Instruction Manual

For
Nickel-Cadmium
Aircraft Batteries

Type
CA-154-01 (28656-002)
&
CA-54-3 (27826-002)

Marathon Power Technologies Company

P.O. Box 8233 8301 Imperial Drive
Waco TX. 76714-8233 Waco, TX. 76712-6588
Phone: (254) 776-0650 Fax: (254) 776-6558
E-Mail: [email protected]

JUL 06/72
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OPERATING AND MAINTENANCE MANUAL
NICKEL-CADMIUM AIRCRAFT BATTERIES

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OPERATING AND MAINTENANCE MANUAL
NICKEL-CADMIUM AIRCRAFT BATTERIES

RECORD OF REVISIONS
Original Issue Date: JUL 06/72

Rev Issue Date Rev Issue Date Rev Issue Dated

No. Date Inserted By No. Date Inserted By No. Date Inserted By
1 02/20/94
2 04/05/01
3 03/15/03
4 06/06/03

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NICKEL-CADMIUM AIRCRAFT BATTERIES

RECORD OF TEMPORARY REVISIONS

Temporary Page Issue Date

Rev. No. Number Date By Removed By

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SERVICE BULLETIN LIST

Number Revision Date

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OPERATING AND MAINTENANCE MANUAL
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LIST OF EFFECTIVE PAGES

Subject Page Date Subject Page Date

Title T-1 JUN 06/03 Assembly 501 MAR 15/03
T-2 JUN 06/03 502 MAR 15/03

Record of RR-1 JUN 06/03 Testing 601 MAR 15/03

Revisions RR-2 MAR 15/03 602 MAR 15/03
603 MAR 15/03
Record of RTR-1 MAR 15/03 604 MAR 15/03
Temporary Revisions RTR-2 MAR 15/03 605 MAR 15/03
606 MAR 15/03
Service SBL-1 MAR 15/03
Bulletin List SBL-2 MAR 15/03 Troubleshooting 701 MAR 15/03
702 MAR 15/03
List of LEP-1 JUN 06/03
Effective Pages LEP-2 MAR 15/03 Storage Instruction 801 MAR 15/03
802 MAR 15/03
Table of Contents TC-1 MAR 15/03
TC-2 MAR 15/03 Special Tools, Fixtures, 901 MAR 15/03
And Test Equipment 901 MAR 15/03
List of Figures, Illustration LF-1 MAR 15/03 903 MAR 15/03
And Tables MAR 15/03 904 MAR 15/03
905 MAR 15/03
Description 1 MAR 15/03 906 MAR 15/03
And Operation 2 MAR 15/03 907 MAR 15/03
3 MAR 15/03 908 MAR 15/03
4 MAR 15/03
5 MAR 15/03 Overhaul Manual 1001 MAR 15/03
6 MAR 15/03 1002 MAR 15/03
7 MAR 15/03 1003 MAR 15/03
8 MAR 15/03 1004 MAR 15/03
9 MAR 15/03
10 MAR 15/03 Light Overhaul 1101 MAR 15/03
1102 MAR 15/03
Disassembly 101 MAR 15/03
102 MAR 15/03

Cleaning 201 MAR 15/03

202 MAR 15/03

Inspection / Check 301 MAR 15/03

302 MAR 15/03

Repair 401 MAR 15/03

401 MAR 15/03

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TABLE OF CONTENTS

Subject Page

Description and Operation 1

Disassembly 101

Cleaning 201

Inspection / Check 301

Repair 401

Assembly 501

Testing 601

Troubleshooting 701

Storage Instruction 801

Special Tools, Fixtures, and Test Equipment 901

Overhaul Manual 1001

Light Overhaul 1101

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OPERATING AND MAINTENANCE MANUAL
NICKEL-CADMIUM AIRCRAFT BATTERIES

LIST OF FIGURES, ILLUSTRATIONS AND TABLES

Battery Unit Figure 1

Battery Unit, Schematic Diagram Figure 2
CA-154-01 Battery Maintenance Flow Diagram Figure 3
CA-54-3 Battery Maintenance Flow Diagram Figure 4
Typical Voltage Time Curve For Constant Current Charging Figure 5
Typical Discharge Voltage Curve Figure 6
Test Equipment Table 1
Special Tools and Fixtures Table 2
Power Cable Figure 7
One-ohm Power Resistor Figure 8
Cell Shorting Clips Figure 9
Battery Unit Shorting Spring Figure 10
Cell Puller Figure 11
Electrolyte Level Checker Figure 12
Electrolyte Removal Tool Figure 13
Exploded View, CA-154-01 Battery Figure 1001
Exploded View, CA-54-3 Battery Figure 1002

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NICKEL-CADMIUM AIRCRAFT BATTERIES

DESCRIPTION AND OPERATION

INTRODUCTION

This section provides the necessary information for shop maintenance of the battery unit (BU) (Figure 1).
Maintenance consists of testing and troubleshooting to isolate malfunctions to a replaceable component, as
well as periodically reconditioning the battery unit. The maintenance flow diagram for the battery unit is
shown in Figures 3 and 4.

Battery Unit
Figure 1

CAUTION: MAINTENANCE OF THE BATTERY UNIT SHOULD NOT BE ACCOMPLISHED IN A LEAD-

ACID BATTERY SHOP. WATER, TOOLS OR HYDROMETERS THAT HAVE BEEN
CONTAMINATED BY CONTACT WITH LEAD-ACID BATTERIES SHOULD NOT BE USED.
ANYTHING ASSOCIATED WITH A LEAD-ACID BATTERY (ACID FUMES INCLUDED)
SHOULD NEVER COME IN CONTACT WITH THE NICKEL-CADMIUM BATTERY OR ITS
ELECTROLYTE. ACID WILL DAMAGE PLATES OF NICKEL-CADMIUM CELLS.

WARNING: THE ELECTROLYTE (POTASSIUM HYDROXIDE) IN THE BATTERY UNIT IS VERY

CAUSTIC AND WILL BURN THE EYES, SKIN, ETC. IT IS RECOMMENDED THAT SAFETY
GLASSES BE WORN WHILE CHARGING, DISCHARGING, AND CLEANING THE BATTERY.
IN CASE OF ACCIDENT, NEUTRALIZE ELECTROLYTE WITH 3% BORIC ACID SOLUTION
AND WASH WITH WATER. RINGS OR OTHER JEWELRY THAT MIGHT COME IN
CONTACT WITH CELL TERMINALS SHOULD NOT BE WORN.

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OPERATING AND MAINTENANCE MANUAL
NICKEL-CADMIUM AIRCRAFT BATTERIES

DESCRIPTION

The battery unit contains 19 nickel-cadmium cells, which are connected in series to furnish nominal 24 volts
DC. A 20-ampere circuit breaker on the front of battery unit protects it from excessive current flow if a short
circuit develops.

The battery unit is contained in an ARING 404 ½ ATR short case. The battery unit is 4.875 inches wide,
6.312 inches high and 14.563 inches deep. Battery unit, P/N 28656-002, weights approximately 27 pounds;
battery unit, P/N 27826-002, weights approximately 16 pounds.

