L-3 Communications Avionics Systems

nd
5353 52 Street, S.E.
Grand Rapids, MI 49512-9704 USA
Telephone (616) 949-6600
Fax (616) 977-6898
www.as.l-3com.com Service Letter
Revision History Rev-U (08- 27-2007)
Rev-V (03-13-2009)
Rev-W (04-28-2010)

SL-80 (Rev. Y)
May 2, 2011

NOTE
Revision Y updates the equipment requirements called out in Table 1.

PS-835( ) - Battery Maintenance

Effectivity: Emergency Power Supply - PS-835,

P/N 501-1228-01, -02, -03, -04, -05, -06, -07

References: TP-329 - Maintenance Manual

TP-336 - Installation Manual

Reason: To provide all service facilities and operators with battery care and charging
information.
It is recommended that the aircraft owners and operators check the
condition of batteries every 3 to 6 months as outlined in Periodic
Checks below.

Approval: This Service Letter contains no modification information that revises the
approved configuration and therefore does not require government or other
regulatory agency approval.

Export Compliance: This technical data is controlled under the Export Administration
Regulations (EAR) and may not be exported without proper authorization
by the U.S. Department of Commerce.

Description: Use these procedures to properly maintain and checkout the PS-835. For
additional information consult the referenced manuals. The list below
outlines the procedures found in this document.
1. Battery Testing
2. Battery Storage
3. Battery/Cell Out-Gassing
4. Recommended Test Equipment
5. Charging Procedures
6. Preflight Check (Recommended)
7. Periodic Check (Required 3 to 6 Months)
8. Capacity Testing (Required Annually)
9. Cell Isolation Test

NOTE
Read these procedures thoroughly before proceeding with any testing.

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 Service Letter SL-80 (Rev. Y)

1. Battery Testing
NOTE
Test functions should be performed only with the main buss not providing
power to the unit (OFF or disconnected).
Toggling the unit TEST SWITCH (Figure 1, Item 4) on the power supply front panel bypasses the
thermostatic heat control system. That, in-turn, applies the battery voltage to the internal battery
heater. While in the TEST mode, the batteries are placed under an approximate 7.5Ω load. The
voltage level detection system then analyzes the battery voltage level and causes the appropriate
OUTPUT VOLTAGE MONITOR LED's (Figure 1, Item 2) to illuminate.

NOTE
Ensure Test Switch is returned to normal position and all LED's are extinguished.
NOTE
If the unit TEST SWITCH or Remote Test Switch is depressed at a battery ambient
temperature of 55°C or greater, the unit internal heater will not turn ON to provide a
test load for the unit battery. This is not an ideal condition for battery state of charge
tests and should not be considered valid.
If the remote test is being performed, the Remote Battery-Voltage Level Lamp momentarily
illuminates, provided the internally loaded battery voltage level is greater than 24Vdc.

NOTE
After testing, it is possible that the lamp will not illuminate again until the batteries are
recharged.
The INDIVIDUAL CELL MONITOR LED's (Figure 1, Item 1) function as GO/NO GO indicators
for each of the PS-835 lead acid cells. In case of low output capacity, these LED's indicate which
cell or cells have failed. Any variation of brightness does not indicate cell condition.

Figure 1: PS-835 Access Panel

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 Service Letter SL-80 (Rev. Y)

2. Battery Storage

The PS-835 is designed to use lead acid batteries that require special handling. Batteries should not
be left in a discharged state under any circumstances. Temperature affects the power supply as
follows:

• Low storage temperatures on charged cells lessen the rate of self-discharge, thus increasing
shelf life.
• High storage temperatures, in access of 29°C (85°F), accelerates self-discharge of the cells and
is not recommended.

Refer to Figure 2 for a graphic representation of battery storage characteristics.

Figure 2: Storage Characteristics

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 Service Letter SL-80 (Rev. Y)

3. Battery/Cell Out-Gassing

CAUTION
Some of the types of gasses that may vent from a cell are toxic and should not be
contained in a closed, non-vented area.

CAUTION
Cell/battery corrosion is EVIDENCE of the loss of seal, likely caused by out gassing.
Cells must be replaced when corrosion is APPARENT.
All lead-acid cells and batteries produce gasses during charging. The amount and type of gas
produced depends on state of charge, rate of charge, chemical composition of the electrolyte, and
general condition of the battery. Normally, gasses produced are recombined within the cells to form
oxides and water. Venting occurs when excessive charge rates are placed on the battery or because
of a defective cell(s), which will subject the remaining good cells to excessive charge rates. Venting
may also result from battery abuse or neglect.
If the odor of rotten eggs becomes apparent in the cockpit, pull the aircraft Emergency Power
Supply circuit breaker. The rotten egg odor is evidence that the lead-acid cells vent due to
prolonged high rate overcharging. Although the possibility of toxic levels is extremely remote, the
precaution of pulling the circuit breaker will prevent increased discomfort from the odor.
Venting is an indication that the Power Supply in not controlling the charging process.
If venting occurs, the factory recommends that the Power Supply be removed from the
aircraft, tested according to the procedures listed in the appropriate Maintenance Manual, and
replace the defective cell(s).
NOTE
With proper maintenance and periodic testing, the likelihood of any battery
developing undetected problems is very remote.

