AIRCRAFT MAINTENANCE MANUAL

XL246-A EMERGENCY BATTERY SYSTEM

100-0202-01/-02

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 Information
Securaplane provides a warranty on the XL246-A electronics for a period of five years
and the battery for (3) years from date of aircraft installation, provided this is not
greater than six months from date of shipment. This warranty coverage is limited to
defective materials or workmanship. The warranty is void if the XL246-A has been
damaged by accident, unreasonable or improper usage, neglect, unauthorized repairs,
or other causes not associated with defects in materials or workmanship. The express
warranty is in lieu of any and all implied warranties of merchantability and fitness for
intended purpose. Securaplane shall not be liable for loss or use of the XL246-S or
other incidental or consequential costs, expenses, or damages incurred by the
customer or other user. While under warranty, the XL246-A unit will be repaired or
replaced, at Securaplane option, when the unit is returned prepaid to Securaplane at
the following address.
Securaplane Technologies
Service Department
10800 N. Mavinee Drive
Tucson, AZ 85737

Contact Securaplane for a Return Authorization number to be entered on the shipping

documents for the returned part. The repair of an XL246-A will not extend the terms or
period of the express warranty stated above.

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.

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Record Of Revisions
Rev Issue Date Rev Issue Date
No. Date Inserted By No. Date Inserted By
Orig May 31/00
Rev A Jan 14/02
Rev B Apr 11/02
Rev C Oct 21/02
Rev D Mar 11/03
Rev E Aug 05/03
Rev F Jan 12/04
Rev G Dec 02/05
8 Dec 08/11

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Record of Temporary Revisions

TR Page Issue Date Date Incorporated
No. No. Date Inserted By Removed By by Rev No.

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ECO/Service Bulletin List

ECO/SB Date Title

Number. Incorporated
021017-1 Oct 21/02 XL246-A [Discrete Polarity Correction]
020607-2 Oct 21/02 XL246-S/A [Foam block QTY in IPC]
030225-1 Mar 11/03 XL246-A [Changed value of R21 in Control Board]
030729-4 Aug 05/03 XL246-A [Deleted irrelevant test procedures]
031216-2 Jan 12/04 Converted Document To Level 1 Troubleshooting

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List of Effective Pages

SUBJECT PAGE DATE SUBJECT PAGE DATE

Title Page T-1 Dec 08/11 15 thru May 31/00

16
Safety/ SWLA-1 Jan 12/04
Warranty/Liability Fault Isolation 101 thru Dec 02/05
Advisory 102
103 May 31/00
Record of Revisions RR-1 Dec 08/11
Maintenance Practices 201 Dec 02/05
Record of Temporary TR-1 May 31/00
Revisions 202 thru Aug 05/03
204
ECO/Service Bulletin SB-1 Jan 12/04
List Servicing 301 May 31/00

List of Effective Pages LEP-1 Dec 08/11 Installation and Storage 401 Dec 02/05

Highlights of Change HOC-1 Dec 08/11 402 Oct 21/02

Table of Contents TOC-1 Jan 12/04 403 Dec 02/05

thru –3
404 thru Dec 08/11
Introduction Intro-1 Jan 12/04 405
thru -3
Adjustment/Test 501 thru Jan 12/04
System Description 1 thru 2 May 31/00 502
3 Apr 11/02 503 thru Dec 02/05
504
4 May 31/00
Inspection/Check 601 thru May 31/00
5 Apr 11/02 602
6 May 31/00 Cleaning/Painting 701 thru May 31/00
702
7 Jan 12/04
Repair 801 May 31/00
8 Aug 05/03
Special Tools Fixtures 901 Dec 02/05
9 Jan 12/04 and Equipment
10 May 31/00 Illustrated Parts Catalog 1001 Jan 12/04
11 Apr 11/02
12 Jan 12/04
13 May 31/00
14 Oct 21/02

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Highlights of Change
TO: Holders of XL246-A Emergency Battery System Aircraft Maintenance Manual,
Revision G, ATA 24-32-06, Dated Dec 02/05.

Effective December 08, 2011, MM-0007-01 for the XL246A Emergency Battery System is revised
per the highlights of change listed here. Change bars in the margin will identify the revised text.

Pages which have been revised, added, or removed are shown below, with the reasons for the
changes. Please replace pages of this manual as necessary.

Subject / Page Change Summary

Title Page, RR, Changed revision level of manual to Rev 8, dated Dec 08/11.
HOC, and LEP
Installation and
Storage
Page 404 Deleted first step about shelf life and renumbered remaining steps.
Page 405 Added second sentence at D.2. “If a red or yellow LED indicator is
illuminated, continue to the Shop Level Charging Test in the
ADJUSTMENT/TEST section on page 503.”

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Table of Contents
Section Page
INTRODUCTION................................................................................................................................ Intro-1
1. Introduction ................................................................................................................................ Intro-1
2. AMM Usage Guide ..................................................................................................................... Intro-1
3. Revision Service ........................................................................................................................ Intro-2
4. Electrostatic Discharge .............................................................................................................. Intro-2
5. Abbreviations and Unit Symbols ................................................................................................ Intro-2
6. Applicable Publications .............................................................................................................. Intro-3
7. Product Support Services .......................................................................................................... Intro-3
SYSTEM DESCRIPTION ............................................................................................................................ 1
1. Battery Overview ................................................................................................................................. 1
2. General Description ............................................................................................................................ 2
3. Specifications ...................................................................................................................................... 3
4. Block Diagram Description .................................................................................................................. 8
A. Introduction ................................................................................................................................... 8
B. XL246-A Inputs ............................................................................................................................. 8
C. Battery Heater............................................................................................................................... 9
D. Electrical Load Budget .................................................................................................................. 9
E. Charging System ........................................................................................................................ 11
5. Battery Voltage Monitoring and Battery Cut-Off ................................................................................ 12
6. Diagnostic and Safety Features ........................................................................................................ 12
A. BITE TEST.................................................................................................................................. 12
B. Battery Energy BATT LEVEL TEST ........................................................................................... 13
C. Circuit Breakers .......................................................................................................................... 14
D. XL246-A Outputs ........................................................................................................................ 14
E. Battery Capacity ......................................................................................................................... 15
FAULT ISOLATION................................................................................................................................. 101
1. Introduction ..................................................................................................................................... 101
2. Test Equipment and Materials ........................................................................................................ 101
3. Pre-Power Resistance Check ......................................................................................................... 103
MAINTENANCE PRACTICES ................................................................................................................ 201
1. Battery Testing Interval ................................................................................................................... 201
2. Recommended Battery Replacement ............................................................................................. 201
3. Material Safety Data Sheets ........................................................................................................... 201
SERVICING ............................................................................................................................................ 301
INSTALLATION AND STORAGE ........................................................................................................... 401
1. General ........................................................................................................................................... 401