OPERATION

General

1. The battery unit (P/N 28656-002) is a nominal 24 volt, 15.0 ampere hour battery capable of providing
30 minutes of power for INS operation when fully charged, and battery unit (P/N 27826-002) is a
nominal 24 volt, 5.0 ampere hour battery capable of providing 15 minutes of power for INS operation
when fully charged. Its purpose is to provide auxiliary power for INS operation when the 115 volt 400
Hz primary input power is interrupted or falls below the required voltage. Power from the battery unit
is used momentarily to initiate INS operation at turn on and for a 12.8-second period during automatic
INS alignment. Refer to Figure 2 for a schematic of the battery.

Battery Unit, Schematic Diagram

Figure 2

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OPERATING AND MAINTENANCE MANUAL
NICKEL-CADMIUM AIRCRAFT BATTERIES

BATTERY CHARGING OR RECONDITIONING OR OTHER SHOP MAINTENANCE FOR

P/N 28656-002 (15 AH)
CAUTIONS:

1. Do not perform any maintenance on BU in a lead-acid battery CLEAN BU

VISUAL INSP BU Needs
shop. BU Needs Cell(s)
Cleaning 1. Use only clean water or compressed air. Replaced
Inspect BU for corrosion, loose connections 2. Do not use wire brushes.
2. Insure ambient temperature for charging BU is between 40°F bad cells, etc. Repair as required. 3. Coat exposed metal with protective
(40°C) and 90°F (32°C). grease.

3. Discontinue charging BU if BU is warm to touch (about 100°F

or 38°C).
BU Needs
4. Never charge or discharge a battery unless there is at least ELECTROLYTE CHECK OUT-OF-SPEC CELL(S) Cell(s)
1/16-inch electrolyte above the plates. Replaced
Check that all cells have a minimum of 1/16 Identify cell(s) with out-of-spec voltages for
5. Charge BU in an upright condition to avoid spillage and allow inch of electrolyte above plates after charge. replacement purposes.
proper venting.
No - There were two
6. Never charge cells (or batteries) that are connected in parallel. or more previous
Reconditioning
DISCHARGE Cycles.
7. Do not remove or loosen vent plugs during discharge. Open
cells may cause the formation of potassium carbonate. Discharge BU through 10-ohm resistor.
Monitor cell voltage and , as a cell reaches
EQUIPMENT REQUIRED: 0.6 volt, short circuit cell. Continue until 14 IS THIS FIRST TIME
cells are short circuited. Place 1-ohm Yes THROUGH CYCLE?
1. 3.0-Amp (±5% regulation) constant current power supply. resistor across each of remaining 6 cells for
3 hours. Then short circuit all cells.
2. 40-mA (±10% regulation) constant current power supply.
BU Fails Capacity
Test or Cell
3. 3.8-ohm (±1%). 150-WATT resistor as BU load during Voltage out of
CHARGE & ADJUST WATER
capacity test. Spec, but Cell not
obviously bad.
Apply a constant current of 3.0 amps for 7
4. 10-ohm (±15%). 150-WATT resistor as BU load during hours. Cell voltage must be 1.50 to 1.68 BU
No
discharge. volts at end of charge and BU voltage must
<29.5V
and Cell
be greater than 29.5 V. >1.50V
5. 1-ohm (±10%). 5-WATT resistors (5 required) as loads on
individual cells during discharge. Add distilled water as required.
Cell Voltage out of
Spec
CELL OBVIOUSLY BAD?
6. Cell shorting clips (19 required). 1. 7/8 (±1/32) inch after 1 hour rest
(OR)
7. BU shorting spring to short pins in BU DPX connector. 2. 3/4 (±1/32 inch after 3 hour rest.

ALTERNATE BATTERY CHARGE PROCEDURE: Yes

Capacity Test Must
Be Done Within 48
1. Apply a constant current of 3.0 AMPS until battery terminal Hours After Charge
voltage reaches 29.0 volts. REPLACE CELL(S)

CAPACITY TEST Both BU and replacement cells must be

2. Continue charging at 3.0 AMPS for an additional 2 hours. BU
discharged to extinction and short circuited
Discharge BU through 3.8 ohm resistor. At Fail before replacing bad cells. After cell
ELECTROLYTE (WATER) ADJUST: 105 minutes after start of test, each cell replacement, check that electrolyte level is a
should measure 1.0 volt minimum and the minimum of 1/16 inch above plates.
1. Add only distilled water to electrolyte. BU terminals should measure no less than
19.0 volts. Monitor cell voltages during
2. Add water only after charge (except when adding water for discharge. Identify cells that fall below 1.0 Replaced Cell(s) to
1/16-inch minimum requirement). volt during test. Vendor for Salvage

3. The electrolyte is 70% distilled water and 30% potassium BU VOLTAGE <29.5 V
hydroxide. Specific gravity is nominal 1.3 (normal range is 1.24 Pass
If BU voltage is less than 29.5 V and all BU
to 1.32).
cells are greater than 1.50 volts, replace
RECHARGE & ADJUST WATER lowest voltage cell(s) until BU voltage is
4. Use reagent grade potassium hydroxide to mix new electrolyte BU
only if it is extremely impractical to return cell to vendor for proper greater than 29.5 V.
Apply a constant current of 3.0 amps for 7 <29.5V
electrolyte adjustment. hours. Cell voltage should be 1.50 to 1.68 and Cell
>1.50V
volts at end of charge and BU voltage must
CELL REVERSAL: be greater than 29.5V.
TRICKLE CHARGE
1. It is recommended that cells which undergo cell reversal Add distilled water as required.
during deep discharge be returned to vendor for evaluation / Cell Voltage out of
Continuous 40-ma trickle charge
1. 7/8 (±1/32) inch after 1 hour rest Spec
salvage.
(OR) 1. Every month adjust water level to ¾
2. If it is not practical to return reversed cells, recondition BU as 2. 3/4 (±1/32 inch after 3 hour rest. (±1/32) inch.
shown in this flowchart except wait 48 hours between main 2. Every 2 months recondition BU.
charge and the capacity test. Any cell which had previously been
reversed and fails the capacity test should be replaced. When BU is Required
for Installation
PREPARATION FOR SHIPMENT:
BU BU Not Req’d for 48
1. Discharge BU to extinction. REQ’D FOR
Hours WATER ADJUST
INSTALLATION?
2. Place shorting spring across pins in DPX connector. Adjust water for ¾ (±1/32) inch above
plates.
3. Put circuit breaker in.
Within 48 Hours
4. Install shipping plugs in place of cell vent plugs, if available.
Figure 3

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OPERATING AND MAINTENANCE MANUAL
NICKEL-CADMIUM AIRCRAFT BATTERIES

BATTERY CHARGING OR RECONDITIONING OR OTHER SHOP MAINTENANCE FOR

P/N 27826-002 (5 AH)
CAUTIONS:

1. Do not perform any maintenance on BU in a lead-acid battery CLEAN BU

VISUAL INSP BU Needs
shop. BU Needs Cell(s)
Cleaning 1. Use only clean water or compressed air. Replaced
Inspect BU for corrosion, loose connections 2. Do not use wire brushes.
2. Insure ambient temperature for charging BU is between 40°F bad cells, etc. Repair as required. 3. Coat exposed metal with protective
(40°C) and 90°F (32°C). grease.

