Heinrich-Diehl-Strasse 2

D-90552 Roethenbach
Germany
Cage Code: D1347
Phone: +49-911-957-2676
Fax: +49-911-957-3042

ABBREVIATED COMPONENT MAINTENANCE MANUAL

3214-31

BATTERY
PN 3214-31

LIST OF REVISIONS

Rev. No. – 1 2 3 4 5 6 7
Rev. Date JUL 08/02

LIST OF EFFECTIVE PAGES

PAGE DATE PAGE DATE PAGE DATE

1 of 18 JUL 08/02 7 of 18 JUL 08/02 13 of 18 JUL 08/02
2 of 18 JUL 08/02 8 of 18 JUL 08/02 14 of 18 JUL 08/02
3 of 18 JUL 08/02 9 of 18 JUL 08/02 15 of 18 JUL 08/02
4 of 18 JUL 08/02 10 of 18 JUL 08/02 16 of 18 JUL 08/02
5 of 18 JUL 08/02 11 of 18 JUL 08/02 17 of 18 JUL 08/02
6 of 18 JUL 08/02 12 of 18 JUL 08/02 18 of 18 JUL 08/02

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TABLE OF CONTENTS

PARA SUBJECT PAGE

1 DESCRIPTION AND OPERATION ............................................................................ 3

2 TESTING AND FAULT ISOLATION ........................................................................... 7

3 SCHEMATICS AND WIRING DIAGRAMS ........................................... (not applicable)

4 DISASSEMBLY .................................................................................... (not applicable)

5 CLEANING .............................................................................................................. 16

6 INSPECTION / CHECK ............................................................................................ 16

7 REPAIR ............................................................................................... (not applicable)

8 ASSEMBLY / STORAGE ......................................................................................... 17

9 FITS AND CLEARANCES .................................................................... (not applicable)

10 SPECIAL TOOLS, EQUIPMENT AND CONSUMABLE MATERIALS ....................... 18

11 ILLUSTRATED PARTS LIST ............................................................... (not applicable)

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1. DESCRIPTION AND OPERATION

A. General

(1) The battery PN 3214-31 is non-repairable.

(2) The battery (Ref. Figure 1) is part of the emergency lighting system of the aircraft.
In case of a breakdown of the aircraft power supply the battery supplies electrical
circuits with its stored energy for a defined time period.

1 Captive screw 5 Battery contact (–)

2 Housing 6 Label
3 Battery contact (+) 7 Notice
4 Connector

BATTERY
Figure 1

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B. Description (Ref. Figure 1)

(1) All parts of the battery are installed in a closed plastic housing (2).

(2) The battery block assembly consists of 5 Nickel-Cadmium cells connected in

series. The space between the cells is filled with elastic and heat-conductive
material in order to suppress vibrations of the cells.

(3) To ensure a high reliability of the battery within a wide range of temperature there
is a heating mat, a sensor for temperature regulating and a thermostat inside.
These components are connected to the connector (4).

(4) The positive (+) battery contact (3) and the negative (-) battery contact (5) are
high current female contacts.

(5) The battery is fixed to the connected emergency power supply unit with four captive
screws (1).

C. Operation (Ref. Figure 2)

(1) During discharging the temperature has an important effect on the voltage
characteristics of the battery and its service. This is due to the reduction in
chemical activity and the increase in battery internal resistance at lower
temperatures.
The performance is optimum at an operation temperature between 20 °C [68 °F]
and 40 °C [104 °F].
At higher temperatures the chemical deterioration may be rapid enough during
discharge to cause a loss in capacity.

(2) At low ambient temperatures the heating mat (R1) keeps the battery temperature
in the required range for best service.
The NTC resistor R2 is the sensor for the temperature regulating circuit which is a
part of the connected emergency power supply unit.
The thermostat S1 opens the heating current circuit at approximately 50 °C
[122 °F] in case of a malfunction of the regulating circuit.
The resistor R3 in parallel to the thermostat S1 is only for test purposes of the
heating circuit.

