Hawker F20/4H1C-R Operating And Maintenance Manual
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Hawker F20/4H1C-R Operating And Maintenance Manual

Hawker F20/4H1C-R Operating And Maintenance Manual

Nickel – cadmium
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Nickel – Cadmium
Batteries
Operating and
Maintenance Manual
UK
AEROSPACE
1
The document reference is online, please check the correspondence between the online documentation and the printed version.

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Summary of Contents for Hawker F20/4H1C-R

  • Page 1 Nickel – Cadmium Batteries Operating and Maintenance Manual AEROSPACE The document reference is online, please check the correspondence between the online documentation and the printed version.
  • Page 2 SAP number: 4635536 Date of issue: 01/01/13 Index of Revision: 01 Name of the Manufacturer: HAWKER GmbH, Dieckstrasse 42, 58089 Hagen © Copyright This document and all information contained herein is the property of EnerSys. Its use is restricted solely to the maintenance of EnerSys Safety Plus Power batteries referenced in table 2 of section 1.6.3.
  • Page 3 Table of effective contents 1.5.11 Airworthiness Abbreviations 1.5.12 End of life capacity. Units (physical) 1.6 Technical data 1.0 Maintenance Manual for the HAWKER ® Ni/Cd Airborne Battery – Purpose 1.6.1 Operational parameters and range and Use of application 1.1. Application of Ni/Cd aircraft batteries 1.6.2 Technical cell data: table 1...

  • Page 4: Table Of Contents

    5.0 Storage Tasks airworthy batteries 10.0 Unscheduled Maintenance - Repair & Replacement – Overhaul Task 5.1 Short-term storage of charged batteries Task 10.1 Inspection and diagnostic 5.2 Long-term storage (up-to 5 years) of discharged batteries Task 10.2 Replacement of upper pole nuts, spring washers Task 5.1 Storage of maintained and links...
  • Page 5 Abbreviations Open circuit voltage Alternating Current Part number CHC’s Chlorinated hyro-carbons Power Direct Current Personal Protective Declaration of Design and Equipment Performance Resistance End point voltage Serial number Current Task = Maintenance Task I-Charge Constant current charge TOCV Top of charge voltage Illustrated parts list Technical Requirement IU-charge...
  • Page 6 1. Maintenance Manual for the HAWKER Ni/Cd ® Airborne Battery – Purpose and Use The manual describes the processes 1.1. Applications of Ni/Cd aircraft batteries HAWKER ® airborne batteries are used for: for trained technicians to maintain • starting engines or APUs, ®...
  • Page 7 1.2.2 THE CELLS Figure two: The cell 1 negative electrode 10 lid 2 positive electrode 11 seal (vent) 3 separator 12 vent (plug) 4 plate stack 13 upper terminal nut 5 negative pole terminal 14 springwasher 6 positive pole terminal 15 lower terminal nut 7 electrolyte level indicator 16 sealing cap...
  • Page 8 1.3.1 CONVERSION OF ENERGY 1.4.3 RATED CAPACITY C During charging, the active masses of the electrodes The rated capacity is the minimum capacity, expressed in convert electrical energy into chemical energy. The Ah, obtained from a charged battery when discharged at discharge process reaction reverses it.
  • Page 9 (battery electrolyte temperature) • For any specific technical data refer to the relevant DDP (Declaration of Design and Performance) or Technical ® Specification which can be requested from the authorised Hawker representative. 1.6.2 TECHNICAL CELL DATA, TABLE 1 Cell designation FP44H1C FP40H1C FP38H1C FP27H1C FP25H1C FP22H1C FP17H1C FP7H1C FP4H1C Rated voltage.
  • Page 10 Cell Nominal Rated Ipr(A) Length Width Height Typ. Weight type type voltage (V) capacity (Ah) to 25°C (mm) (mm) (mm) F20/4H1C-R 3349004 910 2314772 FP4H1C F20/7H1C-E2 3349007 9000 2314845 FP07H1C 13.0 F20/15H1C 3349015 910 2314918 FP15H1C 16,7 F20/17H1C 3349017 910...
  • Page 11 2. Safety measures and instructions 2.1 Safety Instructions, Warnings • Remove electrolyte contaminated and Notes clothes, immediately wash in excess of acetic water “CAUTION” is necessary, if non-adherence or • The potassium hydroxide electrolyte incorrect adherence to the service or working solution is highly corrosive.
  • Page 12 3. Commissioning of new batteries 3.1 Log book The operator shall record and confirm by signature in the log book the process steps and data measured on the battery and its cells. These records are required to provide evidence of the airworthiness of the battery. Failures to comply with this instruction may invalidate the warranty conditions.
  • Page 13 3.3 Commissioning Task 3.2 for new batteries Task 3.2 – Commissioning of new batteries OPERATING INSTRUCTION AND TECHNICAL REQUIREMENTS (TR) INSTRUCTIONS / EVIDENCE WHEN DEVIATIONS FROM TR ATTENTION Never charge, discharge or adjust electrolyte on cells connected in series outside the battery case. 1.
  • Page 14 Figure 4: Electrolyte level indicator ATTENTION If necessary, adjust the electrolyte level to the height that touches the edge of the spacer. ATTENTION The electrolyte level of charged cells decreases after charge while the gas is escaping. Do not adjust electrolyte level further. 9.
  • Page 15 14. Recharge the battery using a method indicated in section 14.1 or 14.2 In case cells fail this requirement, contact the supplier or 14.3 • Adjust the electrolyte level at a current of 0.2*I 15 minutes to 10 minutes prior to end of the charge methods, 14.1, 14.2, and 14.3 •...
  • Page 16 3.4 Release to aircraft Task 3.3: For any additional specific release requirement refer to Task 3.3 below Task 3.3 – Specific release requirements OPERATING INSTRUCTION AND TECHNICAL REQUIREMENTS (TR) INSTRUCTIONS / EVIDENCE WHEN DEVIATIONS FROM TR 1. Install the battery into the aircraft as described in the flight manual.
  • Page 17 4.5 Equipment, Tools and Consumables for maintenance Hawker ® recommends the use of equipment, tools (listed in Appendix 5) and consumable (listed in Appendix 6) for maintenance and repair on Hawker ® batteries. 4.2 Scheduled maintenance procedures 4.2.1 MONTHLY CHECKS ON AIRCRAFT.

