EnerSys BA27-01 User manual

24-01-01
This document contains Data cont
r
olled by the U.S. Export Administration Regulations. Diversion or use contrary to U.S. law is prohibited
SEALED LEAD ACID BATTERY
PART No. BA27-01
(BOEING P/N S281W501-2)
COMPONENT MAINTENANCE MANUAL
WITH
ILLUSTRATED PARTS LIST
DOCUMENT No.
9602-0516 Rev. 11
COMMERCIAL EXPORT ADMINISTRATION REGULATIONS (EAR)
THIS DOCUMENT CONTAINS DATA CONTROLLED BY THE U.S. EXPORT ADMINISTRATION REGULATIONS (ECCN:
9E991). DIVERSION OR USE CONTRARY TO U.S. LAW IS PROHIBITED.
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COMPONENT MAINTENANCE MANUAL
BA27
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UHIGHLIGHTS
To: Holders of battery P/N BA27-01 ATA Reference 24-01-01 component
maintenance manual (CMM)
Herewith Revision No. 11 dated June 26/20
This revision of the component Maintenance Manual has the following modifications:
UCHAPTER UPAGES UACTION
Title T-1 Updated
Highlights HLGHTS-1 Updated
Record of revisions R/R-1 Updated
List of effective pages LEP-1 Updated
Rejection procedure 17 Updated
Repair 25/26 Updated
Vendor 34 Updated
IPL 36 Updated
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COMPONENT MAINTENANCE MANUAL
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This document contains Data controlled by the U.S. Export Administration Regulations. Diversion or use contrary to U.S. law is prohibited

COMPONENT MAINTENANCE MANUAL
BA27
24-01-01
This document contains Data controlled by the U.S. Export Administration Regulations. Diversion or use contrary to U.S. law is prohibited
URECORD OF REVISIONS
REV
No. ISSUE DATE INSERT DATE BY REV No. ISSUE DATE INSERT DATE BY
01 Apr 25/95
02 Jun 30/95
03 Apr 16/99
04 June 09/06
05 Feb 25/10
06 Aug 10/10
07 Ma
y
14/13
08
09 Feb 07/14 Mar 11/16
10 Mar 13/17
11 June 26/20
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COMPONENT MAINTENANCE MANUAL
BA27
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URECORD OF TEMPORARY REVISIONS
TEMPORARY
REV No. PAGE No. ISSUE DATE BY DATE REMOVED BY
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COMPONENT MAINTENANCE MANUAL
BA27
24-01-01
This document contains Data controlled by the U.S. Export Administration Regulations. Diversion or use contrary to U.S. law is prohibited
USERVICE BULLETIN LIST
SERVICE
BULLETIN
UNUMBER REVISION UNUMBER
DATE BULLETIN
INCORPORATED
UINTO MANUAL
UPRODUCT IMPROVEMENTS
Product improvements have been incorporated using service bulletins entered in the service
bulletin list. Service bulletin highlights are as follows:
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COMPONENT MAINTENANCE MANUAL
BA27
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ULIST OF EFFECTIVE PAGES
SUBJECT PAGE DATE SUBJECT PAGE DATE
Title T-1 June 26/20
Disassembly 19 20 May 14/13 Mar 13/17
Highlights HLGTS -1 June 26/20
Cleaning 21 22 June 09/06 Blank
Record of
Revisions R/R-1 June 26/20 Check 23 24 May 14/13 Blank
Record of
Temporary
Revisions
TR-1 June 09/06 Repair 25
26 June 26/20 June 26/20
Service Bulletin
List SBL-1 June 09/06 Assembly 27 28
29
30
June 09/06
Mar 11/16
Mar 11/16
June 09/06
List of effective
Pages LEP-1 Jun 26/20 Special Tools, Fixtures &
Equipment
31
32 Feb 07/14 Blank
Table of Contents T/C-1 June 09/06
Introduction INTRO-1
May 14/13 Illustrated Parts List 33 34
35
36
June 09/06
June 26/20
June 09/06
June 26/20
Description and
Operation 1 2
3
4
5
6
June 09/06
May 14/13
June 09/06
June 09/06
June 09/06
June 09/06
Testing and Fault
Isolation 7 8
9
10
11
12
13
14
15
16
17
18
Mar 13/17
Mar 13/17
Mar 13/17
Mar 13/17
June 09/06
Aug 10/10
Mar 13/17
Mar 13/17
Mar 13/17
Mar 13/17
Aug 10/10
A
ug10/10
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COMPONENT MAINTENANCE MANUAL
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U

