EnerSys 7624308001-003 User manual

ENERSYS Ltd, NEWPORT
(formerly Hawker Energy Products)
SEALED LEAD ACID BATTERY
LEARJET PART NO. 7624308001-003
(ELN PART NO. 9750R0824 Rev04)
COMPONENT MAINTENANCE MANUAL
WITH
PARTS LIST
ELN DOCUMENT NO.
9602-0564
Rev 03
Page T1/2
24-01-03
Aug 25/04

ENERSYS Ltd, NEWPORT
COMPONENT MAINTENANCE MANUAL
LEARJET PART NO.7624308001-003
ELN PART NO.9750R0824-Rev04
RECORD OF REVISIONS
REV
NO. ISSUE DATE INSERT DATE BY REV NO. ISSUE DATE INSERT DATE BY
01
02
03
21 Apr 99
22 Jul 03
25 Aug 04
SAB
CJ
SAB
RR-1/2
24-01-03 Aug 25/04

ENERSYS Ltd, NEWPORT
COMPONENT MAINTENANCE MANUAL
LEARJET PART NO.7624308001-003
ELN PART NO.9750R0824-Rev04
RECORD OF TEMPORARY REVISIONS
TEMPORARY
REV NO. PAGE NO. ISSUE DATE BY DATE REMOVED BY
Page TR-1/2
24-01-03 Apr 21/99

ENERSYS Ltd, NEWPORT
COMPONENT MAINTENANCE MANUAL
LEARJET PART NO.7624308001-003
ELN PART NO.9750R0824-Rev04
SERVICE BULLETIN LIST
SERVICE DATEBULLETIN
BULLETIN REVISION INCORPORATED
NUMBER NUMBER INTO MANUAL
PRODUCT IMPROVEMENTS
Product improvements have been incorporated using service bulletins entered in the
service bulletin list. Service bulletin highlights are as follows:
Page SBL-1/2
24-01-03 Apr 21/99

ENERSYS Ltd, NEWPORT
COMPONENT MAINTENANCE MANUAL
LEARJET PART NO.7624308001-003
ELN PART NO.9750R0824-Rev04
LIST OF EFFECTIVE PAGES
The changes are shown by a vertical line along the edge of the changed page.
The total number of pages in this document is 41, which contains as follows
SUBJECT PAGE NO. DATE
Title Page T-1/2 Aug 25/04
Record of Revisions RR-1/2 Aug 25/04
Record of Temporary Revisions TR-1/2 Apr 21/99
Service Bulletin List & Product Improvements SBL-1/2 Apr 21/99
List of Effective Pages LEP-1/2 Aug 25/04
Contents TC-1 to TC-2 Aug 25/04
Introduction INTRO-1/2 Aug 25/04
Description and Operation 1 Aug 25/04
2 Apr 21/99
3 Apr 21/99
4 Apr 21/99
5/6 Aug 25/04
Testing and Fault Isolation 101 to 103 Apr 21/99
104 Aug 25/04
105 to 107 Apr 21/99
108 Aug 25/04
109/110 Apr 21/99
Automatic Test Requirements Not Applicable -
Disassembly 301/302 Apr 21/99
Cleaning 401/402 Apr 21/99
Check 501/502 Apr 21/99
Repair 601/602 Apr 21/99
Assembly 701/702 Apr 21/99
Fits and Clearances Not Applicable -
Special tools, Fixtures & Equipment Not Applicable -
Parts List 1001/1002 Aug 25/04
LEP - 1/2
24-01-03 Aug 25/04

ENERSYS Ltd, NEWPORT
COMPONENT MAINTENANCE MANUAL
LEARJET PART NO.7624308001-003
ELN PART NO.9750R0824-Rev04
CONTENTS
Chapter No./Section No. Page
INTRODUCTION INTRO-1/2
DESCRIPTION AND OPERATION 1
1. Description 1
2. Operation 3
A. General 3
B. Temperature Effect 3
C. State Of Charge 4
D. Leading Particulars 5/6
TESTING AND FAULT ISOLATION 101
1. General 101
2. Required Test Equipment 101
3. Test Equipment Set Up 102
4. Testing 103
A. Test Equipment 103
B. Condition Of Batteries On Receipt 103
C. Unpacking And Acceptance Checks 103
D. Storage 104
E. Charging Procedures 105
. F. Discharge Test Procedure 106
G. Commissioning Procedure 106
H. Servicing 107
I. Rejection Procedure 108
J. Disposal 108
5. Fault Isolation 109/110
LEP - 1/2
24-01-03 Apr 21/99

ENERSYS Ltd, NEWPORT
COMPONENT MAINTENANCE MANUAL
LEARJET PART NO.7624308001-003
ELN PART NO.9750R0824-Rev04
DISASSEMBLY 301/302
1. General 301/302
CLEANING 401/402
1. General 401/402
CHECK 501/502
1. General 501/502
REPAIR 601/602
1. General 601/602
ASSEMBLY 701/702
1. General 701/702
PARTS LIST 1001/1002
Page TC-2
24-01-03 Aug 25/04

