Bob Burkel, Technical OEM Manager

1. Bob Burkel, Technical OEM Manager In aviation since 1968 as a pilot, battery repair station repairman, managing battery repair stations, battery sales, and Tech Rep. Holds a Commercial Pilots License for Single Engine Land and Multi Engine Land with an Instrument Rating.

2. Lead Acid Aircraft Battery Airworthiness Presented by Concorde Battery Corporation, Manufacturers Of Lead Acid & Lithium Ion Batteries For All Types Of Aircraft

4. Commissioning Flooded And VRLA (RG) Aircraft Batteries What Is Required To Commission A Flooded (Dry Charged) And A Valve Regulated, Recombinant Gas (RG) Battery? Manufacturers are not able to test dry-charged batteries; the installer must verify the airworthiness (capacity) of these batteries after activation with electrolyte and proper charging. RG (Recombinant Gas) batteries are tested at the factory and have passed both high rate and one hour performance standards. Prior to installation the Open Circuit Voltage (OCV) must be checked. If less than 25.5 for 24 Volt batteries or half of that, 12.75 for 12 Volt batteries, they must be boost charged before installation. The installing agency or �a person holding at least a private pilot certificate may approve an aircraft for return to service after performing � preventative maintenance� under the provisions of FAR �43.3(g) and Appendix A �Major Alterations, Major Repairs and PREVENTIVE MAINTENANCE�. Par. (c) Preventive maintenance Par. (24) �REPLACING AND SEVICING BATTERIES� So, the installer is responsible to prove that the serviced dry-charged battery is AIRWORTHY because, until the battery is activated with electrolyte and TESTED, its minimum operational performance is unknown. Manufacturers are not able to test dry-charged batteries; the installer must verify the airworthiness (capacity) of these batteries after activation with electrolyte and proper charging. RG (Recombinant Gas) batteries are tested at the factory and have passed both high rate and one hour performance standards. Prior to installation the Open Circuit Voltage (OCV) must be checked. If less than 25.5 for 24 Volt batteries or half of that, 12.75 for 12 Volt batteries, they must be boost charged before installation. The installing agency or �a person holding at least a private pilot certificate may approve an aircraft for return to service after performing � preventative maintenance� under the provisions of FAR �43.3(g) and Appendix A �Major Alterations, Major Repairs and PREVENTIVE MAINTENANCE�. Par. (c) Preventive maintenance Par. (24) �REPLACING AND SEVICING BATTERIES� So, the installer is responsible to prove that the serviced dry-charged battery is AIRWORTHY because, until the battery is activated with electrolyte and TESTED, its minimum operational performance is unknown.

5. How Do You Know When A Lead Acid Battery is Fully Charged? When You Have Recharged The Battery From: 1) A 100% Depth Of Discharge 2) A 75% Depth Of Discharge 3) A 50% State Of Charge 4) A 75% State Of Charge 5) An Unknown State Of Charge Using a CP or voltage regulated charger, charge until the current stabilizes and continue charging for 2 more hours. Using a CP or voltage regulated charger, charge until the current stabilizes and continue charging for 2 more hours.

6. OCV What Is The Open Circuit Voltage (OCV) Of A Fully Charged Lead Acid Battery? 12.9 or above for 12 volt batteries and 25.8 or above for 24 volt batteries. 12.9 or above for 12 volt batteries and 25.8 or above for 24 volt batteries.

7. Capacity Ratings The 2 hour rate is 26% more than the C/1 rate of 35Ah or 44Ah The 5 hour rate is 38% more than the C/1 rate of 35Ah or 48Ah The 20 hour rate is 55% more than the C/1 rate of 35Ah or 92Ah Note: most non aviation batteries are rated at the 20 hour rate, that is why the Hawker (Odyssey) 17Ah batteries are really only about 11Ah of that rating at C/1. You must compare apples with apples The 2 hour rate is 26% more than the C/1 rate of 35Ah or 44Ah The 5 hour rate is 38% more than the C/1 rate of 35Ah or 48Ah The 20 hour rate is 55% more than the C/1 rate of 35Ah or 92Ah Note: most non aviation batteries are rated at the 20 hour rate, that is why the Hawker (Odyssey) 17Ah batteries are really only about 11Ah of that rating at C/1. You must compare apples with apples

