/A Measuring OCV

17 VDC with accuracy of 1% or better. Available

Mating Connector Various See Connect Battery to

Table 103 Test Equipment

Table 102. List of Test Equipment for 24 Volt Batteries

Description Source Part Purpose

Number

Electronic Load, capable of constant Commercially N/A Capacity Testing

current at C1 ADC and 20-28 VDC Available
with EPV termination at 20 VDC.

Constant Voltage Power Supply, Commercially N/A Constant Potential

capable of 28.00 – 28.50 VDC and at Available Charging
least C1 ADC output.

Constant Current Power Supply, Commercially N/A Constant Current

capable of C1/10 ADC and at least 34 Available Charging
VDC output.

Digital Multimeter (DMM), capable of Commercially N/A Measuring OCV

18-34 VDC with accuracy of 1% or Available
better.

Mating Connector Various See Connect Battery to

Table 103 Test Equipment

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COMPONENT MAINTENANCE MANUAL
RG SERIES MAIN AIRCRAFT BATTERY

6. Test Set Up
A. Refer to Figure 101 for a schematic of the test set up.
B. Make the interconnect cabling locally using mating connectors shown in Table
103.

Figure 101. Test Set Up for RG Series Main Batteries

Table 103. List of Mating Connectors

Battery Receptacle Mating Connector

(Shown on envelope drawing) (Obtain locally)
IEC 60952-2 Type A or B
BAC Type 102 BAC Type 215
IEC 60952-2 Type C MS3349-3
IEC 60952-2 Type Q
MS3509 MS25182-2 or MS3349-2
IEC 60952-2 Type R 14mm or 0.550” diameter pins
M8 Threaded Terminals 8mm or 5/16” ring terminals

NOTE: IF BATTERY RECEPTACLE IS NOT LISTED ABOVE, CONTACT

CONCORDE FOR ASSISTANCE.

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 CONCORDE BATTERY CORPORATION
COMPONENT MAINTENANCE MANUAL
RG SERIES MAIN AIRCRAFT BATTERY

7. Capacity Test Procedure

A. Stabilize the battery at 20EC (68EF) or higher. The battery must be at this
temperature for at least 20 hours.
B. Charge the battery at constant potential per Paragraph 8.
C. Connect the battery to the discharge equipment and discharge at the C1 rate
on the label (ie, 42 Amps for a 42 AH battery).
D. Discharge the battery to an EPV of 20 volts (10 volts for 12 Volt batteries) or
other EPV specified by the airframe or equipment manufacturer.
E. Record the time to the EPV. The battery passes the capacity test if the time to
the EPV is 51 minutes or greater (85% of rated C1 capacity or greater).

NOTE: AIRFRAME OR ACCESSORY EQUIPMENT MANUFACTURERS

MAY SPECIFY A DIFFERENT CAPACITY REQUIREMENT, WHICH
SHOULD TAKE PRECEDENCE.

F. If the battery passes the capacity test, charge at constant potential per
Paragraph 8 and return battery to full state of charge. The battery is
acceptable for installation.
G. If the battery fails the capacity test, perform the conditioning procedure given
in Paragraph 9. After the battery has been conditioned repeat the capacity
test.
H. If the battery passes the second capacity test, return it to service. If the
battery fails the second capacity test, repeat the conditioning charge and
repeat the capacity test.
I. If the battery passes the third capacity test, return it to service. If the battery
fails the third capacity test, the battery should be replaced.
J. If the battery gets very hot (external case temperature greater than
55EC/130EF) during charging, the battery should be replaced.

8. Constant Potential Charge Procedure

NOTE: CONSTANT POTENTIAL CHARGING IS THE PREFERRED

METHOD OF CHARGING THE BATTERY. IF THE BATTERY DOES NOT
PASS THE CAPACITY TEST, THE CONDITIONING CHARGE
PROCEDURE SHOULD THEN BE USED.

