Sei sulla pagina 1di 53

COMPONENT MAINTENANCE MANUAL

For
XL500/5-500H EMERGENCY BATTERY

Sealed Lead Acid Technology


XL500/5-500H

Part No.

100-0206-01/-03

This document supersedes document number SM-0206-01, Service Manual for


the XL500/5 24 VDC Emergency Battery Pack, P/N 100-0206-01 for Installers
and Maintenance Personnel dated 2-22-99. All copies of SM-0206-01 should be
discarded and replaced with this manual MM-0036-01.
THESE COMMODITIES, TECHNOLOGY OR SOFTWARE WERE EXPORTED FROM THE UNITED
STATES IN ACCORDANCE WITH THE EXPORT ADMINISTRATION REGULATIONS.
DIVERSION CONTRARY TO U.S. LAW IS PROHIBITED.
Notice: Products shipped hereunder may be subject to the Export Administration Act (EAA) and the Export
Administration Regulations (15 C.F.R. 730 through 774 and related regulations) or the International Traffic In Arms
Regulation (ITAR) 22 C.F.R. 120-130.
You are advised that improper export of these products may result in civil and criminal penalties.

Initial Issue: Feb 12/02


Manual Part Number: MM-0036-01

24-32-17

Revision No. 3
Jun 03/09

COMPONENT MAINTENANCE MANUAL


XL500/5 500H EMERGENCY BATTERY SYSTEM
100-0206-01/-03

Confidentiality Notice
This document contains confidential and proprietary information, which is
proprietary to Securaplane and shall not be copied or reproduced, in
whole or in part, or the contents divulged or used for manufacture, without
the specific written permission of Securaplane. Recipient, by acceptance,
use, or retention of this document, acknowledges and agrees to the
foregoing and covenants to maintain the contents in confidence.

Warranty/Liability Advisory
Securaplane assumes no responsibility for any Securaplane equipment
that is not maintained and/or repaired in accordance with Securaplanes
published instructions and/or Securaplanes repair authorization. Neither
does Securaplane assume responsibility for special tools and test
equipment fabricated by companies other than Securaplane.
Incorrectly repaired components can affect airworthiness or decrease the
life of the components. Incorrectly fabricated special tooling or test
equipment can result in damage to the product components or give
unsatisfactory results. The equipment or parts that have been repaired or
fabricated by other than Securaplane authorized facilities can increase
the risks of death or personal injury, component failures, and secondary
damage and can void the warranties underwritten by Securaplane.

Aircraft-On-Ground (AOG) Service


For AOG service contact Securaplane at Tel: 1-520-297-0844 (US Toll
Free: 1-800-279-7327). After business hours please follow the AOG
directions in the recorded message.

24-32-17

SWLA-1
Jun 25/04

COMPONENT MAINTENANCE MANUAL


XL500/5 500H EMERGENCY BATTERY SYSTEM
100-0206-01/-03

Record Of Revisions
Rev
No.

Issue
Date

Orig

Feb 12/02

Aug 29/03

Jun 25/04

Jun 03/09

Date
Inserted

By

Rev
No.

Issue
Date

Date
Inserted

24-32-17

By

ROR-1
Jun 03/09

COMPONENT MAINTENANCE MANUAL


XL500/5 500H EMERGENCY BATTERY
100-0206-01/-03

Record Of Temporary Revisions


TR
No.

Page
No.

Issue
Date

Date
Inserted

By

Date
Removed

By

Incorporated
by Rev No.

24-32-17

RTR-1

Feb 12/02

COMPONENT MAINTENANCE MANUAL


XL500/5 500H EMERGENCY BATTERY SYSTEM
100-0206-01/-03

Service Bulletin/Engineering Change Order List


SB/ECO No.

Date
Incorporated

Title

ECO # 031119-2

Jun 25/04

XL500/5 500H

ECO # 040601-2

Jun 25/04

XL500/5 500H

24-32-17

SBL-1
Jun 25/04

COMPONENT MAINTENANCE MANUAL


XL500/5 500H EMERGENCY BATTERY SYSTEM
100-0206-01/-03

List of Effective Pages


SUBJECT

PAGE

DATE

Title Page

T-1

Jun 03/09

Safety/ Warranty/
Liability Advisory

SWLA-1

Jun 25/04

Record of Revisions

ROR-1

Jun 03/09

Record of
Temporary
Revisions

RTR-1

Feb 12/02

Service Bulletin/
ECO List

SBL-1

Jun 25/04

List of Effective
Pages

LEP-1

Jun 03/09

Highlights of
Change

HOC-1

Jun 03/09

Table of Contents

TOC-1
thru 2

Jun 25/04

Introduction

Intro-1

Feb 12/02

Intro-2
4

Jun 25/04

Page 1
thru 2

PAGE

DATE

Page 12
thru 13

Feb 12/02

Page 14
thru 15

Jun 25/04

Page 16

Feb 12/02

Page 17

Jun 25/04

Page 18

Feb 12/02

Page 19

Jun 25/04

Page 20
thru 21

Feb 12/02

101

Jun 03/09

102 thru
105

Feb 12/02

Maintenance
Practices

201 thru
203

Feb 12/02

Disassembly

301

Feb 12/02

Jun 03/09

Cleaning

401 thru
403

Feb 12/02

Page 3

Jun 25/04

Check

501

Feb 12/02

Page 4
thru 6

Feb 12/02

Repair

601

Feb 12/02

Jun 25/04

701 thru
702

Jun 25/04

Page 7
thru 8

Assembly Including
Storage
Fits and Clearances

801

Jun 25/04

Page 9
thru 10

Feb 12/02

901

Jun 25/04

Page 11

Jun 25/04

Special Tools
Fixtures and
Equipment
Illustrated Parts List

1001

Jun 25/04

thru

Description and
Operation

SUBJECT

Testing and Fault


Isolation

24-32-17

LEP -1
Jun 03/09

COMPONENT MAINTENANCE MANUAL


XL500/5 500H EMERGENCY BATTERY SYSTEM
100-0206-01/-03

Highlights of Change
Effective June 03, 2009 the XL500/5 500H Emergency Battery CMM, MM-0036-01 is revised per
the highlights of change listed here, the LEP revision-dated pages, and the Engineering Change
Order or Service Bulletin (if applicable) listed in the incorporated SB page for this manual.

Change Summary
1.

Changed manual Revision level to 3.

2.

Page 1 and 2 Revised unit weight.

3.

Page 101 corrected sentence battery capacity test to battery level test.

24-32-17

HOC -1
Jun 03/09

COMPONENT MAINTENANCE MANUAL


XL500/5 500H EMERGENCY BATTERY SYSTEM
100-0206-01/-03

Table of Contents
Section

Page

INTRODUCTION ............................................................................................................................. Intro-1


1. Scope....................................................................................................................................... Intro-1
2. Product Support Services ........................................................................................................ Intro-2
3. Usage Guide ............................................................................................................................ Intro-2
4. Revision Service ...................................................................................................................... Intro-3
5. Abbreviations and Unit Symbols .............................................................................................. Intro-3
6. Applicable Publications ............................................................................................................ Intro-4
DESCRIPTION AND OPERATION...........................................................................................................1
1. Introduction .......................................................................................................................................1
2. Description ........................................................................................................................................2
A. Front Panel Controls and Display ................................................................................................2
B. Fault/Events Logged in History ....................................................................................................5
C. Remote Fault Outputs..................................................................................................................6
D. Block Diagram Description.........................................................................................................11
E. Battery Capacity.........................................................................................................................19
3. CHARGE METHOD ........................................................................................................................20
4. General Protection ..........................................................................................................................21
A. Safety Thermal Switch ...............................................................................................................21
B. Over-Voltage Protection.............................................................................................................21
TESTING AND FAULT ISOLATION .....................................................................................................101
1. Battery Energy Test ......................................................................................................................101
2. Shop Level Charging ....................................................................................................................101
A. TEST EQUIPMENT FOR CHARGING ....................................................................................101
B. CHARGE PROCEDURE..........................................................................................................102
3. SHOP LEVEL BATTERY CAPACITY TEST .................................................................................102
A. EQUIPMENT REQUIRED........................................................................................................102
B. TEST PROCEDURE................................................................................................................103
4. On-Aircraft Fault Isolation Procedures ..........................................................................................104
5. Off-Aircraft Fault Isolation Procedures ..........................................................................................105
MAINTENANCE PRACTICES ..............................................................................................................201
1. Battery Testing Interval (Required) ...............................................................................................201
2. Recommended Battery Replacement ...........................................................................................201
3. Material Safety Data Sheets .........................................................................................................201
DISASSEMBLY.....................................................................................................................................301
CLEANING............................................................................................................................................401
1. Introduction ...................................................................................................................................401
2. Equipment and Materials ..............................................................................................................402
3. General Cleaning Practices ..........................................................................................................402
4. General Cleaning Procedures.......................................................................................................403
A. External Cleaning.....................................................................................................................403
CHECK .................................................................................................................................................501
1. General Check Procedures...........................................................................................................501
A. Internal Visual Checks .............................................................................................................501
B. External Visual Checks ............................................................................................................501
REPAIR.................................................................................................................................................601
1. Introduction ...................................................................................................................................601