8. Battery Rating System Updates: 1977 The Old WWII Aircraft 5 Hour Battery Rating System Was Changed In 1977 To One Hour. So the generic 9 plates per cell 12 volt �25� and 11 plates per cell �35� series batteries are really 18 Ampere hours for the old �25� and 25 ampere hours for the old �35�. Concorde has improved the performance with their XC models, the RG-25XC is 24 Ah or 33.3% more capacity than the old �25�and the RG-35AXC is 33 Ah or 32% more than the old �35� at the one hour rate. Comparing the automotive cold cranking amps, (CCA) the RG-25XC has 330 CCA compared to the old�25� at 225 CCA or 46.6% more and the RG-35AXC has 440 CCA compared to the old �35� at 250 CCA or 76% more CCA. So the generic 9 plates per cell 12 volt �25� and 11 plates per cell �35� series batteries are really 18 Ampere hours for the old �25� and 25 ampere hours for the old �35�. Concorde has improved the performance with their XC models, the RG-25XC is 24 Ah or 33.3% more capacity than the old �25�and the RG-35AXC is 33 Ah or 32% more than the old �35� at the one hour rate. Comparing the automotive cold cranking amps, (CCA) the RG-25XC has 330 CCA compared to the old�25� at 225 CCA or 46.6% more and the RG-35AXC has 440 CCA compared to the old �35� at 250 CCA or 76% more CCA.

9. Minimum Capacity For Airworthiness What Is The Minimum Lead Acid Battery Capacity for Airworthiness? 80% 80%

10. Return To Service What is the Recommended Minimum Battery Capacity to Return To Service? 85% 85%

11. Verifying Battery Capacity How Often Should You Verify The Battery Capacity? When used as engine starting and emergency power applications, the battery should be capacity checked at different intervals and hours of operation, depending on the battery type. Turbine Main Engine Starting, APU or reciprocating engine starting, or emergency power. When the battery fails to meet 85% capacity, it is replaced. When used as emergency (non engine starting) applications, check the airframe CMM or the applicable ICA available on our web site Once the airworthiness battery time has been proven in a particular aircraft and operation, the replacement battery can be operated for that duration without any capacity checks. When used as engine starting and emergency power applications, the battery should be capacity checked at different intervals and hours of operation, depending on the battery type. Turbine Main Engine Starting, APU or reciprocating engine starting, or emergency power. When the battery fails to meet 85% capacity, it is replaced. When used as emergency (non engine starting) applications, check the airframe CMM or the applicable ICA available on our web site Once the airworthiness battery time has been proven in a particular aircraft and operation, the replacement battery can be operated for that duration without any capacity checks.

12. Scheduled Inspections for Turbine Engine Starting Batteries See latest revision to ICA & CMM on our website: www.concordebattery.com After the useful battery life is established in a particular operation, for the aircraft or operating mode, the actual useful life period in months becomes the indicator for scheduled inspections. After the useful battery life is established in a particular operation, for the aircraft or operating mode, the actual useful life period in months becomes the indicator for scheduled inspections.

13. Scheduled Inspections for Reciprocating Engine Starting / APU After the useful battery life is established in a particular operation, for the aircraft or operating mode, the actual useful life period in months becomes the indicator for scheduled inspections. After the useful battery life is established in a particular operation, for the aircraft or operating mode, the actual useful life period in months becomes the indicator for scheduled inspections.

14. Scheduled Inspections for Emergency Power Batteries

15. Battery Capacity for Certification When Aircraft Are Certified With A Battery, What Is That Capacity? A) 100% B) 90% C) 85% D) 80% E) 72% 72% ��.Batteries are a consumable product; you can have a bald tire that is fully inflated and not airworthy as you can have a fully charged battery that has less than 80% capacity, just because the battery is providing good engine cranking power is NOT a sign that it has enough capacity for essential power. Only a one hour test proves the actual battery capacity. Starting a reciprocating engine usually only requires about one percent and starting a turbine engine generally requires about ten percent of the battery capacity 72% ��.Batteries are a consumable product; you can have a bald tire that is fully inflated and not airworthy as you can have a fully charged battery that has less than 80% capacity, just because the battery is providing good engine cranking power is NOT a sign that it has enough capacity for essential power. Only a one hour test proves the actual battery capacity. Starting a reciprocating engine usually only requires about one percent and starting a turbine engine generally requires about ten percent of the battery capacity

