SAFT ELECTRIC STORAGE BATTERY Gulfstream Aerospace P/N ...
SAFT ELECTRIC STORAGE BATTERY Gulfstream Aerospace P/N ...
SAFT ELECTRIC STORAGE BATTERY Gulfstream Aerospace P/N ...
You also want an ePaper? Increase the reach of your titles
YUMPU automatically turns print PDFs into web optimized ePapers that Google loves.
<strong>SAFT</strong> AMERICA INC.<br />
Component Maintenance Manual<br />
1159SCAV519-1<br />
<strong>SAFT</strong><br />
<strong>ELECTRIC</strong> <strong>STORAGE</strong> <strong>BATTERY</strong><br />
<strong>Gulfstream</strong> <strong>Aerospace</strong><br />
P/N 1159SCAV519-1<br />
<strong>SAFT</strong> <strong>BATTERY</strong> TYPE<br />
5317CH-1<br />
P/N 023805-000<br />
COMPONENT MAINTENANCE MANUAL<br />
WITH<br />
ILLUSTRATED PARTS LIST<br />
24-34-01<br />
R/R-1<br />
Aug 30 96
REVISION<br />
DATE<br />
ISSUE<br />
DATE<br />
<strong>SAFT</strong> AMERICA INC.<br />
Component Maintenance Manual<br />
1159SCAV519-1<br />
RECORD OF REVISIONS<br />
BY REVISION<br />
DATE<br />
ISSUE<br />
DATE<br />
BY<br />
24-34-01<br />
R/R-1<br />
Aug 30 96
TEMPORARY<br />
REV. NO.<br />
PAGE<br />
NUMBER<br />
<strong>SAFT</strong> AMERICA INC.<br />
Component Maintenance Manual<br />
1159SCAV519-1<br />
RECORD OF TEMPORARY REVISIONS<br />
ISSUE<br />
DATE<br />
BY DATE<br />
REMOVED<br />
BY<br />
24-34-01<br />
T/R-1<br />
Aug 30 96
SUBJECT PAGE DATE<br />
Title T-1 Aug 30/96<br />
Record of<br />
Revisions<br />
Record of<br />
Temporary<br />
Revisions<br />
List of<br />
Effective Pages<br />
Table of<br />
Contents<br />
<strong>SAFT</strong> AMERICA INC.<br />
Component Maintenance Manual<br />
1159SCAV519-1<br />
LIST OF EFFECTIVE PAGES<br />
R/R-1 Aug 30/96<br />
TR-1 Aug 30/96<br />
LEP-1 Aug 30/96<br />
T/C-1<br />
T/C-2<br />
Introduction Intro-1<br />
Intro-2<br />
Description of<br />
Operation<br />
Testing and<br />
Troubleshooting<br />
1<br />
2<br />
3<br />
4<br />
5<br />
6<br />
7/8<br />
101<br />
102<br />
103<br />
104<br />
105<br />
106<br />
107<br />
108<br />
109<br />
110<br />
111<br />
112<br />
Aug 30/96<br />
Aug 30/96<br />
Aug 30/96<br />
Aug 30/96<br />
Aug 30/96<br />
Aug 30/96<br />
Aug 30/96<br />
Aug 30/96<br />
Aug 30/96<br />
Aug 30/96<br />
Aug 30/96<br />
Aug 30/96<br />
Aug 30/96<br />
Aug 30/96<br />
Aug 30/96<br />
Aug 30/96<br />
Aug 30/96<br />
Aug 30/96<br />
Aug 30/96<br />
Aug 30/96<br />
Aug 30/96<br />
Aug 30/96<br />
Aug 30/96<br />
Disassembly 301 Aug 30/96<br />
SUBJECT PAGE DATE<br />
302 Aug 30/96<br />
Cleaning 401<br />
402<br />
Inspection 501<br />
502<br />
503<br />
504<br />
505/506<br />
Aug 30/96<br />
Aug 30/96<br />
Aug 30/96<br />
Aug 30/96<br />
Aug 30/96<br />
Aug 30/96<br />
Aug 30/96<br />
Repair 601/602 Aug 30/96<br />
Assembly and<br />
Storage<br />
Tools and<br />
Special<br />
Equipment<br />
Illustrated Parts<br />
List<br />
701<br />
702<br />
703<br />
704<br />
705/706<br />
901<br />
902<br />
903/904<br />
Intro-1001-<br />
1 Intro-<br />
1001-2<br />
Intro-1001-<br />
3<br />
1001<br />
1001-0<br />
1001-1<br />
Aug 30/96<br />
Aug 30/96<br />
Aug 30/96<br />
Aug 30/96<br />
Aug 30/96<br />
Aug 30/96<br />
Aug 30/96<br />
Aug 30/96<br />
Aug 30/96<br />
Aug 30/96<br />
Aug 30/96<br />
Aug 30/96<br />
Aug 30/96<br />
Aug 30/96<br />
24-34-01<br />
LEP-1<br />
Aug 30 96
<strong>SAFT</strong> AMERICA INC.<br />
Component Maintenance Manual<br />
1159SCAV519-1<br />
TABLE OF CONTENTS<br />
SUBJECT PAGE<br />
DESCRIPTION AND OPERATION<br />
1. Description 1<br />
2. Operation 6<br />
TESTING AND TROUBLESHOOTING<br />
1. Testing 101<br />
DISSASSEMBLY<br />
1. Disassembly 301<br />
CLEANING<br />
1. Cleaning the Valves 401<br />
2. Cleaning the Cells 401<br />
3. Cleaning the Case 402<br />
4. Cleaning the Hardware 402<br />
INSPECTION<br />
1. Visual Inspection 501<br />
2. Checking a Valve 501<br />
3. Checking Upper and Lower Nuts for Tightness 502<br />
4. Checking the Connector Receptacle 502<br />
5. Checking the Temperature Sensor Harness Assembly 502<br />
6. Checking the Temperature Sensor Harness Assembly 502<br />
REPAIR<br />
1. Case 601<br />
2. Cells 601<br />
24-34-01<br />
TABLE OF CONTENTS - PAGE 1<br />
Aug 30/96
<strong>SAFT</strong> AMERICA INC.<br />
Component Maintenance Manual<br />
1159SCAV519-1<br />
SUBJECT PAGE<br />
ASSEMBLY AND <strong>STORAGE</strong><br />
1. Assembly 701<br />
2. Storage 702<br />
FITS AND CLEARANCES<br />
TOOLS AND SPECIAL EQUIPMENT 901<br />
ILLUSTRATED PARTS LIST<br />
1. Introduction Intro-1001<br />
2. Illustrated Parts List 1001<br />
24-34-01<br />
TABLE OF CONTENTS - PAGE 2<br />
Aug 30/96
1. General<br />
<strong>SAFT</strong> AMERICA INC.<br />
Component Maintenance Manual<br />
1159SCAV519-1<br />
INTRODUCTION<br />
This component maintenance manual has been prepared in compliance with ATA<br />
specification No. 100 by the (AIR TRANSPORT ASSOCIATION OF AMERICA). Its<br />
purpose is to describe the procedures, applied in the manufacturer's shops to<br />
enable a technician, unfamiliar with the component, to return it to operating<br />
condition or perform an overhaul of the component.<br />
The operations described must be carried out in maintenance shops using special<br />
tools and test equipment.<br />
This manual does not cover standard techniques, maintenance intervals nor details<br />
which are likely to vary depending on the shop facilities available.<br />
2. Format<br />
A. The page numbering system of the manual consists in using a page number<br />
block for each section as follows. As concerns small basic items of<br />
equipment, more than one section can be covered on the same page.<br />
1-100 DESCRIPTION AND OPERATION<br />
101-200 TESTING AND TROUBLESHOOTING<br />
201-300 (NOT ASSIGNED)<br />
301-400 DISASSEMBLY<br />
401-500 CLEANING<br />
501-600 INSPECTION<br />
601-700 REPAIR<br />
701-800 ASSEMBLY AND <strong>STORAGE</strong><br />
801-900 FITS AND CLEARANCES<br />
901-1000 TOOLS AND SPECIAL EQUIPMENT<br />
1001-1100 ILLUSTRATED PARTS LIST<br />
24-34-01<br />
INTRODUCTION - PAGE 1<br />
AUG 30/96
<strong>SAFT</strong> AMERICA INC.<br />
Component Maintenance Manual<br />
1159SCAV519-1<br />
B. In general, all values are expressed in units of International System of<br />
Measurement (meter, kilogram, second) or multiples and sub-multiples of<br />
same.<br />
In some particular cases more appropriate units are employed.<br />
3. Revision<br />
With each revision issued for the manual, detailed instructions are supplied crossreferring<br />
to the page numbers concerned for insertion and deletion. The revised,<br />
added or deleted material is indicated by the letter R printed in the margin.<br />
24-34-01<br />
INTRODUCTION - PAGE 2<br />
AUG 30/96
1. Description<br />
A. General<br />
<strong>SAFT</strong> AMERICA INC.<br />
Component Maintenance Manual<br />
1159SCAV519-1<br />
DESCRIPTION AND OPERATION<br />
The electrical storage battery supplies the aircraft with 25.2 V D.C. until the<br />
generators operate or in case of generator output drop.<br />
It also enables direct or indirect starting of the propulsion engine(s).<br />