A. Connect the battery terminals to the constant potential charging equipment.

B. Apply a constant potential of 28.25 ± 0.25 volts (14.125 ± 0.125 volts for 12
Volt batteries) with a current capability of at least C1 amperes.
C. Continue charging until the charge current remains constant (within 10%) for
3 consecutive hourly readings.
D. Allow the battery to cool down for at least one hour before any other tests are
performed.

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 CONCORDE BATTERY CORPORATION
COMPONENT MAINTENANCE MANUAL
RG SERIES MAIN AIRCRAFT BATTERY

9. Conditioning Charge Procedure

WARNING: THIS PROCEDURE SHOULD ONLY BE DONE IN A WELL

VENTILATED AREA BECAUSE A SIGNIFICANT AMOUNT OF HYDROGEN
GAS MAY BE RELEASED FROM THE BATTERY.

CAUTION: THIS PROCEDURE WILL CAUSE THE BATTERY VOLTAGE TO

GO AS HIGH AS 34 VOLTS WHICH COULD DAMAGE ELECTRONIC
CIRCUITS CONNECTED TO A BATTERY BUS. DO NOT PERFORM A
CONDITIONING CHARGE WHILE THE BATTERY IS INSTALLED IN AN
AIRCRAFT.

CAUTION: A CONDITIONING CHARGE IS ONLY NECESSARY IF THE

BATTERY FAILS THE CAPACITY TEST. THIS PROCEDURE MAY SHORTEN
THE BATTERY=S LIFE IF PERFORMED ON A REPETITIVE BASIS.

NOTE: IF A BATTERY REQUIRES A CONDITIONING CHARGE TO PASS THE

CAPACITY TEST, SUBSEQUENT CAPACITY CHECKS SHOULD BE AT THE
INCREASED FREQUENCY SPECIFIED IN PARAGRAPH 1 OF THIS SECTION
(3 MONTHS/250 HOURS FOR TURBINE ENGINE BATTERIES OR 6
MONTHS/500 HOURS FOR ALL OTHER BATTERIES).

A. Discharge the battery at the C1 rate to an EPV of 20 volts (10 volts for 12 Volt
batteries). If the battery has already been discharged to the EPV, skip this
step.
B. Connect the battery to the constant current charging equipment.
C. Charge at a constant current rate of C1 /10 (i.e., 4.2 Amps for a 42 Ah
battery) until the voltage on charge is 31.0 volts (15.5 volts for 12 Volt
batteries) or higher for 4 hours, then discontinue charging.

CAUTION: IF THE BATTERY BECOMES HOT (ABOVE 55EC/130EF)

DURING THIS CHARGE, STOP THE CURRENT AND ALLOW THE
BATTERY TO COOL TO ROOM TEMPERATURE BEFORE CONTINUING
THE CHARGE.

D. After charging, allow the battery to cool down for at least 8 hours before any
other tests are performed.

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 CONCORDE BATTERY CORPORATION
COMPONENT MAINTENANCE MANUAL
RG SERIES MAIN AIRCRAFT BATTERY

10. Fault Isolation Summary

Symptom Probable Cause Corrective Action

Low voltage / no voltage. Battery partially or fully discharged. Perform capacity test.

Battery fuse blown or circuit breaker Replace fuse or reset circuit

tripped. breaker.

Battery capacity less than Battery cells beyond serviceable life. Replace battery.
85% of rating.

Battery does not hold Battery cells beyond serviceable life. Replace battery.
charge.

Battery gets hot while Battery cells beyond serviceable life. Replace battery.
recharging.

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 CONCORDE BATTERY CORPORATION
COMPONENT MAINTENANCE MANUAL
RG SERIES MAIN AIRCRAFT BATTERY
SCHEMATIC AND WIRING DIAGRAMS

1. General
A. Schematic diagrams and/or polarity markings are shown on the envelope
drawing of each specific battery model.
B. The latest approved envelope drawings are available on Concorde’s website
(see front page of this CMM).
C. If internet access is not available, contact Concorde for assistance (see front
page of this CMM).