24-32-17

TOC -1
Jun 25/04

COMPONENT MAINTENANCE MANUAL


XL500/5 500H EMERGENCY BATTERY SYSTEM
100-0206-01/-03
Section

Page

ASSEMBLY, STORAGE, AND SHIPPING ...........................................................................................701


1. Storage .........................................................................................................................................701
2. Storage Equipment and Materials.................................................................................................701
3. Storage Instructions ......................................................................................................................702
A. Introduction ..............................................................................................................................702
B. Preparing the Unit for Storage or Shipping. .............................................................................702
C. Monitoring Storage Conditions.................................................................................................702
D. Maintaining the Battery Charge During Storage ......................................................................702
E. Shipping Procedures................................................................................................................702
FITS AND CLEARANCES ....................................................................................................................801
SPECIAL TOOLS, FIXTURES, AND EQUIPMENT ..............................................................................901
ILLUSTRATED PARTS LIST ..............................................................................................................1001

List of Figures
Figure

Page

Figure 1. XL500/5 500H Emergency Battery ................................................................................... Intro-1


Figure 2. XL500/5 500H Front Panel Pushbuttons ...................................................................................2
Figure 3. XL500/5 to Aircraft Electrical Interface ......................................................................................7
Figure 4. XL500H to Aircraft Electrical Interface.......................................................................................8
Figure 5. XL500/5 Functional Block Diagram .........................................................................................10
Figure 6.XL500H Functional Block Diagram...........................................................................................11
Figure 7. Five Amp Constant Current Discharge Curve .........................................................................19
Figure 8. Temperature Compensated Trickle Charge ............................................................................20
Figure 101. On Aircraft Fault Isolation Flowchart..................................................................................104
Figure 801. XL500/5 and 500H Outline ................................................................................................801
Figure 901. XL500/5 J1 Adapter Harness.............................................................................................901

List of Tables
Table

Page

Table 1. Applicable Publications ...................................................................................................... Intro-4


Table 2. XL500/5 500H Specifications......................................................................................................1
Table 3. XL500/5 500H Controls and Status Display................................................................................3
Table 4 . XL500/5 500H Fault/Event Description......................................................................................5
Table 5. Remote Fault Outputs.................................................................................................................6
Table 6. XL 500/5 J1 Connector Pin-Outs ................................................................................................9
Table 7. XL 500H J1 Connector Pin-Outs...............................................................................................10
Table 8. Current Limit Thresholds...........................................................................................................14
Table 9. Battery Charger Algorithm ........................................................................................................21
Table 101. J1 Resistance Readings .....................................................................................................105
Table 401. Cleaning Equipment and Materials .....................................................................................402
Table 701. Storage Equipment and Materials.......................................................................................701

24-32-17

TOC -2
Jun 25/04

COMPONENT MAINTENANCE MANUAL


XL500/5 500H EMERGENCY BATTERY SYSTEM
100-0206-01/-03

INTRODUCTION
1. Scope
This Component Maintenance Manual contains the description, theory of operation, on-aircraft
fault isolation procedures for the XL500/5 500H Emergency Battery System. See Figure 1.
Securaplane Technologies, Tucson, AZ, USA manufactures the XL500/5 500H.
The XL500/5 500H provides emergency backup power for avionics and lighting systems during
aircraft ground and airborne operations. A built-in charger and test circuitry eliminates the need to
remove the battery for maintenance. The chassis is a single line replaceable unit (LRU) housed in
a 1/4 ATR short case. The XL500/5 500H is a direct replacement for BFG (JET) units that do not
require AC input.

Figure 1. XL500/5 500H Emergency Battery

24-32-17

Intro-1
Feb 12/02

COMPONENT MAINTENANCE MANUAL


XL500/5 500H EMERGENCY BATTERY SYSTEM
100-0206-01/-03

Securaplanes XL500/5 500H Sealed Lead Acid (SLA) technology batteries provide an improved,
minimal maintenance. The major advantages of the XL500/5 500H are:
(1) Sealed lead-acid batteries which exhibit none of the memory characteristics
associated with NiCad technology,
(2) A SELECT LVLTEST function that loads the battery and accurately displays
battery capacity on the display without removing the battery from the airframe,
(3) Automatic charge of the self-contained sealed lead-acid batteries to 80-90%
energy level in 90 minutes,
(4) Capability to remotely initiate a battery level test from the cockpit,
(5) Automatic monitoring of battery temperature and output voltage,
(6) A battery heater system that activates below a 30C battery temperature.
The battery covered by this document is under warranty and must be returned to Securaplane
or a facility approved by Securaplane for disassembly and repair.

2. Product Support Services


Product support for the XL500/5 500H Emergency Battery System is available from Securaplane.
These services include repair, overhaul, spare parts, and technical documentation. Please
contact:
Securaplane
10800 Mavinee Drive
Tucson AZ 85737 USA
Email: support@securaplane.com

CAGE Code: 0TMJ9


Tel:
1-520-297-0844
Fax
1-520-498-4924
Web: www.securaplane.com

3. Usage Guide
The following list summarizes the contents of this CMM. Refer to the table of contents to find a
specific procedure or data item.
(1)

Description and Operation presents the features, interface, and a functional


description of the XL500/5 500H Emergency Battery System.

(2)

Testing and Fault Isolation contains procedures to test and fault isolate problems
while the unit is on the aircraft.

(3)

Maintenance Practices presents the Maintenance Safety Data Sheets for Hawker
sealed lead acid batteries.

24-32-17

Intro-2
Jun 25/04

COMPONENT MAINTENANCE MANUAL


XL500/5 500H EMERGENCY BATTERY SYSTEM
100-0206-01/-03

(4)

Disassembly Not applicable.

(5)

Cleaning contains general procedures recommended by Securaplane to clean the


XL500/5 500H Emergency Battery system. Disassembly is not required to clean
the unit.

(6)

Check Not applicable.

(7)

Repair Not applicable.

(8)

Assembly Including Storage describes storage procedures for the battery.

(9)

Fits and Clearances shows the outline drawings for the XL500/5 500H
Emergency Battery.

(10)

Special Tools, Fixtures, and Equipment presents a J1 Charge Adapter drawing.

(11)

Illustrated Parts Catalog Not applicable.

This publication is written in agreement with the Air Transport Association of America Spec 2200.

4. Revision Service
This document is written in agreement with the Air Transport Association of America iSpec 2200.
A revised manual is issued when necessary throughout the service life of the unit. A change bar
in the right margin identifies the revised part of the page. If the entire page has changed, a
change bar will appear in the lower right corner. Revisions are summarized in the Highlights of
Change page.

5. Abbreviations and Unit Symbols


Abbreviations, Mnemonics and unit symbols used in this manual are defined below. The following
standards and conventions are used in this manual:

The symbols and special characters are used in agreement with IEEE publication 260 and
IEC publication 27, except special characters contained in the text, which are spelled out.

The signal mnemonics, unit control designators, and test designators are printed in capitals.

The measurements, weights, dimensions, pressure, or torque values (that are changed to
metric equivalents) are shown in parentheses after the United States measurements.

The temperature shown in degrees Fahrenheit use the symbol F.