The battery assembly comprises 21 nickel cadmium series mounted storage<br />
cells contained in a metallic box which accommodates a connector receptacle<br />
and accommodates an additional connector receptacle which is connected to<br />
the temperature sensor/charge control harness assembly.<br />
B. Characteristics<br />
(1) Dimensions and weight<br />
OVERALL DIMENSIONS mm (in.) MAX WEIGHT<br />
IN kg (lb)<br />
MAX LENGTH MAX WIDTH MAX HEIGHT<br />
317 mm<br />
(12.48 in.)<br />
248 mm<br />
(9.76 in.)<br />
(2) Technical features<br />
265 mm<br />
(10.43 in.)<br />
43.1 kg<br />
(95 lb.)<br />
Alkaline, spill-proof, nickel cadmium battery, 25.2 V D.C., 53<br />
Amp hour.<br />
Connector receptacle complying with MS 3509 or equivalent.<br />
24-34-01<br />
PAGE 1<br />
AUG 30/96
Cell<br />
<strong>SAFT</strong> AMERICA INC.<br />
Component Maintenance Manual<br />
1159SCAV519-1<br />
Very thin, plastic bonded cadmium oxide negative<br />
plates, and nickel-hydrate impregnated positive plates.<br />
Composite separator made of synthetic fiber. Ternary<br />
electrolyte (chemically pure potassium hydroxide<br />
aqueous solution).<br />
Polyamide boxes and covers assembled by<br />
thermowelding.<br />
Nickel-plated copper output terminals. Sealing around<br />
the terminals is provided by preformed packings (O-<br />
Rings).<br />
Removable polyamide safety valve located in the center<br />
of the cover.<br />
Nominal capacity (C1) = 53 Ah (at the one hour discharge<br />
rate).<br />
Special characteristics<br />
Two thermostats (T1 & T2) in series with a resistor (R1)<br />
connected to the positive post of the main battery<br />
receptacle. One thermistor fitted to a special mounting<br />
plate. A series resistor (R2) connected to the negative<br />
post of the main battery receptacle. A connector<br />
receptacle located under the main connector receptacle<br />
provides electrical interface with the on board charger.<br />
Operating temperature of the thermostats T1 and T2:<br />
Open on temperature rise at 68°C (154°F).<br />
Thermistor registers 2460 Ohms at 23°C (73.4°F).<br />
R1 and R2 register 32.4K Ohms each.<br />
Temperature sensor/charge control auxiliary connector<br />
complies with MS 24264 R 12 B 12 SN<br />
24-34-01<br />
PAGE 2<br />
AUG 30/96
<strong>SAFT</strong> AMERICA INC.<br />
Component Maintenance Manual<br />
1159SCAV519-1<br />
C. Detailed description (See Fig. 1)<br />
This comprises:<br />
a case assembly (10)<br />
complete cover (20) with an insulating gasket made of silicone elastomer<br />
bonded to the to the inner face.<br />
(a) Box<br />
(2) Storage cells<br />
The case assembly is provided with two vent pipes, four spring<br />
fasteners, and two lifting handles.<br />
An identification plate.<br />
The front face of battery P/N 1159SCAV519-1 supports the base plate<br />
of the connector receptacle connected to the temperature<br />
sensor/charge control harness assembly.<br />
(b) Cover<br />
The cover (20) is laterally provided with four catches intended for<br />
attachment to the box, and with a bar, notched at both ends, intended<br />
for battery mounting through tie-rods secured to a rack.<br />
The twenty one electrical storage cells (30) are arranged in two rows of eight and<br />
one row of five within the battery case.<br />
Each storage cell is equipped with a safety valve (120) fitted with a preformed<br />
packing (130).<br />
The storage cell terminals are made up of two threaded nickel-plated copper rods.<br />
24-34-01<br />
PAGE 3<br />
AUG 30/96
<strong>SAFT</strong> AMERICA INC.<br />
Component Maintenance Manual<br />
1159SCAV519-1<br />
Each storage cell terminal is fitted with:<br />
a preformed packing (40),<br />
a flat washer (50),<br />
two Belleville washers (60),<br />
a preformed washer indicating polarity (+) (70) or (-) (80),<br />
a terminal lower nut (90),<br />
a Belleville washer (100),<br />
a terminal nut (110).<br />
a vent valve assembly (120)<br />
(3) Accessories<br />
The accessories are used to secure the storage cells in the form of a<br />
liner spacer kit (290).<br />
There are:<br />
six end liners,<br />
two notched side liners,<br />
four intermediate liners inserted between the three rows of<br />
storage cells,<br />
twenty two links (140, 150, 160) ensuring series-connection of<br />
storage cells and connection to the main connector receptacle,<br />
24-34-01<br />
PAGE 4<br />
AUG 30/96
<strong>SAFT</strong> AMERICA INC.<br />
Component Maintenance Manual<br />
1159SCAV519-1<br />
NOTE: ITEM NUMBERS ARE THOSE SHOWN<br />
IN IPL, FIG. 1<br />
Description<br />
Figure 1<br />
24-34-01<br />
PAGE 5<br />
AUG 30/96
2. Operation<br />
(4) Connector Receptacle<br />
<strong>SAFT</strong> AMERICA INC.<br />
Component Maintenance Manual<br />
1159SCAV519-1<br />
Main connector receptacle (170) is secured to the box by four Sems<br />
screws (190).<br />
The temperature sensor/charge control auxiliary connector receptacle<br />
is secured to the box by four screws (230) and four locking nuts (240).<br />
A. Principle of Operation<br />
The battery plates store electrical power supplied by a charging source, and<br />
supply power when the battery is connected to a load circuit, i.e. when it<br />
discharges.<br />
During charge, nickel hydroxide Ni (0H)2 of the positive plates is oxidized and<br />
is transformed into superior hydroxide NO O OH; cadmium hydroxide Cd<br />
(OH)2 of the negative plates is reduced and is transformed into cadmium<br />
metal (Cd). Reverse reactions take place during discharge and active<br />
materials return to their initial state. The electrolyte (ternary hydroxide<br />
solution) does not undergo any significant chemical change.<br />
For a battery with a given volume, the nominal capacity of the battery<br />
discharged in 1 hour is determined by the quantity of electricity (Ah) the<br />
battery can supply.<br />
The efficiency of the battery, in terms of quantity of electricity, is 71.5%. This<br />
means that, in order for a 53 Ah battery to supply 100% of its capacity, it must<br />
store a quantity of electricity of 74.2 Ah, i.e. 140% of C1 .<br />
It is only on this condition that complete chemical transformation of the active<br />
materials takes place.<br />
24-34-01<br />
PAGE 6<br />
AUG 30/96
B. Operation in normal use<br />
(1) Charging in normal use<br />
<strong>SAFT</strong> AMERICA INC.<br />
Component Maintenance Manual<br />
1159SCAV519-1<br />
Charging the battery on the aircraft is ensured by an on board<br />
chargers supplied by one (or several) AC generator(s).<br />
NOTE: When a battery, in which the active materials have been<br />
fully transformed, is subjected to an extended charging<br />
operation, the battery becomes overcharged. The<br />
current passing through the assembly gives rise to the<br />
electrolysis of the electrolyte water into its two elements:<br />
oxygen and hydrogen. The rate of decomposition is 1<br />
cm 3 (0.061 cu. in.) of water for an overcharge of 3 Ah.<br />
Water consumption in overcharging conditions is<br />
therefore proportional.<br />
(2) Discharging<br />