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 CONCORDE BATTERY CORPORATION
COMPONENT MAINTENANCE MANUAL
RG SERIES MAIN AIRCRAFT BATTERY
DISASSEMBLY

1. General
A. Batteries covered by this CMM have no field-replaceable components and are
not designed for disassembly/re-assembly.
B. Some battery models are equipped with externally mounted temperature
sensors. Instructions for replacing temperature sensors are contained in
separate maintenance manual supplements for each type of temperature
sensor. These maintenance manual supplements are available on
Concorde’s website (see front page of this CMM). If internet access is not
available, contact Concorde for assistance.

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 CONCORDE BATTERY CORPORATION
COMPONENT MAINTENANCE MANUAL
RG SERIES MAIN AIRCRAFT BATTERY
CLEANING

1. General
A. This section contains general cleaning instructions for Concorde aircraft
batteries.
B. Batteries do not need to be disassembled for cleaning.

CAUTION: DO NOT USE ANY TYPE OF SOLVENT TO CLEAN THE

BATTERY. SOLVENTS MAY DAMAGE THE BATTERY.

2. Tools, Fixtures, Equipment and Consumables

A. Consumables: Lint-free shop cloth (commercially available) and tap water
(commercially available).

3. External Cleaning
A. Clean the outside surfaces of the battery with a lint-free shop cloth that is
clean, dry, and free of oil.
B. If the battery has caked-on dirt or grime, use a cloth dampened with tap
water, then wipe dry.
C. If the electrical connector is contaminated, refer to publication AC43.12
(available from the FAA) for specific cleaning instructions.

4. Internal Cleaning:
A. Internal cleaning is not required.

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 CONCORDE BATTERY CORPORATION
COMPONENT MAINTENANCE MANUAL
RG SERIES MAIN AIRCRAFT BATTERY
CHECK

1. General
A. This section contains general checking instructions for Concorde aircraft
batteries.
B. Batteries do not need to be disassembled for checking.

2. Tools, Fixtures, Equipment and Consumables

A. None required.

3. External Checking
A. Check the outside surfaces of the battery for dents, cracks or corrosion that
may affect the battery=s operation.
B. Check the battery for loose or missing fasteners.
C. Check the identification and informational labels to ensure they are legible
and securely attached.
D. If the above checks reveal items that need attention, contact Concorde for
assistance.

4. Internal Checking
A. Internal checks are not required.

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 CONCORDE BATTERY CORPORATION
COMPONENT MAINTENANCE MANUAL
RG SERIES MAIN AIRCRAFT BATTERY
REPAIR AND DISPOSAL
1. General
A. Batteries covered by this CMM have no internal components that are
repairable. The battery assembly must be replaced when internal components
(eg, battery cells) fail or wear out.
B. Refer to the Section on TESTING AND FAULT ISOLATION to determine if
the battery assembly needs to be replaced.
C. If external repairs are needed to the battery assembly, contact Concorde for
assistance (see front page of this CMM).

2. Disposal
A. Concorde aircraft batteries contain lead, sulfuric acid, and other hazardous
materials. Never discard batteries in the trash or in a landfill.
B. Dispose spent batteries and assemblies in accordance with local ordinances
and regulations.
C. Some batteries are encased in aluminum or titanium containers, which need
to be removed before the battery cells are sent to the lead smelter for
recycling. Make sure the recycling collector is aware of this requirement.
D. See battery Material Safety Data Sheet (MSDS) for additional information.