3. Discontinue charging BU if BU is warm to touch (about 100°F

or 38°C).
BU Needs
4. Never charge or discharge a battery unless there is at least ELECTROLYTE CHECK OUT-OF-SPEC CELL(S) Cell(s)
Replaced
1/16-inch electrolyte above the plates.
Check that all cells have a minimum of 1/16 Identify cell(s) with out-of-spec voltages for
inch of electrolyte above plates after charge. replacement purposes.
5. Charge BU in an upright condition to avoid spillage and allow
proper venting.
No - There were two
or more previous
6. Never charge cells (or batteries) that are connected in parallel. Reconditioning
DISCHARGE Cycles.
7. Do not remove or loosen vent plugs during discharge. Open
Discharge BU through 10-ohm resistor.
cells may cause the formation of potassium carbonate.
Monitor cell voltage and , as a cell reaches
0.6 volt, short circuit cell. Continue until 14 IS THIS FIRST TIME
EQUIPMENT REQUIRED: cells are short circuited. Place 1-ohm Yes THROUGH CYCLE?
resistor across each of remaining 6 cells for
1. 3.0-Amp (±5% regulation) constant current power supply. 3 hours. Then short circuit all cells.

2. 40-mA (±10% regulation) constant current power supply. BU Fails Capacity

Test or Cell
3. 3.8-ohm (±1%). 150-WATT resistor as BU load during CHARGE & ADJUST WATER Voltage out of
capacity test. Spec, but Cell not
obviously bad.
Apply a constant current of 3.0 amps for 3
hours. Cell voltage must be 1.50 to 1.68 BU
4. 10- ohm (±15%). 150-WATT resistor as BU load during <29.5V
No
discharge. volts at end of charge and BU voltage must and Cell
be greater than 29.5 V. >1.50V
5. 1- ohm (±10%). 5-WATT resistors (5 required) as loads on
Add distilled water as required.
individual cells during discharge. Cell Voltage out of
CELL OBVIOUSLY BAD?
Spec
1. 5/8 (±1/32) inch after 1 hour rest
6. Cell shorting clips (19 required). (OR)
2. 1/2 (±1/32 inch after 3 hour rest.
7. BU shorting spring to short pins in BU DPX connector.

Capacity Test Must Yes

ALTERNATE BATTERY CHARGE PROCEDURE:
Be Done Within 48
Hours After Charge
1. Apply a constant current of 3.0 AMPS until battery terminal REPLACE CELL(S)
voltage reaches 29.0 volts.
CAPACITY TEST Both BU and replacement cells must be
BU
2. Continue charging at 3.0 AMPS for an additional 2 hours. discharged to extinction and short circuited
Discharge BU through 3.8 ohm resistor until Fail before replacing bad cells. After cell
BU terminal voltage reaches 19.0 volts. replacement, check that electrolyte level is a
ELECTROLYTE (WATER) ADJUST: Time should be between 45 minutes and minimum of 1/16 inch above plates.
one hour.
1. Add only distilled water to electrolyte.
Replaced Cell(s) to
2. Add water only after charge (except when adding water for Vendor for Salvage
1/16-inch minimum requirement).
BU VOLTAGE <29.5 V
3. The electrolyte is 70% distilled water and 30% potassium Pass
If BU voltage is less than 29.5 V and all BU
hydroxide. Specific gravity is nominal 1.3 (normal range is 1.24
to 1.32). cells are greater than 1.50 volts, replace
RECHARGE & ADJUST WATER lowest voltage cell(s) until BU voltage is
BU greater than 29.5 V.
4. Use reagent grade potassium hydroxide to mix new electrolyte Apply a constant current of 3.0 amps for 7 <29.5V
only if it is extremely impractical to return cell to vendor for proper hours. Cell voltage should be 1.50 to 1.68 and Cell
>1.50V
electrolyte adjustment. volts at end of charge and BU voltage must
be greater than 29.5V.
CELL REVERSAL: TRICKLE CHARGE
Add distilled water as required.
Cell Voltage out of
1. It is recommended that cells which undergo cell reversal Spec
Continuous 40-ma trickle charge
1. 5/8 (±1/32) inch after 1 hour rest
during deep discharge be returned to vendor for evaluation /
(OR)
salvage. 1. Every month adjust water level to ¾
2. 1/2 (±1/32 inch after 3 hour rest. (±1/32) inch.
2. If it is not practical to return reversed cells, recondition BU as 2. Every 2 months recondition BU.
shown in this flowchart except wait 48 hours between main
charge and the capacity test. Any cell which had previously been When BU is Required
for Installation
reversed and fails the capacity test should be replaced.

PREPARATION FOR SHIPMENT: BU BU Not Req’d for 48

REQ’D FOR
Hours WATER ADJUST
1. Discharge BU to extinction. INSTALLATION?
Adjust water for ¾ (±1/32) inch above
plates.
2. Place shorting spring across pins in DPX connector.

3. Put circuit breaker in. Within 48 Hours

4. Install shipping plugs in place of cell vent plugs, if available. Figure 4

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OPERATING AND MAINTENANCE MANUAL
NICKEL-CADMIUM AIRCRAFT BATTERIES

2. A battery charger in the navigation unit automatically charges the battery when the INS is operating
on 115 volt, 400 Hz power. The battery charger senses battery voltage through the battery sense
line. With navigation units not modified in accordance with Service Bulletin 34-40, the charger
provides a two-ampere current whenever the battery voltage drops to 26.5 VDC. The charger
automatically shuts off when modified (MD9) to Service Bulletin 34-40. A 40 milliampere trickle
charge is applied to the battery unit whenever the INS is turned on. In addition, the battery unit is
charged at a constant two-ampere rate whenever the battery voltage drops to 24.0 VDC. The two-
ampere charger automatically shuts off when the battery voltage reaches 29.0 VDC. Although the
charger keeps the battery unit charged, the inherent characteristics of a nickel-cadmium battery make
it necessary to periodically return the battery unit to a maintenance shop for reconditioning.

Charge

1. During charge, the charging current causes the cadmium-oxide material of the negative plate to
gradually lose its oxygen and become metallic cadmium. The nickel-oxide material of the positive
plate is brought to higher state of oxidation by the charging current. As long as the current continues,
changes takes place until both materials are completely converted.

2. Toward the end of this charging process, and during overcharge, the cells form gas. This is a result
of electrolysis of the water component of the electrolyte. The gas created at the negative plates is
hydrogen and that at the positive plates is oxygen. The amount of gas created is dependent upon the
temperature and the amount of charging current.

3. The cells accept a charge at temperatures ranging from –65 to +165°F. The electrolyte does not
enter into any chemical reaction with either the negative or positive plates, but acts merely as a
conductor of current between them. There is no significant change in the specific gravity of
electrolyte, since it acts only as a conductor. Therefore, the specific gravity cannot be used as an
indication of the state of charge of the battery unit, as it is used in lead-acid batteries.

4. Figure 5 shows a representative curve of battery voltage while a completely discharged battery is
being charged at a constant current. The voltage curve has a typical knee (or change in voltage)
which occurs when the battery is charged to approximately 70% of capacity. Up to the occurrence of
this knee, a higher charging current can be used but, when the battery voltage increases as shown, a
lower charging current must be used to prevent excessive gassing and battery overheating. The
knee in the curve shifts to the left if the battery is partially discharged.

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Typical Voltage Time Curve For Constant Current Charging

Figure 5

Typical Discharge Voltage Curve

Figure 6

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NICKEL-CADMIUM AIRCRAFT BATTERIES

Discharge

1. During discharge, an action that is the reverse of that which occurs during charge is immediately
initiated when electrical energy is withdrawn form the cell. The negative plate gradually gains back
oxygen, and the positive plate gradually loses oxygen. There is no gassing on normal discharge due
to this interchange of oxygen.