The temperature shown in Celsius (centigrade) is designated by the C symbol.
ATR

Austin Trumbull Radio racking

CAGE

Civilian and Government Entity

PTC

Positive Temperature Coefficient

SLA

Sealed Lead Acid

24-32-17

Intro-3
Jun 25/04

COMPONENT MAINTENANCE MANUAL


XL500/5 500H EMERGENCY BATTERY SYSTEM
100-0206-01/-03

6. Applicable Publications
Related publications applicable to the XL500/5 500H are shown in Table 1.
Table 1. Applicable Publications
Securaplane

Document Number

Top Assembly Drawing, XL500/5

101-0206-01

Outline Drawing, XL500/5

100-0206-01

Product Specification XL500/5

200-0206-01

Qualification Test Report Emergency Battery XL500/5

225-0206-01

Top Assembly Drawing, 500H

101-0206-03

Outline Drawing, 500H

100-0206-03

Product Specification, 500H

200-0206-03

Qualification by Similarity Emergency Battery XL-500H

225-0206-03

Commercial
Environmental Conditions and Test Procedures For
Airborne Equipment

Document Number
RTCA/DO-160C

7. Electrostatic Discharge
The items susceptible to electrostatic discharge are handled in agreement with IPC-A-610. Refer
to the IPC-A-610C specification Sections 3.2 and 3.3 for the definition of the standards and
conditions.

24-32-17

Intro-4
Jun 25/04

COMPONENT MAINTENANCE MANUAL


XL500/5 500H EMERGENCY BATTERY SYSTEM
100-0206-01/-03

DESCRIPTION AND OPERATION


1. Introduction
This section describes the XL500/5 500H Emergency Battery System by listing the specifications
(Table 2), describing controls and indicators, identifying the functional elements in a block
diagram (see Figure 5), and then describing the operation of the battery protection system.
The XL500/5 500H emergency battery provides emergency backup DC power to avionics and
lighting systems on fixed wing turbojet and similar aircraft types. The XL500/5 500H consists of
two sets of six 2V 6Ah Hawker Cyclon lead acid batteries with charge control and protection
circuitry located in the assembly. The batteries are configured in a series combination to yield a
24 VDC, 5 Ah battery. A power diode applies aircraft 28 VDC bus to the output load. If the bus
drops below 21.7 VDC, the battery automatically supplies the output load.
The XL500/5 500H provides low maintenance, extended battery service life, and overall safety.
The unit does not need to be removed from the aircraft for any reason except for an outright
failure, or battery replacement. Refer to the Fits and Clearances section (page 801) for mounting
dimensions.
Table 2. XL500/5 500H Specifications
Parameter
Input:

Specifications

Voltage

21.7-36 VDC (28 VDC Nominal)

Current

12 Amps (Heaters, Lighting, and Charger operating)

Connector, Interface, J1

ARINC DPXB-13-34P-0101, polarized

Connector, Mating

DPXB-13-33S-0001

Output:
Voltage

24 VDC Nominal

Current

3.5 Amps: 60 minutes minimum (@+25 to +60C) (New unit)

Current Maximum

12 Amps peak.

Emergency Lighting
Converter

2.5 to 5.5 VDC, 35 Watts Max.

Operating Temp Range


Cooling:

Normal operating temperature -55C to +60C


Convection (no forced air)

Physical:
Height

7.68 in (19.50 cm) maximum

Width

2.39 in (6.07 cm) maximum

Length

14.75 in (37.47cm) maximum

Weight

14.35 0.50 lbs (6.50 0.23 kg) (XL500/H only)


14.30 1.20 lbs (6.49 0.54 kg) (XL500/5 only)

Environmental
Qualification:

DO-160C 4(F2), 5(B), 6(C), 7, 8(C), 9(X), 10 (W), 12(D), 13(F),


14(S), 16(Z), 17(A), 18(Z), 19(Z), 20(W,R), 22(B3), 23(X), 24(A)

24-32-17

Page-1
Jun 03/09

COMPONENT MAINTENANCE MANUAL


XL500/5 500H EMERGENCY BATTERY SYSTEM
100-0206-01/-03

2. Description
The emergency battery pack incorporates a dedicated battery charger and monitoring system to
ensure that the internal batteries are always maintained at their fullest possible capacity. The
charge function is automatic, and turns on as soon as aircraft input power is available. Charge
current is limited to approximately 8 amperes peak. If the heaters are active, an extra 3.5
amperes is added to the peak.
The XL500/5 500H emergency batteries require minimum maintenance. If the plane is going to be
out of service for 60 days or longer, the battery should be placed on shop charge. (Refer to Shop
Level Charging on page 101). The XL500/5 500H does not need to be removed from the aircraft
for any reason except for an outright failure, or preventative maintenance battery replacement.
The XL500H is identical to the XL500/5 except that it provides three additional discrete signals
that (1) indicate whether the input bus or internal batteries are switched to the output, (2) allows
manual inhibiting of the internal batteries, and (3) continuously monitors the unit for latched faults.
These discretes are described on pages 14 and 15. As shown in the Fits and Clearances section
(page 801), the system is contained in a 1/4 ATR chassis 14.75 in (37.47cm) L by 2.39 in (6.07
cm) W by 7.68 in (19.50 cm) H chassis. The XL500H weighs 14.35 0.50 lbs (6.50 0.23 kg).
The XL500/5 weighs 14.30 1.20 lbs (6.49 0.54 kg).

A.

Front Panel Controls and Display


The XL500/5 500H front panel contains three pushbutton switches, MENU, RESET, and
SELECT and an 8-character LED Display that indicates Charger faults and Battery status.
The front panel switches and indicators shown in Figure 2 are described in Table 3.

Figure 2. XL500/5 500H Front Panel Pushbuttons

24-32-17

Page-2
Jun 03/09

COMPONENT MAINTENANCE MANUAL


XL500/5 500H EMERGENCY BATTERY SYSTEM
100-0206-01/-03

Table 3. XL500/5 500H Controls and Status Display


Press MENU
Until:

Press SELECT Until:


Charger status
is indicated as
shown on the
right when the
SELECT switch
is pressed or on
power up.

STATUS

TEMPS

HISTORY

Function or Parameter
Displayed

Bus Low

Input bus below 21.7 VDC

Shutdown

Charger has shutdown

CDT Mode

Charging in conditioning mode

Bulk

Charging in bulk mode

Trickle

Charging in trickle mode

Pause

Charge converter has paused

Bat XX.XV

Battery voltage

Bt +/-XX.XA

Battery current

Bus XX.XV

Input bus voltage

Bus XX.XA

Input bus current

Out XX.XV

Output voltage

Cvt XX.XV

5 VDC converter voltage

LvlTest?

To perform a level test press the RESET


pushbutton for at least 5 seconds.

Chgr+/-XXC

Charger converter temperature

Box +/-XXC

XL500/5 500H internal temperature

Bat1 +/-XXC

Battery pack #1 temperature

Bat2 +/-XXC

Battery pack #2 temperature

#XXX

Latest event history. Scroll by pressing the


SELECT switch

Fault/Event Name

Refer to Table 4 for list of logged events.

Mo/Day/Year

Date (GMT)

Hr/Min/Sec

Time (GMT)

24-32-17

Page-3
Jun 25/04

COMPONENT MAINTENANCE MANUAL


XL500/5 500H EMERGENCY BATTERY SYSTEM
100-0206-01/-03
Table 3. XL500/5 500H Controls and Status Display (Continued)
CONFIG

Rev XXXXX

Software revision

Mo.Day.Year

Current date (GMT)

Hr.Min.Sec.

Current time (GMT)

XXXXXX Hrs

Operating hrs

Adj 5V?

Sys Rst?

TIME SET

Year
Month
Day
Hour
Min
Sec
Set?

When RESET is pressed, the +5V converter


voltage will be displayed. Press MENU to
increase or SELECT to decrease the
voltage. Press RESET to finish and store the
new setting. Note: Converter 28 VDC input
must be connected (see Figure 3).
When RESET is pressed, a System/CPU
reset is initiated.
Clock setting. Step through the items by
pressing the SELECT switch. To adjust an
item press RESET.

Press the RESET switch to finish and store


the new settings.

24-32-17

Page-4
Feb 12/02

COMPONENT MAINTENANCE MANUAL


XL500/5 500H EMERGENCY BATTERY SYSTEM
100-0206-01/-03

B.