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B A T T E R Y

B 1
R 1 R 2

S 1
R 3

1 2 4 3 5 6

C O N N E C T O R

CIRCUIT DIAGRAM
Figure 2

D. Technical Data

Battery type ................................... Nickel-Cadmium

Nominal voltage ............................. 6 V
Capacity ........................................ 4 Ah
Number of cells .............................. 5
Heating mat ................................... 37 Ω / 20 W

Temperature sensor
Type .......................................... NTC resistor
Resistance at 25 °C [77 °F] ....... 12 kΩ

Thermostat
Function ................................... opens
Set point .................................... 50 °C ± 5 °C [122 °F ± 9 °F]
Operating temperature ................... -15 °C to +40 °C [+5 °F to +104 °F]
Storage temperature ...................... -40 °C to +50 °C [-40 °F to +122 °F]
Dimensions (max.) ......................... 115.5 x 80.5 x 65 mm [4.6 x 3.2 x 2.6 in.]
Mass (weight) ................................ 1.01 kg [2.2 lb.]

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E. Definitions and Recommendations

(1) Definitions
Our recommendations are based on the following terms:

Shelf Life:
The shelf life is the lifetime of the battery. It is a combination of the storage life
and the service life of the battery. After expiry of the shelf life period an exchange
of the battery is recommended because experience shows an increasing failure
rate thereafter.

Storage Life:
The storage life indicates the time the battery can be stored (Ref. paragraph 8
'ASSEMBLY / STORAGE') without having to expect any failure after putting it into
service.

Service Life:
The service life indicates the time the battery is installed in an emergency power
supply unit which is in service.

(2) Recommendations
The recommendations of DLE regarding the battery PN 3214-31 are as follows:
– Shelf Life: approx. 60 months
– Storage Life: approx. 36 months
– Service Life: approx. 36 months

(3) Additional Information

The shelf life of the battery depends to a great extent on the amount of charge
and discharge cycles, the ambient conditions and the correct storage – including
the periodical testing of the battery in accordance with paragraph 8 'ASSEMBLY /
STORAGE'.
The recommended shelf life of 60 months shall not be exceeded, even though the
recommended storage life and service life in combination would allow it.

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2. TESTING AND FAULT ISOLATION

This section contains the test procedure for the battery. The results of the complete test
procedure must be satisfactory before the battery can be returned to service.

A. Test Equipment

Table 1 shows the test equipment required to test the battery.

NOTE: Equivalent substitutes may be used.

ITEM DESCRIPTION SPECIFICATION QTY VENDOR

1 DC power supply Voltage: 1 commercial

1 V ... 10 V, adjustable
Current limitation:
0.05 A ... 0.5 A, adjustable
2 Load resistor 0.88 Ω ± 2 %, 100 W 1 commercial
resistance of connecting leads included
3 Digital multimeter Ri ≥ 1 MΩ 1 commercial
(DMM)
4 Megohmmeter 500 V DC, 0 ... 100 MΩ 1 commercial
5 Climatic chamber Temperature adjustable 1 commercial
10 °C ... 60 °C [50 °F ... 140 °F]
6 Stop watch Elapsed time 30 minutes 1 commercial
7 Contact pin PN 774-115-79 (see Figure 3) 2 D1347
8 Flatbed recorder Selectable chart speed, 1 commercial
(e.g. 24 cm/h [9.45 in./h])
input impedance ≥ 1 MΩ,
voltage range 10 V

TEST EQUIPMENT
Table 1

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B. Special Tools

Figure 3 shows the tool required for the test procedure (2 pins required).

M a te r ia l: c o p p e r b r a s s

3 .6 ± 0 .2 m m
7 m m [0 .3 in .] [0 .1 4 ± 0 .0 1 in .]

1 m m [0 .0 4 in . ]
8 .5 ± 0 .2 m m [0 .3 3 ± 0 .0 1 in .]

CONNECTING PIN
Figure 3

C. Test Conditions

The necessary environmental conditions for the test procedure are:

– Ambient temperature ........................................... +18 °C to +30 °C [64 °F to 86 °F]
– Relative humidity ............................................................................. less than 80 %
– Atmospheric pressure ....................................................................... local standard

D. Test Procedure
(1) Visual Check
(a) Examine the surface of the battery for mechanical damage, signs of
corrosion or defective finish.
(b) Examine the external connectors for damage and security of attachment.