The nominal capacity C1 of the battery corresponds to the 1 hour rate<br />
of discharge; that is, the battery can supply a 53 amp current for 1<br />
hour, when it is at 100% state of charge.<br />
However, the battery can, without danger, supply currents greatly<br />
exceeding the nominal discharge current. For instance, a battery with<br />
a 53 Ah nominal capacity can supply, in peak conditions, currents<br />
about twenty times its nominal rating.<br />
24-34-01<br />
PAGE 7/8<br />
AUG 30/96
<strong>SAFT</strong> AMERICA INC.<br />
Component Maintenance Manual<br />
1159SCAV519-1<br />
TESTING AND TROUBLESHOOTING<br />
NOTE: Tools and special equipment to be used are listed under "Tools and<br />
Special Equipment".<br />
1. Testing<br />
A. Setting into service<br />
(1) Ground maintenance<br />
(a) Operating voltage<br />
The nominal charging voltage for 21-cell batteries is 31.5 V<br />
D.C. at 20C (68F). An end-of-charge current matching the<br />
water consumption is obtained at this voltage level.<br />
In case the water consumption is excessive during the<br />
service cycle, i.e. more than 88 cm 3 ( 5.39 cu.in.) per cell<br />
[see para. B . (3) (b) ], check the voltage above, or the usual<br />
temperature of the batteries in service (see aircraft<br />
Maintenance Manual).<br />
(b) Insulation<br />
Electrolyte condensation or overflowing may reduce the<br />
value of the insulation between the battery electrical circuit<br />
(connector receptacle disconnected and the box.<br />
The value of the insulation under 250 V D.C. should be<br />
greater than 10 megohms.<br />
(c) Charge condition<br />
The battery can be charged in flight up to 100%. When this<br />
state is reached, the open-circuit voltage is about 31.5 V<br />
D.C.<br />
24-34-01<br />
PAGE 101<br />
AUG 30/96
<strong>SAFT</strong> AMERICA INC.<br />
Component Maintenance Manual<br />
1159SCAV519-1<br />
When the off-load voltage of the battery after an idle period<br />
is greater than 25.5 V D.C., it can be deemed at least 50%<br />
charged. If required (see aircraft maintenance manual),<br />
perform fast-charging [see para. A (2) (c) ].<br />
(d) Maintenance periods<br />
Maintenance on the aircraft is defined by the corresponding<br />
specifications. The workshop maintenance periods and<br />
removal conditions are covered in the aircraft manuals and<br />
determined by the users, taking account of the operating<br />
conditions.<br />
The maintenance operations can be broken down as follows:<br />
the complementary fast-charging operations above,<br />
Charging and topping up of the electrolyte level including :<br />
residual discharge [see para. B. (2) (a) ],<br />
fast charging as per the procedure mentioned in paragraph<br />
A. (2) (c) 1st method,<br />
topping up the of electrolyte level and valve cleaning [see<br />
para. B. (3) (b)]<br />
visual inspection of the thermostat (see "Inspection"),<br />
Reconditioning, including:<br />
residual discharge,<br />
balancing as required,<br />
complete charging and topping up of the electrolyte levels,<br />
valve cleaning<br />
checking the thermostat for operation,<br />
24-34-01<br />
PAGE 102<br />
AUG 30/96
<strong>SAFT</strong> AMERICA INC.<br />
Component Maintenance Manual<br />
1159SCAV519-1<br />
checking the capacity (discharge and complementary<br />
checks as required),<br />
final charging after checking the insulation,<br />
Overhaul, including:<br />
disassembling the battery,<br />
cleaning,<br />
inspection,<br />
assembling the battery.<br />
This operation is to be performed during reconditioning, after<br />
the capacity check and before the final charging.<br />
It is either scheduled or to be performed when cells are to be<br />
replaced.<br />
(2) Charging in workshop<br />
(a) General conditions<br />
Equipment required :<br />
battery charger,<br />
valve wrench.<br />
CAUTION: CHARGING SHOULD BE PERFORMED ONLY IN<br />
CLEAN AND VENTILATED PREMISES WHICH<br />
ARE NOT USED FOR LEAD BATTERIES (ACID<br />
ATMOSPHERE).<br />
REMOVE THE COVER OF THE <strong>BATTERY</strong> AND<br />
LOOSEN, BUT DO NOT REMOVE, THE VALVES<br />
(USING THE WRENCH), ALLOWING THE<br />
GASES PRODUCED TO BE DISSIPATED<br />
WITHOUT PLACING THE ELECTROLYTE IN<br />
CONTACT WITH THE AMBIENT AIR (RISKS OF<br />
CARBONATION).<br />
24-34-01<br />
PAGE 103<br />
AUG 30/96
<strong>SAFT</strong> AMERICA INC.<br />
Component Maintenance Manual<br />
1159SCAV519-1<br />
NOTE: After charging a discharged battery for 5 min., and some or all of the<br />
individual cell voltages indicate greater than 1.5 V D.C. [see para. B.<br />
(3)] add 10 to 15 cm 3 of distilled water to these cells. The high<br />
voltage reading may be a result of being dry.<br />
When this can be foreseen, it is advisable to check the voltages of<br />
each cell at the beginning of the charging operation.<br />
During charge, and particularly near the end of the charging period, a<br />
production of foam may occur. This phenomenon is generally due to:<br />
the presence of greasy matter inside the cell (for instance, grease<br />
or oil which could have accidentally ingressed through the valve<br />
clearing hole),<br />
excessive reduction of the specific gravity of the free electrolyte<br />
above the plates. This can happen particularly when distilled water<br />
is added to a cell having consumed all (or even more than) its<br />
content of water reserve. In this case, it is necessary to add a<br />
large volume of distilled water, which does not immediately mix<br />
with the concentrated electrolyte remaining in the cell.<br />
To stop this phenomenon, it is generally sufficient to interrupt the<br />
charging operation and to perform a discharge allowing the electrolyte<br />
to mix. The next charging operation will further improve electrolyte<br />
dispersion and the phenomenon should then disappear.<br />
In the case where the foam is formed by the contact with greasy matter<br />
inside the cell, practically nothing can be done except preventing the<br />
foam from spreading over the covers and flowing between the cells.<br />
This can easily be performed by fitting a water-absorbent cotton pad in<br />
place of the valve.<br />
(b) Slow-rate low-current charging<br />
For a new battery or after removing a discharged battery from storage;<br />
charge the battery at 5.3 amps constant current for 10-12 hours to<br />
obtain 30 V D. C. As measured across the terminals, then continue<br />
with the same rate<br />
24-34-01<br />
PAGE 104<br />
AUG 30/96
<strong>SAFT</strong> AMERICA INC.<br />
Component Maintenance Manual<br />
1159SCAV519-1<br />
5.3 A for 4 additional hours. Charging can be performed in two<br />
periods provided that the first period lasts at least 8 hours.<br />
Do not interrupt the charging operation for the last 5 hr. (to ensure<br />
normal topping up of the electrolyte levels).<br />
(c) Fast-rate charging (discharged battery)<br />
This charging operation is performed at two successive regulated<br />
current rates :<br />
First method<br />
First charge at 26.5 A up to 32.5 V D.C. (2 hr.40 min. maximum<br />
depending on the actual capacity of the battery), then charge at<br />