Fault/Events Logged in History


Fault and Events shown in Table 4 will be logged into History. Date and time will also
be logged for each item. The XL500/5 500H/5 displays SHUTDOWN when a fault has
occurred.
Table 4 . XL500/5 500H Fault/Event Description
Fault/
Event

Displayed
Fault/Event
ID
5 V Convtr

Fault

Event

Bat O.C.
Chg Ctrl
CPU
OverTemp
WatchDog
Post ROM
Post RAM
Post RTC
Post EE
Post Ana
Post Htr
B.TempHi
Cdt Mode
Bulk
Trickle
Bus Low
Pause
Shutdown
Chg Temp
Cut Off
L.Tst OK
L.TstLow
NoEvents
Power Dn
Power Up

R.Tst OK
R.TstLow

Fault/Event Description

Auxiliary +5 VDC Converter not within +2 to +6.5 VDC


window.
Battery current is more than 15A.
Charger converter watchdog timed out.
CPU Fault.
Internal safety shut down at 80C.
Failure of the microcontroller watchdog.
ROM checksum test failure.
RAM test failure.
Real time clock test failure.
EEPROM test failure.
Analog loopback test failure.
Heater test failure.
Pause in charge when a battery reaches 71C, resets at
70C.

Charger changed to one of the listed states.

Pause in battery converter operation at 75C, resets at 70C.


Battery cut-off voltage less than 18 VDC.
Front panel initiated level test 65%.
Front panel initiated level test < 65%.
No faults or events have been logged.
Battery system in standby mode.
Battery system powered up from standby, by application of
load, input power, test inputs, or user initiated System/CPU
restart.
Remote initiated level test 65%.
Remote initiated level test < 65%, or system fault has
occurred.

24-32-17

Page-5
Feb 12/02

COMPONENT MAINTENANCE MANUAL


XL500/5 500H EMERGENCY BATTERY SYSTEM
100-0206-01/-03

C.

Remote Fault Outputs


Latched faults that will cause a fault indication (J1-pin 6) during a remote test are shown
in Table 5.
Table 5. Remote Fault Outputs
Fault Name
Micro Fault
Battery Over-Current
Fault
Charger Fault
Temp Fault
CPUDET Fault

Fault Condition
Hardware fault in the processor.
Battery current more than 15A detected.
Watchdog timer has determined that the processor is
not controlling battery charging.
The XL500/5 500H internal temperature is greater than
80C.
Microcontroller detected fault.

24-32-17

Page-6
Feb 12/02

COMPONENT MAINTENANCE MANUAL


XL500/5 500H EMERGENCY BATTERY SYSTEM
100-0206-01/-03

Figure 3. XL500/5 to Aircraft Electrical Interface

24-32-17

Page-7
Jun 25/04

COMPONENT MAINTENANCE MANUAL


XL500/5 500H EMERGENCY BATTERY SYSTEM
100-0206-01/-03

Figure 4. XL500H to Aircraft Electrical Interface

24-32-17

Page-8
Jun 25/04

COMPONENT MAINTENANCE MANUAL


XL500/5 500H EMERGENCY BATTERY SYSTEM
100-0206-01/-03
Table 6. XL 500/5 J1 Connector Pin-Outs
J1 - Pin

Function

Description

RESERVED

Reserved

REMOTE TEST SWITCH INPUT

The remote TEST SWITCH INPUT signal held


low from the cockpit initiates a BITE TEST and
battery Level Test.

SPARE

SPARE

SPARE

SPARE

+5 VDC CONVERTER OUTPUT

Provides an emergency lighting output.

TEST LAMP fault output discrete

Discrete fault output to the flight deck indicates


a fault as shown in Table 5 or a failed Battery
Level Test.

POWER GROUND

Provides a return path for both the aircraft


+28 VDC input and the +24/28 VDC output.

SPARE

SPARE

CONVERTER +28 VDC Input

+28 VDC Input to +5 VDC Converter Output

10

+28 VDC INPUT

The +28 VDC INPUT is connected to the


aircrafts 28 VDC protected aircraft bus source.

11

+24/28 VDC OUTPUT

The +24/28 VDC OUTPUT is connected to the


28 VDC protected aircraft bus through pin 11.

12

POWER GROUND

Provides a return path for both the aircraft


+28 VDC input and the +24/28 VDC output.

13

CONVERTER +28 VDC Input

+28 VDC Input to +5 VDC Converter Output

Notes:

Interface connector is: DPXB-13-34P-0101


Mating connector is: DPXB-13-33S-0001.

24-32-17

Page-9
Feb 12/02

COMPONENT MAINTENANCE MANUAL


XL500/5 500H EMERGENCY BATTERY SYSTEM
100-0206-01/-03

Table 7. XL 500H J1 Connector Pin-Outs


J1 - Pin

Function

Description

RESERVED

Reserved

REMOTE TEST SWITCH INPUT

The remote TEST SWITCH INPUT signal held


low from the cockpit initiates a BITE TEST and
battery Level Test.

BATTERY POWER AVAILABLE


OUTPUT

Discrete line that indicates whether input bus


or internal batteries are switched to the output.

BATTERY POWER ON/OFF


OUTPUT

Discrete line that allows manual inhibiting of


the internal batteries.

+5 VDC CONVERTER OUTPUT

Provides an emergency lighting output.

TEST LAMP fault output discrete

Discrete fault output to the flight deck indicates


a fault as shown in Table 5 or a failed Battery
Level Test.

POWER GROUND

Provides a return path for both the aircraft


+28 VDC input and the +24/28 VDC output.

CONTINUOUS FAULT OUTPUT

Discrete output that continuously monitors the


unit for latching faults.

CONVERTER +28 VDC Input

+28 VDC Input to +5 VDC Converter Output

10

+28 VDC INPUT

The +28 VDC INPUT is connected to the


aircrafts 28 VDC protected aircraft bus source.

11

+24/28 VDC OUTPUT

The +24/28 VDC OUTPUT is connected to the


28 VDC protected aircraft bus through pin 11.

12

POWER GROUND

Provides a return path for both the aircraft


+28 VDC input and the +24/28 VDC output.

13

CONVERTER +28 VDC Input

+28 VDC Input to +5 VDC Converter Output

Notes:

Interface connector is: DPXB-13-34P-0101


Mating connector is: DPXB-13-33S-0001.

24-32-17

Page-10
Feb 12/02

COMPONENT MAINTENANCE MANUAL


XL500/5 500H EMERGENCY BATTERY SYSTEM
100-0206-01/-03

D.

Block Diagram Description


The following paragraphs describe the functional elements of the block diagrams shown
in Figure 5 and
(1)

EMI/Transient Filter
The unit is protected from electro-magnetic interference and transient events
on its input bus by the transient filter.

(2)

Battery Pack (Hawker 5 Ah Cells)


The XL500/5 500H contains two 5 Ah Hawker Cyclon lead acid battery packs
with a temperature sensor located in the assembly. The battery packs are
configured in a series combination to yield a 24 VDC, 5 Ah battery.

(3)

Battery Heater
In order to maintain optimum battery performance, two 35-Watt heaters warm
the batteries if the battery compartment temperature drops below 30C (86F).
The heaters will raise the battery temperature sufficiently within 20 minutes,
under cold soak conditions, to recover 90 per cent of the batterys capacity.
The heaters turns off when the battery temperature reaches 30C again. The
battery heaters are also used as the battery load during a BATTERY LEVEL
TEST.
The integrity of the heater is checked by measuring the heater current and
voltage. If the calculated heater resistance is more than 13 ohms, a fault is
registered in the History Log.

(4)

FET Switch
Under normal operating conditions, a steering diode applies the aircraft
28 VDC bus to the output load. If the input bus drops below 21.7 VDC, the
battery automatically supplies the output load via a BILATERAL FET
described in the next paragraph.

Several devices protect the battery system from over-discharge, over-current, and
over-temperature conditions.
(5)

BILATERAL FET {Battery Cut-off Switch}


A solid state battery Cut-Off Switch is incorporated in the battery output line to
prevent deep discharge of the battery. This FET switch removes the load from
the battery when the voltage drops below 18 VDC for more than 60 seconds.