  • Page 18: Storage Tasks Airworthy Batteries

    5.0 Storage Tasks for airworthy batteries 5.1 Short-term storage of charged 5.2 Long-term storage (up-to 5 years) of batteries discharged batteries Maintained and charged batteries can be stored for 3 Batteries can be stored between 3 months and 5 years months at 35°C in a secured area.

  • Page 19: Task 5.2 Preparation For Long-Term Storage

    Task 5.2 - Preparation for long term storage OPERATING INSTRUCTION AND TECHNICAL REQUIREMENTS (TR) INSTRUCTIONS / EVIDENCE WHEN DEVIATIONS FROM TR 1. Carry out the scheduled maintenance procedure on the battery in accordance with Task 7.3. 2. Discharge the battery to an average of 1V per cell using current rates between I and 0.1*I 3.
  • Page 20 Figure 4: Electrolyte level indicator ATTENTION If necessary, adjust the electrolyte level to the height that touches the edge of the spacer. ATTENTION The electrolyte level of charged cells decreases after charge while the gas is escaping. Do not adjust electrolyte level further.
  • Page 21 11. Recharge the battery using a method indicated in section In case cells fail this requirement, contact the supplier. 12.1 or 12.2 or 12.3. • Adjust the electrolyte level at a current of 0.2*I 15 minutes to 10 minutes prior to end of the charge methods, 12.1, 12.2, and 12.3 •...

  • Page 22: Transportation Of Batteries

    6. Transportation of batteries Refer to Task 6.1 below: Shipment of batteries Task 6.1 – Shipment of batteries OPERATING INSTRUCTION AND TECHNICAL REQUIREMENTS (TR) INSTRUCTIONS / EVIDENCE WHEN DEVIATIONS FROM TR 1. Discharge the battery to 1 Volt per cell using currents between I and 0.1*I .to an end point of 1 V times number of cells.

  • Page 23: Maintenance Tasks

    7. Maintenance Tasks Task 7.1 – Monthly on “aircraft” check OPERATING INSTRUCTION AND TECHNICAL REQUIREMENTS (TR) INSTRUCTIONS / EVIDENCE WHEN DEVIATIONS FROM TR Note: The battery can be inspected visually fitted in the aircraft Check the locks for defects, if the lid cannot be removed. or alternatively removed and inspected on the airfield.
  • Page 24 5. Tighten and torque the upper nuts as detailed in section 1.6.2, table 1 6. Inspect visually harnesses with temperature switches, thermistors, Any damage found, record defect and replace in accordance with thermocouples, and for loose wiring, cracks, dents, connector pins Repair Task 10.4.
  • Page 25 15. Recharge the battery using either 15.1, or 15.2 or 15.3 Identify cells for replacement. Refer to Task 10.7. • Adjust the electrolyte level at a current of 0.2*I 15 minutes to 10 minutes prior to end of the charge methods, 15.1, 15.2, and 15.3. •...

