24-32-17 Cmm Secra Plane Emergency Pack

Revision No. 3Initial Issue: Feb 12/02 Manual Part Number: MM-0036-01 24-32-17 Jun 03/09

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.

COMPONENT MAINTENANCE MANUAL XL500/5 500H EMERGENCY BATTERY SYSTEM

100-0206-01/-03

SWLA-124-32-17 Jun 25/04

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 Securaplane’s published instructions and/or Securaplane’s 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.


100-0206-01/-03

ROR-124-32-17 Jun 03/09

Record Of Revisions

Rev No.

Issue Date

Date Inserted

By

Rev No.

Issue Date

Date Inserted

By

Orig Feb 12/02

A Aug 29/03 B Jun 25/04 3 Jun 03/09

COMPONENT MAINTENANCE MANUAL XL500/5 500H EMERGENCY BATTERY

100-0206-01/-03

RTR-1 24-32-17 Feb 12/02

Record Of Temporary Revisions

TR No.

Page No.

Issue Date

Date Inserted

By

Date Removed

By

Incorporated by Rev No.


100-0206-01/-03

SBL-1 24-32-17 Jun 25/04

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


100-0206-01/-03

LEP -124-32-17 Jun 03/09

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 thru 4

Jun 25/04

Description and Operation

Page 1 thru 2

Jun 03/09

Page 3 Jun 25/04

Page 4 thru 6

Feb 12/02

Page 7 thru 8

Jun 25/04

Page 9 thru 10

Feb 12/02

Page 11 Jun 25/04

SUBJECT 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

Testing and Fault Isolation

101 Jun 03/09

102 thru 105

Feb 12/02

Maintenance Practices

201 thru 203

Feb 12/02

Disassembly 301 Feb 12/02

Cleaning 401 thru 403

Feb 12/02

Check 501 Feb 12/02

Repair 601 Feb 12/02

Assembly Including Storage

701 thru 702

Jun 25/04

Fits and Clearances 801 Jun 25/04

Special Tools Fixtures and Equipment

901 Jun 25/04

Illustrated Parts List 1001 Jun 25/04


100-0206-01/-03

HOC -124-32-17 Jun 03/09

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”.


100-0206-01/-03

TOC -124-32-17 Jun 25/04

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


100-0206-01/-03

TOC -224-32-17 Jun 25/04

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


100-0206-01/-03

Intro-124-32-17 Feb 12/02

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


100-0206-01/-03

Intro-224-32-17Jun 25/04

Securaplane’s 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 30°C 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 CAGE Code: 0TMJ9 10800 Mavinee Drive Tel: 1-520-297-0844 Tucson AZ 85737 USA Fax 1-520-498-4924 Email: [email protected] 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.


100-0206-01/-03

Intro-324-32-17 Jun 25/04

(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


100-0206-01/-03

Intro-424-32-17 Jun 25/04

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 Document Number

Environmental Conditions and Test Procedures For Airborne Equipment

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.


100-0206-01/-03

Page-124-32-17 Jun 03/09

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 Specifications Input:

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 +60°C) (New unit)

Current Maximum 12 Amps peak.

Emergency Lighting Converter

2.5 to 5.5 VDC, 35 Watts Max.

Operating Temp Range Normal operating temperature -55°C to +60°C Cooling: 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)


100-0206-01/-03

Page-224-32-17 Jun 03/09

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


100-0206-01/-03

Page-324-32-17 Jun 25/04

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

Press MENU Until: Press SELECT Until: 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

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

Pause Charge converter has paused

STATUS 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

TEMPS

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)

HISTORY

Hr/Min/Sec Time (GMT)


100-0206-01/-03

Page-424-32-17 Feb 12/02

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

Rev XXXXX Software revision

Mo.Day.Year Current date (GMT)

Hr.Min.Sec. Current time (GMT)

CONFIG

XXXXXX Hrs Operating hrs

Adj 5V?

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).

Sys Rst? When RESET is pressed, a System/CPU reset is initiated.

Year Month Day Hour Min Sec

Clock setting. Step through the items by pressing the SELECT switch. To adjust an item press RESET.

TIME SET

Set? Press the RESET switch to finish and store the new settings.