5.3 A for 4 hr. (the voltage is then about 35 V D.C.)<br />
Second method<br />
First charge at 53 A up to 32.9 V D.C. (1 hr. 15 min. max.<br />
depending on the actual capacity of the battery), then charge at<br />
5.3 A for 4 hr. (the voltage is then about 35 V D.C.).<br />
NOTE: The high current phase is limited by the voltage, in order not to<br />
overload (or underload) batteries with excessively different capacities<br />
and to completely charge the battery in about 6 hr.<br />
(d) Charging a battery whose charge is unknown<br />
Applicable when a complement of charge is needed, or if the battery<br />
has not been used for a period of less than 2 months, if it is not<br />
possible to perform complete recycling :<br />
charge at 5.3 A until the voltage reaches 32.5<br />
24-34-01<br />
PAGE 105<br />
AUG 30/96
B. Recycling<br />
<strong>SAFT</strong> AMERICA INC.<br />
Component Maintenance Manual<br />
1159SCAV519-1<br />
or charge at 26.5 A until the voltage reaches 35 volts.<br />
or charge at 53 A until the voltage reaches 35 volts.<br />
(1) Equipment and product required<br />
(a) Equipment<br />
Battery charger.<br />
D.C.voltmeter, 0 to 3 V/0 to 40 V, class 0.5.<br />
Stopwatch/Timer<br />
20 resistors (1 ohm approx.10W min. each) fitted at both ends<br />
with "alligator" clips.<br />
Plastic syringe fitted with a cylindrical adaptor and a stop. (P/N<br />
20916-1)<br />
Valve wrench. (P/N 93365 see Fig. 902)<br />
(b) Product<br />
Distilled water.<br />
(2) Residual discharge and rebalancing<br />
(a) Residual discharge<br />
After removing the battery for scheduled maintenance or after in<br />
flight detection of a fault, discharge the unit as follows:<br />
24-34-01<br />
PAGE 106<br />
AUG 30/96
<strong>SAFT</strong> AMERICA INC.<br />
Component Maintenance Manual<br />
1159SCAV519-1<br />
Discharge 100% of C1 at a constant current, i.e. 53 A (or 50%<br />
C1, 26.5 A), and note the time necessary to obtain a voltage of<br />
21 V D.C. across the battery terminals. The current should<br />
automatically or manually be regulated. When the voltage<br />
across the terminals passes between 22 and 21 V D.C. (in other<br />
words, if sudden voltage drops occur), measure the voltage of<br />
each cell in order to detect and localize imbalance. If the V<br />
between cells is practically nil (normal battery), let the battery<br />
cool down before performing a new charging operation and<br />
topping up of levels [see para. (3) ].<br />
(b) Reconditioning<br />
As soon as the voltage of one or several cell(s) drops below 1 V<br />
D.C., or, as a limit, when the voltage across the terminals of the<br />
battery reaches 21 V D.C., stop discharging (and note the<br />
discharge duration). Continue the discharge. Use a 1-ohm<br />
resistor to shunt each cell and keep the resistors in place for 16<br />
to 24 hr.<br />
In these conditions, each cell will discharge at a slow rate<br />
through its individual resistor without danger or reversing the<br />
polarities.<br />
NOTE: The complimentary checks covered in paragraph (4) (b)<br />
provide a means of classifying the cells after their capacity; this<br />
in not covered at this stage.<br />
(3) Complete charging and topping up of the electrolyte level<br />
(a) Charging<br />
Charge the battery as per paragraph A. (2) (b) or A. (2) (c) to<br />
ensure complete charging to 140% of the available capacity.<br />
This charging provides a quantity of electricity equal to 140% of<br />
the capacity of the battery. During the final stage, a certain<br />
quantity of water from the electrolyte is decomposed and will<br />
have to be replaced as per the following operation.<br />
At the end the 4hr. overcharge, the electrolyte is at its maximum<br />
level (presence of H2 and 0 bubbles on and between the plates)<br />
and the voltage of the battery is 33 to 33.6 V D.C. [between 15<br />
24-34-01<br />
PAGE 107<br />
AUG 30/96
<strong>SAFT</strong> AMERICA INC.<br />
Component Maintenance Manual<br />
1159SCAV519-1<br />
and 25C (59 and 77F) ]. The individual voltages of the cells<br />
should be homogeneous and about 1.6 V D.C.<br />
(b) Topping up the electrolyte level<br />
During the last charging hour, as close as possible to the end of<br />
charge, and keeping the charge at 5.3 A, add distilled water to<br />
top up the level of the liquid in each cell.<br />
NOTE: In case of simultaneous recharging of several batteries,<br />
consider the time required to top up their levels. If necessary,<br />
extend the charging time by a few minutes so as to complete<br />
this operation.<br />
Checking the level as described below is valid only if it is<br />
performed at the end of charging, while the current flows.<br />
CAUTION: IF THIS ADJUSTMENT IS NOT PERFORMED AS PER THESE<br />
SPECIFICATIONS, THE CELLS WILL OVERFLOW.<br />
The level of the electrolyte should be 20mm below the valve seat (the<br />
valve and valve seal should be removed to obtain accurate<br />
measurement).<br />
To adjust the level, after removing each valve, use a plastic syringe<br />
whose adapter is provided with a tube and a stop; the end of the<br />
syringe should be a 20mm (0.79 in.) below the valve seat (see Fig.<br />
101).<br />
By maintaining the stop shoulder in contact with the valve seat, and by<br />
pulling the syringe piston, checking for correct topping up is<br />
immediate.<br />
if the level is too low, the syringe piston will come up "dry",<br />
any excess fluid will be sucked into the syringe until the level<br />
coincides with the tip of the tube.<br />
If the volume of water added to any cell is greater than 88cc, check<br />
the conditions of use [see para. A. (1) (a)]. For new batteries with a<br />
normally correct level, the volume of added water should not exceed<br />
88cc.<br />
24-34-01<br />
PAGE 108<br />
AUG 30/96
<strong>SAFT</strong> AMERICA INC.<br />
Component Maintenance Manual<br />
1159SCAV519-1<br />
TOPPING UP WITH A SYRINGE FITTED WITH CALIBRATED ADAPTER<br />
FIGURE 101<br />
24-34-01<br />
PAGE 109<br />
AUG 30/96
<strong>SAFT</strong> AMERICA INC.<br />
Component Maintenance Manual<br />
1159SCAV519-1<br />
NOTE: Clean the valves (see "Cleaning", para.1) while the levels are<br />
being adjusted. Leave the cells unplugged for as short as time<br />
as possible.<br />
CAUTION: NEVER USE ACID OR A SOLUTION OF ACID AND WATER<br />
TO ADJUST CELL LEVELS IN NICKEL-CADMIUM<br />
BATTERIES. ANY TRACE OF ACID, HOWEVER SMALL,<br />
WILL PERMANENTLY DAMAGE THE <strong>BATTERY</strong>. ONLY USE<br />
EQUIPMENT WHICH HAS NEVER BEEN USED FOR LEAD<br />
BATTERIES. AVOID USING CHEMICALLY PURIFIED WATER<br />
WHICH CONTAINS ACID OR CHLORINATED ELEMENTS.<br />
(4) Checking the thermostat for operation (see "Inspection").<br />
(5) Capacity check<br />
(a) Discharge<br />
Within 24 hours after charging and topping up the level,<br />
discharge the battery down to 1 volts per cell [see para. (2) (a) ].<br />
Note the discharge duration and the time when some cells drop<br />
below 1 V D.C. Stop discharging when reaching 21 V D.C.<br />
across the battery terminals.<br />