ENERSYS Ltd, NEWPORT
COMPONENT MAINTENANCE MANUAL
LEARJET PART NO.7624308001-003
ELN PART NO.9750R0824-Rev04
INTRODUCTION
The instructions in this manual provide the information necessary for an experienced shop
mechanic to service batteries with no specialised training.
The manual is divided into separate sections:
1. Title Page 4. Table of Contents
2. Record of Revision 5. Introduction
3. List of Effective Pages 6. Procedures and PL Sections
The disassembly, repair and assembly sections generally contain only specific instructions
to be used on the equipment covered herein. Most standard aerospace practices are not
described herein.
All weights and measurements in the manual are in English units, unless otherwise stated.
EnerSys Ltd
Stephenson Street
NEWPORT
South Wales
NP19 4XJ
U.K.
Tel: [phone]
Fax: [phone]
Verification:
Testing/Fault Isolation Apr 21/99
Repair Apr 21/99
Disassembly Apr 21/99
Cleaning Apr 21/99
Assembly Apr 21/99
Page INTRO-1/2
24-01-03 Aug 25/04

ENERSYS Ltd, NEWPORT
COMPONENT MAINTENANCE MANUAL
LEARJET PART NO.7624308001-003
ELN PART NO.9750R0824-Rev04
DESCRIPTION & OPERATION
1. Description
The EnerSys 24 volt 10 ampere-hour, Sealed Lead Acid Battery covered by this
Maintenance Manual (Ref.Fig.1) is used as the emergency battery for the standby
instrumentation on board Learjet 45 aircraft. It is also used to ensure that the
avionics bus-bar remains powered during engine starts. Its emergency power duties
include ensuring airspeed and altitude indicators remain operational as well as
supplying power to illuminate the essential displays.
The Battery consists of two 12 volt Sealed Lead Acid monoblocs connected in
series, enclosed in a metal outer case, which incorporates the battery main terminal
connector. The monoblocs are packed tightly into the outer case and secured by the
use of sheet rubber around the interior of the case and rubber hold down blocks
placed on top of the monoblocs.
Each monobloc incorporates a resealing safety valve to guard against the effects of
abusive use of the battery.
EnerSys Aerobatic Sealed Lead-Acid Aircraft Batteries are classified as Non-
Spillable and exempt from hazardous goods transportation requirements, in
accordance with :-
1) US Dept of Transportation - 49 CFR Section 173.159 para d.
2) ICAO/IATA Packing Instruction 806, Special Provision A67
.
3) IMDG Class 8, UN ID 2800, exemption for Non-Spillable batteries.
4) ADR 2003 and RID 2003 Special Provisions 238, 295 and 598
Page 1
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ENERSYS Ltd, NEWPORT
COMPONENT MAINTENANCE MANUAL
LEARJET PART NO.7624308001-003
ELN PART NO.9750R0824-Rev04
Sealed Lead Acid Battery
Figure 1 Page 2
24-01-03 Apr 21/99

ENERSYS Ltd, NEWPORT
COMPONENT MAINTENANCE MANUAL
LEARJET PART NO.7624308001-003
ELN PART NO.9750R0824-Rev04
2. Operation
A. General
The battery is charged on the aircraft by constant potential.
CAUTION: The battery is maintenance free. Under no circumstances
should any attempt be made to introduce any substances, eg.,
acid, distilled water or alkali, to the battery.
B. Temperature Effect
The ideal environmental temperature for battery operation is 20°C(68°F) to
25°C(77°F). Long term exposure to temperatures above 30°C (86°F) can
shorten the life of the battery.
As the temperature falls, the available capacity of the battery is reduced,
which causes a reduction in performance. However, this is not a permanent
condition and the capacity will be restored as the temperature rises. Long
term exposure to low temperatures will not damage the battery. Figure 2
shows variation of available capacity with temperature.
75
80
85
90
95
100
105
110
0 5 10 15 20 25 30 35
Temperature (°C)
%
Capacity
Figure 2 Page 3
24-01-03 Apr 21/99

ENERSYS Ltd, NEWPORT
COMPONENT MAINTENANCE MANUAL
LEARJET PART NO.7624308001-003
ELN PART NO.9750R0824-Rev04
C. State of Charge
Figure 3 shows percentage State-of-Charge versus Open-circuit Voltage.
0
10
20
30
40
50
60
70
80
90
100
23.623.824.024.224.424.624.825.025.225.425.625.826.0
Open Circuit Voltage
after Rest
% State
of
Charge
(C1)
Figure3
Page 4
24-01-03 Apr 21/99

ENERSYS Ltd, NEWPORT
COMPONENT MAINTENANCE MANUAL
LEARJET PART NO.7624308001-003
ELN PART NO.9750R0824-Rev04
D. Leading Particulars
Battery Voltage: Nominal 24.0 Volts
Battery Weight: 11.4 Kg Max (25.1lbs)
Dimensions: Overall Height 155.50 mm Max (6.122")
Overall Width 194.00 mm Max (7.638")
Overall Length 249.00 mm Max (9.803")
Connector: MS 3509 Style 1
Rated Capacity: 10 ampere-hours at the one hour rate
Monobloc Case Material: Flame Retardant Plastic
Battery Case Material: 1.5 mm thick Alloy to EN 485-2: 1994, Alloy EN
AW-5251/H22
Or
1.5mm thick Alloy to 5154A to BS1470/H4
Page 5/6
24-01-03 Aug 25/04