100-0206-01/-03

Page-524-32-17 Feb 12/02

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

Fault/Event Description

5 V Convtr Auxiliary +5 VDC Converter not within +2 to +6.5 VDC window.

Bat O.C. Battery current is more than 15A. Chg Ctrl Charger converter watchdog timed out. CPU CPU Fault. OverTemp Internal safety shut down at 80°C. WatchDog Failure of the microcontroller watchdog.

Fault

Post ROM Post RAM Post RTC Post EE Post Ana Post Htr

ROM checksum test failure. RAM test failure. Real time clock test failure. EEPROM test failure. Analog loopback test failure. Heater test failure.

B.TempHi Pause in charge when a battery reaches 71°C, resets at 70°C.

Cdt Mode Bulk Trickle Bus Low Pause Shutdown

Charger changed to one of the listed states.

Chg Temp Pause in battery converter operation at 75°C, resets at 70°C. Cut Off Battery cut-off voltage less than 18 VDC. L.Tst OK Front panel initiated level test ≥ 65%. L.TstLow Front panel initiated level test < 65%. NoEvents No faults or events have been logged. Power Dn Battery system in standby mode. Power Up Battery system powered up from standby, by application of

load, input power, test inputs, or user initiated System/CPU restart.

R.Tst OK Remote initiated level test ≥ 65%.

Event

R.TstLow Remote initiated level test < 65%, or system fault has occurred.


100-0206-01/-03

Page-624-32-17 Feb 12/02

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 Fault Condition Micro Fault Hardware fault in the processor. Battery Over-Current Fault

Battery current more than 15A detected.

Charger Fault Watchdog timer has determined that the processor is not controlling battery charging.

Temp Fault The XL500/5 500H internal temperature is greater than 80°C.

CPUDET Fault Microcontroller detected fault.


100-0206-01/-03

Page-724-32-17 Jun 25/04

Figure 3. XL500/5 to Aircraft Electrical Interface


100-0206-01/-03

Page-824-32-17 Jun 25/04

Figure 4. XL500H to Aircraft Electrical Interface


100-0206-01/-03

Page-924-32-17 Feb 12/02

Table 6. XL 500/5 J1 Connector Pin-Outs

J1 - Pin Function Description

1 RESERVED Reserved

2 REMOTE TEST SWITCH INPUT The remote TEST SWITCH INPUT signal held low from the cockpit initiates a BITE TEST and battery Level Test.

3 SPARE SPARE

4 SPARE SPARE

5 +5 VDC CONVERTER OUTPUT Provides an emergency lighting output.

6 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.

7 POWER GROUND Provides a return path for both the aircraft +28 VDC input and the +24/28 VDC output.

8 SPARE SPARE

9 CONVERTER +28 VDC Input +28 VDC Input to +5 VDC Converter Output

10 +28 VDC INPUT The +28 VDC INPUT is connected to the aircraft’s 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.



Notes: Interface connector is: DPXB-13-34P-0101 Mating connector is: DPXB-13-33S-0001.


100-0206-01/-03

Page-1024-32-17 Feb 12/02

Table 7. XL 500H J1 Connector Pin-Outs

J1 - Pin Function Description

1 RESERVED Reserved

2 REMOTE TEST SWITCH INPUT The remote TEST SWITCH INPUT signal held low from the cockpit initiates a BITE TEST and battery Level Test.

3 BATTERY POWER AVAILABLE OUTPUT

Discrete line that indicates whether input bus or internal batteries are switched to the output.

4 BATTERY POWER ON/OFF OUTPUT

Discrete line that allows manual inhibiting of the internal batteries.

5 +5 VDC CONVERTER OUTPUT Provides an emergency lighting output.

6 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.


8 CONTINUOUS FAULT OUTPUT Discrete output that continuously monitors the unit for latching faults.


10 +28 VDC INPUT The +28 VDC INPUT is connected to the aircraft’s 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.



Notes: Interface connector is: DPXB-13-34P-0101 Mating connector is: DPXB-13-33S-0001.


100-0206-01/-03

Page-1124-32-17 Jun 25/04

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 30°C (86°F). The heaters will raise the battery temperature sufficiently within 20 minutes, under cold soak conditions, to recover 90 per cent of the battery’s capacity.

The heaters turns off when the battery temperature reaches 30°C 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.


