BASEWEST 790 Series Installation and operation manual

BASEWEST
Operating & Maintenance Manual
“Smart” Battery Power Unit,
Escape Slide Lighting System
Model 790, 800, & 900 Series
Released
July 9, 2021
BASEWEST INC.
4240 116th Terrace N • Clearwater FL 33762
Tel: [phone] •Fax: [phone]
E-mail: [email protected]
www.basewest.com
25-60-53

BASEWEST Operating & Maintenance Manual
“Smart” Series Battery Power Unit
Page 2 of 825-60-53
July 9, 2021
1.0 INTRODUCTION
1.1 Scope
This manual covers the installation, test, and maintenance of the output regulated, non-
rechargeable, alkaline-based Model 790, 800, and 900-Series escape slide lighting bat-
tery power units (batteries) for LED-based non-overwing escape slide lighting systems
manufactured by BaseWest Inc., in the following part number formats:
•Model 790-Series (P/N 7-1089-201 & P/N 7-109X-201)
•Model 800-Series (P/N 7-08XX-201)
•Model 900-Series (P/N 7-09XX-201)
These devices are designed for installation on non-overwing aircraft evacuation slides
and slide/rafts to provide power to integral escape slide lighting systems comprising light
emitting diode (LED) luminaires. For specific instructions relative to operation and instal-
lation on a specific escape slide, please refer to the corresponding OEM escape slide or
slide/raft manual. Batteries for overwing applications have differing activation switching
means that are not covered in this manual.
1.2 Battery Type
The “smart” battery power units covered by this manual, hereinafter “battery(ies”), con-
tain non-rechargeable alkaline manganese dioxide “AA” and or “AAA” cells manufac-
tured by Energizer® Battery Company. Information on these battery cells is available on
the internet at the Energizer® website.
2.0 THEORY OF OPERATION
2.1 General Description
Batteries covered by this manual comprise a series or series/parallel arrangement of AA
and/or AAA cells connected to an electronic regulation circuit in a cylindrical package
with integral switching means and wire leads provide power output and battery test.
Activation of the battery is accomplished upon inflation of the host device; an activating
lanyard with a switch plug is installed in the switch end of the pack. This switch plug is
captured by a retaining clip secured in a protective annulus. The switch plug, when in-
stalled, depresses the plunger of a normally open snap-action microswitch housed in the
pack, rendering the battery power circuit OPEN, and the system OFF. The lanyard is
short-rigged and tied-off, so that inflation and extension of the escape slide causes the
switch plug to be pulled from the pack, allowing the microswitch to snap to the CLOSED
circuit (ON) condition, providing power to the installed slide light harness. A nylon tie-
cord is provided to secure the battery to its mounting on the escape slide structure.

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“Smart” Series Battery Power Unit
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Fig. 1 General Battery Configuration
Fig. 2 Installation of Switch Plug in Retaining Clip
2.2 “Smart” Batteries
The “smart” series of batteries covered by this manual are designed by BaseWest spe-
cifically for use with LED-based escape slide lighting systems. They include electronic
circuits which regulate battery output and provide for testing of the battery condition.
a) All “Smart”Batteries
•Regulated outputs from this circuitry remain relatively constant throughout the
useful discharge life of the smart battery.
•Testing of a complete escape slide lighting system (a battery connected to a
lighting harness) is accomplished by connecting the battery’s test lead to a
Model TS-420 test set. With this connection two types of tests can be per-
formed: (a) a voltage test of the battery cell stack under a selectable load, or
(b) an electrical current test of the connected LED harness with power pro-