2. This process results in the conversion of the chemical energy of the plates into electrical energy. The
rate at which this conversion takes place is primarily determined by the external resistance imposed
by the electrical circuit to which the cell is connected. There is extremely low internal resistance
within the cells. The chemical nature of the electrolyte and its specific gravity remain unchanged
during discharge. The relative constancy of the battery voltage during discharge is due mainly to
these factors.

3. Figure 6 shows a typical discharge curve under load. This curve shows the basically constant voltage
that is maintained by a nickel-cadmium battery during discharge. It also illustrates the apparent loss
of capacity that occurs when the battery needs reconditioning.

Cell Unbalance and Reconditioning

1. A characteristic observed in nickel-cadmium batteries is a loss of capacity over a period of time even
though the battery is kept charged. This loss of capacity is caused by imbalances between cells
because of differences in temperature, charge efficiency, and self-discharge rate of the cells. The
battery can be restored to its original capacity by reconditioning.

2. Reconditioning basically consists of completely discharging the battery and then recharging at a low
constant current rate. The individual cells are checked for proper voltage while still on charge. The
frequency of reconditioning is dependent on the type of battery operation and charging while installed
in the aircraft.

Water Dissociation

1. Water dissociation, or the electrolysis of water into gaseous hydrogen and oxygen, occurs when the
battery is overcharged beyond its ampere-hour capacity. Oxygen is generated at the positive
electrode and hydrogen at the negative electrode. These gases are generated under pressure and
are vented to the atmosphere through the vent plugs. Thus water is lost each time the battery is
overcharged. Periodic addition of distilled water to the 30% potassium hydroxide –70% water content
is therefore required to assure adequate capacity.

2. Water dissociation occurs at a relatively constant rate and is a function of temperature and current.
Water is dissociated in the battery unit at the approximate rate of 1 cc of water per three ampere
hours of overcharge at room temperature. The water available for dissociation is the water that is
available above the plates of the cell. When the battery is put into service and subjected to
overcharging (through battery charger operation and trickle charging), water is lost from the battery.
Eventually distilled water will have to be added to the electrolyte to make up for this water loss.

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NICKEL-CADMIUM AIRCRAFT BATTERIES

Self-Discharge and Trickle Charge

1. Self-discharge starts taking place as soon as the battery is taken off charge. The dissolved oxygen
gas that is always present in the electrolyte encounters the metallic cadmium of the plates and reacts
with it to form cadmium hydroxide. This conversion of cadmium hydroxide is the same conversion
that takes place when the battery is discharged through a load. Thus, a battery unit will self-
discharge and lose capacity even though it is not used. It is desirable to maintain the battery on a
constant current trickle charge to compensate for this self-discharging characteristic.

2. In theory, a trickle charge just sufficient to counter-balance the self discharge rate will maintain
battery capacity indefinitely. In practice, it is extremely difficult to provide the precise degree of trickle
charge required to counterbalance self discharge. Therefore, a trickle charge current that is larger
than the self-discharge rate is used in order to maintain the battery at full capacity. However, this
overcharge by the trickle current will cause water dissociation and thus increase the need for periodic
water addition.

Cell Reversal

1. Cell reversal can occur if one cell is slightly lower in capacity that the other and if, during deep
discharge, its voltage falls to less than 0.6 volt. The battery will continue to discharge through the low
voltage cell, thus charging it in the reverse direction. The cell may reverse its polarity and be
damaged under this condition.

Battery Unit Electrical Characteristics

The electrical characteristic of the battery unit are as follows:

1. The closed circuit voltage is the typical voltage when the battery is discharged into rated load at 70°F.
This voltage is between 1.20 and 1.28 volts for an individual cell, or 22.8 to 24.3 volts for the battery
unit.

2. The open circuit voltage of a battery under no load conditions at room temperature. This voltage is
between 1.25 and 1.43 volts for an individual cell, or 23.8 to 27.2 volts for the battery unit.

3. The end of charge voltage is the final voltage at the end of charge. This voltage is between 1.50 and
1.68 volts for an individual cell at completion of charge, or 28.5 to 31.9 volts for the battery unit.

4. The end of discharge voltage is the final voltage to which a battery is normally discharged under rated
load. Typically, this is 1.0 volt per individual cell or 19.0 volts for the battery unit.

5. Trickle charge voltage is the back emf developed by the battery when it is being trickle charged. A 40
ma trickle charge current will develop a trickle charge voltage of approximately 1.39 volts per cell or
26.4 volts per battery unit at 70°F.

6. The capacity of a battery is given in ampere hours. Ampere hours is the product of the discharge
current and time in hours that this current flows. The ampere hour capacity varies with the discharge
rate.

7. Charge retention is the ability of fully charged nickel-cadmium battery to maintain capacity under no-
load condition. A typical battery will retain 60% of its capacity after one year at 80°F, or 90% after
one year at 0°F.

8. Efficiency of a nickel-cadmium battery is typically 80%. A 120% overcharge is required to return a

battery to its original capacity.

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CONSTRUCTION

General

Each cell of the battery unit contains positive and negative plates. The active material of the negative plate is
cadmium oxide. The active material of the positive plate is nickel oxide. The plates are submerged in an
electrolyte of potassium hydroxide and distilled water. The positive and negative plates are connected to
terminals on the top of the cell. Inspection of electrolyte can be accomplished by removing a vent plug on the
top of the cell. The vent plugs permit discharge of hydrogen and oxygen gases which are formed by
electrolysis of the water during charging.

The principal parts of the nickel-cadmium battery are:

1. Plate Structure
Sintered and chemically impregnated positive and negative tabbed electrodes.

2. Separator Matrix
Comprised of a three layer matrix of nonwoven polyamide – microporous membrane – nonwoven
polyamide.

3. Cell
The cell is assembled into its final form by welding the tabs of the negative plates to one terminal post
and the tabs of the positive plates to a second terminal post. Once assembled, it is inserted into a
polyamide case and fitted with a cover-and-vent assembly that permits the terminal posts to project
through the top of the case. The complete unit is then sealed.

4. Cell Vent
Each cell is equipped with a vent plug and filler cap. It can be removed for cleaning or adjustment of
the electrolyte. When excessive gases developing the cell during charge, they escape through the
vent hole. The vent relieves gas pressure by remaining closed until a pressure of at least 2 psi is
reached and will open at a pressure below 10 psi. Except when releasing gas, the vent remains
sealed to prevent electrolyte leakage, the entry of foreign material into the cell or contamination of
electrolyte by exposure to air high in carbon dioxide.

5. Electrolyte
The electrolyte used in nickel-cadmium batteries is a 30% by weight solution by potassium hydroxide
(KOH) in distilled water. It provides a conducting path for the current, which flows between the
positive and negative plates. The electrolyte does not take part in the chemical reaction in nickel-
cadmium batteries, but acts as an ion carrier. The specific gravity remains constant at 1.240 to 1.320
whether the battery is in a charged or discharged state and cannot be used to measure state of
charge.

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1.0 DISASSEMBLY

Disassembly of the battery unit usually involves removal and replacement of items such as battery
cells, intercell connectors, latch handles, electrical connector, circuit breaker, and other parts found
defective in the inspection, troubleshooting, and testing sections. Removal and replacement of most
defective items is simple, and no special instructions are needed.