Conclusions to be drawn from the above test :<br />
the battery is correct if the duration of the first discharge of the<br />
battery [see para. (2) (a) ]. is greater than 30 min. If using the<br />
discharge current of C1 or 60 min. if using the discharge<br />
current of 0.5C1, and the duration the second discharge is at<br />
least equal to 1 hr. 100% charge using C1 or 122 min. using<br />
0.5C1,<br />
if the duration of the first discharge is less than 30 min. using<br />
the discharge current of C1 or 60 min. using the discharge of<br />
0.5C1, and the duration of the second discharge is correct (1<br />
hr. at C1 or 122 min. at 0.5C1, minimum), the condition of the<br />
battery is correct, but it is not completely charged and the<br />
operating conditions should be checked,<br />
if some cells remain shorted during discharge, discard them.<br />
24-34-01<br />
PAGE 110<br />
AUG 30/96
<strong>SAFT</strong> AMERICA INC.<br />
Component Maintenance Manual<br />
1159SCAV519-1<br />
if the duration of the second discharge is less than 1 hr. At<br />
C1 (less than 122 min. At 0.5C1), or if the voltage of some<br />
cells is less than 1 V D.C. within 1 hour of discharge (122<br />
min. At 0.5C1 ), the battery should undergo a more complete<br />
overhaul. Perform the complementary checks [see para.<br />
(b)].<br />
(b) Complementary checks<br />
The capacity supplied by the battery is :<br />
53 A • number of minutes before 21 V D.C. / 60 = Number of<br />
Ampere-hours (Ah), or divide by 122 if using 0.5C1<br />
If the capacity is not greater than 53 Ah, or if the voltage of each cell<br />
rises too quickly during charging, drops, or is excessively low at the<br />
end of charge, some cells may have been insufficiently balanced, the<br />
volume of added water is insufficient, or the cell separators are<br />
damaged.<br />
Repeat the balancing operations more accurately by discharging at<br />
10 A.<br />
Meanwhile, regularly measure and note the voltage of each cell,<br />
observing the sequence of measurement. Locate and shunt the cells<br />
whose voltage drops below 1 to 0.9 V D.C. using a 1-ohm (10 W)<br />
resistor.<br />
Stop discharging at the latest when the voltage reaches 10 V across<br />
the battery terminals. Keep the shunts in place as described in<br />
paragraph (2) (b).<br />
Repeat the remaining operations: slow-rate charging [see para. A. (2)<br />
(b)], checking the levels [see para. (3) (b)] and a new test discharge<br />
[see para (a)].<br />
Regularly check the voltage of each cell during the first and last hour<br />
of charging.<br />
At the end of this test, discard the following cells whose operation is<br />
defective:<br />
cells not reaching 1.2 V D.C. after 5 min. Charging,<br />
24-34-01<br />
PAGE 111<br />
AUG 30/96
<strong>SAFT</strong> AMERICA INC.<br />
Component Maintenance Manual<br />
1159SCAV519-1<br />
cells whose voltage is less than 1.5 V D.C. at the end of 5.3 A<br />
charging,<br />
cells whose voltage is greater than 1.78 V D.C. at the end of<br />
charging [at 20C (68 F)],<br />
cells whose voltage still falls below 1 V D.C. before 1 hr's.<br />
discharge, (122 min. at 0.5C1) when the last test discharge is<br />
performed.<br />
NOTE: A more accurate procedure intended to discard the defective cells<br />
consists in extending the end of charge described in paragraph A. (2)<br />
(b) for 4 to 5 hr. under 5.3 A and localizing the cells whose voltage<br />
falls below 1.5 V D.C.<br />
(c) Replacing cells<br />
Replacing cells requires disassembly and reconditioning of the battery.<br />
After replacing the cells, perform a fast-rate charging [see para. A. (2)<br />
(c) ].<br />
The capacity of the replacement cells and remaining cells should be<br />
approximately the same, to avoid creating new unbalance. Only a<br />
small number of new cells can be installed in a battery comprised of<br />
average cells. It is advisable to series-connect average cells to obtain<br />
balanced batteries.<br />
The tests as described in paragraph (b), together with an accurate<br />
control of the voltage rise of the cells during charging, allow for<br />
qualitative classification and thus economical use of the cells.<br />
(6) Final charging<br />
Check for insulation [see para. A. (1) (b) ] before performing this<br />
charging operation prior to setting into service. Perform a fast-range<br />
charging [see para. A. (2) (a) and A. (2) (c) ].<br />
24-34-01<br />
PAGE 112<br />
AUG 30/96
<strong>SAFT</strong> AMERICA INC.<br />
Component Maintenance Manual<br />
1159SCAV519-1<br />
DISASSEMBLY<br />
NOTE: See "Testing and Troubleshooting" to determine the condition of the<br />
unit or the most likely cause of faulty operation.<br />
Tools and special equipment to be used are listed under "Tools and Special Equipment".<br />
1. Disassembly (See IPL, Fig. 1)<br />
Remove cover (20) .<br />
CAUTION: MAKE SURE THAT THE <strong>BATTERY</strong> IS COMPLETELY DISCHARGED<br />
BEFORE PERFORMING THE FOLLOWING OPERATIONS.<br />
Remove terminal nuts (110), spring washers (100), and rigid links (140,and<br />
150) interconnecting cells (30).<br />
Detach the temperature sensor harness assembly (220) ring terminals from<br />
the connector adapter (170) interconnecting links (160) by removing the two<br />
screws (270) and lock nuts (280).<br />
Extract the first cell in each row using wrench. (P/N 17556 see Fig. 901) The<br />
remaining cells may be removed by hand thereafter.<br />
Remove the liner spacers (300).<br />
Unscrew the four attaching sems screws (190), and remove connector<br />
receptacle (170) ; recover preformed packing (180).<br />
Remove cell valves (120) using wrench 93365 (use the two lugs provided to<br />
facilitate unlocking); recover preformed packing (130).<br />
Remove the four screws (230) and four locking nuts (240) retaining the<br />
temperature sensor harness assembly (220).<br />
24-34-01<br />
PAGE 301<br />
AUG 30/96
<strong>SAFT</strong> AMERICA INC.<br />
Component Maintenance Manual<br />
1159SCAV519-1<br />
Remove the temperature sensor harness assembly (220) through the<br />
opening in liner and spacer bracket.<br />
Disassemble the temperature sensor harness assembly (220) from the plate<br />
and stud assembly (250) by removing the four retaining lock nuts (260).<br />
Remove the temperature sensor harness assembly (220).<br />
24-34-01<br />
PAGE 302<br />
AUG 30/96
1. Cleaning the valves<br />
<strong>SAFT</strong> AMERICA INC.<br />
Component Maintenance Manual<br />
1159SCAV519-1<br />
CLEANING<br />
CAUTION: THE USE OF GASOLINE, CHLORINATED SOLVENT OR ANY<br />
OTHER SOLVENT IS STRICTLY PROHIBITED.<br />
Remove the valves and soak them for a sufficient time to dissolve any salts that are<br />
present in a container filled with distilled water or, if not available, with very clean<br />
and non-acid water.<br />
The purpose of this dipping operation is to dissolve the salts likely to accumulate<br />
within the valve clearing ports.<br />
While the valves are immersed, take all appropriate precautions to prevent foreign<br />
