Teledyne 7639-27, 7639-30LT, 7639-34, 7638-36, 7638-48P Maintenance Manual
COMPONENT MAINTENANCE MANUAL
LT-Valve-Regulated Lead -Acid Batteries
Part Numbers Applicable to this CMM
7639-27
7639-30LT
7639-34
7638-36
7638-48P
Q01-4000 Rev G December 16, 2016
CONTENTS
Section Description Page
1
2
3
4
5
6
Revisions ………………………………………………………………………….. 1
Scope ……………………………………………………………………………… 2
Description of Valve-R e gu l ated Lea d-Acid batteries ………………………… 3
Definition of Battery Specifications …………………………………………….. 4
State of Charge Vs Voltage …………………………………………………….. 5
Service Instructions ……………………………………………………………… 6
Charging, Constant Potential …………………………………………………… 8
Charging, Constant Current …………………………………………………….. 9
Charging, Float …………………………………………………………………… 9
Charging, Initial …………………………………………………………………… 10
Routine Maintenance …………………………………………………………….. 12
Continued Airworthiness Testing ……………………………………………….. 12
Reconditioning Battery …………………………………………………………... 13
7
8
9
10
11
Deep Discharge Recovery ………………………………………………………. 13
Monitoring Batteries in Long Term Storage …………………………………… 14
Unscheduled Removals …………………………………………………………. 16
Troubleshooting Guide …………………………………………………………... 17
Transportation …………………………………………………………………….. 18
Recycling …………………………………………… …… ………… …………….. 19
Glossary …………………………………………………………………………… 21
Appendix A ……………………………………………………………………….. 22
Q01-4000 Rev G December 16, 2016
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Revised to correct Maintenance Flow Chart
review with Embraer
Revised charging processes, Inspection /
requirements for battery approval
1. REVISIONS
Revision Description of Change Approved By Date
NC New document JMR May 3, 2012
A
B
C
D Added part number 7639-30LT JMR Apr 2, 2014
E Added part number 7638-48P JMR Sep 3, 2014
F Revised Inspection /Service Period JMR Mar 9, 2016
G
and various directions in Service Ma nual per
Revised / Added temperature conversions
from °F to °C
service period and minimum capacity
Revised Flowchart and references to
Capacity checks from 80% to 85%
JMR July 23, 2012
JMR Dec 19, 2012
JMR Nov 6, 2013
JMR Dec 16, 2016
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The CMM will take precedence over all other printed materials regarding respective batteries.
The latest version of the CMM can be found on our website at:
http://www.gillbatteries.com/maintenance.aspx
2. SCOPE
This manual provides Maintenance Procedures for Gill 7000 Series LT Valve-Regulated LeadAcid (LT VRLA) Aircraft Batteries manufactured under FAA Parts Manufacturer Approval
number PQ1006NM.
This manual is applicable for the following batteries: 7639-27, 7639-30LT, 7639-34, 7638-36
and 7638-48P.
This manual has been written for the purpose of guidance only; consult Teledyne Battery
Products (TBP) Technical Support for further information.
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WARNING
WARNING
3. VALVE-REGULATED LEAD-ACID BATTERIES
3.1 DESCRIPTION
3.1.1. The 7000 series LT valve-regulated lead-acid (LT-VRLA) batteries are designed
with an optimum lead alloy with tin and copper to provide the best possible
electrode characteristics necessary for performance. These LT-VRLA batteries
contain electrolyte absorbed in glass-mat separators, with no free electrolyte and
are sometimes referred to as “sealed” or “recombinant-gas” batteries.
ALL VRLA batteries contain sulfuric acid, which is highly corrosive and which can
cause serious physical injury if it comes in contact with skin. It can also cause serious
eye injury or blindness if it comes into contact with the eyes.
Caution must be exercised to avoid damage to the exterior case which could allow
the contents to escape or come in physical contact with external materials or
personnel.
If a battery case is found to be damaged, handle the battery with care and avoid
contact with the skin. Inspect all areas adjacent to the battery for evidence of
corrosion.
3.1.2. TBP valve-regulated lead-acid batteries have vent caps (with valves enclosed)
that are sealed in place and cannot be accessed for maintenance. At no time
must these vent caps be removed.
During normal operation, the batteries will vent very small amounts of gases that
must be vented away from the battery and aircraft. The venting mechanisms consist
of nozzles (in the battery cover) and vent tubes that are designed to exhaust the
battery compartment. Ensure that the vent tubes are not restricted or disabled in
any way.
3.1.3. The electrolyte is contained in an absorptive glass-mat (AGM ) sep arator that
retains and immobilizes the electrolyte. These batteries can be operated in any
orientation without spilling electrolyte.
3.1.4. The battery consists of twelve cells connected in series internally, making up a
24V battery. These cells are not replaceable.
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3.1.5. Each cell is constructed of premium grade LT electrodes (plates) that are
electrically isolated by AGM separators.
3.2 DEFINITION OF BATT ERY SPECIFI CATIONS:
3.2.1 TBP battery ratings are defined by the following:
3.2.1.1 The One-Hour Rate
This is the rate of discharge a battery can endure for one hour with the battery
voltage at or above 1.67 volts per cell, or 20 volts for a 24 volt lead-acid battery.
Capacity, measured in Ampere Hours or Ah, is the product of the discharge rate
and time (in hours) to the specified end voltage.