24-32-17

Page-11
Jun 25/04

COMPONENT MAINTENANCE MANUAL


XL500/5 500H EMERGENCY BATTERY SYSTEM
100-0206-01/-03

18-36 VDC
(28 VDC)
Nominal

10

Power FET
Solid State
S/W

EMI/
Transient
Filter

Current
Sense

Power FET
Solid State
S/W

VICOR VI-J00
DC/DC Converter
Battery
Charger

12

24/28 VDC Output

Current
Sense

11

Analog Control

Power FET
Solid State
S/W

Current Sense
Output Cutoff

Batt O/Volt Cutoff

Reserved

Reserved

Spare

Spare

5 VDC
Power
Supply

Over Voltage Sense

Charger Control
Bus Bulk Control
Heater Control

Power FET
Solid State
S/W

D/A
Converter

Real
Tim e
Clock

Voltage Control

Current
Sense
Power FET
Solid State
S/W

EEPROM
Event
History

Level Test Control

A/D Converter

Processor
68HC705

Fault

Battery

Voltage Sense

(12) Hawker (Gates) 5AH


Cells

Heater

Current Sense

Battery/Heater
Tem p Sense

Alphanumeric LED
Display

Current Sense
5

Voltage Sense

+5 VDC Out

Reset
Switch

Conv +28 VDC In


13

2.25 to 5.5 VDC


Adjustable
Converter

Temp Sense

BIT

Voltage Sense
M enu
Switch

Select
Switch

UNIT FRONT
PANEL
Cockpit Test S/W Input
2

Figure 5. XL500/5 Functional Block Diagram

24-32-17

Page-12
Feb 12/02

COMPONENT MAINTENANCE MANUAL


XL500/5 500H EMERGENCY BATTERY SYSTEM
100-0206-01/-03

18-36 VDC
(28 VDC)
Nominal

J1
10

Power FET
Solid State
S/W
J1

EMI/
Transient
Filter

Current
Sense

Power FET
Solid State
S/W

VICOR VI-J00
DC/DC Converter
Battery
Charger

12

11

Analog Control

Power FET
Solid State
S/W

Current Sense
Output Cutoff
3

24/28 VDC Output

Current
Sense

Batt O/Volt Cutoff


5 VDC
Power
Supply

Reserved

Batt Power Available

Over Voltage Sense

Charger Control
Bus Bulk Control
Heater Control

Power FET
Solid State
S/W

D/A
Converter

Real
Tim e
Clock

Voltage Control

Current
Sense
Power FET
Solid State
S/W

A/D Converter

Battery
(12) Hawker (Gates) 5AH
Cells

Heater

EEPROM
Event
History

Level Test Control

Battery/Heater
Temp Sense

Processor
68HC705

8
Continuous Fault
6

Voltage Sense

Remote Test Fault

Current Sense

Alphanumeric LED
Display

Current Sense
5

Voltage Sense

+5 VDC Out

Reset
Switch

Conv +28 VDC In


13

2.25 to 5.5 VDC


Adjustable
Converter

Tem p Sense

BIT

Voltage Sense
M enu
Switch

Select
Switch

9
4
2

Power ON/OFF Input


Cockpit Test S/W Input

SOLID STATE
SW ITCH

UNIT FRONT
PANEL

Figure 6.XL500H Functional Block Diagram

24-32-17

Page -13
Feb 12/02

COMPONENT MAINTENANCE MANUAL


XL500/5 500H EMERGENCY BATTERY SYSTEM
100-0206-01/-03

(6)

CAUTION:

Immediately following an emergency power total


discharge, 28 VDC power must be provided to the
XL500/5 500H to recharge the battery. The batteries do
not require a cool down period prior to recharging (as
nickel-cadmium battery technology may require) after
usage. Failure to heed this Caution may result in
sulfating damage to the battery.

NOTE:

If the XL500/5 500H battery will not take a charge after


being left discharged, the batteries may have become
sulfated. The indication of sulfating is that the battery
will not accept a full charge. Securaplane does not
warranty damage due to sulfating.

Current Sense
The electronic current sense circuit cuts off the battery from the output pin
during an over-current fault on the +24/28 VDC output line. The current
limit threshold is time dependent, to facilitate large inrush peaks such as
might be encountered when powering incandescent lights. The time delay
for shutdown is a function of the current. Refer to Table 8 for shutdown
delays. Reset is initiated by pressing the front panel RESET switch.
Table 8. Current Limit Thresholds

(7)

Current

Shutdown Delay

50A

0.5 Seconds

40A

5.0 Seconds

30A

10.0 Seconds

20A

20.0 Seconds

15A

Indefinitely

Battery Power Available (J1-3) (XL500H ONLY)


Each unit contains a discrete line that indicates whether the input bus or
internal batteries are switched to the output. If the input bus does not fall
below 21.7 VDC, internal batteries are isolated from the output and the
discrete line is Ground. When the input bus falls below 21.7 VDC, internal
batteries are connected to the output and the discrete line goes to an open
state.

24-32-17

Page -14
Jun 25/04

COMPONENT MAINTENANCE MANUAL


XL500/5 500H EMERGENCY BATTERY SYSTEM
100-0206-01/-03

(8)

Battery Power On/Off Input (J1-4) (XL500H ONLY)


Each unit contains a discrete input line allowing manual inhibiting of the
XL500H internal batteries. With the discrete line connected to Ground
(1.0 VDC maximum input voltage), the internal batteries are cutoff and
input bus power is routed to the output. An open state (1Meg minimum
resistance to Ground) at the discrete line allows normal operation of the
unit (Bus or batteries).

(9)

Battery Temperature Sensors


Two thermistor temperature sensors monitor battery temperatures. The
internal level test load temperature is sensed by PTC thermistors to
ensure that the test load will be removed from the battery if either
thermistor temperature is +71C. The load will be reconnected when both
battery temperatures are below 70C.

(10)

Continuous Fault Output (J1-8) (XL500H ONLY)


A discrete fault output is provided that continuously monitors the XL500H
for latching system faults. This output is independent of battery state and
provides a Ground (5 maximum resistance) during normal conditions.
In the event of a latching system fault this output will automatically latch in
an open state (10meg minimum resistance). Once the fault condition is
corrected, pressing the front panel Reset switch will return this output to its
normal Ground state. The output is short circuit protected and is disabled
for currents more than of 1.5A. This function is under microprocessor
control.

(11)

Level Test Function


On command from the front panel LEVEL TEST function, an internal test
load (heater) is placed across the battery, and the battery is disconnected
from the output terminals, for 5 seconds to check the battery energy level.
The LED display indicates TEST OK for an energy level above 65 per cent
(provided no latching faults, as shown in Table 5, exist) and TEST LOW
for an energy level below 65 per cent.
It is recommended that the battery capacity test be performed at least
once a year.
The internal load is thermally protected and will not allow a level test if the
load temperature exceeds 80C. As a result, level test can be performed
as many as three times in a row before time must be allowed for the load
to cool down.

24-32-17

Page -15
Jun 25/04

COMPONENT MAINTENANCE MANUAL


XL500/5 500H EMERGENCY BATTERY SYSTEM
100-0206-01/-03

The battery energy level test is more accurate when the


XL500/5 500H has been off-of-charge for at least 2 hours
(preferably 8-24 hours). Test accuracy increases with elapsed
time off charge owing to the voltage level-settling characteristic
of sealed lead batteries that have been charged above their
normal 2 volt per cell voltage.

NOTE:

(12)

Remote TEST
The remote test interface consists of a cockpit mounted switch and a
remote test lamp. When the remote test switch is closed it causes the
hardware controlled output fault register to be reviewed for stored faults. If
a fault does not exist, and the battery energy is above 65% the lamp will
illuminate. The remote test switch must be held closed and the remote
Test lamp illuminated for at least 5 seconds to verify battery energy is
above 65%.

(13)

Power Down Mode


The XL500/5 500H is equipped with a power down mode that reduces the
internal power consumption during extended periods of non-use. The
XL500/5 500H remains fully powered after removal of aircraft power. After
one hour of inactivity, including no aircraft bus present, no loads present,
and no test activity, the XL500/5 500H reverts to the power down mode.
Transitions to and from power down mode are recorded in the History Log.