matter from falling inside the cells, and to avoid the reaction of the electrolyte in<br />
contact with the ambient air.<br />
Before fitting back the valves on the cells, check them for operation (see<br />
"Inspection").<br />
2. Cleaning the cells<br />
Two cleaning procedures can be used :<br />
cleaning with well-filtered compressed air,<br />
cleaning by washing.<br />
A. Cleaning with compressed air<br />
NOTE: To avoid any short-circuit, blow with a rubber hose or a pipe fitted with<br />
an insulating adaptor.<br />
Thoroughly blow on the cell covers, in order to expel outside the box the dust and<br />
the salts likely to have accumulated on the covers.<br />
24-34-01<br />
PAGE 401<br />
AUG 30/96
<strong>SAFT</strong> AMERICA INC.<br />
Component Maintenance Manual<br />
1159SCAV519-1<br />
B. Cleaning by washing (cells removed)<br />
3. Cleaning the box<br />
This procedure is more rational and consists in washing the terminals,<br />
covers and cell walls with warm water and a smooth non-metallic<br />
brush, in order to remove any trace of potassium or salts.<br />
Before cleaning, make sure that the cell vent valves are installed and<br />
secure.<br />
Never immerse the cells in water.<br />
Wipe each cell, then let in dry in ambient air.<br />
Do not submerge or force water in vent valve area.<br />
Wash with water and let dry in the ambient air after wiping.<br />
4. Cleaning the nuts, links, spring washers, endplates and sideplates<br />
Clean with warm water and a brush, and let dry in ambient air.<br />
Discard any corroded or mechanically defective part.<br />
24-34-01<br />
PAGE 402<br />
AUG 30/96
<strong>SAFT</strong> AMERICA INC.<br />
Component Maintenance Manual<br />
1159SCAV519-1<br />
INSPECTION<br />
NOTE: Tools and special equipment to be used are listed under "Tools and<br />
Special Equipment".<br />
1. Visual inspection<br />
Inspect the box on the outside and make sure that it does not show any trace<br />
of impact.<br />
Check the cells for condition, in order to detect any electrolyte seepage<br />
around the terminals, traces of shorting, corrosion by potassium, cover lifting,<br />
cracked cells, etc.<br />
Discard and replace any corroded or damaged parts.<br />
2. Checking a valve<br />
Remove the valve.<br />
Screw the valve fitted with its seal on a manifold fitted with an appropriate<br />
adapter.<br />
Connect this tube to an adjustable pressure reducing valve and then to a<br />
compressed air line or a compressed air cylinder.<br />
Adjust the pressure to 0.5 bar (7.25 psi) and dip the valve in a container filled<br />
with water. If the valve is in good condition, air bubbles should come off.<br />
If there are no bubbles, increase pressure until the air escapes, then<br />
gradually decrease pressure to 0.5 bar (7.25 psi) and note the value for<br />
which the air stops escaping.<br />
Discard any valve whose operating pressure is greater than 0.7 bar (10 psi)<br />
after this "lifting" operation is performed, and replace the valve by a duly<br />
tested spare valve. Also discard any valve whose operating pressure is less<br />
than 0.14 bar (2 psi).<br />
24-34-01<br />
PAGE 501<br />
AUG 30/96
<strong>SAFT</strong> AMERICA INC.<br />
Component Maintenance Manual<br />
1159SCAV519-1<br />
Install the valve using wrench p/n 93365. (see Fig. 902)<br />
Check the packing (O-Ring) for condition.<br />
3. Checking the nuts for tightness<br />
Check that all nuts are correctly tightened:<br />
lower terminal nuts; torque 60 ± 8 in. lbs. (6.8 Nm)<br />
upper terminal nuts; torque after assembly: 113 in. lbs. (13 Nm)<br />
4. Checking the connector receptacle<br />
Check the connector receptacle pins for condition; replace the connector receptacle<br />
if the pins show any trace of arcing or excessive oxidization.<br />
5. Visual inspection of the temperature sensor harness assembly<br />
Visually check the temperature sensor harness and auxilliary connector receptacle<br />
for condition.<br />
Check in particular that:<br />
the thermistor is secure to the mounting plate,<br />
the connecting leads or cable between the connector receptacle and the<br />
various components are not damaged.<br />
6. Checking the thermostat<br />
A. Functional check (see Fig. 501)<br />
Dip the thermostats in a 0.5 liter (0.109 Imp. Gal; 0.132 US Gal.)<br />
beaker, three quarters full of water. Make sure that the thermostats<br />
are not in contact with the container walls.<br />
24-34-01<br />
PAGE 502<br />
AUG 30/96
<strong>SAFT</strong> AMERICA INC.<br />
Component Maintenance Manual<br />
1159SCAV519-1<br />
Dip a thermometer in the container, being careful to place the bulb of<br />
the thermometer in the immediate vicinity of the thermostat.<br />
Connect the test circuit (ohmmeter or closed circuit detector) to the<br />
connector receptacle contact #8 and the positive ring terminal of the<br />
harness assembly.<br />
Gradually heat the container water, being careful to maintain the water<br />
at a temperature close to 140F (60C) for about 10 minutes. This is<br />
necessary to bring all thermostat components to the same temperature<br />
as the water.<br />
Continue to heat the water gradually and note on the thermometer the<br />
temperature at which the thermostat operates. (Opens on temperature<br />
rise)<br />
Thermostat opening is indicated by the ohmmeter pointer moving from<br />
32.4K to the infinity position or by the light exstinguishing on the<br />
closed-circuit detector.<br />
Thermostat operation is correct if the temperature noted is within<br />
138.6F (59.2C) and 169.4F(76.3C).<br />
As soon as the thermostats open, stop heating the water and place the<br />
.5 liter (0.109 Imp. Gal; 0.132 US Gal.) beaker in a 1 liter (0.219 Imp<br />
Gal.; 0.264 US Gal.) container.<br />
Slowly pour cold water into the larger container until the water level is<br />
the same in the two containers.<br />
Note the temperature at which the thermostat contacts close (falling<br />
temperature). When the contacts close, the ohmmeter pointer<br />
resumes the 32.4K position or the closed circuit detector indicater<br />
illuminates.<br />
Thermostat operation is correct if the difference between the opening<br />
and closing temperatures is between 7.2F and 18F (4C and 10C).<br />
In the case of operating temperatures recorded not being within<br />
tolerance limits, perform the above tests again.<br />
Remove the thermostats from the container and dry thoroughly.<br />
24-34-01<br />
PAGE 503<br />
AUG 30/96
B. Testing the thermistor<br />
<strong>SAFT</strong> AMERICA INC.<br />
Component Maintenance Manual<br />
1159SCAV519-1<br />
Connect an ohm meter to pins #11 and #12.<br />
The ohmmeter shall indicate 2460 ± 10% at 73F (23C).<br />
C. Testing the resistors<br />
Connect an ohmmeter to pin #8 of the connector receptacle and<br />
positive ring terminal of harness assembly.<br />
The ohmmeter shall indicate 32.4K ± 10% at 73F (23C).<br />
Connect an ohmmeter to pin #9 of the connector receptacle and the<br />
negative ring terminal of the harness assembly.<br />
The ohmmeter shall indicate 32.4K ± 10% at 73F (23C).<br />