(2) Insulation Resistance

(a) Connect the negative terminal of the megohmmeter to the negative (-) battery
contact and the positive terminal to contact no. 1 of the connector.
(b) Set the test voltage to 500 V DC.
Make sure that the insulation resistance is ≥ 10 MΩ.

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(c) Set the test voltage to 0 V.

Remove the megohmmeter terminal from contact no. 1 and connect it to
contact no. 3 of the connector.
(d) Set the test voltage to 500 V DC.
Make sure that the insulation resistance is ≥ 10 MΩ.
(e) Set the test voltage to 0 V.
Remove the megohmmeter terminal from the negative (-) battery contact
and connect it to contact no. 1 of the connector.
(f) Set the test voltage to 500 V DC.
Make sure that the insulation resistance is ≥ 10 MΩ.
(g) Set the test voltage to 0 V.
Remove the battery from the megohmmeter.

(3) Functional Test

(a) General
Make sure that the battery temperature is stable between +18 °C and +30 °C
[64 °F and 86 °F].

CAUTION: USE ONLY PINS AS SHOWN IN FIGURE 3 TO CONNECT A

TEST CIRCUITRY TO THE NEGATIVE (-) AND POSITIVE (+)
CONTACT OF THE BATTERY IN ORDER TO AVOID
IRREVERSIBLE DAMAGE OF THE CONTACTS.
(b) Discharge
1 Set the DMM to measure the DC voltage.
2 Refer to Figure 4 and connect the discharge circuitry to the battery as
shown.

CAUTION: • DO NOT ALLOW THE BATTERY VOLTAGE TO

DECREASE TO LESS THAN 5 VOLTS. THE
POLARITY OF THE CELLS CAN BE REVERSED.
• A DISCHARGE VOLTAGE OF 4.5 VOLTS OR LESS
WILL DESTROY THE CELLS IMMEDIATELY.

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(B u tto m v ie w )

O F F O N 1
0 .8 8

V
2

1 Load resistor (Ref. Table 1, item 2)

2 DMM (Ref. Table 1, item 3)

DISCHARGE CIRCUITRY
Figure 4

3 Set the test equipment switch to ON.

Discharge the battery into the load until the DMM shows a voltage
between 5 V and 5.3 V.
4 Set the test equipment switch to OFF and disconnect the discharge
circuitry from the battery.

(c) Charge
1 Set the output voltage of the DC power supply to 7.5 V + 0.3 V and
the short circuit limitation to a current of 400 mA + 20 mA.
2 Make sure that the polarity of the DC power supply is correct.
Connect the DC power supply with two contact pins (Ref. Table 1,
item 7) to the positive (+) and negative (–) battery contacts.
3 Switch on the DC power supply and charge the battery for 14 hours.
4 Switch off the DC power supply and remove it from the battery.

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(d) Test of Several Circuits (Ref. Figure 5)

1 6

V
( > 5 .6 V )
(5 k to 2 5 k )

(3 3 .3 to 4 0 .7 )

TEST CIRCUITRY
Figure 5

1 Set the DMM to measure the DC voltage.

Connect the DMM to the negative (-) battery contact and to contact
no. 6 of the connector.
Make sure that the voltage is > 5.6 V.
Disconnect the DMM from the battery.
2 Set the DMM to measure the resistance.
Connect the DMM to contact no. 1 and no. 4 of the connector.
Make sure that the resistance is between 33.3 Ω and 40.7 Ω.
Disconnect the DMM from the battery.
If the resistance is much higher, apply a current of max. 1 A for approx. 3
seconds between the contacts no. 1 and no. 2 of the connector. The
current conduction will clean the contacts of the internal thermostat S1.
3 Set the DMM to measure the resistance.
Connect the DMM to contact no. 3 and no. 5 of the connector.
Make sure that the resistance is between 5 kΩ and 25 kΩ.
Disconnect the DMM from the battery.