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2. XL246-A As Replacement For AMPS 2000 .................................................................................... 401

A. Mounting Tray ........................................................................................................................... 401
B. New Mounting Tray Modification .............................................................................................. 401
3. XL246-A Installation Preparation .................................................................................................... 403
4. Storing the XL246-A ........................................................................................................................ 404
A. Storage Equipment and Materials ............................................................................................ 404
B. Storage Instructions .................................................................................................................. 404
C. Preparing the Unit for Storage. ................................................................................................. 405
D. Storage And Shipping Procedures ........................................................................................... 405
E. Monitoring Storage Conditions. ................................................................................................ 405
ADJUSTMENT/TEST .............................................................................................................................. 501
1. General ........................................................................................................................................... 501
2. General Maintenance Philosophy ................................................................................................... 501
3. Battery Capacity and BITE TEST Interval ....................................................................................... 501
A. On-Aircraft Battery Capacity Test Procedure (Using BATT LEVEL TEST Switch) ................... 501
4. On-Aircraft BITE TEST Procedure .................................................................................................. 502
5. Fault Indication ................................................................................................................................ 502
6. Shop Level Charging Test .............................................................................................................. 503
A. Test Equipment For Shop Level Charging................................................................................ 503
B. Shop Level Charge Test Procedures........................................................................................ 503
C. Shop Level Capacity Test - Equipment Required ..................................................................... 504
D. Shop Level Battery Capacity Discharge Test Procedures ........................................................ 504
INSPECTION/CHECK............................................................................................................................. 601
1. Introduction ..................................................................................................................................... 601
2. Equipment and Materials ................................................................................................................ 601
3. General Check Procedures ............................................................................................................. 601
A. External Visual Checks ............................................................................................................. 601
4. Aircraft Level Checkout, Existing Installation .................................................................................. 602
CLEANING/PAINTING ............................................................................................................................ 701
1. Introduction ..................................................................................................................................... 701
2. Cleaning Equipment and Materials ................................................................................................. 701
3. General Cleaning Practices ............................................................................................................ 702
4. General Cleaning Procedures ......................................................................................................... 702
A. External Cleaning ..................................................................................................................... 702
REPAIR ................................................................................................................................................... 801
SPECIAL TOOLS FIXTURES AND EQUIPMENT .................................................................................. 901
1. Shop Test Equipment ..................................................................................................................... 901
ILLUSTRATED PARTS CATALOG....................................................................................................... 1001

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List of Figures
Figure Page

Figure 1. XL246-A Emergency Battery ....................................................................................................... 1

Figure 2. XL246-A Emergency Battery Pack Dimensions........................................................................... 4
Figure 3. J1 Signal Pin Nomenclature ........................................................................................................ 5
Figure 4. XL246-A Controls and Indicators ................................................................................................. 6
Figure 5. XL246-A Functional Block Diagram ........................................................................................... 10
Figure 6. Battery Energy Management ..................................................................................................... 13
Figure 7. XL246-A 6 Amp Constant Current Discharge ............................................................................ 15
Figure 8. XL246-A 200 Watt Constant Power Discharge (New Battery) ................................................... 16
Figure 9. XL246-A 11.5 Amp Constant Current Discharge (New Battery) ................................................ 16

Figure 401. Typical ARINC 404A Rack ................................................................................................... 402

Figure 901. Bench Charge Harness ....................................................................................................... 901

List of Tables
Table Page

Table 1. Applicable Publications ................................................................................................................. 3

Table 2. XL246-A Specifications ................................................................................................................. 3
Table 3. XL246-A Pin Nomenclatures ......................................................................................................... 5
Table 4. XL246-A Controls and Indicators .................................................................................................. 7

Table 101. Test Equipment and Materials .............................................................................................. 101

Table 102. General Troubleshooting Guide ............................................................................................ 102
Table 103. J1 Connector Pins Resistance Readings .............................................................................. 103

Table 401. Storage Equipment and Materials ......................................................................................... 404

Table 701. Cleaning Equipment and Materials ....................................................................................... 701

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INTRODUCTION

1. Introduction

This Aircraft Maintenance Manual (AMM) contains the description and theory of operation for
the XL246-A series Emergency Battery System. Material Data Safety Sheets are provided in
MAINTENANCE PRACTICES section on page 201.

2. Aircraft Maintenance Manual Usage Guide

(1) Systems Description presents the features, interface, and a functional description of
the XL246-A Series Emergency Battery System.
(2) Fault Isolation contains level one on-aircraft procedures to identify a faulty LRU.
(3) Maintenance Practices presents battery testing interval and replacement schedules,
and the Material Safety Data Sheets for the Hawker batteries.

(4) Servicing Not Applicable.

(5) Installation/Storage contains LRU Installation procedures and Storage procedures.
(6) Adjustment/Test procedures show the BITE pass/fail conditions of the unit. A
battery capacity test indicates the remaining battery energy level.
(7) Inspection/Check contains Securaplane’s recommended check procedures for the
XL246-A Emergency Battery.
(8) Cleaning/Painting contains general procedures recommended by Securaplane to clean
the XL246-A. Disassembly is not required to clean the unit.
(9) Repairs Not Applicable.
(10) Special Tools, Fixtures and Test Equipment presents the adapter wiring schematic
needed to charge the battery on the bench.
(11) Illustrated Parts Catalog Not Applicable.

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3. Revision Service

This publication 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 will identify 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.

4. 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.

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 mnemonics 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, the pressure or torque values
(changed to metric equivalents) are shown in parentheses after the United
States measurements.
• Temperature is shown in degrees Fahrenheit (°F). Celsius (centigrade) is
represented by the (°C) symbol.

ATR Austin Trumbull Radio Racking

CAGE Civilian and Government Entity
SLA Sealed Lead Acid
IEC International Electrotechnical Commission
IEEE Institute of Electrical and Electronics Engineers
IRS Inertial Reference System

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6. Applicable Publications

Related publications applicable to the XL246-A are shown in Table 1.