COMPONENT MAINTENANCE MANUAL
BA27
24-01-01
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TABLE OF CONTENTS
UParagraph TitleUUPage
Description and Operation ..................................................... 1
Testing and Fault Isolation .................................................... 7
Automatic Test Requirements (not applicable) ......................
Disassembly .......................................................................... 19
Cleaning ................................................................................ 21
Check .................................................................................... 23
Repair .................................................................................... 25
Assembly .............................................................................. 27
Fits and clearances (not applicable) ......................................
Special Tools, Fixtures and Equipment ................................. 31
Illustrated Parts List ............................................................... 33
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COMPONENT MAINTENANCE MANUAL
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COMPONENT MAINTENANCE MANUAL
BA27
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This document contains Data controlled by the U.S. Export Administration Regulations. Diversion or use contrary to U.S. law is prohibited
UINTRODUCTION
The instructions in this manual provide the information necessary for an experienced shop
mechanic to service and if required, re-block 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 IPL 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.
An explanation of the use of the illustrated Parts List (IPL) is provided in the introduction to
that section.
All weights and measurements in the manual are in English units, unless otherwise stated.
The BA27 battery is manufactured by:
EnerSys Ltd
Stephenson Street
NEWPORT
S. Wales
NP19 4XJ
U.K.
Tel: [phone]
Fax: [phone]
Corporate Office:
EnerSys
2366 Bernville Road
Reading,
PA 19605
USA
Tel: [phone]
Fax: [phone]
Page INTRO-1
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COMPONENT MAINTENANCE MANUAL
BA27
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COMPONENT MAINTENANCE MANUAL
BA27
24-01-01
This document contains Data controlled by the U.S. Export Administration Regulations. Diversion or use contrary to U.S. law is prohibited
UDESCRIPTION & OPERATION
1. UDescription
The EnerSys 24 volt 5 ampere-hour Sealed Lead Acid Battery, covered by this
Maintenance Manual (Ref. Fig. 1) is connected to the Flight Controls DC Power
Supply Assembly to produce fill-in power to its Flight Controls DC Bus while switching
between permanent magnet generator (PMG), transformer rectifier unit (TRU) and Hot
Battery Bus Sources.
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.
Each Monobloc incorporates resealing safety valves to guard against the effects of
abusive use of the battery.
As the EnerSys Flight Controls (FC) battery is sealed, there are no restrictions as to
transportation. The batteries are classified as non-hazardous cargo when transported
by air, land or sea.
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COMPONENT MAINTENANCE MANUAL
BA27
24-01-01
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Sealed Lead Acid Battery
Figure 1
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COMPONENT MAINTENANCE MANUAL
BA27
24-01-01
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2. UOperation
A General
The battery is charged (and also sustained) on the aircraft by a modified
constant potential mode via a series 0.75 ohm resistance and relay contacts
from the flight controls dc bus within the Flights Controls Power Supply
Assembly. Whenever the aircraft engines are in operation, the relay contacts
are closed and the flight controls dc bus is powered from two regulated
converters supplying a regulated 28.2 V dc. When the aircraft engines are not
in operation (ground operation), the battery is connected to the flight controls
bus via the 0.75 ohm resistance and relay contacts only when the voltage on
the flight controls bus is within the range of 26.5 V dc and 30.0 V dc. Under
operation with ground service power, the flight controls dc bus voltage is
normally between 27.0 and 27.5 V dc. The operation of the relay contacts that
connect the battery (via the resistance) to the flight controls dc bus is controlled
by logic circuitry within the Flight Controls Power Supply Assembly.
The battery is capable of supporting short duration fill-in and path check loads
of approximately 15 A dc as well as a parasitic demand of 1.5 mA dc (when the
airplane is without electrical power) and an emergency condition loading of up
to 30 A dc for up to one minute duration. The worse case daily usage (with
twelve flights per day) and with no emergency is approximately 0.25 Ah.
UCAUTION U: The battery is maintenance free. Under no circumstances
should any attempt be made to introduce any substances, e.g.,
acid, distilled water or alkali, to the battery.
B Temperature Effect
The ideal environmental temperature for battery operation is 23°C (73°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.
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COMPONENT MAINTENANCE MANUAL
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C State of Charge
The battery is designed to commence discharge when the open circuit voltage
(OCV) is within the 80 - 100% of nominal capacity range. At no time should the
battery OCV be below 25.4 volts.
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