100-0206-01/-03

Page-12 24-32-17 Feb 12/02

Figure 5. XL500/5 Functional Block Diagram

Processor68HC705

D/AConverter

18-36 VDC(28 VDC)Nominal

Cockpit Test S/W Input

Voltage Control

Heater Control

Fault

Reserved

Spare

Output Cutoff

Battery/HeaterTemp Sense

MenuSwitch

SelectSwitch

ResetSwitch

Alphanumeric LEDDisplay

UNIT FRONTPANEL

Spare

EEPROM

RealTimeClock

+5 VDC Out

Reserved

24/28 VDC Output

Voltage Sense

Voltage Sense

Current Sense

A/D Converter

Temp SenseConv +28 VDC In

Power FETSolid State

S/W

Batt O/Volt Cutoff

Bus Bulk Control

Z

2

CurrentSense

Current Sense

Analog ControlPower FETSolid State

S/W


S/W

5 VDCPowerSupply

10

12

3

4

5

2

7

8

13

9

1Over Voltage Sense

CurrentSense

Battery(12) Hawker (Gates) 5AH

Cells

CurrentSense

EMI/Transient

Filter

Current Sense

Voltage Sense

11

6

BIT


S/W

Heater

Solid StatePower FET

S/WLevel Test Control

2.25 to 5.5 VDCAdjustableConverter

VICOR VI-J00DC/DC Converter

BatteryCharger

Charger Control

EventHistory


100-0206-01/-03

Page -13 24-32-17 Feb 12/02

Figure 6.XL500H Functional Block Diagram

Processor68HC705

D/AConverter

18-36 VDC(28 VDC)Nominal

Cockpit Test S/W Input

Voltage Control

Heater Control

Remote Test Fault

Output Cutoff

Battery/HeaterTemp Sense

MenuSwitch

SelectSwitch

ResetSwitch

Alphanumeric LEDDisplay

UNIT FRONTPANEL

EEPROM

RealTimeClock

+5 VDC Out

Reserved

24/28 VDC Output

Voltage Sense

Voltage Sense

Current Sense

A/D Converter

Temp SenseConv +28 VDC In


S/W

Batt O/Volt Cutoff

Bus Bulk Control

Z

CurrentSense

Current Sense

Analog ControlPower FETSolid State

S/W


S/W

5 VDCPowerSupply

10

12

4

5

2

7

13

9

1Over Voltage Sense

CurrentSense

Battery(12) Hawker (Gates) 5AH

Cells

CurrentSense

EMI/Transient

Filter

Current Sense

Voltage Sense

11

6

BIT


S/W

Heater

Solid StatePower FET

S/WLevel Test Control

2.25 to 5.5 VDCAdjustableConverter

VICOR VI-J00DC/DC Converter

BatteryCharger

Charger Control

EventHistory

SOLID STATESWITCH

8

3

Power ON/OFF Input

Continuous Fault

Batt Power Available

J1 J1


100-0206-01/-03

Page -1424-32-17 Jun 25/04

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.

(6) 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

Current Shutdown Delay

50A 0.5 Seconds

40A 5.0 Seconds

30A 10.0 Seconds

20A 20.0 Seconds

15A Indefinitely

(7) 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.


100-0206-01/-03

Page -1524-32-17 Jun 25/04

(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 (1MegΩ 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 +71°C. The load will be reconnected when both battery temperatures are below 70°C.

(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 Ω maximum resistance) during normal conditions. In the event of a latching system fault this output will automatically latch in an open state (10megΩ 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 80°C. 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.


100-0206-01/-03

Page -1624-32-17 Feb 12/02

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.

(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.


100-0206-01/-03

Page -1724-32-17 Jun 25/04

(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 65°C and cycled back on again at a temperature of 60°C. 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.


100-0206-01/-03

Page -1824-32-17 Feb 12/02

(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.


100-0206-01/-03

Page -1924-32-17 Jun 25/04

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


100-0206-01/-03

Page-2024-32-17 Feb 12/02

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.

-55

-45

-35

-25

-15

-5

5

15

25

35

45

55

65

26 27 28 29 30 31

Charge Voltage

Tem

pera

ture

(°C

)

Figure 8. Temperature Compensated Trickle Charge


100-0206-01/-03

Page-2124-32-17 Feb 12/02

Table 9. Battery Charger Algorithm

Battery Condition Charge Current Source and Mode

End of Step Criteria

Initial battery condition determined by constant potential applied to battery.