(14)

Power-On Self-Test
Immediately upon power on, the XL500/5 500H steps through the
following Power On Self Tests (POST):
(1)

PROM check sum test **

(2)

RAM check **

(3)

EEPROM check

(4)

Real-time clock check

(5)

A/D-D/A wrap around test

(6)

Heater check

If any of the POST tests fail, the event is recorded in the History Log. ** If
any of these tests fail, the charger will be shutdown.

24-32-17

Page -16
Feb 12/02

COMPONENT MAINTENANCE MANUAL


XL500/5 500H EMERGENCY BATTERY SYSTEM
100-0206-01/-03

(15)

Charge Converter Temperature


The charge converter temperature is measured by a temperature sensor.
The charge converter is turned off (or paused) when the temperature
reaches 65C and cycled back on again at a temperature of 60C. A
charger converter over-temperature event is recorded in the History Log.

(16)

Charger Watchdog
A one minute charger watch dog function monitors the microcontroller
enhanced battery charging. If for any reason the microcontroller is not
commanding battery charge, the watchdog times out and applies the
aircraft input bus power to charge the battery in the BULK power mode. A
charger fault is recorded in the History Log and a fault is present at the
fault output discrete.

(17)

Input Bus Low


When the input bus voltage is below 21.7 VDC, the charger is turned off
and an event is recorded in the History Log. This feature ensures that no
charging takes place from the aircraft battery.

(18)

CPU Monitor
The microcontroller contains software code to check the operational status
of the running software. A detectable software failure causes a CPU fault
to be recorded in the History Log. The microcontroller also monitors the
operational status of a number of hardware circuits. A detected hardware
failure or problem is recorded in the History Log. A hardware circuit is
used to verify the operation of the microcontroller. If the circuit detects a
failure of the microcontroller, an attempt will be made to log a WatchDog
fault in the History Log.

(19)

Input Power Monitor


Both input voltage and input current from the aircraft bus is displayed
when requested through the front panel.

(20)

Auxiliary +5 VDC Converter


The Auxiliary +5VDC Converter output voltage is monitored and the
reading is output to the display when requested. The voltage is adjustable
using the front panel momentary contact switches. The MENU switch is
used to increment the voltage up to +5.5 VDC and the SELECT switch is
used to decrement the voltage down to +2.5 VDC. The output current of
the auxiliary +5VDC converter is internally limited to less than eight amps.
An out of range measurement is made on the +5 VDC converter and a
fault is registered in the History Log if the output voltage is outside of a
+2 VDC to +6.5 VDC window.

24-32-17

Page -17
Jun 25/04

COMPONENT MAINTENANCE MANUAL


XL500/5 500H EMERGENCY BATTERY SYSTEM
100-0206-01/-03

(21)

XL500/5 500H Display Panel


(1.)

LED DISPLAY
The XL500/5 500H contains an eight-character, 5X7 dot-matrix
alpha-numeric LED display that indicates status information. The
display is mounted on the front panel.

(2.)

Front Panel Switches


Three momentary contact switches are located adjacent to the
LED display. The function of each switch listed below:

MENU Switch
When the MENU switch is depressed the display scrolls through
the items listed in Table 3. This switch is also used to increase
the +5V converter voltage in the +5 V adjust mode.

SELECT Switch
When a particular menu item is desired, pressing the SELECT
switch scrolls through the items listed in Table 3. This switch is
also used to decrease the +5 V converter voltage in the +5 V
adjust mode.

RESET Switch
Initiates the battery test with the associated menu item.
Sets the clock.
Initiates the +5 V converter adjust mode and stores the current
setting along with the associated menu item.
Initiates a System/CPU restart in conjunction with the associated
menu item.
Resets all latched faults including an over-current fault that will
restore battery voltage to the output connector regardless of the
currently selected menu item.

24-32-17

Page -18
Feb 12/02

COMPONENT MAINTENANCE MANUAL


XL500/5 500H EMERGENCY BATTERY SYSTEM
100-0206-01/-03

E.

Battery Capacity
The XL500/5 500H battery is nominally rated at 3.5 amperes for 60 minutes or 5
amperes for 40 minutes. Figure 7 shows the output curve for a constant 5.0 ampere
discharge of a fresh battery set. A battery set is considered at the end of its service life
when it is unable to drive a 5 ampere load for more than 40 minutes.

Figure 7. Five Amp Constant Current Discharge Curve

24-32-17

Page -19
Jun 25/04

COMPONENT MAINTENANCE MANUAL


XL500/5 500H EMERGENCY BATTERY SYSTEM
100-0206-01/-03

3. CHARGE METHOD
The emergency battery charger maintains the internal batteries at their full capacity while
minimizing temperature fatigue cycles. Charge control is automatic and turns on as soon as
aircraft power is available. The batteries are charged directly from the aircraft 28 VDC bus.
Charge current is limited to 8 amperes. Charge time is typically 2.0 hours from full discharge to
full charge.
The charge method consists of (3) three modes of operation; Conditioning mode, Bulk mode and
Trickle mode. The charge algorithm is shown in Table 1. The Temperature Compensated Trickle
Charge is shown in Figure 8.

65
55
45

Temperature (C)

35
25
15
5
-5
-15
-25
-35
-45
-55
26

27

28

29

30

31

Charge Voltage

Figure 8. Temperature Compensated Trickle Charge

24-32-17

Page-20
Feb 12/02

COMPONENT MAINTENANCE MANUAL


XL500/5 500H EMERGENCY BATTERY SYSTEM
100-0206-01/-03
Table 9. Battery Charger Algorithm
Battery Condition

Initial battery condition


determined by constant
potential applied to
battery.

Charge Current
Source and Mode

End of Step Criteria

Conditioning Mode
Charge from charge converter,
constant potential source of 30.5
VDC. Charge current measured at
1 minute intervals.

Bulk Charge Mode

End of conditioning mode.

a) 10A if battery
temperature 30C
OR
b) 7.5A if battery
temperature <30C
Charger current is less than
2.0 Amps.

Charge from A/C 28VDC bus


End of bulk charge mode
from aircraft bus.

When the input line


current is reduced to:

Bulk Charge Mode

When charge current is less


than 300 mA.

Charge from charge converter


at a constant potential of 30.5 VDC.
With a current limit of 4.5 Amps.
Trickle Charge Mode

End of bulk mode.

Temperature compensated trickle


charge from charge converter.

Charger remains in trickle


mode as long as aircraft 28
VDC is applied

4. General Protection
A.

Safety Thermal Switch


The internal temperature of the XL500/5 XL500H is measured with a thermal switch set
to trip at 80C. The thermal switch is a redundant safety feature that ensures the
shutdown of both the charger and the heater in the event an unsafe temperature exists.
An over-temperature event is recorded in the History Log and a fault is present at the
fault output discrete.

B.

Over-Voltage Protection
Proper recharge of sealed lead acid batteries requires returning 110 percent of the
energy used during discharge. This approach to charging overcomes the problem of the
batteries cycling-down over time. The XL500/5 500H charge algorithm causes the
battery terminal voltage to rise to 30.5 VDC in order to return this excess energy to the
batteries. Over-voltage protection is included to ensure that during charging, the output
voltage will not exceed 29 VDC.

24-32-17

Page-21
Feb 12/02

COMPONENT MAINTENANCE MANUAL


XL500/5 500H EMERGENCY BATTERY SYSTEM
100-0206-01/-03

TESTING AND FAULT ISOLATION


1. Battery Energy Test
On command from the front panel LEVEL TEST function, an internal test load (two 35 Watt
heaters) is placed across the battery for 5 seconds to check its energy level.
NOTE:

The battery energy level test is more accurate when the


XL500/5 500H has been off-of-charge for at least 2 hours
(preferably 8-24 hours). Test accuracy increases with elapsed
time off charge owing to the voltage level-settling characteristic
of sealed lead batteries that have been charged above their
normal 2 volt per cell voltage.

It is recommended that the battery level test be performed at least once per year.
The internal load is thermally protected and will not allow a level test if the load temperature
exceeds 80C. As a result, level test can be performed as many as three times in a row before
time must be allowed for the load to cool down.
The effect of ambient temperature on the batterys energy content is included in the indication.
For example, a fully charged battery sitting in a minus 20C ambient temperature, loses 20-25%
energy due to the cold temperature.