Table 1. Applicable Publications

SECURAPLANE Document Number

Top Assembly Drawing, XL246-A 101-0202-01

Product Specification 200-0202-01

Functional Test Procedure 215-0202-01

Service Manual for XL246-A Emergency Battery SM-0007-01

Commercial Document Number

Environmental Conditions and Test Procedures RTCA/DO-160C

For Airborne Equipment
Institute for Interconnecting and Packaging, IPC-A-610C
Acceptability of Electronic Assemblies

7. Product Support Services

Product support for the XL246-A Series 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 Telephone 1-520-297-0844
Tucson AZ 85737 USA Fax 1-520-498-4924
Email: support@securaplane.com Web: www.securaplane.com

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SYSTEM DESCRIPTION

1. Battery Overview

The Securaplane XL246-A provides an improved, minimal maintenance, direct replacement

battery for the URDC AMPS 2000. The major advantages of the XL246-A are achieved
through:
• use of aviation-proven Hawker Sealed Lead Acid batteries (classified as dry
cells) rather than Nickel-Cadmium batteries as used in the AMPS 2000.
• use of total low-loss, solid-state switching rather than mechanical relays, and
• advanced diagnostics that preclude the need to remove the unit to test battery
capacity.
There are two XL246-A models: the –01 Model has a 15-amp circuit breaker, the –02 Model a
10-amp circuit breaker.

Figure 1. XL246-A Emergency Battery

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2. General Description

The XL246-A Emergency Battery Pack consists of a 24 VDC Hawker Sealed Lead Acid
Battery (actually two 12 VDC batteries in series), a charge management system, a battery
heater system, and a logic controlled solid-state switching system. The 18.63 lb XL246-A is
contained in a ½ ATR (short) chassis.
The XL246-A can provide 19 to 24 VDC at 6 amperes for a minimum of one hour, or for
example, it can drive a 200-watt load (2.9 ohms) for 45 minutes. These outputs are based on
the batteries being at a normal operating temperature (i.e. heater controlled) temperature of
(60°F (15°C) or greater).
The charging system can recharge a cold, discharged battery to an 80-90% energy level in
one hour, providing the aircraft’s 28 VDC system furnishes an initial current of 12 amperes
(for the first 2-3 minutes). The operator does not need to cycle aircraft electrical power to
induce the unit to charge. The charge management system maintains the battery in a charged
state whenever bus power is supplied to the unit. Cycling power to the XL246-A is not
recommended.
The XL246-A is designed for minimum maintenance. The unit does not need to be removed
from the aircraft except for an outright failure (which can be determined while installed), or
preventative maintenance battery replacement at the end of the unit’s service life.
The unit self-determines if a failure occurs in the battery system, charging system, or battery
heater system. Additionally, a front panel BATT LEVEL TEST pushbutton tests battery
capacity. A second pushbutton, BITE TEST (Built In Test Equipment), tests various XL246-A
circuits so that it is not necessary to remove the unit to confirm that it is functioning properly.
The XL246-A battery heater system activates when the battery temperature is below 60°F
(15°C). The 70-watt heater blanket is supplied energy from the aircraft 28 VDC bus. It
consumes approximately 2.1 amps of the maximum current draw (6 amperes) specified
above. The heater is automatically controlled by an electronic thermostat. There is also an
electro-mechanical thermostat “safety valve” that discontinues the heating process if the
electronic thermostat fails in the “ON” position.
To be directly compatible with the URDC AMPS 2000, the XL246-A automatically switches
(solid-state) from the aircraft 28 VDC BUS to the 24 VDC battery when the aircraft BUS
voltage drops below approximately 20 VDC. The XL246-A is designed to pre-filter and
automatically switch either the aircraft 28 VDC or the battery 24 VDC to the essential
equipment outputs.

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3. Specifications
Table 2 presents the specifications for the XL246-A Emergency Battery Pack.
Table 2. XL246-A Specifications

Parameter Specifications
Input:
Voltage 20-35 VDC (28 VDC nominal)
Current 14.1 Amps (maximum) Note 1
Current: Battery Heater 2.1 Amps (11.6 ohms)
Current: Charger 12 Amps (short term peak)
Current: Switched 15 Amps (Model –01) 10 Amps (Model –02)
Connector DPXBMA-D8P-34B
Connector, Mating DPXBMA-D8S-33B
Connector, Keying Pin 7 on Model –01 (15A); Pin 12 on Model-02 (10A)
Outputs:
Battery Output 19 – 24 VDC
Battery Current 20 Amps (maximum)
Battery Duration 19.5 VDC Cutoff
(New Unit @23°C) • 6 Amps: 1 hour minimum
• 200 W load: (2.9 ohms) 45 minutes minimum.
• 11.5 Amps: 27 minutes minimum
• 15 Amps: 21 minutes minimum
“Fault” Output 500 mA sink (maximum)
“Battery On” Output 160 mA source (maximum)
Battery Heater:
Voltage 28 VDC (from A/C Bus)
Current 2.1 Amps (when on) Note 2
Resistance 11.6 ohms
Operating Temp Range: Normal operating temperature -55°C to +71°C Note 3
Physical:
Height 07.70 inches (19.55 cm) maximum
Width 04.83 ±.03 inches (12.27 cm) nominal
Length 14.37 inches (36.49 cm) maximum
Weight 18.63 lb (8.45 kg) maximum
Environmental: Refer to XL246-A Product Specification, 200-0202-01.
Notes: 1 A dead battery may cause 12 amps of initial current for approximately 20-30 seconds.
An additional 2.1 amperes of heater current results in a total of 14.1 amperes.
2 On is a battery temperature below 60°F (15°C); Off is battery temperature above 60°F.
3 Battery is specified by the manufacturer to 65°C, however 71°C will not cause damage.

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Figure 2. XL246-A Emergency Battery Pack Dimensions

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The electrical interface and connector information is shown in Figure 3. J1 Signal Pin
Nomenclature.

XL246-A

J1

1 NO CHARGE (FAULT) OUTPUT

2 CHARGE INHIBIT INPUT

3 SPARE

4 BATTERY ON OUPUT

5 +28VDC IN

6 INPUT POWER GND

7 OUTPUT POWER GND

8 BATT (24VDC) POWER OUT

Figure 3. J1 Signal Pin Nomenclature

Table 3. XL246-A Pin Nomenclatures

CONN. NAME CHARACTERISTICS SOURCE

J1-1 “No Charge” (Fault) Output Logic (Active = Ground) XL246-A
J1-2 Charge Inhibit Input Logic (Active = 28 VDC) Aircraft
J1-3 Spare ---- ----
J1-4 “Battery On” Output Logic (Active = 28 VDC) XL246-A
J1-5 28 VDC In 12 Amps Maximum(1) Aircraft
J1-6 Input Power Ground Ground ----
J1-7 Output Power Ground (Internally tied to pin 6) ----
J1-8 Battery (IRS) Power Out 15 Amps; Model-01 (or XL246-A
10 Amps; Model–02) Maximum

Notes: (1) A dead battery may cause 12 amperes of initial current for approximately 20-30 seconds.
An additional 2.1 amperes of heater current results in a total of 14.1 amperes.