(e) Capacity Test

1 General
The following procedure
– checks the capacity of the battery
– detects batteries with the memory effect

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NOTE: Begin the capacity test within 24 hours after the charge cycle.

2 Procedure
a Set the DMM to measure the DC voltage.
b Refer to Figure 6 and connect the test circuitry to the battery as
shown.

CAUTION: • DO NOT ALLOW THE BATTERY VOLTAGE TO

DECREASE TO LESS THAN 5 VOLTS. THE
POLARITY OF THE CELLS CAN BE REVERSED.
• A DISCHARGE VOLTAGE OF 4.5 VOLTS OR LESS
WILL DESTROY THE CELLS IMMEDIATELY.

(B o tto m v ie w )

O F F O N 1

0 .8 8
2 3
V
F L A T B E D
R E C O R D E R

1 Load resistor (Ref. Table 1, item 2)

2 DMM (Ref. Table 1, item 3)
3 Flatbed recorder (Ref. Table 1, item 8)

TEST CIRCUITRY – CAPACITY TEST

Figure 6

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c Do the following:
• Start the flatbed recorder.
• Set the switch of the test circuitry to ON in order to start the
discharge operation, and at the same time start the stop
watch to measure the elapsed time.
• Look at the voltmeter and make sure that the voltage at the
beginning of the discharge is ≥ 6 V.
d When 15 minutes have elapsed:
• Measure the voltage of the battery.
• Make sure that the shown value is not less than 5.6 V.
e Set the switch of the test circuitry to OFF when the battery
voltage reaches 5.0 V.
f Stop the flatbed recorder.

g Refer to Figure 7 and examine the plotted discharge curve.

Make sure that the curve does not show the memory effect
(second discharge stage).

V o lts

D IS C H A R G E C U R V E W IT H O U T M E M O R Y E F F E C T

S ta rt
5 .0

T im e

V o lts

D IS C H A R G E C U R V E W IT H M E M O R Y E F F E C T

S ta rt 2 . S ta g e
5 .0

T im e

DISCHARGE CURVE UNDER LOAD

Figure 7

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(f) Test of the Thermostat

CAUTION: IN THE FOLLOWING TEST EXTREMELY HIGH

TEMPERATURES WILL STRESS THE BATTERY. IT IS
RECOMMENDED TO DO THIS TEST ONLY IF THERE IS
THE SUBSTANTIAL SUSPICION OF A DEFECTIVE
THERMOSTAT.
1 Put the battery into the climatic chamber.
2 Increase the temperature of the chamber to 60 °C [140 °F] within 30
minutes and hold the temperature for a period of 90 minutes.
3 Set the DMM to measure the resistance.
4 Remove the battery from the climatic chamber and connect the DMM
to the contacts no. 1 and no. 4 of the connector.
5 Make sure that the resistance is between 3.3 kΩ and 3.374 kΩ.
6 Disconnect the DMM from the battery and store the battery at an
ambient temperature of 15 °C to 20 °C [59 °F to 68 °F] for at least 2
hours.
7 Set the DMM to measure the resistance.
Connect the DMM to contact no. 1 and no. 4 of the connector.
Make sure that the resistance is between 33.3 Ω and 40.7 Ω.
Disconnect the DMM from the battery.

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E. Fault Isolation

(1) General
This section gives the fault isolation information for the battery.
Examine the external wiring and serviceability of the test circuitry components first
before you begin to test the battery.

(2) Fault Isolation Chart

Table 2 shows a list of faults including probable cause and correction for the
battery PN 3214-31.