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4. Recommended Test Equipment

Table 1 provides a list of recommended equipment needed to test and charge the PS-835.
NOTE
Equivalent substitutes may be used for listed items.

Item Description Manufacturer - Model / Part No.

1 Power Supply Regulated Commercial Power Supply

Minimum Requirements: Maintain 29.5 VDC ±
0.5 at 10 amps 300 watts or greater.
2 Multimeter Commercially Available.
Minimum Requirements: 0 to 35 Vdc 0.1%
accuracy, 10 amps 1% accuracy
3 Stopwatch Commercially Available.
Minimum Requirements: Able to provide minutes
and seconds indications.
4 Load Resistor WireMasters, Inc.
7Ω ±1% 150 watt (minimum), Ceramic wire 136 Alpha Drive,
wrap Franklin, TN 37064. Cage Code: 0FVD7
Tel: 800-635-5342
(Part Number WM910053 …300 watt version)
5 Isolation Diode WireMasters, Inc.
15 Amp, 50 Volt PIV (Part Number WM1N3208)
6 Mating Connector for PS-835 A to D, & G P/N: DPXB-13-33S-0001
7 Mating Connector for PS-835 E and F P/N: DPXB-13-33S-0019
8 Wire, 16 AWG Local Manufacturer
9 BC-815 Battery Charger (Optional - used in Avionics Systems Part No. 501-1321-01
place of DC power supply)

Table 1: List of Equipment and Hardware

5. Charging Procedures

A. Constant-Voltage Charging Method

Locally manufacture a power cable using 16AWG wire and the appropriate mating connector.
Include a Diode (15 ADC (min), 50.0 PIV or greater) to prevent battery discharge in case of
loss of power from the power source.

Using the external power supply (Table 1, Item 1), apply 29.0 ± 0.5 Vdc (10A maximum
current limited) to J1 connector pins 11 (+) and 7 (-) and charge the unit for 16 hours. The
batteries should reach 80% capacity within 1 hour and full charge at 16 hours.

Figure 3: Interface Diagram

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B. Constant-Voltage Float (trickle) Charging Method

Use the locally manufactured power cable, including the appropriate mating connector and
diode, to connect a regulated/constant voltage source (28.5 ± 0.5 Vdc) to the PS-835. This
method will provide a long-term constant voltage to maintain the fully charged condition of the
PS-835 unit when not in service, without any other maintenance action.

NOTE
The trickle charge method can be maintained indefinitely without damage to the
charging batteries.

C. BC-815 Battery Charger Method

Install the BC-815 Battery Charger (Avionics Systems part number 501-1321-01) into the PS-
835 Emergency Power Supply and charge for no-less-than 23 hours. Charge time depends upon
the batteries state-of-charge. Charging for 23 hours will essentially guarantee a full charge.

The BC-815 provides a constant charging current of either 0.5 A or 0.25 A, selectable by a
switch on the face of the unit. The AMBER LED illuminates when power is applied by placing
the ON / OFF switch to ON. When the unit being charged is within 90.0% of full charge, the
GREEN LED illuminates indicating that the BC-815 has automatically switched to the trickle
charge mode. The charger/battery combination may be operated in this mode indefinitely
without damage to the BC-815 or to the batteries being charged.

D. BC-815 Battery Float (trickle) Charging Method

Install the BC-815 Battery Charger (Avionics Systems part number 501-1321-01) into the PS-
835 Emergency Power Supply. This method will provide a long-term constant voltage to
maintain the fully charged condition of the PS-835 unit when not in service, without any other
maintenance action.
NOTE:
The trickle charge method can be maintained indefinitely without damage to the
charging batteries.

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6. Preflight Check (Recommended)

NOTE
This check indicates an accurate condition of the unit only upon the initial attempt.
Repeated checks will not reveal accurately because stored energy is used each time the
TEST SWITCH is depressed.
A. Pre-Flight Check for Aircraft with Remote Test Capability

CAUTION
Do not leave the emergency power supply switch in the on/armed position after
aircraft shutdown. Battery discharge will cause irreversible damage to cells.
With no power applied to the PS-835 Emergency Power Supply, press and hold for 5 seconds
the cockpit remote TEST SWITCH in the TEST position. The remote test lamp must, at least,
momentarily illuminate to indicate that the Power Supply is adequately charged. If no
illumination of the remote test lamp is apparent for the period that switch is held, the
Emergency Power Supply is incapable of providing power in an emergency.