1.1 Battery Cell Replacement

Replace a cell in the battery unit as follows:

a) Pull circuit breaker out.

b) Clean battery unit as specified in Cleaning section.

c) Discharge battery unit to extinction using procedure described in Testing section.

d) After all cells have been shorted, remove shorting straps and cell connection straps from
defective cell.

e) Loosen vent plugs to relieve cell internal pressure.

f) Remove cell from battery case by lifting cell by terminals. A cell puller, fabricated locally,
will aid in this operation. Refer to Special Tools, Fixtures, and Test Equipment section for
cell puller fabrication information.

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2.0 CLEANING
This section contains the necessary information to clean the tops of cells and inside of case of the
battery unit.

2.1 Cleaning Procedure

a) Loosen any white deposits from tops of cells using a stiff, nylon bristle brush.

CAUTION: DO NOT USE WIRE BRUSHES FOR CLEANING BATTERY UNIT.

b) Remove loosened deposits by an air hose or by flushing with water. Do not let this
loosened material come in contact with eyes.

c) Clean tops of cells, intercell connectors, and inside of case using cotton swabs or cloth
moistened with distilled water.

NOTE: DO NOT RUB PROTECTIVE COATING OFF INTERNAL HARDWARE.

d) Dry clean areas using a cotton swab.

e) After cleaning, apply coat of protective grease to all exposed mental on tops of cells. Use
a grease such as Shell Darina #2 or petroleum jelly.

f) Check that intercell connections are tight. See Assembly section for torquing
requirements.

g) Clean each vent plug by sloshing in warm water. Check that the vent passage is clear of
obstructions.

NOTE: A RECOMMENDED METHOD TO CHECK VENT PASSAGE IS TO APPLY 10

PSI MAXIMUM COMPRESSED AIR TO BOTTOM OF VENT PLUG WHILE
PLUG IS SUBMERGED IN WATER. BUBBLES EMERGING FROM UNDER
RUBBER COLLAR OVER VENT SLOT INDICATE A CLEAR PASSAGE.

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3.0 INSPECTION / CHECK

This section contains the necessary information to perform visual-mechanical inspection of the
battery unit.

3.1 Inspection Procedure

a) Inspect vent plugs for foreign matter. Clean as required. (See Cleaning section.)

b) Inspect intercell connectors for corrosion, excess spewage, and discoloration. Clean as
required. Tighten cell terminal screws to torque requirements listed in Assembly section.

c) Inspect circuit breaker for operation. Replace if defective, observing torque requirement
in Assembly section.

d) Inspect wiring for fraying or broken insulation. Replace if defective.

e) Inspect cell holddown bar for cleanliness and tightness. Clean and tighten as required in
Assembly section.

f) Inspect latch handles for operation, tightness, and mechanically integrity. Replace if
defective.

g) Inspect electrical connector for corrosion and condition of pins. Replace it defective.

h) Inspect cover, cover screen and cover latches for proper operation and cleanliness.
Clean or replace as required.

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4.0 REPAIR

Repair of the battery unit usually involves removal and replacement of items such as battery cells,
intercell connectors, latch handles, electrical connector, circuit breaker, and other parts found
defective in the inspection troubleshooting, and testing sections. Removal and replacement of most
defective items is simple, and no special instructions are needed.

4.1 Battery Cell Replacement

Replace a cell in the battery unit as follows:

a) Pull circuit breaker to out position.

b) Clean battery unit as specified in Cleaning section.

c) Discharge battery unit to extinction using procedure described in Testing section.

d) After all cells have been shorted, remove shorting straps and cell connection straps from
defective cell.

e) Loosen vent plugs to relieve cell internal pressure.

f) Remove cell from battery case by lifting cell by terminals. A cell puller, fabricated locally,
will aid in this operation. Refer to Special Tools, Fixtures, and Test Equipment section for
cell puller fabrication information.

g) Install new cell that has been previously discharged and short circuited. Make certain cell
polarity is correct. If cell is difficult to insert, apply a light coat of petroleum jelly or
silicone grease (Shell Darina #2) to sides of cell.

h) Reinstall cell connector straps. Tighten cell terminal screws to torque of 30 to 35 pound-
inches for P/N 28656-002 or 15 to 18 pound-inches for P/N 27826-002.

g) Check that cell electrolyte level is at least 1/16 inch above plates. Add only distilled water
if required to bring level up to 1/16 inches above the plates. Charge battery and perform
a capacity test as described in the Testing section.

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5.0 ASSEMBLY

5.1 Torque Requirements

a) Tighten cell terminal screws to a torque of 30 to 35 pound-inches for P/N 28656-002 or

15 to 18 pound-inches for P/N 27826-002.

b) Tighten ground stud and circuit breaker nuts to a torque of 15 –20 pound-inches.

c) Tighten the cell holddown bar screws to a torque of 12 to 15 pound-inches.

5.2 Vent Plugs

Keep vent plugs in place at all times except when inspecting and adjusting electrolyte level.
Carbon dioxide, absorbed from the air, forms potassium carbonate, effectively diluting the
electrolyte.

5.3 Celll Replacement

See Repair section for cell replacement procedures.

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6.0 TESTING

This section contains procedures for reconditioning and capacity testing the battery unit. Figures 3 &
4 present this information in condensed flow diagram format. Reconditioning a battery unit includes
discharging the battery unit to extinction, charging the battery, adjusting the electrolyte level,
performing a capacity test, and recharging the battery before returning it to service. The only reliable
test of a nickel-cadmium battery is a controlled discharge of a fully charged battery. It is
recommended that every battery unit undergoing maintenance should undergo a reconditioning cycle.
Assuming cells are all good, reconditioning cycle will restore capacity loss.

6.1 Tools and Test Equipment

A complete description of the test equipment and tools required for testing the battery unit are
contained in the Special Tools, Fixtures, and Test Equipment section of this subject. A
summary is given below:

Description Usage

3.0 amp Constant Current DC Source (Lamda or Equiv.) Battery Charging

3.8 ohm ±1%, 150 watt Resistor (Ohmite or Equiv.) Capacity Test

10 ohm ±15%, 150 watt Resistor (Ohmire or Equiv.) Battery Discharge

1 ohm ±10%, 5 watt Resistor (5 Required) Shorting Cells with Load

(Ohmite or Equiv.)

Shorting Clips (19 Required) Shorting Cells

Shorting Spring Shorting Battery

40 ma Constant Current source (Lamda or Equiv.) Battery Trickle Charge

Marathon PCA 131 Battery Charger-Analyzer Complete Battery Analyzer

6.2 General Precautions

The following precautions should be observed while charging or discharging the battery unit.

WARNING: THE ELECTROLYTE (POTASSIUM HYDROXIDE) IN THE BATTERY UNIT IS

VERY CAUSTIC AND WILL BURN THE EYES, SKIN, ETC. IT IS
RECOMMENDED THAT SAFETY CLASSES BE WORN WHILE CHARGING,
DISCHARGING, AND CLEANING THE BATTERY. IN CASE OF ACCIDENT,
NEUTRALIZE ELECTROLYTE WITH 3% BORIC ACID AND WASH WITH
WATER. RINGS OR OTHER JEWELRY THAT MIGHT COME IN CONTACT
WITH CELL TERMINALS SHOULD NOT BE WORN.