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Figure 4. XL246-A Controls and Indicators

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Table 4. XL246-A Controls and Indicators

Reference
Function
Designator
OUTPUT BREAKER 15 Amps for Model -01 (10 Amps for Model-02) Circuit Breaker
for Battery Out.
CHR’G Charger Fault illuminates red when charger has a fault or if a
-fault- fault occurs during a BITE test.
CELL(S) Battery Cell(s) Fault illuminates when the battery pack
-fault- comparison logic detects a battery cell failure fault or if a fault
occurs during a BITE test.

BITE Pressing and holding the BITE TEST pushbutton starts the Built
TEST In Self Test that loads a fault causing the CHR’G and CELL(S)
LEDs to momentarily illuminate and then tests the functionality of
the charger and the battery. See BITE TEST on page 12.

BATT Pressing and holding the BATT LEVEL TEST for 5 seconds,
LEVEL loads the heater blanket across the battery for 5 seconds and
TEST roughly indicates battery capacity on one of three LEDs. This
test is valid after aircraft power has been off for more than one
hour. See Battery Energy BATT LEVEL TEST on page 13.

Green LED Green LED indicates 75 to 100 per-cent of battery energy is

available.

Yellow LED Yellow LED indicates 50 to 75 per-cent of battery energy is

available.

Red LED Red LED indicates 0 to 50 per-cent of battery energy is

available.

HEATER Green LED illuminates whenever the BATT LEVEL TEST or

ON heater control is driving current through the heater blanket.

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4. Block Diagram Description

A. Introduction
This section provides a block diagram description and a functional description of the
XL246-A Emergency Battery Pack. Refer to Figure 5 throughout the block diagram
description.
The XL246-A provides emergency back-up power (19-24 VDC @ 6 AH) to essential
aircraft equipment when experiencing loss of aircraft 28 VDC, which normally powers
the essential equipment. The XL246-A provides noise filtering for the equipment,
whether powered by the aircraft 28 VDC or the emergency battery.

B. XL246-A Inputs

(1.) Charger Inhibit (J1-2)

The charger inhibit function either:
(1) sheds loads from the aircraft 28 VDC power system, or
(2) suspends battery charging while a connected device (i.e. inertial reference
system) conducts a self-test that includes testing the output capability of the
XL246-A.
Charger Inhibit is activated by applying 28 VDC continuously to the INHIBIT pin J1-2
during the inhibit period. This action de-activates the Bulk Charge path, the Precision
Charge path, and the Heater path. The charger inhibit function should not be used any
more than necessary, as it precludes recharging the unit after discharge.

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C. Battery Heater
The XL246-A incorporates a 70-watt heater blanket that maintains the battery at a
temperature of at least +60°F (15°C). This temperature ensures that the battery is capable
of holding at, or near, its rated capacity.
The heater blanket is electronically controlled by solid state switches in series with the
heater. The battery heat management thermal sensor is also inserted in series with the
heater blanket.
For safety purposes, a redundant, high-reliability electro-mechanical thermal switch is
inserted in series with the battery heater. This normally closed switch, opens at 165°F
(74°C), and closes at 115°F (46°C).
The battery heat management thermal sensor and electro-mechanical thermal switches are
located within cavities formed in the battery pack when the two 12 VDC batteries are
assembled bottom to bottom. The heater blanket is wrapped around the exterior of the
joined battery housings.
A heater monitor circuit is included in the BITE circuitry. It confirms appropriate operation of
the heater system by verifying that heater current flows when heating is required. If heater
current does not flow, the FAULT output is asserted. Refer to Section D. (1.) on page 14 for
fault information.
A green HEATER ON LED illuminates whenever the heater is on (i.e. when the battery is
below 60°F (15°C)). The HEATER ON LED also illuminates when the BATT LEVEL TEST is
active, because the heater blanket is used as the battery test load.

D. Electrical Load Budget

The XL246-A 28 VDC electrical load demand from the aircraft is 14.1 amperes maximum.
This represents an initial current demand where 12 amps is used for bulk charging a flat
battery and 2.1 amperes is used for the heater blanket if the battery ambient temperature is
below 60°F (15°C).
After the first 30 seconds, the charge current decreases to less than 10 amps. When the
battery is fully charged, the charge current decreases to less than 200 milliamperes
(excluding heater current).

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Figure 5. XL246-A Functional Block Diagram

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E. Charging System
The XL246-A uses constant current voltage charging methods to recharge the battery
pack. The battery pack draws current in proportion to the voltage difference between
the battery and applied power source. Thermal runaway, a drawback of nickel-
cadmium battery technology when charging with a non-current limited power source,
does not occur.
Recharging is accomplished in two modes; (1) bulk mode and (2) precision charge
mode.

(1.) Bulk Charge Mode

Bulk Charge mode provides a large amount of current to the battery directly from the
aircraft 28 VDC bus (through a low-loss solid state switch). Bulk charging may
momentarily (less than 30 seconds) draw 10 to 12 amps when recharging a flat
battery pack. An additional 2.1 amperes will be drawn if the heater blanket is on
(ambient temperature <60°F). As the battery charges, the current draw decreases to
less than 200 milliamperes. The Bulk Charge mode is active for the first 15 minutes
after bus power is applied to the XL246-A.
At Bulk Charge termination, the XL246-A switches from the Bulk Charge mode to
Precision Charge mode.

(2.) Precision Charge Mode

Precision Charge mode maintains a (temperature-compensated, based-on-battery-
temperature) float charge voltage in accordance with the battery manufacturer’s
specifications. The voltage may differ from the aircraft bus voltage by a one or two
volts. Precision Charge mode can supply up to 7.5 amps to the battery. Input current
to the XL246-A reduces to less than 200 milliamperes when maintaining a float
charge upon the charged battery pack.
The battery will reach a 90% charged state (from a fully discharged state) in less
than one hour.