  • Page 26: Task 7.3: Annual Maintenance Of Airborne Batteries

    Task 7.3 – Annual maintenance of airborne batteries OPERATING INSTRUCTION AND TECHNICAL REQUIREMENTS (TR) INSTRUCTIONS / EVIDENCE WHEN DEVIATIONS FROM TR 1. Remove the lid and check that the gasket is fully adhered to Any damage found, record defect and replace in accordance with the lid.
  • Page 27 12. Discharge the 24 V battery at I to 20 V. (pay particular attention to If the requirement is not met, then continue with Task 8.1, previously marked cell in step 8). “Reconditioning.” Requirement: The voltage of each cell after 48 minutes must be equal / greater than 1.0V.
  • Page 28 18. Reassembly the battery CAUTION: Incorrect assembly harms the airworthiness of the battery and will result in additional repair work. Use always the battery components in accordance with the corresponding IPL. • Fit the main connector into the battery case (if replaced) •...
  • Page 29 27. Allow the battery to soak to room temperature, which can take up to 8 hours 28. Recharge the battery using either 28.1, or 28.2 or 28.3 • Adjust the electrolyte level at a current of 0.2*I 15 minutes to 10 minutes prior to end of the charge methods, 28.1, 28.2, and 28.3 •...
  • Page 30 8. Sub-Tasks of maintenance / commissioning procedures Task 8.1 – Reconditioning of cells underperforming discharge capacity requirements OPERATING INSTRUCTION AND TECHNICAL REQUIREMENTS (TR) INSTRUCTIONS / EVIDENCE WHEN DEVIATIONS FROM TR Note: For charged batteries from service containing cells returning less than 80% of its nominal capacity output, this reconditioning is advised.

  • Page 31: Of The Lower Pole Nuts

    6. Charge the battery for 7 hours at 0.2*I as shown in Appendix 2, Identify cells for replacement. Refer to Task 10.7. adjust the electrolyte level and read and file cells end of charge voltages prior to the end of charge Requirement: ≥ 1.56 V. 7.

  • Page 32: Requirements

    Task 8.3 – Insulation resistance measurement OPERATING INSTRUCTION AND TECHNICAL REQUIREMENTS (TR) INSTRUCTIONS / EVIDENCE WHEN DEVIATIONS FROM TR CAUTION Read the safety instructions for the High voltage – Insulation resistance tester. 1. Measure the insulation resistance with a MΩ-meter at 250 V DC If the insulation resistance is below 0.5 MΩ...

  • Page 33: Task 8.5 Testing Vents Response Pressure After Cleaning

    Task 8.5 – Testing vents response pressure after cleaning OPERATING INSTRUCTION AND TECHNICAL REQUIREMENTS (TR) INSTRUCTIONS / EVIDENCE WHEN DEVIATIONS FROM TR ATTENTION: • Spare parts used for any repair listed below have to comply with the IPL. • Do not store wet vents in plastic bags. NOTE Before testing the vents ensure they have been cleaned in accordance to Task 8.6.

  • Page 34: Task 8.7 Functional Test On Thermostats / Thermistors And Temperature Switch Assemblies

    Task 8.7 – Functional Test on thermostats / thermistors and temperature switch assemblies OPERATING INSTRUCTION AND TECHNICAL REQUIREMENTS (TR) INSTRUCTIONS / EVIDENCE WHEN DEVIATIONS FROM TR ATTENTION Spare parts used for replacement have to comply with the IPL. Before disassembly, discharge the battery with 0.2*I to 0.5 V per cell.
  • Page 35 Test 2: Thermostats below ambient temperature CAUTION Spraying human skin and tissue with coolant causes serious injuries (burns) by freezing. Read safety instructions about cooling spray. 2.a Identify the thermostat type and its switching temperature according to the Appendix 4 2.b Disassemble the battery to the state necessary to remove the switch assembly together with the corresponding connector 2.c Fix the link with the thermostat on the test fixture...
  • Page 36 9. Fault finding (Unscheduled maintenance) The table below identifies the tests and inspections to diagnose a fault condition as a result of an unscheduled removal of the battery from aircraft. Problem Possible Reason Check Refer Corrective action to Task Zero volt at battery connector Intercell links broken, 10.1 Task 10.2...

  • Page 37: Maintenance)

    10. Unscheduled Tasks Task 10.1 – Inspection and diagnostic OPERATING INSTRUCTION AND TECHNICAL REQUIREMENTS (TR) INSTRUCTIONS / EVIDENCE WHEN DEVIATIONS FROM TR 1. Remove the lid and check that the gasket is fully adhered Any damage found, record defect and replace in accordance to the lid.
  • Page 38 Note: If the discharge at the I rate is not feasible, select a different rate and criteria from the table below. Discharge current rate Time (min) cell voltage Voltage requirement reading for cells (V) ≥1.0 0.2*I ≥1.0 0.4*I ≥1.0 0.6*I ≥1.0 0.8*I ≥1.0...