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a) Never charge or discharge the battery unit unless each individual cell has at least 1/16
inch water above the plates. Add distilled water only if necessary to meet this
requirement.

b) Do not adjust electrolyte level except after charge during reconditioning or as required to
meet the 1/16 inch minimum requirement.

c) The battery case should never be more than slightly warm to the touch (approximately
100°F) during charge. Higher temperatures are an indication of too high a charging
current. It is recommended that charging be discontinued until the temperature returns to
normal.

d) It is recommended that charging be accomplished at ambient temperature between

+40°F and +90°F. Higher or lower temperatures could be detrimental.

e) If any cells have undergone reversal, recondition the battery as described in this section
except wait 48 hours between charge and capacity test. Any cell which had previously
been reversed and fails the capacity test after a 48 hour rest period should be replaced.

f) Charge battery unit in an upright condition to avoid spillage and allow proper venting.

g) Never charge or discharge cells (or batteries) that are connected in parallel.

h) Keep vent plugs in place at all times except when inspecting and adjusting electrolyte
level. Carbon dioxide, absorbed from the air, forms potassium carbonate, effectively
diluting the electrolyte. The potassium carbonate significantly increases internal cell
resistance could cause overheating and eventual failure.

6.3 Maintenance Procedures

6.3.1 Reconditioning
The following reconditioning procedure must be followed whenever the battery unit is
received for reconditioning or fails the capacity test.

a) Inspect the battery for evidence of physical damage, swollen cells, loose
connecting bars and corrosion. (See Inspection/Check section).

b) Measure leakage current between positive battery terminal and battery case
ground stud, and between negative battery terminal and ground stud. If current
is greater than 50 milliamperes, disassemble battery unit and thoroughly clean it.
(See Cleaning section.)

c) Remove vent plugs and visually inspect the water level in each cell. Fill all cells
having a water level below the top of the plates to a level approximately 1/16 inch
above the plates. Clean and inspect the vent plugs as follows:

• Immerse each vent plug in a container of warm water and clean by sloshing.
Check that the vent passage is clear of obstructions.

NOTE: A RECOMMENDED METHOD TO CHECK VENT PASSAGE IS TO

APPLY 10 PSI MAXIMUM COMPRESSED AIR TO BOTTOM OF
VENT PLUG WHILE PLUG IS SUBMERGED IN WATER.
BUBBLES EMERGING FROM UNDER RUBBER COLLAR OVER
VENT SLOT INDICATE A CLEAR PASSAGE.

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• Check that rubber collar and “O” ring are not damaged. Replace vent plug if
necessary.

• Reinstall vent plugs.

d) Discharge battery unit to extinction as indicated in procedure 6.3.2.

e) Charge battery and check water level as indicated in procedure 6.3.3.

f) Perform the battery capacity test described in procedure 6.3.4.

g) Recharge battery and check water level as indicated in procedure 6.3.3. It is not
necessary to discharge a battery to extinction before recharging after successful
completion of battery capacity test.

6.3.2 Battery Discharge Procedure

a) Discharge battery by installing a 10 ohm ± 15 percent, 150 watt resistor across

battery terminal.

b) Monitor battery terminal voltage. Continue discharging until battery terminal

voltage drops to 2.5 volts or less. Do not disconnect resistor.

c) Monitor cell terminal voltages. As each cell drops below 0.6 volt, place a shorting
clip across cell terminals. Continue until 14 cells are shorted. Do not disconnect
shorting clips.

d) Place a 1 ohm, ± 10 percent, 5 watt resistor across each of the remaining

unshorted cells.

e) Leave battery in this condition for a minimum of 3 hours; then install shorting
clips in place of the 1 ohm resistor.

f) Battery unit is ready for charge immediately after all cells are shorted. If there is
to be a lapse of time before charging, keep the battery in a short circuited
condition.

6.3.3 Battery Charge and Water Adjustment Procedure

a) Remove all shorting devices and/or resistor from cells or battery.

b) (1) P/N 28656-002. Apply a 3.0 ampere constant current for 7 hours.

(2) P/N 27826-002. Apply a. 3.0 ampere constant current for 3 hours.

c) Towards end of charging period, with charging current still applied to the battery,
measure battery terminal voltage. Battery terminal voltage must be 29.5 through
33.25 VDC. If this requirement is not met, follow the instruction in paragraph
6.3.5 below.

d) Towards end of charging period, with charging current applied, measure

individual cell voltage. Voltage of each cell must be 1.55 through 1.75 VDC.
Replace all cells, which do not meet this requirement. (Refer to Repair section
for cell replacement procedures.)
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e) (1) P/N 28656-002. Remove vent plugs and adjust water level, if required, to 7/8
(±1/32) inch above top of plates after a 1 hour wait, or to ¾ (±1/32) inch
above top of plates after 3 hour wait.

(2) P/N 27826-002. Remove vent plugs and adjust water level, if required, to 5/8
(±1/32) inch above top of plates after a 1 hour wait, or to ½ (±1/32) inch
above top of plates after 3 hour wait.

f) Reinstall vent plugs and tighten to a torque of 8 to 10 pound inches.

6.3.4 Battery Capacity Test, P/N 28656-002

The battery capacity test described below should be performed within 48 hours after
the battery has been charged. Measure individual cell voltages before starting test.
If any cell has an open circuit voltage of less than 1.25 volts, discharge the battery to
extinction and recharge as described above.

NOTE: BECAUSE THE CAPACITY TEST IS TIME DEPENDENT, START TIMING

IMMEDIATELY WHEN THE 3.8 OHM RESISTOR IS CONNECTED
ACROSS THE BATTERY.

a) Discharge battery by installing a 3.8 ohm (±1 percent), 150 watt resistor across
the battery terminals.

b) At 105 minutes after start of discharge, each cell shall be 1.0 volt minimum and
the BU terminal voltage must be not less than 19.0 volts. Because of the sharp
decline in cell voltage that occurs when a cell approaches extinction, and
because of the large number of cells that must be measured, individual cell
voltages should be monitored during discharge, prior to the 105 minute mark.

c) If the battery passes the capacity test, remove the 3.8 ohm resistor in preparation
for charging. (See procedure 6.3.3.) It is not necessary to discharge a battery to
extinction after successful completion of the capacity test.

d) If the battery fails the capacity test, replace the 3.8 ohm resistor with a 10 ohm
resistor and discharge to extinction. (See procedure 6.3.2.) Replace any
obviously bad cells at this time. If any cells are marginal, recondition the battery
unit a maximum of two times and then replace cells which still fail the capacity
test.

6.3.5 Battery Capacity Test, P/N 27826-2 (5 AH)

The battery capacity test described below should be performed within 48 hours after
the battery has been charged. Measure individual cell voltages before starting test.
If any cell has an open circuit voltage of less than 1.25 volts, discharge the battery to
extinction and recharge as described above.

NOTE: BECAUSE THE CAPACITY TEST IS TIME DEPENDENT, START TIMING

IMMEDIATELY WHEN THE 3.8 OHM RESISTOR IS CONNECTED
ACROSS THE BATTERY.