16. Secondary Batteries If A Single Engine Aircraft Has Electronic Instrumentation (Glass Cockpit) And Or Electronic Ignition And Or Electronic Fuel Injection And The Aircraft Is Certified With A Dual (Split Buss) Or Secondary Electric System; Generator Or Alternator With A 2nd Battery For Standby Or Essential Power That Is Not Used For Engine Cranking, How Often Must These Secondary Batteries Be Checked For Airworthiness? See airframe manufacturers ICA See airframe manufacturers ICA

17. Airworthy Batteries Example This Is An Example Of A Fly By Wire Aircraft With 155 People Thankful For Airworthy Batteries. Several Aircraft Models That Are Fly-By-Wire Do Not Have Any Mechanical Flight Controls TodaySeveral Aircraft Models That Are Fly-By-Wire Do Not Have Any Mechanical Flight Controls Today

18. IPP / IPR Ratings What Are IPP And IPR Ratings? The International Electrotechnical Commission (IEC 60952-1) Standard for High rate performance for Aircraft Batteries The International Electrotechnical Commission (IEC 60952-1) Standard for High rate performance for Aircraft Batteries

19. IPP What Does IPP Stand For? Instant Peak Power, amperes the battery is producing at three tenths of the first second of the high rate discharge test, holding a constant voltage of half (12) the nominal voltage of a (24) volt battery at three battery temperatures , 23C, -18C and -30C Instant Peak Power, amperes the battery is producing at three tenths of the first second of the high rate discharge test, holding a constant voltage of half (12) the nominal voltage of a (24) volt battery at three battery temperatures , 23C, -18C and -30C

20. IPR What Does IPR Stand For? Instant Power Rating, amperes the battery is producing at the 15 second point of the high rate test Instant Power Rating, amperes the battery is producing at the 15 second point of the high rate test

21. Why Do Concorde Aircraft Batteries Have Copper Terminals? The old steel bolts, cast in lead with steel wing nuts and steel split lock washers came from the original lawn and garden tractor batteries that were first installed in the Aeroncas, Cubs and T-Crafts that were built after WWII, that had wind driven generators added on for electric systems and these tractor terminals have remained on light aircraft batteries ever since. Every year there are M & D�s about these steel bolts melting off from the lead terminals, either caused by dissimilar metal corrosion (with a copper wire cable terminal attached to a lead terminal with steel parts) or by loose wing nuts that were not torqued properly. Concorde copper terminals have M8 silicon bronze bolts and conical washers (real aircraft hardware that is torqued to 70 inch pounds). Because the metric system is the international standard and the U.S. Military Specifications are metric, Concorde has adapted to them. The M8 diameter is .002 of an inch smaller than the old 5/16� stud, so the difference is neglegible when used with the 5/16� battery cable ring terminal The old steel bolts, cast in lead with steel wing nuts and steel split lock washers came from the original lawn and garden tractor batteries that were first installed in the Aeroncas, Cubs and T-Crafts that were built after WWII, that had wind driven generators added on for electric systems and these tractor terminals have remained on light aircraft batteries ever since. Every year there are M & D�s about these steel bolts melting off from the lead terminals, either caused by dissimilar metal corrosion (with a copper wire cable terminal attached to a lead terminal with steel parts) or by loose wing nuts that were not torqued properly. Concorde copper terminals have M8 silicon bronze bolts and conical washers (real aircraft hardware that is torqued to 70 inch pounds). Because the metric system is the international standard and the U.S. Military Specifications are metric, Concorde has adapted to them. The M8 diameter is .002 of an inch smaller than the old 5/16� stud, so the difference is neglegible when used with the 5/16� battery cable ring terminal

22. Replacement When Should An Aircraft Battery Be Replaced? When its capacity falls below 85% Like a tire or brake they have wear limits for airworthiness and that depends on the use or abuse, how many discharges and recharge cycles and the depth of discharge and recharge. Your car battery probably lasts 4-5 years and gets 10,000 shallow discharge and recharge cycles, the same battery in an electric wheel chair will only have a life span of 300 deep discharges and recharge cycles When its capacity falls below 85% Like a tire or brake they have wear limits for airworthiness and that depends on the use or abuse, how many discharges and recharge cycles and the depth of discharge and recharge. Your car battery probably lasts 4-5 years and gets 10,000 shallow discharge and recharge cycles, the same battery in an electric wheel chair will only have a life span of 300 deep discharges and recharge cycles