3.2.1.2 The Emergency Rate
This is the rate of discharge a battery can endure for thirty minutes with the
battery voltage at or above 1.67 volts per cell, or 20 volts for a 24 volt lead-acid
battery.
The Emergency Rate is the total essential load, measured in amperes, required
to support the essential bus for thirty minutes.
3.2.1.3 I
, Peak Power Current: This is the discharge current delivered at 0.3 seconds
pp
while testing during a 15 second power discharge controlled to maintain a
constant terminal voltage of half the nominal battery voltage.
I
, Constant Voltage Current: This is the discharge current at the conclusion of
pr
a 15 second power discharge controlled to maintain a constant terminal voltage
of half the nominal battery voltage.
3.2.2 State of charge using voltage measurements should be used as a guide only.
Figure 1 indicates the relationship between Battery Open-Circuit Voltage (OCV)
and % State-of-Charge (SOC). Note: This voltage measurement is valid when
the battery has been off charge for at least two hours.
3.2.3. All valve-regulated batteries operate best in controlled temperatures. Excessive
excursions above 100°F can shorten the life of lead-acid batteries. The optimum
operating temperature is around 80°F.
Available capacity declines as the temperature drops. This decline is primarily
related to the state of the electrolyte and easily recoverable once the battery has
warmed up sufficiently.
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Figure 1
This voltage is valid under no load and approximately
batteries, the voltages would be half these values.
two hours after any charge of flying session. For 12
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4. SERVICE INSTRUCTIONS
4.1 SHIPMENT OF BATTERIES
4.1.1 The batteries are shipped upright, conditioned and fully charged.
4.1.2 Each battery is identified with a unique serial number label and indelibly marked
manufacturing date on the right side of the battery (side adjacent to the positive
4.2 INSPECTION FOR SHIPPING DAMAGE
4.2.1 Upon receipt, the packages must be examined for any shipping damage before
4.2.2 Type verification can be performed by checking the serial number label on the
4.3 STORAGE REQUIREMENTS
4.3.1 TBPs 7000 series LT VRLA batteries can be stored between -20°F (-29°C) and
Storage temperatures will determine inspection requirements. These requirements
4.3.2 TBPs 7000 series LT VRLA batteries have a maximum of 24 months of
4.3.3 If stored between 95°F (35°C) to 110°F (43°C), the battery must be inspected on a
terminal, with the terminals facing forward). Please use this manufacturing date
for future reference.
they are placed in storage or use. If any damage is noted, contact the shipping
company immediately.
packaging against the accompanying FAA Form 8130-3 or Certificate of
Compliance.
+110°F (43°C). Ideal battery storage temperature is 80°F (27°C). Stora ge at
temperatures other than these, can lead to permanent damage.
are identified under this section.
inspection-free storage life, IF stored at temperatures between 40°F (4°C) to 80°F
(27°F).
monthly basis. It is not recommended to store any VRLA batteries at these
temperatures for excessive periods of time (maximum 3 months storage).
Prolonged storage at high temperatures (over 110°F or 43°C) will reduce battery
life due to various deleterious reaction mechanisms at higher temperatures.
During these monthly inspections, the battery must be recharged per Section 5.2
and returned to storage. If the storage period has exceeded the time
recommended in this section, contact Teledyne Battery Products for disposition.
4.3.4 All batteries returned from service after initial use must be fully charged per
Section 5.2 and stored. The storage start date and battery voltage must be
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Visually inspect the battery to ensure there is no damage. Remove the
WARNING
corrosion.
logged on the outer package or marked on the battery. The inspection intervals
for these batteries will be the same as outlined in section. See Figure 1, for state
of charge at various voltages.
4.3.5 Long term storage at temperatures less than 0°F (-18°C) will not detrimentally
affect the life of the battery, provided the battery is at a reasonably high state of
charge (over 80%) before placing in storage. The battery may be stored at lower
temperatures, but will need to be warmed up to 0°F (-18°C) before use.
4.3.6 Please call TBP technical support if there are any questions regarding shelf life
and recharge periods.
4.4 INITIAL INSPECTION
4.4.1
protective cap over the terminal pins and ensure that the pins are clean and there
is no corrosion. The pins have been installed with the correct torque at the
factory and do not require any re-seating. Call TBP Technical Support if you find
any discrepancy.
4.4.2 DO NOT remove the lid. The vents are sealed in the cover and cannot be
removed for maintenance.
4.4.3 Inspect the open circuit voltage and review handling requirements, according to
the measured voltage, per Section 5.5. Before placing the battery in service, it
must be fully charged. Review Section 5 as needed.
For basic charging, constant potential is the preferred charging method. Deepdischarge recovery will usually require application of Constant-Current and/or
Constant-Potential charging (see Sections 6.3 and 6.4). If there are any concerns
with recharging, please contact Tech Support at Teledyne Battery Products.
ALL VRLA batteries contain sulfuric acid, which is highly corrosive and which can
cause serious physical injury if it comes in contact with skin or if inhaled. It can also
cause serious eye injury or blindness if it comes into contact with the eyes.
Caution must be exercised to avoid damage to the exterior case which could allow
the contents to escape or come in physical contact with external materials or
personnel.
If a battery case is found to be damaged, handle the battery with care and avoid
contact with the skin. Inspect all areas adjacent to the battery for evidence of
Q01-4000 Rev G Page 7 of 28 Teledyne Battery Products
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