Conditioning Mode

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

When the input line current is reduced to:

a) 10A if battery temperature ≥ 30°C OR b) 7.5A if battery temperature <30°C

End of conditioning mode. Bulk Charge Mode

Charge from A/C 28VDC bus

Charger current is less than 2.0 Amps.

End of bulk charge mode from aircraft bus.

Bulk Charge Mode

Charge from charge converter

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

When charge current is less than 300 mA.

End of bulk mode. Trickle Charge 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 80°C. 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.


100-0206-01/-03

101 24-32-17 Jun 03/09

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 80°C. 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 battery’s energy content is included in the indication. For example, a fully charged battery sitting in a minus 20°C 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.


100-0206-01/-03

102 24-32-17 Feb 12/02

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.


100-0206-01/-03

103 24-32-17 Feb 12/02

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.


100-0206-01/-03

104 24-32-17 Feb 12/02

4. On-Aircraft Fault Isolation Procedures

Use Figure 101 to isolate faults while the XL500/5 500H is on the aircraft. Devices

connectedto output not

on

UNITINSTALLED?

INSTALLUNIT

CONNECTEDTO A/C

HARNESS?

DEVICESON?

N

CONNECTTO A/C

HARNESSN

A/C HARNESSWIRED

CORRECTLY?

Y

ENDY

CORRECTHARNESSERRORS

N

Y

MEASUREVOLTAGEAT J1-11

Y

N

VOLTAGE AT J1-11AT LEAST 20VDC?

Y

NSHORT ON

OUTPUTWIRING?

CHECK FOROUTPUT WIRING

SHORT

REMOVEOUTPUTWIRING

SHORT ANDPRESSRESET

SWITCH

Y

N

DEVICESON?

PRESSRESET

SWITCH

Y

RETURN UNIT TOSECURAPLANE

N

DEVICESON?

N

Y Figure 101. On Aircraft Fault Isolation Flowchart


100-0206-01/-03

105 24-32-17 Feb 12/02

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 >2MegΩ Chassis (500/5-500H) J1-5 >2MegΩ Chassis (500/5-500H) J1-6 >2MegΩ Chassis (500/5-500H) J1-7 >2MegΩ Chassis (500/5-500H) J1-9 >2MegΩ Chassis (500/5-500H) J1-10 >2MegΩ Chassis (500/5-500H) J1-11 >2MegΩ Chassis (500/5-500H) J1-12 >2MegΩ Chassis (500/5-500H) J1-13 >2MegΩ Chassis (500 H Only) J1-3 >2MegΩ Chassis (500 H Only J1-4 >2MegΩ

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


100-0206-01/-03

201 24-32-17 Feb 12/02

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 lead-acid 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 Customer’s 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.


100-0206-01/-03

202 24-32-17 Feb 12/02


100-0206-01/-03

203 24-32-17 Feb 12/02


100-0206-01/-03

301 24-32-17 Feb 12/02

DISASSEMBLY

Not applicable.


100-0206-01/-03

401 24-32-17 Feb 12/02

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.


100-0206-01/-03

402 24-32-17 Feb 12/02

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.


100-0206-01/-03

403 24-32-17 Feb 12/02

4. General Cleaning Procedures

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

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

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

damage.


100-0206-01/-03

501 24-32-17 Feb 12/02

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 unit’s 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.


100-0206-01/-03

601 24-32-17 Feb 12/02

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.


100-0206-01/-03

701 24-32-17 Jun 25/04

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)


100-0206-01/-03

702 24-32-17 Jun 25/04

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 125°F)(52°C) • 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. 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.

C. 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 77°F (25°C).

(3) Control humidity to prevent moisture contamination of the unit.

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

E. 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.


100-0206-01/-03

801 24-32-17 Jun 25/04

FITS AND CLEARANCES

Figure 801. XL500/5 and 500H Outline


100-0206-01/-03

901 24-32-17 Jun 25/04

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


100-0206-01/-03

100124-32-17 Jun 25/04

ILLUSTRATED PARTS LIST Not Applicable

Documents

24-32-17 Cmm Secra Plane Emergency Pack