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a) Discharge battery by installing a 3.8 ohm (± 1 percent), 150 watt resistor across
the battery terminals.

b) At 45 minutes after start of discharge, each cell shall be 1.0 volt minimum and
the BU terminal voltage must be not less than 19.0 volts. Because of the sharp
decline in cell voltage that occurs when a cell approaches extinction, and
because of the large number of cells that must be measured, individual cell
voltages should be monitored during discharge, prior to the 45 minute mark.

c) If the battery passes the capacity test, remove the 3.8 ohm resistor in preparation
for charging. (See procedure 6.3.3.) It is not necessary to discharge a battery to
extinction after successful completion of the capacity test.

d) If the battery fails the capacity test, replace the 3.8 ohm resistor with a 10 ohm
resistor and discharge to extinction. (See procedure 6.3.2.) Replace any
obviously bad cells at this time. If any cells are marginal, recondition the battery
unit a maximum of two times and then replace cells which still fail the capacity
test.

6.3.6 Battery With Less Than 29.5 Volts After Charge

The battery voltage should be between 29.5 and 33.25 volts at the termination of
charge (3.0 A for 7 hours). If the battery terminal voltage is lower than 29.5 volts,
continue to charge at 3.0 amperes for an additional hour. If at the end of this time the
battery terminal voltage is less than 29.5 volts and all cell voltages are above 1.50
volts:

a) Record individual cell voltages.

b) Follow the discharge procedures of procedure 6.3.3 above.

c) Replace the cell(s) having the lowest voltage(s) with fully charged cells until the
battery terminal voltage is greater than 29.5 volts. (See Repair section for cell
replacement procedures.)

d) Follow steps (f) through (g) in reconditioning procedure 6.3.1 above.

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7.0 TROUBLESHOOTING
This section contains troubleshooting information relating to typical malfunctions encountered in the
maintenance of the battery unit.

7.1 Excessive Spewage

Excessive spewage of electrolyte resulting in large crystalline deposits on tops of cells. In

some cases, a considerable amount of liquid collects in the bottom of the battery case. This
condition indicates that battery unit has been subjected to high charge voltages or high
ambient temperatures during charge. Electrolyte level may also have been improperly
adjusted. To correct this condition, clean battery unit as indicated in Cleaning section and
perform reconditioning procedures specified in Testing section.

7.2 Distortion Of Cell Cases

Distorted cell cases may have been caused by high charge voltages or high ambient
temperatures during charge. Replace damaged cell(s) following procedures located in
Repair section.

7.3 Frequent Addition Of Water

If one or more cells require more water than the others, cells may be out of balance. Perform
testing and reconditioning procedures specified in Testing section.

7.4 Burn Marks On Connectors

The appearance of burn marks on intercell connectors indicates that connectors are not
properly tightened. Clean affected area per instructions in Cleaning section and then tighten
intercell connectors. Refer to Assembly section for torque requirements. Burn marks on
external electrical connectors may indicate connector failure. Replace battery unit connector
or its mating connector if required.

7.5 Cell Leakage Current

Cell leakage current may result from a damaged case-to-cover seal of an individual cell or a
conductive path of electrolyte spillage. If cleaning does not stop the current leakage
determine which cell is damaged by performing the following procedure:
a) Place probe of a voltmeter on either the positive or negative battery terminal and the
other probe on the battery ground stud.

b) Observe the voltage.

c) While leaving the probe on the ground stud, move the other probe from cell terminal to
cell terminal.

d) The indicated voltage should decrease and finally go negative. The leaking cell will be
found at the voltage changeover point.

e) Inspect surrounding cells and hardware for damage.

f) Replace leaking cell with new cell. (Refer to Cell Replacement procedures in Repair
section.)

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7.6 Electrolyte Level

For checking the electrolyte level after completion of constant current charge, it is
recommended that a six inch long by ¼ inch O.D., by 1/8 inch inside diameter
polystyrene tube, open at both ends with the interior roughened to prevent
capillary action, be used as follows (See Special Tools, Fixtures, and Test
Equipment section).

a) Remove the vent plug and insert the tube into the filler opening deep enough
to touch the top of the plates or plastic insert.

b) Place a finger over the top open end of the tube and remove the tube from
the filler well, noting the height of liquid in the tube.

c) (1) P/N 28656-002. If the liquid is less than 7/8 (±1/32) inch above the
plates after a three hour stand, add distilled water to the cell until the
proper level is reached.

(2) P/N 27826-002. If the liquid is less than 5/8 (±1/32) inch above the
plates after a one hour stand or less than ½ (±1/32) inch above the
plates after a three hour stand, add distilled water to the cell until the
proper level is reached.

d) If the liquid is above the specified level, remove excess electrolyte with an
electrolyte remove tool (See Special Tools, Fixtures, and Test Equipment
Section).

7.7 Foreign Material Within Cell Cases

Cells which must be removed because of failure to respond to normal charging

may contain visible foreign substances. These substances, which my be gray,
black, or brown in color, are usually introduced into the cell through the addition
of impure water or water contaminated with acid. Foreign substances within the
cells can also be caused by extremely high rate charging, charging without
sufficient electrolyte in the cells, too high a concentration of electrolyte, or a
combination of these conditions.

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8.0 STORAGE INSTRUCTIONS

The battery unit may be stored in either a charged or in an uncharged condition. It is
recommended that the battery unit be stored in a charged condition with a 40 mA trickle
charge if the battery is to be kept available for installation in an airplane. The battery
should be discharged and stored in a shorted condition for long term storage.

8.1 Storage Of Charged Battery Unit

a) Perform the following procedures if the battery unit is to be stored in a

charged condition:

• Recondition the battery unit (See Testing section).

• Place the battery unit on a trickle charge of 40 mA constant current. This

trickle charge may be left on continuously.

b) Perform the following while the battery unit is on trickle charge:

• Every month adjust the electrolyte level in each cell so that it is 3/8
(±1/32) inch above the plates. Use distilled water only.

• Every two months recondition the battery unit as described in the Testing
section.

c) Perform the following when the battery unit is to be removed from charged
storage:

• If the battery unit is to be installed in an airplane, adjust the electrolyte

level in each cell. Use distilled water only.

• If the battery unit is to be shipped, perform procedures in step 8.2 below.

8.2 Storage Of Uncharged Battery Unit

a) Perform the following if the battery is to be stored in an uncharged condition:

• Clean battery unit as specified in Cleaning section.

• Completely discharge battery unit to extinction with all cells shorted (see
Testing section).

• Insure that battery unit circuit breaker is pushed in.

• Install shorting spring around all eight pins of battery unit external
electrical connector. Attach a caution tag to battery unit indicating
installation of the shorting spring.

• Remove cell shorting clips.

• Install dust cover over battery unit external electrical connector.

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b) Perform the following after uncharged battery unit is removed from storage:

• If the battery unit is to be installed in an airplane, recondition the battery

unit (See Testing section).

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9.0 SPECIAL TOOLS, FIXTURES AND TEST EQUIPMENT

9.1 Test Equipment

Table 1 lists the test equipment required to test and troubleshoot the battery unit.
Equivalent items may be substituted.