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5. Battery Voltage Monitoring and Battery Cut-Off

The two 12 VDC batteries in series are voltage compared. Battery comparison is an effective
means of detecting a bad, shorted, open, or partially defective cell(s).
In addition to battery voltage comparison, the overall battery (24 VDC) level is also monitored
for proper level. To prevent the batteries from being deep discharged, and thus face the risk
of sulfating and shortening battery life, the battery output is shut off at a pre-determined level
depending on average current drain. The cut-off point varies between 19 and 22 VDC. This
point is consistent with 96-98% energy removal, thus there is negligible energy loss sacrificed
for the significant increase in battery reliability.

CAUTION: Immediately following an emergency power total discharge,

28 VDC power must be provided to the XL246-A to
recharge the battery. The batteries do not require a cool
down period prior to recharging (as do nickel-cadmium
battery technology) after usage.

Note: If the XL246-A battery pack will not take a full charge after
being left discharged, the batteries may have become
sulfided. In this case, if still under the initial warranty,
return the unit to Securaplane. If out of warranty, return the
unit to Securaplane for battery pack replacement.

6. Diagnostic and Safety Features

The XL246-A provides front panel switches and LEDs to determine and indicate battery
capacity and the XL246-A’s operational integrity through Built-In-Test-Equipment (BITE).

A. BITE TEST
The XL246-A BITE circuitry is active whenever CB-1 is closed, whether aircraft bus
power is present or not. When the BITE TEST pushbutton is pressed and held, test
circuitry exercises the circuits that monitor battery cell conditions and the battery
charge management conditions.
Both the CHRG’R and CELL(S) LED’s illuminate verifying that the introduction of a
false fault into the BITE circuits was detected and reported.
When the BITE TEST switch is depressed the FAULT output provides a FAULT output
signal. Refer to FAULT Output (J1-1) on page 14.

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B. Battery Energy BATT LEVEL TEST

Owing to the nature of sealed lead acid batteries, it is possible to measure the energy
content of a battery while it is still installed in the airplane (as opposed to Nickel-
Cadmium batteries). Simply press the BATT LEVEL TEST pushbutton to engage the
battery energy test circuitry in the XL246-A.
When the BATT LEVEL TEST pushbutton is pressed, logic performs a qualitative test
(green, yellow, or red LED) of the battery energy available. In contrast to Ni-Cad
batteries, sealed lead acid batteries can be checked for energy when voltage is
measured under a known constant load. The energy level accuracy can be within five
percent when the energy test is conducted 60 minutes or more after external 28 VDC
is removed from the XL246-A. An optimum time to conduct this test is before applying
electrical power to the aircraft at the start of maintenance or preflight operations.
When the BATT LEVEL TEST button is pressed and held, the XL246-A connects the
battery to the heater load (70 watts) and measures battery energy. The green
HEATER ON LED illuminates, indicating that current is flowing through the heater
blanket. The battery energy is determined by measuring the voltage across a constant
load (the heater blanket).

Figure 6. Battery Energy Management

As shown in Figure 6 the battery level indication is via three (green, yellow, and red)
LEDs. The energy values are:
Green = 75-100%
Yellow = 50-75%
Red = 0-50%

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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. This reduction is
accounted for (included) in the energy test.

C. Circuit Breakers
As shown in Figure 5 there is one circuit breaker (CB-1) on the XL246-A front panel
that limits the output current. CB1 is 15 Amps for the Model –01 XL246-A and
10 Amps for the Model–02.

D. XL246-A Outputs

(1.) FAULT Output (J1-1)

A FAULT output (sink-to-ground) discrete closes if a failure occurs in the charger,
heater, or battery. This discrete line is normally open through an NPN transistor. It is
grounded to report a failure to the aircraft’s fault monitoring system.
Should a fault condition occur during flight, the XL246-A will still pass bus power and
provide battery power in response to a subsequent emergency. Removal of an XL246-
A is interpreted by the aircraft fault monitoring system as a fault.

(2.) Direct Battery Out (IRS) (J1-8)

The XL246-A provides a non-logic controlled direct output that provides up to 15 amps
of battery current. A 15 amp circuit breaker (Model–01) is in series with the battery
output; or a 10 amp circuit breaker for (Model–02). A low-voltage solid-state switch is
also in series with the output; however, it is closed until the battery voltage reaches
the cut-off point discussed in Section 5 on page 12.
Aircraft 28 VDC is routed through the input noise filter, a blocking diode, and through a
solid state switch and output filter to the Direct Battery Output. .

(3.) Battery ON Output (J1-4)

Battery ON output occurs when the battery is being drained by greater than 350 mA.
The Battery ON output signal is a 28 VDC signal limited to 160 mA MAX. The Battery
ON detector circuit includes a time constant so that momentary load transients do not
cause unnecessary cockpit concern.

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E. Battery Capacity
The XL246-A battery is nominally rated at 6.0 amps for a one hour rate at 24 VDC.
The IRS output (P1, pin 8) on the XL246-A provides a direct output path through an
electronic switch for the battery. Figure 7 shows the output curve for a constant 6.0
amp discharge of a fresh battery set. Output control switches provide a nominal half
volt drop between the battery and the essential equipment outputs. A battery set is
considered at the end of its service life when it is unable to drive a 6 ampere load for
more than 45 minutes.
The XL246-A is able to power 200 watt requirements for a minimum of 30 minutes to
satisfy FAA Emergency Power Requirements for flight instruments. See Figure 8.
Conversely, the XL246-A provides a maximum sustained 11.5 amps for meeting FAA
In Flight Emergency Power Requirements. See Figure 9.

Figure 7. XL246-A 6 Amp Constant Current Discharge

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Figure 8. XL246-A 200 Watt Constant Power Discharge (New Battery)

Figure 9. XL246-A 11.5 Amp Constant Current Discharge (New Battery)

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FAULT ISOLATION

1. Introduction

This section contains procedures required to identify a faulty XL246-A.

WARNING: Before the equipment called out in this publication is

used, understand the handling precautions recommended
by the manufacturers or suppliers. Failure to obey the
manufacturers’ or suppliers’ recommendations can result
in personal injury. Refer to the MSDS on page 201.
CAUTION: This unit contains an assembly that is susceptible to
damage from incorrect handling. Do not drop or hit the
unit during these procedures.
CAUTION: This unit contains components that can be damaged by
electrostatic discharge. These procedures must be
performed at a static-free station.