• If the Test Indicator does not illuminate follow the Capacity Testing procedures on page 8.

B. Pre-Flight Check for Aircraft with NO Remote Test Capability

Access the Emergency Power Supply. Perform the check as listed in paragraph 7, Periodic
Checks.

7. Periodic Check (Required 3 to 6 Months)

With no power applied to the PS-835 Emergency Power Supply, press TEST SWITCH (Figure 1,
Item 4) (or remote cockpit test switch) into TEST position for 5 seconds.
The PS-835 indicates that it is adequately charged when the VOLTAGE LEVEL 24Vdc LED
(Figure 1, Item 2) (or remote test indicator), at least, illuminates momentarily, AND the 20Vdc LED
(Figure 1, Item 6) remains lit during the test.

NOTE
Ensure Test Switch is returned to normal position and all LED's are extinguished.

If the VOLTAGE LEVEL 24Vdc LED does not, at least, momentarily illuminate while the 20Vdc
LED is illuminated, the Emergency Power Supply is incapable of providing power in an emergency.
Proceed to Cell Isolation Test on page 9.

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8. Capacity Testing (Required Annually)

NOTE
The PS-835 Emergency Power Supply must have completed a full charge prior to any
discharge testing.

A. Capacity Test

Press and hold TEST SWITCH (Figure 1, Item 4) and observe the OUTPUT VOLTAGE
MONITOR LED's (Figure 1, Item 2).
NOTE
Ensure Test Switch is returned to normal position and all LED's are extinguished.

1) If the 24VDC OUTPUT VOLTAGE MONITOR LED comes on, proceed with either
Discharge Test procedures.

2) If OUTPUT VOLTAGE MONITOR LED's do not come on, check Fuse A1F1 (See
Installation Manual TP-336, for more information) and replace if blown. Perform Cell
Isolation Test (page 9) if fuse is not blown.

B. Discharge Test

Use the discharge test to determine if unit under test requires service.

CAUTION
Prior to performing discharge test, the batteries must be at full capacity. See Charging
Procedures on page 5.

1) Position all individual Cell Dip Switches (Figure 1, Item 5) to the ON position.

a. If the individual Cell Monitor LED DS12 (DS1 for models E and F) is the only LED
not illuminated, proceed to Cell Isolation Test (page 9).

2) Place a DVM (Table 1, Item 2) across pins J1-11 (+) and J1-7 (-).

3) Place a 7.0 ohm load across pins J1-11 (+) and J1-7 (-). Use 7.0Ω load resister described in
Table 1, Item 4 or a 150.0 watt (or greater) variable resistor set to 7.0Ω ± 1.0%. Begin
timing the discharge period with stopwatch (Table 1, Item 3).

a. For Models PS-835 (A, C, and E):

• Output voltage observed on DVM at 20 minutes must be greater then 20 Vdc.

b. For Models PS-835 (B, D, F, and G):

• Output voltage observed on DVM at 48 minutes must be greater then 20 Vdc.

c. If Output voltage is not greater then 20 Vdc then the unit requires service.

d. All individual Cell Monitor LED’s (Figure 1, Item 1) must remain on during the test.
Any LED that does go OFF represent's a defective individual cell that must be
replaced.

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 Service Letter SL-80 (Rev. Y)

4) Position all individual Cell Dip Switches (Figure 1, Item 5) to the OFF position.

5) If the requirements are meet in steps a thru d then proceed to Charging Procedures on
page 5.

CAUTION
Recharge the PS-835() within 2 hours after discharging to reduce the possibility of
damage to battery cells.

6) Remove DVM and 7.0Ω load resistor or Variable resistor as applicable from pins J1-11 (+)
and J1-7 (-).

9. Cell Isolation Test

NOTE
No power should be applied to PS-835 Emergency Power Supply during test.

A. Press and hold TEST SWITCH (Figure 1, Item 4). If no OUTPUT VOLTAGE MONITOR
LED's come on:
NOTE
Ensure Test Switch is returned to normal position and all LED's are extinguished.

1) Position all INDIVIDUAL CELL DIP SWITCHES (Figure 1, Item 4) to the ON position.

2) Press and hold TEST SWITCH (Figure 1, Item 4) and observe the INDIVIDUAL CELL
MONITOR LED's (Figure 1, Item 1).

a. If all INDIVIDUAL CELL MONITOR LED’s come on except DS12, the unit is
damaged and requires repair at an authorized repair station.

b. If all INDIVIDUAL CELL MONITOR LED’s are on, there exists a low-battery
voltage condition. Perform the Charging Procedures on page 5.

For additional assistance call L-3 Avionics Systems, Customer Service (800-453-0288 or 616-949-6600).

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