TABLE 1
Test Equipment

Item Recommended Type Function

Constant Voltage/Constant To provide a constant current, ±

HP6290A (0-40 V. 0-3 A) with
Current Power Supply (with 5% regulation at voltage up to 32
diode protection
power cable. See Figure 7) VDC for battery charging

To provide a constant 40 ma
Constant Voltage/Constant
HP6218A (0-50 V, 0-200 mA) current, ± 10% regulation at a
Current Power Supply (with
with diode protection nominal 26.4 volts for battery
power cable – see Figure 7)
trickle charging

Power Resistor (with power Ohmire Style 210-225 (5 ohm, 3.8 ohm ± 15% 150 watt resistor
cable – see Figure 7) adjustable, 225 watt) for capacity test

Power Resistor (with power Ohmite Style 270-175 (10 ohm, 10 ohm ± 15% 150 watt resistor
cable – see Figure 7) fixed, 175 watt) for discharging battery unit

Power Resistor - - 5 required Ohmite Style 995-5B (1 ohm, 1 ohm ± 10%, 5 watt resistor for
(with clips – see Figure 7) fixed) discharging individual cells

Test battery unit voltage and

Volt-Ohm-Milliameter Simpson 260
current leakage

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9.2 Special Tools and Fixtures

a) Table 2 lists the special tools and fixtures required to recondition the battery
unit. These items can be locally fabricated. Equivalent items may be
substituted.

TABLE 2
Special Tools and Fixtures

Item Recommended Type Function

To connect power supplies or

Power Cables (4 required) See Figure 7 power resistors to the battery
unit

Cells Shorting Clips To short the cell terminals

See Figure 9
(19 required) together

To short together the pins of the

BU Shorting Spring See Figure 10
battery unit DPX Connector

To aid in the removal of cells

Cell Puller (2 required) See Figure 11
from the battery unit

To aid in checking electrolyte

Electrolyte Level Checker See Figure 12
level in individual cells

To aid in the removal of

Electrolyte Removal Tool See Figure 13
electrolyte from a cell

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b) Power Cables are required to connect to the power supplies or the power
resistors. A suggested cable is shown in Figure 7. Variations, such as
substituting alligator clips for the DPX connector, are permissible.

Power Cable
Figure 7

c) One-ohm ± 10 percent, 5 watt power resistors with alligator clips are required
to discharge individual cells during battery unit discharge procedures.

One-ohm Power Resistor

Figure 8

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d) Cell shorting clips are required to short circuit individual cells.

Cell Shorting Clips

Figure 9

e) Battery unit shorting spring is required to short circuit the connector pins of
the battery unit DPX connector. This shorting spring is furnished with the
battery unit during its initial long term storage of the battery unit.

Battery Unit Shorting Spring

Figure 10

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f) A cell puller is required to replace battery cells. A cell puller can be

fabricated locally using the information contained in Figure 11

Cell Puller
Figure 11

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g) An electrolyte level checker is useful in checking the electrolyte level in the

individual cells. Insert tube into filler opening deep enough to touch top of
plates. Place a finger over top open end of tube and remove tube from filler
well. The electrolyte level in the tube is a measure of the electrolyte level in
the cell.

7/8"

5/8"

FOR P/N: 28656-002

3/4"

FOR P/N: 27826-002

1/2"
POLYSTYRENE TUBES
OPEN ON BOTH ENDS
ABOUT 1/8" INSIDE
DIAMETER.
1/16" WIDE MARKS
ON BOTH ENDS
OF EACH TUBE
ROUGHEN INSIDE OF TUBES
TO INHIBIT CAPILLARY ACTION.

Electrolyte Level Checker

Figure 12

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h) An electrolyte removal tool is useful when it is necessary to remove excess

electrolyte from a cell.

Electrolyte Removal Tool

Figure 13

• Distance (d) from end of tube to centerline of hole should be selected in

accordance with the following:

For P/N 28656-002 batteries

• 7/8 inch if electrolyte is checked on hour after completion of charge.
• ¾ inch if electrolyte is checked three hours after completion of
charge.

For P/N 27826-002 batteries

• 5/8 inch if electrolyte is checked one hour after completion of charge.
• ½ inch if electrolyte is checked three hours after completion of
charge.

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10.0 OVERHAUL MANUAL

Figure Part Nomenclature Units Per

Item Number 1 2 3 4 Assembly

1001-1 28656-2 Battery Unit RF

1001-2 28848 . Battery Assembly RF
1001-3 28798 . . Connector and Lead Assembly 1
1001-4 15111-89 . . Nut 1
1001-5 16128-28 . . Washer, Spring, Belleville 39
1001-6 18100-36 . . Washer 1
1001-7 10488-31 . . Screw, Cap Stock Head 38
1001-8 25636-1 . . Washer, Double “D” 38
1001-9 27882-2 . . Screw, Flat Head 4
1001-10 28278-3 . . Spring, Short Out 2
1001-11 28801 . . Wire and Lug Assembly 2
1001-12 27873-1 . . Circuit Breaker 1
1001-13 10371-136 . . Connector 4
1001-14 27135-8 . . Connector 2
1001-15 10371-124 . . Connector 11
1001-16 24941-5 . . Cell Assembly 19
1001-17 28800 . . Separator 1
1001-18 28799 . . Spacer 1
1001-19 27872-1 . . Handles, Latch 2
1001-20 23492-6 . . Screw, Flat Head, 100° Phillips 4
1001-21 28796-2 . . Battery Box and cover Assembly 1

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Figure 1001

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Figure Part Nomenclature Units Per

Item Number 1 2 3 4 Assembly

1002-1 27826-002 Battery Unit RF

1002-2 28866 . Battery Assembly RF
1002-3 28749 . . Connector and Lead Assembly 1
1002-4 23053-10 . . Clamp, Cable 3
1002-5 26702-3 . . Screw, Pan Head 3
1002-6 28752 . . Washer. D 3
1002-7 15013-7 . . Nut, Lock 3
1002-8 15111-89 . . Nut, Hex 1
1002-9 16128-28 . . Washer, Belleville 43
1002-10 18100-36 . . Washer, Flat 5
1002-11 15111-58 . . Nut, Hex 38
. . Screw, Flat Head
1002-12 27882-2 4
. . Spring Short Out
1002-13 28278-3 2
. . Cable, Cell
1002-14 28751 1
. . Circuit Breaker
1002-15 27873-1 . . Holddown, Cell 1
1002-16 28736-1 . . Screw, Pan Head 3
1002-17 26702-3 . . Connector 9
1002-18 16102-127 . . Connector 9
1002-19 16102-128 . . Cell Assembly (V34122) 19
1002-20 19804-8 . . Latch (V34122) 2
1002-21 27872-1 Attaching Parts
1002-22 10246-24 . . Screw, Machine, Hex Head (V34122) 4
1002-23 28745-2 . . Battery Box and Cover Assembly 1

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Figure 1002

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11.0 LIGHT OVERHAUL

This section contains procedures for light overhaul to examine units on an interim service
life basis to determine the units’ condition for continued service without complete
teardown and rebuild

11.1 Light Overhaul Procedure

Every 200 flight hours perform the following checks on the BU.

a) Remove BU from rack and open cover of BU, examine battery for spewage.
Clean off if necessary, following procedures outlined in cleaning section 2.1
(a through e) (Page 201).

b) Using a Simpson multimeter, check individual cell voltages. If all cell

voltages are within 0.07 volts of each other, unit light overhaul check can be
continued. If cell voltages differ by more than 0.07 volts, remove BU from
service and proceed with testing (Pages 601-607).

c) If voltage check is satisfactory, remove vents and ascertain if there is an

adequate liquid level in each cell. If not, adjust liquid level using distilled
water, then replace vents.

NOTE: LIQUID LEVEL IS TO BE ADJUSTED ONLY IF BATTERY IS FULLY

CHARGED (I.E., INDIVIDUAL VOLTAGE READINGS ARE 1.28 VOLTS
OR GREATER). DO NOT ADD WATER TO ANY BATTERY NOT
FULLY CHARGED.

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