2. Test Equipment and Materials

Table 101 shows the equipment and the materials necessary to complete the tests.
Equivalent substitutes may be used.
Table 101. Test Equipment and Materials
Equipment /Materials Description/Manufacturer
Test Adapter Cable (See Figure 901) Securaplane
Digital Voltmeter 1% accuracy Fluke 87 or equivalent
Digital Ohmmeter 1% accuracy Fluke 87 or equivalent
Needle (fine point) probe for volt meter Commercially available

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Table 102. General Troubleshooting Guide presents a concise, Level One

troubleshooting guide for the XL246-A.

Table 102. General Troubleshooting Guide

SYSTEM POSSIBLE CAUSE REMEDY
A/C devices powered by 1. XL246-A installation errors. 1. Verify XL246-A is installed. Check
XL246-A not on. electrical connector for bent pins.
2. Check for power at device. 2. A/C wiring check.
3. If device switches off, after 3. Check for circuit overload or wiring
being on. short. Reset XL246-A.
4. Devices on one output circuit 4. Check for open A/C wire.
not on at all. Otherwise, send to repair shop.
XL246-A won’t charge. 1. Aircraft input circuit breaker 1. Close circuit breaker.
open.
2. Inhibit line active (28 VDC). 2. Reset inhibit control switch on
3. No 28 VDC power to connector system.
J1B, Pin 5. 3. Check for broken A/C wire.
XL246-A won’t turn on. 1. Check CB-1 on XL246-A. 1. Open and set CB-1.
2. Check control switches. 2. Repair, replace as necessary.
3. A/C wiring fault. 3. Repair, replace as necessary.
ON annunciator not on 1. Annunciator lamps out. 1. Check and replace as required.
when XL246-A is on.
XL246-A fault reported to 1. CHG’R LED illuminated. 1 & 2. Reset CB-1 and A/C breaker
cockpit fault display. 2. CELL(S) LED illuminated. at same time. Conduct BITE
TEST. If LED still on, send to
repair shop.
3. A/C wiring fault. 3. Check/fix A/C wiring.
HEATER ON LED not 1. Battery pack above 60°F 1. No problem.
illuminate. (15°C). 2. Determine if heater LED turns on
2. Fault within XL246-A. while BITE is engaged.
If yes, no problem.
If no, send to repair shop.
Circuit breaker on XL246- 1. A/C output circuit shorted. 1. Troubleshoot respective output
A front panel trips open. circuit and connected devices.
2. Output circuit within XL246-A 2. Reset CB and retest. If fault within
damaged. XL246-A, send to repair shop.
Battery Level Test- Yellow 1. Battery not fully charged. 1. Charge battery for 2 hours and
LED on. repeat level test. If same result,
schedule battery replacement at
next maintenance period.
Battery Level Test- Red 1. Battery not charged or is 1. Charge battery for 2 hours and
LED on. defective. repeat level test. If same result,
send to repair shop.

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3. Pre-Power Resistance Check

(1) Pull the Output Breaker on the XL246-A.

(2) Using an ohmmeter, verify the resistance readings in Table 103.

Table 103. J1 Connector Pins Resistance Readings

Neg Probe Pos Probe Meter Reading Signal

J1-6 Chassis <1.0 Ω -
J1-6 J1-1 >100 KΩ No Charge Fault
J1-6 J1-2 >100 KΩ Inhibit
J1-6 J1-3 >100 KΩ Spare
J1-6 J1-4 >100 KΩ Batt On
J1-6 J1-5 >100 KΩ A/C 28 VDC Bus
J1-6 J1-6 <1.0 Ω Input Gnd
J1-6 J1-7 <1.0 Ω Output Gnd
J1-6 J1-8 >100 KΩ Batt 24 VDC Out

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MAINTENANCE PRACTICES

1. Battery Testing Interval

Run the On-Aircraft Battery Capacity Test Procedure (Using BATT LEVEL TEST Switch) at
least once every year. Refer to Adjustment/Test on page 501.

2. Recommended Battery Replacement

The battery manufacturer, Hawker 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 an
XL246-A battery.
It is in the Customer’s best interest, to replace the batteries (two in each XL246-A) 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.

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SERVICING
Not Applicable

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INSTALLATION AND STORAGE

1. General

This section describes procedures to install and store the XL246-A.

Note: See Testing and Fault Isolation, to determine the condition
of the XL246-A.

2. XL246-A As Replacement For AMPS 2000

The XL246-A is a direct replacement for the URDC AMPS 2000. However, the XL246-A
weighs 2 pounds more than the AMPS 2000 because Sealed Lead Acid batteries weigh
approximately 15 percent more than equivalent NI-CAD batteries as used in the AMPS
2000.

A. Mounting Tray
The XL246-A is designed to mount in an ARINC type ½ ATR 404A or equivalent
(i.e. L404A-50-S-1/DPXB-0) tray. See Figure 401. In applications where the XL246-A
is a direct replacement for an AMPS 2000, if the interchangeability is covered by an
STC or TC, the replacement will normally allow using the same tray as the AMPS
2000.
The XL246-A fits any ½ ATR tray designed to receive the AMPS-2000.
Note: Inspect an existing AMPS-2000 mounting tray for physical
integrity before installing the XL246-A.

For new applications a tray should be selected that is consistent with the particular
aircraft structural (loads) requirement. The XL246-A was FAA DO-160A approved for
vibration per curve “R”, sinusoidal (i.e. 5g, 5-350HZ, and 10G, 350-2000HZ). It was
“shock” and “crash safety” approved per DO-160C sections 7.2 and 7.3.1. A Barry
mounting tray (R404A-4-R-A/DPXB-1200, or equivalent) is a more robust redesign of
the older light weight 404A. This tray has sufficient strength to operate in installations
that would require high “g” (i.e. 5-10g) compliance.

B. New Mounting Tray Modification

The AMPS-2000 and XL246-A require modification to a standard ½ ATR mounting
tray, such as the Barry 404A-50-X010 (or equivalent), before they can be installed in
the aircraft. The back panel of the tray must be relocated upward such that the center
bolt holes for the tray electrical connector are 1.150 +/- .005 above the tray. Contact
Securaplane for assistance when installing the XL246-A in new applications.

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Figure 401. Typical ARINC 404A Rack

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3. XL246-A Installation Preparation

CAUTION: Make certain that the installation design precludes the

XL246-A from feeding a load when all aircraft power is
OFF, otherwise the battery could discharge to zero
capacity.

(1) Remove the XL246-A from its shipping container.

(2) Close CB-1.
(3) Verify BITE status LED’s are not illuminated.
(4) Run a battery capacity test by holding the BATT LEVEL TEST button in for 5
seconds. Verify that the HEATER ON LED illuminates and the green energy level
LED illuminates.