FAULT PROBABLE CAUSE CORRECTION

Insulation resistance out • Short circuit between Replace battery
of tolerance heating mat, battery block
and/or other circuits
• Connector faulty
Resistance of heating mat • Connection between wiring Replace battery
circuit out of tolerance and connector defective
• Heating mat faulty
Resistance of temperature • Connection between wiring Replace battery
sensor circuit out of and connector defective
tolerance
• Temperature sensor
defective
Voltage out of tolerance Capacity too low, or battery Recondition battery,
during capacity test block defective refer to paragraph (3).
Battery shows memory Decrease of capacity Recondition battery,
effect refer to paragraph (3).
Fails test of thermostat Thermostat defective Replace battery

FAULT ISOLATION CHART

Table 2

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(3) Reconditioning of the Battery

CAUTION: USE ONLY PINS AS SHOWN IN FIGURE 3 TO CONNECT A TEST

CIRCUITRY TO THE POSITIVE (+) AND NEGATIVE (–) BATTERY
CONTACTS.
(a) Refer to section 'Discharge' (page 9) and discharge the battery.
(b) Refer to section 'Charge' (page 10) and charge the battery.
(c) Refer to section 'Discharge' (page 9) and discharge the battery.
(d) Refer to section 'Charge' (page 10) and charge the battery.
(e) Refer to section 'Capacity Test' (page 11) and repeat the capacity test.
(f) In case the battery does not show a noticeable improvement and does not
fulfill the requirements, replace the battery.

3. SCHEMATICS AND WIRING DIAGRAMS

Not applicable

4. DISASSEMBLY
Not applicable

5. CLEANING
Refer to the local approved workshop procedures for cleaning of the battery.
Special instructions are not required.

6. INSPECTION / CHECK
Check all parts for obvious defects in accordance with standard industry practices.

7. REPAIR
Not applicable

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8. ASSEMBLY / STORAGE
A. Assembly
Not applicable

B. Storage (immediate serviceability not required)

(1) Prepare and store the battery in accordance with the standard industry practices.
(2) The ambient conditions for storage are:
• Temperature ..................................................................... -40 °C ... +50 °C
[-40 °F ... +122 °F]
with an average of ............................................................. +10 °C ... +25 °C
[+50 °F ... +77 °F]
• Relative humidity ................................................ annual average 60 % max.

(3) After storage of 12 months do a capacity test before using. Refer to 'Testing and
Fault Isolation', section 'Capacity Test' (page 11).

C. Storage (immediate serviceability required)

(1) Storage under Trickle Charge

(a) Discharge and charge the battery in accordance with 'Testing and Fault
Isolation', sections 'Discharge' (page 9) and 'Charge' (page 10).
(b) Store the battery under workshop environmental conditions and connected
to a constant current source with a charge current of 90 mA to 110 mA
(UBatmax = 7.5 V + 0.3 V DC).
(c) Remove the battery from the constant current source after 6 months and do
a functional test in accordance with 'Testing and Fault Isolation', sections
'Discharge' (page 9) thru 'Capacity Test' (page 11).

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(2) Storage without Trickle Charge

NOTE: Seeing that the self-discharge rate decreases at reduced temperatures,

refrigerated storage is recommended.

(a) Discharge and charge the battery in accordance with 'Testing and Fault
Isolation', sections 'Discharge' (page 9) and 'Charge' (page 10).
(b) Store the battery at a temperature of approx. -5 °C [+23 °F] up to +10 °C
[+50 °F]. The loss of capacity will be 10 % to 20 % within 2 months.

NOTE: • There is no special packaging necessary to store the battery at

low temperatures.
• Before using or any testing let the battery warm up to approx.
+20 °C [+68 °F]. Do not apply any additional heating.
• Remove dew drops caused by the warm-up of the battery with a
clean soft and lint-free cloth.

(c) To compensate the self-discharge of the battery charge the battery every
two months with a constant current of 400 mA + 20 mA for 3 hours
(UBatmax = 7.5 V + 0.3 V DC).
(d) After 12 months do a functional test in accordance with 'Testing and Fault
Isolation', sections 'Discharge' (page 9) and 'Charge' (page 10).

CAUTION: THE BATTERY CONTAINS THE POLUTANT CADMIUM.

FOR SCRAP DISPOSAL OBEY THE LOCAL LEGAL REGULATIONS.

9. FITS AND CLEARANCES

Not applicable

10. SPECIAL TOOLS, EQUIPMENT AND CONSUMABLE MATERIALS

Ref. Table 1 (page 7)

11. ILLUSTRATED PARTS LIST

Not applicable

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