23. Damage If An Aircraft Battery Has Been Dropped, What Is The Acceptable Type Of Damage That The Case May Have And Still Be Considered Airworthy? No external damage is acceptable No external damage is acceptable

24. Aircraft Airworthiness Is An Aircraft Airworthy With A Dead Or Discharged Battery? Only if it was certified with a dead or discharged battery Only if it was certified with a dead or discharged battery

25. Discharge Minimums What Is The Minimum Voltage A Lead Acid Battery Can Be Discharged Before Damaging It Internally? A) 11 volts for a 12 volt battery OR 22 volts for a 24 volt battery B) 10 volts for a 12 volt battery OR 20 volts for a 24 volt battery C) 9 volts for a 12 volt battery AND18 volts for a 24 volt battery D) 0 volts for EITHER a 12 or 24 volt battery �C� is the correct answer, discharging a battery below these limits may cause one or more cells to go into a chemical reversed polarity. When this happens the battery usually is not recoverable. Batteries that exhibit high recharge current and heat up on the recharge must be taken out of service �C� is the correct answer, discharging a battery below these limits may cause one or more cells to go into a chemical reversed polarity. When this happens the battery usually is not recoverable. Batteries that exhibit high recharge current and heat up on the recharge must be taken out of service

26. Recharging A Dead Battery If An Aircraft With Dead Battery(ies) Is Started With External Power, How Long Does It Take To Recharge Lead Acid Batteries With The Aircraft Generating System? 3.5 to 4 hours at battery operating temperatures above 50F or 10C 3.5 to 4 hours at battery operating temperatures above 50F or 10C

27. True Or False Why Shouldn�t You Store Charged Batteries On The Ground Or On A Concrete Floor? Beats me, gravity is gravity, the electrons don�t get sucked out faster on any particular surface Beats me, gravity is gravity, the electrons don�t get sucked out faster on any particular surface

28. Boost Charging Schedule At What Time Should An Inactive Lead Acid Battery Be Boost Charged To Prevent It From Sulfating? A) Every Month B) Every 3 Months C) Any Time The Voltage Falls Below 12.5 Volts for a 12V Battery or 25.0 Volts for a 24V Battery �C� is the correct answer �C� is the correct answer

29. Boost Charging Schedule

30. Fast Charge Is It OK To Fast Charge A Lead Acid Battery? Yes, as long as the voltage is regulated, they are not rate sensitive Yes, as long as the voltage is regulated, they are not rate sensitive

31. Controlling Fast Charge If You Fast Charge A Lead Acid Battery, It Is Best To Control A) The Current B) The Voltage As long as the voltage is regulated, they are not rate sensitive As long as the voltage is regulated, they are not rate sensitive

32. Check The Charge When Should You Check The Aircraft Charging Voltage? Annually In The Spring In The Summer In The Fall In The Winter Only If The Operator Feels It�s Necessary At least annually, but the correct charging voltage depends on the battery operating temperature, Automobiles have had temperature compensated voltage regulation for at least 40 years; we still don�t have that luxury in our aircraft today. At least annually, but the correct charging voltage depends on the battery operating temperature, Automobiles have had temperature compensated voltage regulation for at least 40 years; we still don�t have that luxury in our aircraft today.

33. Conditioning What Can Be Done To Correct Lead Acid Batteries That Are �Sulfated� Due To Inactivity Or Being Over Discharged And Will Not Accept A Charge? Often, they can be �conditioned� with a constant current charge rate of 1/10th of the battery one hour capacity rating for 16 hours Example: 1/10th of a 42Ah �C� rate is 4.2 amps for 16 hours Often, they can be �conditioned� with a constant current charge rate of 1/10th of the battery one hour capacity rating for 16 hours Example: 1/10th of a 42Ah �C� rate is 4.2 amps for 16 hours

34. TSOA / PMA Aircraft Batteries Some Batteries Are Technical Standard Order Authorized And Some Parts Manufacturing Approved Concorde Battery Corporation is leading other battery manufacturers in getting their batteries TSOA (Technical Standard Order Approved). TSOA-C173 parts (lead acid batteries) are used in any aircraft meeting those minimum operating performance standards / MOPS. PMA parts approved for specific models. Concorde Battery Corporation is leading other battery manufacturers in getting their batteries TSOA (Technical Standard Order Approved). TSOA-C173 parts (lead acid batteries) are used in any aircraft meeting those minimum operating performance standards / MOPS. PMA parts approved for specific models.