2. Shop Level Charging


A.

TEST EQUIPMENT FOR CHARGING


A)

Bench Charge Harness- This can be a simple two wire (use wire size (AWG 16
or 18) arrangement with female mating pins to connect to the XL500/5 500H
connector pins.

B)

A 28 VDC power supply capable of 15 amperes output.

C)

An ammeter capable of indicating 15 amperes. .

D)

A digital 1% VOM.

24-32-17

101
Jun 03/09

COMPONENT MAINTENANCE MANUAL


XL500/5 500H EMERGENCY BATTERY SYSTEM
100-0206-01/-03

B.

CHARGE PROCEDURE
A)

Connect the 2-wire harness to J1-10 (+28 VDC) and J1-7 (GND).

B)

Connect the other ends of the wires to the 28 VDC supply, ensuring correct
polarity. Do not turn the supply on at this time. Connect an ammeter in series
with the +28 VDC lead (15 ampere capability).

C)

Adjust the power supply to 28.5 +/- 5 VDC.

D)

Turn power supply on, note the input current. A low battery will cause up to
15 amps to flow for a few seconds, then settle down at 10 amps or below. The
current will then slowly decrease to less than 300mA. Allow battery to charge
until one of two events occur; 1) The charge status (from the front panel display)
indicates Trickle Charge, or 2) The Input bus current falls below 300mA.

E)

At the conclusion of the charging period, allow the XL500/5 500H to sit
uncharged for at least 8-24 hours.

F)

After the 8-24 hours, perform a Level Test (Table 3 and page 2-10). The
following section outlines a more accurate test of battery energy.

3. SHOP LEVEL BATTERY CAPACITY TEST


A.

EQUIPMENT REQUIRED
A)

A 4.8 ohm, 150 watt power resistor or a 5 ampere constant current load bank
capable of dissipating up to 150 watts.

NOTE: Securaplane uses a Kikasusi PL2302W load bank capable of


constant current, constant power, or constant resistance.

24-32-17

102
Feb 12/02

COMPONENT MAINTENANCE MANUAL


XL500/5 500H EMERGENCY BATTERY SYSTEM
100-0206-01/-03

B.

TEST PROCEDURE
A)

Remove 28VDC input for the duration of the test.

B)

Connect the load between XL500/5 500H connector J1-11 (+24/28 VDC output)
and J1-7 (GND).

C)

Connect a digital voltmeter across the load.

D)

Have a stop watch available that reads in elapsed time up to 1 hour and 20
minutes.

E)

Begin timing.

F)

Allow the XL500/5 500H to discharge until the battery output is cut off.

G)

An elapsed time of 40 minutes is the standard for a new battery.

H)

If a new unit does not pass the 40-minute test, the unit should be returned to
Securaplane for analysis and repair.

CAUTION:

Immediately following the discharge test, recharge the battery


following the procedures outlined in the Shop Level Charging
Section page 101. Perform this procedure even if the unit did
not pass the required time test. Failure to heed this CAUTION
will result in sulfating damage to the battery.

24-32-17

103
Feb 12/02

COMPONENT MAINTENANCE MANUAL


XL500/5 500H EMERGENCY BATTERY SYSTEM
100-0206-01/-03

4. On-Aircraft Fault Isolation Procedures


Use Figure 101 to isolate faults while the XL500/5 500H is on the aircraft.
Devices
connected
to output not
on

UNIT
INSTALLED?

INSTALL
UNIT

Y
M EASURE
VOLTAGE
AT J1-11

VOLTAGE AT J1-11
AT LEAST 20VDC?

DEVICES
ON?

CHECK FOR
OUTPUT W IRING
SHORT

SHORT ON
OUTPUT
W IRING?

END

REMOVE
OUTPUT
W IRING
SHORT AND
PRESS
RESET
SW ITCH

N
Y

CONNECTED
TO A/C
HARNESS?

CONNECT
TO A/C
HARNESS

N
Y

A/C HARNESS
W IRED
CORRECTLY?

CORRECT
HARNESS
ERRORS

DEVICES
ON?

Y
PRESS
RESET
SW ITCH

DEVICES
ON?

RETURN UNIT TO
SECURAPLANE

Figure 101. On Aircraft Fault Isolation Flowchart

24-32-17

104
Feb 12/02

COMPONENT MAINTENANCE MANUAL


XL500/5 500H EMERGENCY BATTERY SYSTEM
100-0206-01/-03

5. Off-Aircraft Fault Isolation Procedures


Use Table 101 to troubleshoot basic resistance to the battery.
1. Remove the XL500/5 500H from the aircraft.
2. Using an ohmmeter, measure the following resistances with the polarity
and scales indicated in Table 101.
3. If the resistances are not correct, return the unit to Securaplane for repair.
Table 101. J1 Resistance Readings
Negative
Probe

Positive
Probe

Meter
Reading

Chassis (500/5-500H)

J1-2

>2Meg

Chassis (500/5-500H)

J1-5

>2Meg

Chassis (500/5-500H)

J1-6

>2Meg

Chassis (500/5-500H)

J1-7

>2Meg

Chassis (500/5-500H)

J1-9

>2Meg

Chassis (500/5-500H)

J1-10

>2Meg

Chassis (500/5-500H)

J1-11

>2Meg

Chassis (500/5-500H)

J1-12

>2Meg

Chassis (500/5-500H)

J1-13

>2Meg

Chassis (500 H Only)

J1-3

>2Meg

Chassis (500 H Only

J1-4

>2Meg

4. Connect the negative lead of the ohmmeter to J1-12 and the positive lead to J1-8 and verify
resistance is 100.

24-32-17

105
Feb 12/02

COMPONENT MAINTENANCE MANUAL


XL500/5 500H EMERGENCY BATTERY SYSTEM
100-0206-01/-03

MAINTENANCE PRACTICES
1. Battery Testing Interval (Required)
Run the Battery Energy Level Test, using the LEVEL TEST function at least once every year.
Refer to page 101.

2. Recommended Battery Replacement


The manufacturer, Hawker Energy Products states that a properly- maintained sealed leadacid battery in a non-hostile environment can live for up to eight years in a total stand-by
(float) application. A total float is when the battery is sitting 24 hours per day with a charge
voltage applied similar to a computer back-up application. Since an airplane is not totally a
float application nor a totally cycling application, Securaplane considers four years to be an
average life span for the XL500/5 500H battery.
It is in the Customers best interest, to replace both battery packs (two in each XL500/5 500H)
in the 4th year as a PREVENTATIVE MAINTENANCE activity, and thus prevent an
unscheduled maintenance event. In an effort to promote scheduled replacement,
Securaplane has instituted an appealing battery replacement price (call for quote).

3. Material Safety Data Sheets


The following pages present the MSDS for the Hawker Energy Sealed Lead Battery.

24-32-17

201
Feb 12/02

COMPONENT MAINTENANCE MANUAL


XL500/5 500H EMERGENCY BATTERY SYSTEM
100-0206-01/-03

24-32-17

202
Feb 12/02

COMPONENT MAINTENANCE MANUAL


XL500/5 500H EMERGENCY BATTERY SYSTEM
100-0206-01/-03

24-32-17

203
Feb 12/02

COMPONENT MAINTENANCE MANUAL


XL500/5 500H EMERGENCY BATTERY SYSTEM
100-0206-01/-03

DISASSEMBLY
Not applicable.

24-32-17

301
Feb 12/02

COMPONENT MAINTENANCE MANUAL


XL500/5 500H EMERGENCY BATTERY SYSTEM
100-0206-01/-03

CLEANING
1. Introduction
This section contains general procedures recommended by Securaplane to clean the XL500/5
500H Emergency Battery system. There is no disassembly required to clean the unit.
WARNING: Before the materials called out in this publication are used,
know the handling, storage and disposal precautions
recommended by the manufacturer or supplier. Failure to
heed the manufacturers or suppliers recommendations can
result in personal injury or disease.
CAUTION: These procedures must be done at a static-free workstation in
order to prevent damage to electrostatic sensitive
components.
CAUTION: This unit contains assemblies that are susceptible to damage
from incorrect handling. Do not drop or hit the unit during
these procedures.
CAUTION: These procedures must be done in a clean environment in
order to prevent damage to mechanical components.