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“Smart” Series Battery Power Unit
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vided by a regulated 5VDC power supply within the TS-420 through the bat-
tery power leads.
b) Model 790-Series Batteries Only
•Power is only available to the power leads only if a load is connected to
the battery at the instant the activating switch is pulled. If the load is per-
manently disconnected from an activated smart battery, the battery will
immediately deactivate and can only be re-activated if the switch plug is
re-inserted and pulled again. This smart battery design feature is intend-
ed to discourage inadvertent activation or electrical shorting when the bat-
tery is not connected to the slide lighting system.
2.3 Schematic
The Model 790-Series batteries utilize a linear mode regulation circuit, and the Model
800- and 900-Series provide output regulation through a switch-mode regulator. The
figures below provide schematics for each of the non-overwing batteries.
Control
Circuit
(Linear
Regulator)
"SMART" BATTERY POWER SUPPLY,
MODEL 789 & 790-SERIES
ESCAPE SLIDE LIGHT HARNESS (LED)
TEST
CONNECTOR
NO POWERLEAD
QUICK
DISCONNECTS
BLU (+)
WHT (-)
R
4
3
1
2
4
3
1
2
TS-420 TEST SET
5VDCPOWER SUPPLY
& AMMETER
VOLTMETER WITH
LOADSELECTOR
ACTIVATING SWITCH
(NORMALLYOPEN)
BLU (+)
WHT (-)
TAPPED CELL
REPRESENTATIVE SERIESCELL STACK
PTC
ACTIVATING SWITCH/PLUG LANYARD
(SWITH ISOPEN WHEN INSTALLED)
Fig. 3 Model 790-Series Battery (Linear Regulator)
Regulator
Circuit
(Switch-Mode
Type)
"SMART" BATTERY, MODEL 800 & 900 SERIES
ESCAPE SLIDE LIGHT HARNESS (LED)
TEST
CONNECTOR
NO POWER LEAD
QUICK
DISCO NNECTS
BLU (+ )
WHT (-)
ACTIVATING SWITCH
(NORMALLY OPEN)
4
3
1
2
4
3
1
2
TS-420 TEST SET
5VDC POWER SUPPLY
&AMMETER
VOLTMET ER WITH
LO AD S EL ECT OR
BLU (+ )
WHT (-)
CELL STACK:COMPRISING
NON-RECHARGEBLE
ENERGIZER
ALKALINE CELLS PTC
ACTIVATING SWITCH/PLUG LANYARD
(SWITH ISOPEN WHEN INSTALLED)
Fig. 4 Model 800- and 900-Series Battery (Switch Mode Regulator)

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2.4 Limitations
2.4.1 The batteries covered by this manual are designed only for use with escape slide lighting
systems specifically identified by the escape slide manufacturer’s component mainte-
nance manual (CMM). No other use of the batteries is intended or authorized.
2.4.2 The batteries covered by this manual comprise non-rechargeable AA and/or AAA alka-
line cells, manufactured by Energizer® Battery Company. The user is encouraged to re-
fer to Energizer technical publications on these cells for specific information regarding
limitations, usage, storage, and disposal.
2.4.3 Any battery can pose a potential fire, explosion, or burn hazard. The user is encouraged
to refer to Energizer technical publications on these cells for specific information regard-
ing limitations, usage, storage, and disposal.
3.0 INSTALLATION, RIGGING & OPERATION
3.1 General
Install these batteries in accordance with escape slide manufacturer's component
maintenance manual (CMM) procedures. The following information is provided as gen-
eral guidance only.
3.2 Rigging
Secure the end of the activating lanyard to the escape slide structure and route it to the
battery in accordance with the escape slide manufacturer's CMM. Fully seat the switch
plug (located on the end of the activating lanyard) into the clip at the switch end of the
battery per Fig. 2. DO NOT safety-tie switch plug in place.
3.3 Packing
Care must be taken during the packing process to ensure that sufficient slack is provided
in the activating lanyard to ensure that folding, packing, and compression will not inad-
vertently place sufficient tension on the activating lanyard to cause it to pull from the re-
taining clip in the end of the battery; such a condition will result in inadvertent activation
of the lighting system within the slide pack and premature depletion of the battery.
Take care to avoid placing the battery in a location that will result in bending stresses, or
point load compression against hard surfaces (e.g., bottles or regulators) within the pack
that could compromise the battery.
3.4 Operation
The battery, when properly installed, secured and rigged in accordance with the escape
slide manufacturer’s instructions, will operate automatically upon inflation of the escape
slide. The activating lanyard is “short-rigged” to the escape slide such that the activating
switch plug will be pulled from the battery when the escape slide is inflated.