35. Does a TSOA Product Have A Different Classification Than A PMA�d Product? Class I Class II Class III TSOA / PMA Aircraft Batteries Yes, TSOA is a Class II and PMA is Class III Definitions of FAA Class I product is a complete Type Certified Aircraft, Engine or Propeller. FAA Class II product is a major component of a Class I product, (e.g., wings, fuselage etc. OR ANY PART, MATERIAL, OR APPLIANCE, APPROVED AND MANUFACTURED UNDER THE TECHNICAL STANDARD ORDER (TS0) SYSTEM IN THE �C� SERIES SEVERAL OF THE CONCORDE AIRCRAFT BATTERIES AND EMERGENCY BATTERY PACKS ARE MANUFACTURED UNDER TSO-C173 FAA Class III product is any part or component which is not a Class I or Class II product and includes standard parts, i.e. AN, MS, SAE, etc. IF A BATTERY IS NOT TSOA AND IS FAA-PMA IT IS A CLASS III PRODUCT Yes, TSOA is a Class II and PMA is Class III Definitions of FAA Class I product is a complete Type Certified Aircraft, Engine or Propeller. FAA Class II product is a major component of a Class I product, (e.g., wings, fuselage etc. OR ANY PART, MATERIAL, OR APPLIANCE, APPROVED AND MANUFACTURED UNDER THE TECHNICAL STANDARD ORDER (TS0) SYSTEM IN THE �C� SERIES SEVERAL OF THE CONCORDE AIRCRAFT BATTERIES AND EMERGENCY BATTERY PACKS ARE MANUFACTURED UNDER TSO-C173 FAA Class III product is any part or component which is not a Class I or Class II product and includes standard parts, i.e. AN, MS, SAE, etc. IF A BATTERY IS NOT TSOA AND IS FAA-PMA IT IS A CLASS III PRODUCT

36. Are TSOA Products Approved For Specific Aircraft Models As PMA�d Products? TSOA / PMA Aircraft Batteries No, they meet a FAA minimum operational performance standard (MOPS) if the TSOA battery is equivalent to the original battery it can be installed as a replacement with the TC, STC or 337. Cessna started these years ago when the FAA approved their Service Bulletins that have Concorde VRLA Batteries with temperature sensors that are equivalent to the sensors installed in their nickel cadmium batteries. This made the Concorde valve regulated lead acid (VRLA) batteries interchangeable with their NiCad�s with only a log book entry showing compliance with a Factory Service Bulletin. No, they meet a FAA minimum operational performance standard (MOPS) if the TSOA battery is equivalent to the original battery it can be installed as a replacement with the TC, STC or 337. Cessna started these years ago when the FAA approved their Service Bulletins that have Concorde VRLA Batteries with temperature sensors that are equivalent to the sensors installed in their nickel cadmium batteries. This made the Concorde valve regulated lead acid (VRLA) batteries interchangeable with their NiCad�s with only a log book entry showing compliance with a Factory Service Bulletin.

37. What Are The Differences Between Component Maintenance Manuals (CMM) Including Instructions For Continued Airworthiness (ICA) And Owner/Operator Manuals: O/O? CMM, ICA, O/O Manuals All are available on our web site CMM provides IFCA and each revision requires FAA approval , applies to all CB Series Batteries and includes RG� Series TSO batteries CMM is geared for the AMT with detailed instructions for capacity testing Separate CMM�s for Emergency, Starting , RG Series & CB Batteries. Information in the CMM takes precedence over information in the O/O Manual.s Owner/Operator manual for RG Series Batteries or OR Owner/Operator manual Batteries for CB Batteries. O/O is a practical guide including installation and operating instructions not included in the CMM O/O refers to the CMM for detailed servicing instructions. All are available on our web site CMM provides IFCA and each revision requires FAA approval , applies to all CB Series Batteries and includes RG� Series TSO batteries CMM is geared for the AMT with detailed instructions for capacity testing Separate CMM�s for Emergency, Starting , RG Series & CB Batteries. Information in the CMM takes precedence over information in the O/O Manual.s Owner/Operator manual for RG Series Batteries or OR Owner/Operator manual Batteries for CB Batteries. O/O is a practical guide including installation and operating instructions not included in the CMM O/O refers to the CMM for detailed servicing instructions.

38. Thank You For Choosing Concorde�s Lead Acid Aircraft Battery Airworthiness Presentation Please visit our website: www.concordebattery.com