  • Page 39: Task 10.2 Replacement Of Upper

    17.3 II charge method (Appendix 3) • Charge the fully discharged battery with parameters selected from table below and afterwards charge for two hours at 0.2*I • Check battery current switching to 0.2*I at the stage 1(max) time presented in the table below. current Stage 1 time (max) 0.4*I...

  • Page 40: Task 10.3 Replacement Of Lower Pole

    Task 10.3 – Replacement of lower pole nuts, sealing caps and seals OPERATING INSTRUCTION AND TECHNICAL REQUIREMENTS (TR) INSTRUCTIONS / EVIDENCE WHEN DEVIATIONS FROM TR • Only in case of corrosion and or leakage replacement can be considered. ATTENTION: • Spare parts used for any repair listed below have to comply with the IPL •...

  • Page 41: Thermostat Switch Assembly

    Task 10.4 – Replacement of the Thermostat Switch Assembly OPERATING INSTRUCTION AND TECHNICAL REQUIREMENTS (TR) INSTRUCTIONS / EVIDENCE WHEN DEVIATIONS FROM TR ATTENTION: • Spare parts used for any repair listed below have to comply with the IPL • Before disassembly, discharge the battery with 0.2*I to 0.5 V per cell •...

  • Page 42: Case And Or Battery Lid

    Task 10.6 – Replacement of the Battery Case and or Battery Lid OPERATING INSTRUCTION AND TECHNICAL REQUIREMENTS (TR) INSTRUCTIONS / EVIDENCE WHEN DEVIATIONS FROM TR ATTENTION Spare parts used for any repair listed below have to comply with the IPL Before disassembly, discharge the battery with 0.2*I to 0.5 V per cell.

  • Page 43: Task 10.7 Replacement Of Cell(S)

    Task 10.7 – Replacement of Cell(s) OPERATING INSTRUCTION AND TECHNICAL REQUIREMENTS (TR) INSTRUCTIONS / EVIDENCE WHEN DEVIATIONS FROM TR ATTENTION: • Spare parts used for any repair listed below have to comply with the IPL • Before disassembly, discharge the battery with 0.2*I to 0.5 V per cell •...

  • Page 44: Task 10.9 Commissioning Of Repaired Batteries

    Task 10.9 - Commissioning of repaired batteries OPERATING INSTRUCTION AND TECHNICAL REQUIREMENTS (TR) INSTRUCTIONS / EVIDENCE WHEN DEVIATIONS FROM TR 1. Measure the insulation resistance in accordance with Task 8.3 Carry out battery cleaning, Task 8.6. Requirement: R>0.5 MΩ 2. Remove the lid from the battery. 3.

  • Page 45: Iui Charge

    APPENDIX 1: IUI-CHARGE APPENDIX 2: CONSTANT CURRENT CHARGE: The document reference is online, please check the correspondence between the online documentation and the printed version.

  • Page 46: Ii-Charge

    APPENDIX 3: II-CHARGE The document reference is online, please check the correspondence between the online documentation and the printed version.
  • Page 47 APPENDIX 4: TEMPERATURE HARNESSES Battery Mat. No Thermostat Mat. No Amount of Colour NCC/ NOC Switching SAP No assembly SAP No Thermostats range Buttonthermostat 70°C F 20/7 H1C T-E2 334 9007 3001 Temperature sensor 308 9946 191 1x Thermostat Yellow 70°C ±...

  • Page 48: Appendix 5

    Commercial unit 0-100°С tolerance ±1 Digital thermometer Temperature test Commercial unit 50…+150°С ® Tool box with special HAWKER tools Size No: 42 For batteries 44/40/38/27 (Ah) Battery maintenance 929 1480 770 Complete: aerometer, thermometer, protective gloves, brush, funnel, spec. wrench, valve spanner, spare parts (5 vents, 5 pole nuts, 5 limiting caps, 5 sealing rings, 5 spring washers).

  • Page 49: Appendix 6

    Coating metallic surface of battery case and Commercial live parts APPENDIX 7: DISPOSAL Dispose of in accordance with local regulations. If in doubt, contact ® HAWKER GmbH / EnerSys Dieckstrasse 42 58089 Hagen Germany Phone: +49 (0)23 31-372-0 Fax: +49 (0)23 31-372-183 email: info@de.enersys.com...
  • Page 50 Notes ................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................
  • Page 51 Notes ................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................
  • Page 52 European Headquarters: Local contact: Local contact: address for details of your address for details of your EnerSys EMEA EnerSys EMEA Hawker GmbH Hawker GmbH nearest EnerSys office. nearest EnerSys office. EH Europe GmbH EH Europe GmbH Dieckstraße 42 Dieckstraße 42 Löwenstrasse 32...

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