24-32-17

401
Feb 12/02

COMPONENT MAINTENANCE MANUAL


XL500/5 500H EMERGENCY BATTERY SYSTEM
100-0206-01/-03

2. Equipment and Materials


Table 401 presents the required equipment and materials. Equivalent equipment/material can be
used.
Table 401. Cleaning Equipment and Materials
Equipment/Materials

Manufacturer

Brush (soft bristle fibers)

Commercially available

Cloth

Commercially available

Isopropyl alcohol
(Federal Specification TT-I-735)

Commercially available

Methyl-ethyl-ketone (MEK)
(Federal Specification TT-M-261)

Commercially available

Solvent
(Micro Care Proclean)
(with solvent miser grip, ESD safe
brush, in agreement with MIL 2000)

Micro Care Chemical Corp.,


34 Ronzo Rd,
Bristol, CT 06010

3. General Cleaning Practices


A.

Each part must be cleaned with the procedures referred to in this section or the equivalent
procedures used by an approved overhaul facility. Solutions specified must be made with
the instructions in this manual or to the instructions supplied by the product manufacturer.

B.

These procedures agree with good shop procedures as used by the Securaplane facility.
Clean parts are important to satisfactory operation.

C.

Use clean, dry, filtered, compressed air at a maximum of 20 psig (138 kPa) to dry parts.

24-32-17

402
Feb 12/02

COMPONENT MAINTENANCE MANUAL


XL500/5 500H EMERGENCY BATTERY SYSTEM
100-0206-01/-03

4. General Cleaning Procedures


WARNING:

A.

Clean parts in an area open to the air, with good light, and
sufficient safety and fire prevention equipment.

External Cleaning
NOTE:

Cleaning shall be limited to external cleaning only.

WARNING:

Use appropriate personal protection. This chemical/solution


can cause skin, eye, and lung damage. Danger and handling
precautions for each chemical is different.

(1)

Clean the outside surfaces of the unit with a clean lint-free cloth moistened with
an approved solvent (Micro Care Proclean, isopropyl alcohol or MEK).

(2)

Scrape off corrosion and clean the connector with a soft bristle brush lightly
moistened with the approved solvent (Micro Care Proclean, isopropyl alcohol or
MEK). Remove solvent residue with a clean, dry lint-free cloth.

(3)

Use methyl-ethyl-ketone (MEK) to remove adhesive from parts.


NOTE:

(4)

Use approved caps, plugs and barrier materials for part storage
after cleaning. Do not use tape, loose plastic, or rags to protect
clean parts.

Install a protective cap on the connector to protect against contamination and


damage.

24-32-17

403
Feb 12/02

COMPONENT MAINTENANCE MANUAL


XL500/5 500H EMERGENCY BATTERY SYSTEM
100-0206-01/-03

CHECK
1. General Check Procedures
A.

Internal Visual Checks


NOTE: Internal visual checks shall only be done at an approved
Securaplane facility.

B.

External Visual Checks


NOTE: These checks are limited to external visual checks only. Refer to
Testing and Fault Isolation section to verify the operational status
of the unit.
(1)

Examine the unit for nicks, cracks, scores, dents, scratches, corrosion,
or broken welds that may affect the units operation.

(2)

Examine the exterior painted surfaces for cracked, chipped, blistered, or


deteriorated paint film.

(3)

Examine identification, information and instruction placards and ensure


they are legible and securely attached.

(4)

Check connector for broken, bent, or loose pins, and ensure it is


mounted correctly.

(5)

Verify LED display mounting integrity and acceptability of appearance.

(6)

Check chassis assembly for loose or missing fasteners.

(7)

Verify the electrical bonding integrity of the mounting plate.

24-32-17

501
Feb 12/02

COMPONENT MAINTENANCE MANUAL


XL500/5 500H EMERGENCY BATTERY SYSTEM
100-0206-01/-03

REPAIR
1. Introduction
Refer to Testing and Fault Isolation section to determine the operational status of the unit.
NOTE: Owing to the level of disassembly required and the specialized
repair techniques involved; repair of an inoperative XL500/5
500H, during the warranty period, shall only be accomplished at a
Securaplane approved repair facility.

24-32-17

601
Feb 12/02

COMPONENT MAINTENANCE MANUAL


XL500/5 500H EMERGENCY BATTERY SYSTEM
100-0206-01/-03

ASSEMBLY, STORAGE, AND SHIPPING


1. Storage
This section contains the storage procedures for the XL500/5 500H. Assembly of this unit
is presently restricted to Securaplane facilities.
CAUTION: These procedures must be done at a static-free station in
order to prevent damage to electrostatic sensitive
components.
WARNING: Before the materials called out in this publication are used,
know the handling, storage and disposal precautions
recommended by the manufacturer or supplier. Failure to
obey the manufacturers or suppliers recommendations can
result in personal injury or disease.
CAUTION: These procedures must be done in a clean environment in
order to prevent damage to mechanical components.
CAUTION: This unit contains an assembly that is susceptible to damage
from incorrect handling. Do not drop or hit the unit during
these procedures.

2. Storage Equipment and Materials


Table 701 shows the equipment and materials necessary to prepare the unit for storage or
shipping. Equivalent equipment/materials can be used.
Table 701. Storage Equipment and Materials
Equipment/Materials

Manufacturer

Barrier material

(MIL-B-131B)

Cloth

Commercially available

Dehydrating agent

(MIL-D-21576)

24-32-17

701
Jun 25/04

COMPONENT MAINTENANCE MANUAL


XL500/5 500H EMERGENCY BATTERY SYSTEM
100-0206-01/-03

3. Storage Instructions
A. Introduction
The presence of certain environmental conditions during storage can cause damage to
parts. Some of these conditions are:
Moisture
High temperature (over 125F)(52C)
Fuel or solvents
Fumes that can cause corrosion
Mechanical stresses
Ultraviolet light
Localized electromagnetic fields
NOTE: Refer to Check and Cleaning sections before storing the XL500/5 500H.
B.

C.

D.

Preparing the Unit for Storage or Shipping.


(1)
Clean the external surfaces with a clean, lint-free cloth.
(2)

Put protective a cap on the connector.

(3)

Wrap the unit in barrier paper.

(4)

Place cushions at sharp corners to prevent damage to the barrier material and
pack the container with the dehydrating agent. Enclose the prepared part in the
applicable size barrier material.

Monitoring Storage Conditions.


(1)
Store the unit in an area away from high temperatures, dust, moisture and fumes
that can cause corrosion.
(2)

The recommended storage temperature is 77F (25C).

(3)

Control humidity to prevent moisture contamination of the unit.

Maintaining the Battery Charge During Storage


(1)
While the battery is stored, perform a battery capacity check using the ENERGY
LEVEL TEST function (page 101) at least every 60 days.
(2)

E.

If required, recharge the battery using the Charge procedure on page 102.

Shipping Procedures
(1)
Use the Securaplane shipping box or equivalent.
(2)

Before shipping the unit, call Securaplane (refer to page Intro-2) for a Return
Authorization Number and include that with the unit. Please include a failure
report including aircraft type and serial number.

24-32-17

702
Jun 25/04

COMPONENT MAINTENANCE MANUAL


XL500/5 500H EMERGENCY BATTERY SYSTEM
100-0206-01/-03

FITS AND CLEARANCES

Figure 801. XL500/5 and 500H Outline

24-32-17

801
Jun 25/04

COMPONENT MAINTENANCE MANUAL


XL500/5 500H EMERGENCY BATTERY SYSTEM
100-0206-01/-03

SPECIAL TOOLS, FIXTURES, AND EQUIPMENT


Figure 901 presents a Test Adapter for bench charging the XL500/5. Use wire size AWG
16 or 18 for the harness.

Connector is DPXB-13-33S-0001

Figure 901. XL500/5 J1 Adapter Harness

24-32-17

901
Jun 25/04

COMPONENT MAINTENANCE MANUAL


XL500/5 500H EMERGENCY BATTERY SYSTEM
100-0206-01/-03

ILLUSTRATED PARTS LIST


Not Applicable

24-32-17

1001

Jun 25/04