Note: If the red LED, or the yellow LED illuminates before

7 seconds, a bench charge is needed before installing the
XL246-A in the aircraft. Refer to Shop Level Charge Test
Procedures on page 503.

(5) Open CB-1. Install the XL246-A in the battery rack and tighten the J hooks.
(6) Proceed with the aircraft installation. Go to Aircraft Level Checkout, Existing
Installation on page 602.

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4. Storing the XL246-A

A. Storage Equipment and Materials

Table 401 shows the equipment and materials necessary to prepare the unit for
storage. Equivalent equipment/materials can be used.
Table 401. Storage Equipment and Materials

Equipment/Materials Manufacturer
Barrier material (MIL-B-131B)
Cloth Commercially available
Dehydrating agent (MIL-D-21576)

B. Storage Instructions

1. 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: This is not an inclusive list of conditions that can inflict
damage.
2. Parts that have been stored where these conditions may be present must be
examined for damage and replaced as necessary.

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C. Preparing the Unit for Storage.

Note: Refer to Cleaning section before storing the XL246-A.

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

2. Put a protective cap on the connector.
3. Wrap the unit in barrier material.
4. Place cushions at the 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.

D. Storage And Shipping Procedures

1. Always store or ship the XL246-A with CB-1 pulled.
2. Perform a battery capacity test at least every 90 days using the BATT LEVEL TEST
switch. CB-1 must be engaged for the test. If a red or yellow LED indicator is
illuminated, continue to the Shop Level Charging Test in the ADJUSTMENT/TEST
section on page 503.
3. Use the Securaplane shipping box or equivalent.
4. Always include a failure report including aircraft type and serial number.

E. Monitoring Storage Conditions.

1. Keep the unit in an area away from high temperatures, dust, moisture, and fumes that
can cause corrosion.
2. Do not store the XL246-A above 85°F (30°C) as it accelerates self discharge and
reduces battery life.
3. The recommended storage temperature is less than 100°F (38°C) and must not be
more than 125°F (52°C).
4. Control humidity to prevent moisture contamination of the unit.

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ADJUSTMENT/TEST

1. General

This section describes procedures to test XL246-A. Adjustments are not required on this unit.

2. Maintenance Philosophy

The XL246-A does not need to be removed from the aircraft to perform BITE or CAPACITY
testing. These tests can be run using the XL246-A front panel pushbuttons and indicators. For
shop level tests, however, the XL246 does need to be removed from the aircraft.

3. Battery Capacity and BITE TEST Interval

It is recommended that the BITE and CAPACITY tests be performed at least once a year. The
tests can be performed, while the unit is installed in the aircraft, by pressing the front panel
BITE TEST pushbutton.

A. On-Aircraft Battery Capacity Test Procedure (Using BATT LEVEL TEST

Switch)
(1) Ensure that the XL246-A has a maximum charge before testing.
This would be assured if the aircraft just returned from a two-hour flight, or if the
aircraft 28 VDC Bus had been ON for two hours.

(2) The aircraft needs to sit, with the 28 VDC OFF (not feeding the XL246-A), for more
than one hour (accuracy increases with time) in an ambient temperature of 65° to
90°F, directly after the two-hour charge time described in step (1).

(3) Depress and hold the BATT LEVEL TEST switch for approximately 5 seconds. At
the end of 5 seconds a green, yellow, or red LED will be illuminated. The colors
indicate:

Green approximately 75-100 percent of (as new) capacity remains.

Yellow approximately 50-75 percent of (as new) capacity remains.
Red approximately 0-50 percent of (as new) capacity remains.

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A red or yellow LED indicates insufficient charge time existed or the battery is weak and
should be replaced.

Note: This Battery Level Test is a coarse indication of battery

capacity remaining based on the original as-new
condition of the battery. The BATT LEVEL TEST does not
address run time for any airplane load. This must be
sized by the installation agency. A more accurate
capacity test is described in Shop Level Charging Test
Procedures on page 503.

4. On-Aircraft BITE TEST Procedure

Depress the BITE TEST pushbutton and hold. Both the CHRG’R and CELL(S) LED’s should
illuminate verifying that the introduction of a false fault into the BITE circuits was detected and
reported. When the BITE TEST switch is depressed the FAULT output also furnishes a FAULT
output signal. Refer to FAULT Output (J1-1) on page 14.

5. Fault Indication

Any fault detected in the BATTERY, CHARGER, or HEATER system will result in a fault
output activation and cause the CHRG’R or CELL(S) LED to illuminate, depending on which
has failed. A fault in the HEATER will be confirmed by the HEATER ON LED not lluminating
when the BATT LEVEL TEST is activated.

Note: The aircraft 28 VDC must be ON to illuminate the

CHRG’R, CELL(S), or HEATER ON LED, except when
performing manual tests, in which case the battery
provides energy to illuminate the BATT LEVEL TEST,
CHRG’R, CELL(S) and HEATER ON LEDs.

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6. Shop Level Charging Test

Note: Always disconnect aircraft 28 VDC and pull the XL246-A
CIRCUIT BREAKER before removing the XL246-A from
its mounting rack.

A. Test Equipment For Shop Level Charging

Note: You may use the URDC 221TF101-01 test if you have
one. If you do, make certain the test set is in the normal
charge mode, and NOT in the trickle charge mode.

a. Bench Charge Harness - This can be a simple two wire (use wire size AWG 16 or 18)
harness with female mating pins to connect to the XL246-A pins. See Figure 901.

Note: Securaplane offers a ready made mating connector harness

for charging and discharging the battery. Call Securaplane
for information.
b. A 28 VDC power supply capable of 20 amperes output.
c. A digital 1% VOM.
d. An ammeter capable of indicating 15 amperes. An ammeter integral to the 28 VDC
power supply is ideal.

B. Shop Level Charge Test Procedures

(1) Ensure that CB-1 is pulled.
(2) Connect the 2-wire harness or Securaplane Connector harness (see Figure 901)
to P1B-5 (+28 VDC) and P1B-6 (GND).
(3) Connect the other ends of the wires to the 28 VDC supply, checking that the polarity is
correct.
Note: If an ammeter is not included on the 28 VDC supply,
connect an ammeter in series with the +28 VDC lead
(15 amp capability).
(4) Adjust the power supply to 28.5±0.5 VDC.
(5) Engage CB-1 on the XL246-A. Readjust the power supply to 28.5±0.5 VDC.
(6) Record the input current.
Note: A low battery will cause up to 11-12 amps to flow for a few
seconds, then settle at (10) amps or below, and slowly
decrease to less than 500 mA.
(7) Allow the XL246-A to charge for four hours or longer. The input current for a fully
charged battery (when new) will normally fall to less than 300 mA.
Note: If the input current is greater than 1 ampere, after four hours,

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it indicates a potentially sulphided battery

(8) After charging the XL246-A, pull CB-1 and allow it to sit for 8-24 hours.
(9) After the 8-24 hours in step (8) above, engage CB-1 and perform a capacity check
using the BATT LEVEL TEST switch or (for more accuracy) the procedure in
Paragraph D. Shop Level Battery Capacity Discharge Test Procedures below.