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“Smart” Series Battery Power Unit
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4.0 TESTING
4.1 General
BaseWest escape slide light systems are designed to be tested with BaseWest's Model
TS-420 series test set. Refer to the escape slide manufacturer’s CMM and BaseWest
Technical Manual No. 25-60-41 for specific instructions regarding set-up and use of the
TS-420 series test set. The following general instructions are for guidance only.
Figure 5. TS-420 General Arrangement
4.2 Battery Test
This test is designed to verify the serviceability of the battery only. This test may be
used for receiving inspection, pre-installation and pre- or post-packing tests.
(a) Set the TS-420 Mode Selector to “Voltmeter”, and Load Selector to setting speci-
fied by the slide manufacturer’s CMM (A through F).
(b) Connect battery test lead to the center receptacle on the test set’s connector block.
(c) Ensure the activating switch plug is fully seated in the battery’s switch end cap.
LCD Display
SELF-TEST Indicator
(Green / Red LED)
LOW BATT Indicator
(Amber LED)
Mode Selector
(Voltmeter/Ammeter)
Load Selector
Press to Test
Battery Charger
Receptacle
Receptacle
Connector Block
(See Fig 6)

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“Smart” Series Battery Power Unit
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(d) Press down the RED “Press to Test”button and hold for 3-5 seconds to observe
and record the battery voltage. Compare this reading to acceptance limits noted in
the slide manufacturer’s CMM.
(e) After the voltage reading is taken, release the “Press to Test”button and discon-
nect the battery test lead from the test set.
Figure 6. TS-420 Connector Block Arrangement
4.3 Battery and LED Harness System Test
This section provides a functional test of a connected battery and LED harness system
in a pre-pack condition when the LED harness can be observed. This test is not con-
ducted while connected to the TS-420 test set.
a) Ensure the battery power lead is properly connected to the escape slide light har-
ness in accordance with slide manufacturer instructions.
b) With the escape slide laid out fully and the LED harness luminaires visible (inflated
or non-inflated), pull the activating switch plug from the battery. Observe that the
LED harness luminaires function properly. IMMEDIATELY reinstall the switch plug
to de-activate the lighting harness.
NOTE: If the system fails to operate properly, re-install the activating switch plug
into the battery, and verify that the power lead connectors are properly engaged in-
to the mating connectors on the LED lighting harness. Repeat the test.
CAUTION: PROLONGED OPERATION OF THE LIGHTING HARNESS WITH THE INSTALLED
BATTERY CAN DEPLETE THE BATTERY BEYOND SERVICEABLE LIMITS.
4.4 LED Harness Test through Connected Battery
Functional testing of LED harness alone may be conducted before or after packing with
the battery connected to the LED harness. This test requires the TS-420 test set. Follow
instructions in the slide manufacturer’s CMM. The following guidance is provided:
4-Contact Receptacle for
Battery Test Lead Connector

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“Smart” Series Battery Power Unit
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NOTE: Power to the LED harness is provided by a power supply within the TS-
420 test set and not the battery itself. This IS NOT a test of the serviceability of
the battery.
a) Ensure the activating switch plug is fully seated in the switch retaining clip.
b) Ensure the battery power lead is properly connected to the slide light harness.
c) Connect the battery test lead connector to the center receptacle on the TS-420
connector block.
d) Set the TS-420 Mode Selector switch to “Ammeter”.
e) Press and release the “Press to Test”button and record the current (mA) on the
TS-420’s display. Refer to the slide manufacturer’s CMM for acceptable current
levels.
NOTE: In the “Ammeter” mode, the TS-420 will remain ON for approximately 20
seconds and turn OFF automatically. Power can be interrupted at any time after
the readings are recorded by removing the battery test connector from the test set.
5.0 MAINTENANCE
5.1 General
BaseWest's slide lighting batteries are non-repairable, life-limited devices. Repairs are
not authorized.
5.2 Storage
The batteries should be stored inside in a dry, protected area within a temperature range
of -40°C to +60°C (-40°F to +140°F). Always store the battery with the activating switch
plug/lanyard in place. Do not expose the power lead contacts to contact with conductive
materials, or to contact with each other. Maintain connector housings on power lead
wires at all times.
5.3 Service Life
The batteries covered by this manual are approved for a seven (7) year service life from
date of manufacture. The slide manufacturer may specify adjustment of this service life
down to five (5) years for certain batteries. Battery nameplates are marked with replace-
by dates per slide manufacturer instructions.
Care should be taken to use batteries on a first-in-first-out inventory rotation basis to
maximize available service life.
6.0 ACCESSORIES
The TS-420 test set and certain test and calibration cables are available from BaseWest.
TS-420 operating and calibration manuals (25-60-41 and 25-60-42) are available upon
request, or may be downloaded from the BaseWest website at www.basewest.com.