D. Testing the shunt<br />
Connect an ohmmeter to pins #4 and #6 of the connector receptacle.<br />
The ohmmeter shall indicate zero ohms at all temperatures.<br />
E. Insulation test<br />
Using a megohmmeter, measure the insulation of each pin of the<br />
connector receptacle and the outer metal shell.<br />
The insulation resistance shall be greater than or equal to 30M <br />
under 250 Volts D.C.<br />
24-34-01<br />
PAGE 504<br />
AUG 30/96
<strong>SAFT</strong> AMERICA INC.<br />
Component Maintenance Manual<br />
1159SCAV519-1<br />
CHECKING THE THERMOSWITCH<br />
FIGURE 501<br />
24-34-01<br />
PAGE 505/506<br />
AUG 30/96
1. Box<br />
2. Cells<br />
<strong>SAFT</strong> AMERICA INC.<br />
Component Maintenance Manual<br />
1159SCAV519-1<br />
REPAIR<br />
Straighten out the sides of the box and remove any dents which have been<br />
produced following impact.<br />
Repair essentially consists in the replacement of cells acknowledged defective (see<br />
"Testing and Troubleshooting", para. 1.B.(4)(c). New cells must first be discharged<br />
(see "Testing and Troubleshooting", para. 1.B.(2) (a)).<br />
24-34-01<br />
PAGE 601/602<br />
AUG 30/96
<strong>SAFT</strong> AMERICA INC.<br />
Component Maintenance Manual<br />
1159SCAV519-1<br />
ASSEMBLY AND <strong>STORAGE</strong><br />
NOTE: The products to be used are listed under "List of Products".<br />
1. Assembly<br />
Tools and special equipment to be used are listed under "Tools and<br />
Special Equipment".<br />
NOTE: In case cells must be replaced, see "Testing and Troubleshooting",<br />
para. 1.B.(4)(c).<br />
Secure the two series mounted thermostats to the thermostat mounting plate<br />
(250) with four locking nuts (260) through the opening provided in the<br />
insulator plate. Install this assembly in the case assembly by threading the<br />
temperature sensor harness assembly through the spacer bracket of the<br />
case assembly.<br />
Apply a small amount of silicone sealant (General Electric RTV 108 or<br />
equivalent) to the harness connector O-Ring and mating surface.<br />
Install the thermostat connector receptacle from the inside of the box and<br />
secure it with four screws (230) and four lock nuts (240). Place the<br />
remainder of the temperature sensor harness assembly outside the box.<br />
Apply a small amount of silicone sealant (General Electric RTV 108 or<br />
equivalent) to the connector receptacle gasket (180).<br />
Install connector receptacle (170), fitted with its preformed packing (180), and<br />
secure with four Sems screws (190).<br />
Preposition the two notched insulator plates, and intermediate insulator<br />
plates between the three rows of the case assembly. Place end plate<br />
insulators in position as individual cell rows are occupied by installed cells.<br />
Install cells, strictly complying with polarities (see Fig. 701).<br />
24-34-01<br />
PAGE 701<br />
AUG 30/96
<strong>SAFT</strong> AMERICA INC.<br />
Component Maintenance Manual<br />
1159SCAV519-1<br />
Install the temperature sensor thermistor/plate assembly between cells #6<br />
and #9 in the center row of cells. (See Fig. 701)<br />
HINT: Installing the center row of cells first, with the thermistor/plate<br />
assembly, and installing the center cell of each row last after all other<br />
cells have been put in place eases assembly.<br />
NOTE: Install a sufficient number of end plate insulators to obtain<br />
approximately 30 lbs of pull to remove individual cells.<br />
Check the torque on the cell lower terminal nuts [60 in. lbs.(6.8 Nm)].<br />
Install intercell connector links (140, and 150).<br />
Secure the negative and positive leads of the temperature sensor<br />
harness assembly to intercell connector links (160) with screws (270)<br />
and lock nuts (280).<br />
Install the intercell connector link (160) on the receptacle adapter and<br />
cell #1 and #21.<br />
Secure the intercell connector links with nuts (110), and washers<br />
(100).<br />
Tighten the nuts using a torque wrench [torque: 113 in lbs.(13 Nm)].<br />
Lightly coat the exposed areas of the terminals, nuts, and intercell<br />
connector links with non acid petroleum jelly or neutral light machine<br />
oil.<br />
Measure the insulation resistance value [see "Testing and<br />
Troubleshooting", para. .A.(1)(b)].<br />
Charge the battery [see "Testing and Troubleshooting", para. 1.B.(5)].<br />
24-34-01<br />
PAGE 702<br />
AUG 30/96
2. Storage<br />
<strong>SAFT</strong> AMERICA INC.<br />
Component Maintenance Manual<br />
1159SCAV519-1<br />
A. Preparing the battery for storage<br />
After re-establishing the electrolyte level [see "Testing and<br />
Troubleshooting", para. 1.B.(3)], discharge the battery with a constant<br />
current of 26.5 A until the voltage across the terminals falls to 21 V<br />
D.C.<br />
Using non acid petroleum jelly or neutral light machine oil (non acid),<br />
lightly coat the exposed areas of the terminals, nuts, intercell<br />
connector links and connector receptacle contacts, and the metal parts<br />
which are likely to be damaged by atmospheric agents.<br />
Install the cover and place the battery in its normal upright position.<br />
B. Storage premises<br />
Store the equipment in a dust-free, dry area.<br />
C. Temperature requirements<br />
The battery can be stored between -60 and +60C (-76 to 140F).<br />
Optimum storage temperatures range from 0 to +30C (+32 to +86F).<br />
D. Storage life<br />
10 years from date of manufacture<br />
E. Packing<br />
The battery is usually packed in a fiberboard container with fiberboard<br />
spacers.<br />
For long term storage or overseas transportation, it is advisable to<br />
enclose the equipment in a plastic sealed envelope.<br />
24-34-01<br />
PAGE 703<br />
AUG 30/96
F. Transportation<br />
<strong>SAFT</strong> AMERICA INC.<br />
Component Maintenance Manual<br />
1159SCAV519-1<br />
It is important that all required precautions should be taken to<br />
transport the battery in its normal upright position. To this effect, the<br />
transportation container should bear the inscriptions "Top" and<br />
"Bottom". Consult IATA regulations on the transportation and handling<br />
of semi-sealed non spillable nickel cadmium batteries.<br />
G. Removal from storage<br />
Charge the battery at a slow or fast rate, as required (see "Testing and<br />
Troubleshooting")<br />
If difficulty occurs in charging a unit that has been in long term storage<br />
is experienced, it may be necessary to:<br />
1. Terminate the charge sequence where the difficulty occurs. (Voltage<br />
plateau or temperature rise.)<br />
2. Completely discharge the battery [see "Testing and Troubleshooting"<br />
para. 1.B.(2)(a)]<br />
3. Repeat the above charge/discharge sequence until the unit accepts a<br />
full charge and delivers its rated capacity or a reason for the difficulty<br />
is determined. (Loose hardware, defective component etc.)<br />
24-34-01<br />
PAGE 704<br />
AUG 30/96
<strong>SAFT</strong> AMERICA INC.<br />
Component Maintenance Manual<br />
1159SCAV519-1<br />
Cell Position (numerical designation) is determined by its position relative to the positive<br />