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 CONCORDE BATTERY CORPORATION
COMPONENT MAINTENANCE MANUAL
RG SERIES MAIN AIRCRAFT BATTERY
ASSEMBLY

1. General
A. Batteries covered by this CMM have no field-replaceable components and are
not designed for disassembly/re-assembly.
B. Some battery models are equipped with externally mounted temperature
sensors. Instructions for replacing temperature sensors are contained in
separate maintenance manual supplements for each type of temperature
sensor. These maintenance manual supplements are available on
Concorde’s website (see front page of this CMM). If internet access is not
available, contact Concorde for assistance.
.

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 CONCORDE BATTERY CORPORATION
COMPONENT MAINTENANCE MANUAL
RG SERIES MAIN AIRCRAFT BATTERY

FITS AND CLEARANCES

1. General
A. Refer to the envelope drawing for each specific battery model. The envelope
drawing provides overall dimensions, mounting provisions, and maximum
weight of the battery.
B. The latest approved envelope drawings are available on Concorde=s website
(see front page of this CMM).
C. If internet access is not available, contact Concorde for assistance (see front
page of this CMM).

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 CONCORDE BATTERY CORPORATION
COMPONENT MAINTENANCE MANUAL
RG SERIES MAIN AIRCRAFT BATTERY
SPECIAL TOOLS, FIXTURES, EQUIPMENT AND CONSUMABLES

1. Tools
A. Not applicable.

2. Fixtures
A. Not applicable.

3. Equipment
A. Refer to Tables 901, 902 and 903.

NOTE: EQUIVALENT SUBSTITUTES MAY BE USED FOR THESE ITEMS.

4. Consumables
A. Lint-free cloth (commercially available).
B. Tap water (commercially available).

Table 901. List of Test Equipment for 12 Volt Batteries

Description Source Part Purpose

Number

Electronic Load, capable of constant Commercially N/A Capacity Testing

current at C1 ADC and 10-14 VDC Available
with EPV termination at 10 VDC.

Constant Voltage Power Supply, Commercially N/A Constant Potential

capable of 14.0 – 14.25 VDC and at Available Charging
least C1 ADC output.

Constant Current Power Supply, Commercially N/A Constant Current

capable of C1/10 ADC and at least 17 Available Charging
VDC output.

Digital Multimeter (DMM), capable 9- Commercially N/A Measuring OCV

17 VDC with accuracy of 1% or better. Available

Mating Connector Various See Connect Battery to

Table 903 Test Equipment

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COMPONENT MAINTENANCE MANUAL
RG SERIES MAIN AIRCRAFT BATTERY

Table 902. List of Test Equipment for 24 Volt Batteries

Description Source Part Purpose

Number

Electronic Load, capable of constant Commercially N/A Capacity Testing

current at C1 ADC and 20-28 VDC Available
with EPV termination at 20 VDC.

Constant Voltage Power Supply, Commercially N/A Constant Potential

capable of 28.0 – 28.5 VDC and at Available Charging
least C1 ADC output.

Constant Current Power Supply, Commercially N/A Constant Current

capable of C1/10 ADC and at least 34 Available Charging
VDC output.

Digital Multimeter (DMM), capable of Commercially N/A Measuring OCV

18-34 VDC with accuracy of 1% or Available
better.

Mating Connector Various See Connect Battery to

Table 903 Test Equipment

Table 903. List of Mating Connectors

Battery Receptacle Mating Connector

(Shown on envelope drawing) (Obtain locally)
IEC 60952-2 Type A or B
BAC Type 102 BAC Type 215
IEC 60952-2 Type C MS3349-3
IEC 60952-2 Type Q
MS3509 MS25182-2 or MS3349-2
IEC 60952-2 Type R 14mm or 0.550” diameter pins
M8 Threaded Terminals 8mm or 5/16” ring terminals

NOTE: IF BATTERY RECEPTACLE IS NOT LISTED ABOVE, CONTACT

CONCORDE FOR ASSISTANCE.