C. Shop Level Capacity Test - Equipment Required

A 3.8 ohm, 200 watt power resistor or a 6 amp 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.

D. Shop Level Battery Capacity Discharge Test Procedures

Note: You may use the URDC 221TF101-1 for the discharge test.

(1) Remove 28 VDC input for total test.

(2) Disengage CB-1 on the XL246-A.
(3) Connect the load between XL246-A connector P1B-8 output and P1-6.
(4) Connect a digital voltmeter across the load.
(5) Have a stop watch available that reads elapsed time up to 1 hour 20 minutes.
(6) Engage CB-1 and start the stop watch.
(7) Allow the XL246-A to discharge until it cuts the battery output OFF (battery output
falls sharply to less than 10 VDC). The elapsed time should be at least 60 minutes
for a newly installed battery, or 45 minutes for an in-service battery.
(8) If the new XL246-A does not pass the new battery 60-minute test, it should be
returned to Securaplane for analysis.
(9) If an in-service XL246-A does not pass the 45 minute test, return the unit to
Securaplane for warranty repair.

CAUTION: Immediately following the discharge test, re-charge the

battery again per paragraph B. - even if it did not pass the
required time test.

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INSPECTION/CHECK

1. Introduction

This section contains Securaplane’s recommended inspection and check procedures for the
XL246-A Battery Charger. Disassembly is not required to check this unit.

CAUTION: This unit contains an assembly that can be damaged by

incorrect handling. Do not drop or hit unit during these
procedures.

2. Equipment and Materials

Not applicable.

3. General Check Procedures

A. 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 which 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 connectors for damaged or loose pins; ensure they are 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.

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4. Aircraft Level Checkout, Existing Installation

The functional checkout of the XL246-A is the same as the AMPS-2000. The same XL246-A
switches perform the same functions as the AMP-2000 switches.
(1) Activate aircraft electrical power system.
(2) Open the aircraft input circuit breaker to the XL246-A under test.
(3) If the CHARGER INHIBIT function is not incorporated in the aircraft, verify connector
P1-2 is permanently grounded. Go to step (7) below.
(4) If the CHARGER INHIBIT function is incorporated in the aircraft, activate the avionics
system or control system that controls the charger inhibit function.
(5) Verify the inhibit control (28 VDC) on connector P1-2.
(6) Verify the charge inhibit function is not engaged during checkout of the XL246-A.
(7) Install XL246-A in its mounting tray. Secure the J-bolts.
(8) Close XL246-A CB-1.
(9) Close the aircraft input circuit breaker.
(10) Open aircraft input circuit breakers to the rest of the emergency battery packs controlled
through the same switch cluster. The cockpit Not armed/OFF indicator light should be
illuminated.
(11) Engage the cockpit ON switch. The logic controlled outputs should illuminate and apply
power to connected aircraft devices. The ON indicator light illuminates.
(12) Engage the OFF switch. Aircraft devices powered from the XL246-A turn off.
(13) Engage the ARM switch.
(14) Open the aircraft input circuit breaker to remove aircraft 28 VDC from the XL246-A. The
XL246-A logic controlled outputs turn on and apply power to connected aircraft devices.
The ON indicator light illuminates.
(15) Engage the cockpit OFF switch. There shall be no change in XL246-A operation.
(16) Close the aircraft input circuit breaker, restoring 28 VDC to the XL246-A.
(17) Engage either the cockpit OFF or ARM switch to de-power connected aircraft devices.
If the OFF switch is engaged, the Not ARMED/OFF indicator will illuminate. If the ARM
switch is engaged, neither ARM or OFF indicators will illuminate.
(18) Close XL246-A CB.
(19) Leave DC power on the A/C for 1 hr to recharge the unit following installation checkout.

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CLEANING/PAINTING

1. Introduction

This section contains general procedures recommended by Securaplane to clean the XL246-A
Emergency Battery system. There is no disassembly required to clean the unit.
WARNING: Before the materials called out in this publication are
used, understand 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 work
station 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.

2. Cleaning Equipment and Materials

Table 701 presents the required equipment and materials. Equivalent equipment/material can
be used.
Table 701. Cleaning Equipment and Materials

Equipment/Materials Manufacturer

Brush (soft bristle fibers) Commercially available

Cloth Commercially available
Isopropyl alcohol Commercially available
(Federal Specification TT-I-735)
Methyl-ethyl-ketone (MEK) Commercially available
(Federal Specification TT-M-261)
Solvent Micro Care Chemical Corp.,
(Micro Care Proclean) 34 Ronzo Rd,
(with solvent miser grip, ESD safe Bristol, CT 06010
brush, in agreement with MIL 2000)

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3. General Cleaning Practices

• 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.

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

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

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) The connectors shall be free of dirt or corrosion. Scrape off the corrosion and
clean the connectors 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.
Note: Use an approved cap, plug and barrier material for part
storage after cleaning. Do not use tape, loose plastic, or
rags to protect clean parts.
(3) Install a protective cap on the connector to guard against contamination and
thread damage.

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REPAIR
Not Applicable

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SPECIAL TOOLS FIXTURES AND EQUIPMENT

1. Shop Test Equipment

The Bench Charge Harness (Securaplane part number, TE-0011-01) is identified in Figure
901. The wires connected to pin 5 and pin 6 should be 16 gauge or larger, less than 2 meters
(6.5 feet) in length, and terminated in banana plugs or termination compatible with shop
equipment. The terminals connected to pin 7 (optional) and pin 8 may be insulated terminal
posts or banana jacks. They may be soldered directly to the contact; otherwise, a convenient
length of insulated 16-gauge wire is required. If the terminals are to be connected directly to
the contact, it may be necessary to relocate the battery return next to the NAV (IRS) output
terminal in pin 8. Pins 6 and 7 are connected together inside the XL246-A.

Figure 901. Bench Charge Harness

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ILLUSTRATED PARTS CATALOG

Not Applicable

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