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 CONCORDE BATTERY CORPORATION
COMPONENT MAINTENANCE MANUAL
RG SERIES MAIN AIRCRAFT BATTERY

STORAGE (INCLUDING TRANSPORTATION)

1. Storage Conditions
A. Batteries are serviced and charged at the factory prior to shipment.
B. To prolong shelf life, batteries should be stored in a cool location, ideally
below 20EC (68EF).
C. The open circuit voltage (OCV) of a fully charged battery is approximately
26.0 volts (13.0 volts for 12 Volt batteries). As the battery state of charge
drops due to self-discharge, its OCV also declines.
D. Batteries should be boost charged per Paragraph 6 when the OCV declines to
25.0 volts (12.5 volts for 12 Volt batteries).
E. Batteries with an OCV below 25.0 volts (12.5 volts for 12 Volt batteries) due to
improper or inadequate boost charging must be capacity tested per
Paragraph 7 before being placed in service.

CAUTION: WHEN BATTERIES ARE INSTALLED IN AIRCRAFT DURING STORAGE (OR

EXTENDED PERIODS OF NON-USE), IT IS BEST TO DISCONNECT THE BATTERY
CONNECTOR. THIS PRACTICE WILL ELIMINATE UNNECESSARY DRAIN ON THE
BATTERY WHEN PARASITIC LOADS ARE PRESENT. OTHERWISE, THE BATTERY
SERVICE LIFE MAY BE ADVERSELY AFFECTED.

2. Storage Facilities
A. Concorde valve regulated lead-acid aircraft batteries may be stored and
serviced in any battery facility, including nickel-cadmium service facilities.
These batteries are sealed to prevent cross contamination of the electrolyte.
B. Lead-acid batteries can produce explosive mixtures of hydrogen and oxygen
while being charged or discharged. Never service batteries in an airtight or
sealed enclosure and make sure the work area is well ventilated.

3. Tools, Fixtures, Equipment and Consumables

A. Refer to Table 101 for 12 volt batteries and Table 102 for 24 volt batteries.
B. Refer to Table 103 for mating connectors.

4. Test Set Up
A. Refer to Figure 101.

5. Preparation for Installation

A. Remove battery from the shipping carton and visually inspect the battery for
signs of damage. Do not use the battery if it appears to be damaged, contact
Concorde for assistance.
B. Measure the battery=s open circuit voltage (OCV) with a DMM.
C. If the OCV equals or exceeds 25.5 volts (12.75 volts for 12 Volt batteries), the
battery can be installed in the aircraft without boost charging.
D. If the OCV equals or exceeds 25.0 volts and is less than 25.5 volts (12.5 and
12.75 volts for 12 Volt batteries), apply a boost charge per Paragraph 6. The
battery can then be installed in the aircraft.

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COMPONENT MAINTENANCE MANUAL
RG SERIES MAIN AIRCRAFT BATTERY

E. If the OCV is below 25.0 volts (12.5 volts for a 12 volt battery), perform a
capacity test per Paragraph 7 before installing in the aircraft.

6. Constant Potential Charge Procedure

NOTE: CONSTANT POTENTIAL CHARGING IS THE PREFERRED METHOD OF

CHARGING THE BATTERY. IF THE BATTERY FAILS THE CAPACITY TEST, THE
CONDITIONING CHARGE PROCEDURE SHOULD BE USED.

A. Connect the battery terminals to the constant voltage charging equipment.

B. Apply a constant potential of 28.25 ± 0.25 volts (14.125 ± 0.125 volts for 12
Volt batteries) with a current capability of at least C1 amperes.
C. Continue charging until charge current remains constant (within 10%) for 3
consecutive hourly readings.
D. Allow the battery to cool down for at least one hour before any other tests are
performed.

7. Capacity Test Procedure

A. Stabilize the battery at 20EC (68EF) or higher. The battery must be at this
temperature for at least 24 hours.
B. Constant potential charge the battery per Paragraph 6.
C. Connect the battery to the discharge equipment and discharge at the C1 rate
on the label (ie, 42 Amps for a 42 AH battery).
D. Discharge the battery to an end point voltage of 20 volts (10 volts for 12 volt
batteries) or other EPV specified by the airframe or equipment manufacturer.
E. Record the time to the EPV. The battery passes the capacity test if the time to
the EPV is 51 minutes or greater (85% of rated C1 capacity or greater).

NOTE: AIRFRAME OR ACCESSORY EQUIPMENT MANUFACTURERS MAY

SPECIFY A DIFFERENT CAPACITY REQUIREMENT, WHICH SHOULD TAKE
PRECEDENCE.

F. If the battery passes the capacity test, charge at constant potential per
Paragraph 6 and return battery to full state of charge. The battery is
acceptable for installation.
G. If the battery fails the capacity test, perform the conditioning procedure given
in Paragraph 8. After the battery has been conditioned repeat the capacity
test.
H. If the battery passes the second capacity test, it is acceptable for installation.
If the battery fails the second capacity test, repeat the conditioning charge
and repeat the capacity test.
I. If the battery passes the third capacity test, it is acceptable for installation. If
the battery fails the third capacity test, the battery should be replaced.
J. If the battery gets very hot (external case temperature greater than
55EC/130EF) during charging, the battery should be replaced.

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 CONCORDE BATTERY CORPORATION
COMPONENT MAINTENANCE MANUAL
RG SERIES MAIN AIRCRAFT BATTERY

8. Conditioning Charge Procedure

WARNING: THIS PROCEDURE SHOULD ONLY BE DONE IN A WELL

VENTILATED AREA BECAUSE A SIGNIFICANT AMOUNT OF HYDROGEN
GAS MAY BE RELEASED FROM THE BATTERY.

CAUTION: THIS PROCEDURE WILL CAUSE THE BATTERY VOLTAGE TO

GO AS HIGH AS 34 VOLTS WHICH COULD DAMAGE ELECTRONIC
CIRCUITS CONNECTED TO A BATTERY BUS. DO NOT PERFORM A
CONDITIONING CHARGE WHILE THE BATTERY IS INSTALLED IN AN
AIRCRAFT.

CAUTION: A CONDITIONING CHARGE IS ONLY NECESSARY IF THE

BATTERY FAILS THE CAPACITY TEST. THIS PROCEDURE MAY SHORTEN
THE BATTERY=S LIFE IF PERFORMED ON A REPETITIVE BASIS.

A. Discharge the battery at the C1 rate to an EPV of 20 volts (10 volts for 12 Volt
batteries). If the battery is already discharged to 20 volt EPV, skip this step.
B. Connect the battery to the constant current charging equipment.
C. Charge at a constant current rate of C1 /10 (i.e., 4.2 Amps for a 42 Ah
battery) until the voltage on charge is 31.0 volts (15.5 volts for 12 Volt
batteries) or higher for 4 hours, then discontinue charging.

CAUTION: IF THE BATTERY BECOMES HOT (ABOVE 55EC/130EF)

DURING THIS CHARGE, STOP THE CURRENT AND ALLOW THE
BATTERY TO COOL TO ROOM TEMPERATURE BEFORE CONTINUING
THE CHARGE.

E. After charging, allow the battery to cool down for at least 8 hours before any
other tests are performed.

9. Transportation
A. If the OCV is less than 25.5 volts (12.75 volts for 12 Volt batteries), charge the
battery per paragraph 6 before shipment.
B. The battery should be packaged in its original container. If the original
container is not available, follow local packaging regulations applicable to the
mode of transport.
C. RG Series batteries are classified as a “NONSPILLABLE BATTERY” and
comply with Special Provision A67 of the International Air Transport
Association (IATA) Dangerous Goods regulations. As such, they can be
shipped as non-hazardous by any means.

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COMPONENT MAINTENANCE MANUAL
RG SERIES MAIN AIRCRAFT BATTERY

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