post of the main battery receptacle. i.e. the cell directly connected to the positive post of<br />
the battery receptacle is cell number 1. Follow the intercell connector path (from the<br />
positive post of the battery receptacle) to determine cell number.<br />
CONNECTION DIAGRAM<br />
FIGURE 701<br />
24-34-01<br />
PAGE 705/706<br />
AUG 30/96
<strong>SAFT</strong> AMERICA INC.<br />
Component Maintenance Manual<br />
1159SCAV519-1<br />
TOOLS AND SPECIAL EQUIPMENT<br />
NOTE: Equivalent items of equipment may be used in place of those listed.<br />
PART NUMBER DESCRIPTION<br />
17756<br />
Cell Extraction Tool (Fig. 901)<br />
93365<br />
Simpson 260<br />
(or equivalent)<br />
Amprobe AMB-4D<br />
(or equivalent)<br />
Valve Wrench (Fig 902)<br />
Multi-Meter<br />
Meg-Ohm Meter<br />
T<br />
E<br />
S<br />
T<br />
I<br />
N<br />
G<br />
X<br />
X<br />
X<br />
USE<br />
D<br />
I<br />
S<br />
A<br />
S<br />
S<br />
E<br />
M<br />
B<br />
L<br />
Y<br />
X<br />
R<br />
E<br />
P<br />
A<br />
I<br />
R<br />
X X<br />
X<br />
X<br />
C<br />
L<br />
E<br />
A<br />
N<br />
I<br />
N<br />
G<br />
X<br />
24-34-01<br />
PAGE 901<br />
AUG 30/96
<strong>SAFT</strong> AMERICA INC.<br />
Component Maintenance Manual<br />
1159SCAV519-1<br />
NOTE: ALL DIMENSIONS ARE IN MM<br />
CELL EXTRACTING WRENCH<br />
FIGURE 901<br />
24-34-01<br />
PAGE 902<br />
AUG 30/96
<strong>SAFT</strong> AMERICA INC.<br />
Component Maintenance Manual<br />
1159SCAV519-1<br />
NOTE: ALL DIMENSTIONS ARE IN INCHES<br />
VALVE WRENCH<br />
FIGURE 902<br />
24-34-01<br />
PAGE 903/904<br />
AUG 30/96
INTRODUCTION<br />
1. General<br />
<strong>SAFT</strong> AMERICA INC.<br />
Component Maintenance Manual<br />
1159SCAV519-1<br />
ILLUSTRATED PARTS LIST<br />
The Illustrated Parts List (IPL) is prepared in compliance with ATA 100. the IPL is<br />
intended to identify all the components of the unit.<br />
The Illustrated Parts List contains the following sections:<br />
Introduction<br />
Vendors Code List<br />
List of Circuit Symbols (if applicable)<br />
Alphanumeric Index of Manufacturer's Part Numbers<br />
Detailed Parts List<br />
2. How to Use Detailed Parts List<br />
The Detailed Parts List includes the nomenclature and illustrations of the unit<br />
components.<br />
The Detailed Parts List columns are arranged as follows:<br />
1st column : Fig. Item - Figure and Item Number.<br />
2nd column : Part Number - Manufacturer's Part Number.<br />
3rd column : Nomenclature.<br />
4th column : Usage Code - Effectivity.<br />
5th column : Units per Assy. - Quantity per next higher assembly.<br />
24-34-01<br />
INTRO 1001 - PAGE 1<br />
AUG 30/96
A. Figure and Item Numbers<br />
<strong>SAFT</strong> AMERICA INC.<br />
Component Maintenance Manual<br />
1159SCAV519-1<br />
The figure number, covering items listed, is indicated on the first line at the<br />
top of each page.<br />
Each part-numbered assembly, sub-assembly or item listed in the parts list is<br />
assigned an item number followed by a letter identifying the variant. The<br />
basic variant is lettered A.<br />
Assemblies, sub-assemblies and parts listed, but not illustrated, are identified<br />
by a dash (-) preceding the corresponding item numbers.<br />
A "lettered index" appearing before the item number is a cross reference to<br />
the illustration of the variant called out from the corresponding main figure.<br />
B. Manufacturer's Part Number<br />
Each of the assemblies, sub-assemblies and detail parts, illustrated or not, is<br />
assigned a manufacturer's part number.<br />
When the manufacturer's actual part number exceeds 15 characters, an<br />
equivalent assigned part number is listed in the "Part Number" column<br />
preceded by the following annotation:<br />
ORDER OVERLENGTH... MADE BY V...<br />
Both part numbers are listed in the Alphanumeric Index in their logical order;<br />
the actual overlength part number is cross-referenced to the assigned part<br />
number preceded by the annotation, "SEE...".<br />
C. Nomenclature<br />
The nomenclature is indented to show the relationship between the parts<br />
listed, as follows:<br />
1 2 3 4 5 6 7<br />
24-34-01<br />
INTRO 1001 - PAGE 2<br />
AUG 30/96
Assembly<br />
Detail parts for assembly<br />
Sub-assembly<br />
<strong>SAFT</strong> AMERICA INC.<br />
Component Maintenance Manual<br />
1159SCAV519-1<br />
Attaching parts and/or storage parts for sub-assembly<br />
+ + +<br />
Detail parts for sub-assembly<br />
Sub-sub-assembly<br />
Attaching parts and/or storage parts for sub-sub-assembly<br />
+ + +<br />
Detail parts for sub-sub-assembly etc.<br />
A vendor code is indicated for all items or articles not made by the prime<br />
manufacturer of the assembly.<br />
This vendor code or the abbreviation "NP" (nonprocurable) is placed at the<br />
extreme right-hand side of the first line of the nomenclature.<br />
D. Effectivity (Usage Code)<br />
An alphanumeric usage code indicates the applicability of sub-assemblies<br />
and detail parts to the next higher assembly(ies) or sub-assembly(ies).<br />
When the applicability is general, the usage code column is left blank.<br />
The usage code corresponds to the figure/item number of the next higher<br />
assembly(ies) or sub-assembly(ies), e.g., effectivity 1A, 1B, 1C is written<br />
1ABC.<br />
E. Units per Assembly<br />
The Units per Assy column shows the number of units required for the next<br />
higher assembly.<br />
In some cases, this information is replaced by the letter REF (reference) or<br />
AR (as required).<br />
24-34-01<br />
INTRO 1001 - PAGE 3<br />
AUG 30/96
3. Terms and Abbreviations Used<br />
<strong>SAFT</strong> AMERICA INC.<br />
Component Maintenance Manual<br />
1159SCAV519-1<br />
AR: As Required<br />
ATTACHING PARTS<br />
DELETED<br />
DET: Detail<br />
LH and RH: Left and Right<br />
MADE BY<br />
MADE FROM<br />
MATCHED PART<br />
MODIFIED PART<br />
NHA: Next Higher Assembly<br />
NP: Nonprocurable<br />
OPT TO: Optional Parts<br />
ORDER OVERLGTH MPN: Actual part number exceeding 15 characters<br />
OVERSIZE: Oversize repair parts<br />
POST SB: After applying Service Bulletin instructions<br />
R: Modified<br />
REF: For Reference<br />
SEE<br />
SEL FROM: Select from parts<br />
<strong>STORAGE</strong> PARTS<br />
SUPSD BY: Superseded by<br />
SPUSDS: Supersedes<br />
UNDERSIZE: Undersize repair parts<br />
4. Updating<br />
When an item is revised, added or deleted, the letter "R" is shown in the RH margin<br />
(the page date of issued changes).<br />
The letter "R" appears in the RH margin opposite the page number when all the item<br />
numbers are changed.<br />
24-34-01<br />
INTRO 1001 - PAGE 4<br />
AUG 30/96
<strong>SAFT</strong> AMERICA INC.<br />
Component Maintenance Manual<br />
1159SCAV519-1<br />
ILLUSTRATED PARTS LIST<br />
24-34-01<br />
PAGE 1001<br />
AUG 30/96
<strong>SAFT</strong> AMERICA INC.<br />
Component Maintenance Manual<br />
1159SCAV519-1<br />
<strong>BATTERY</strong> <strong>STORAGE</strong><br />
FIGURE 1<br />
24-34-01<br />
PAGE 1001-0<br />
AUG 30/96
FIG.<br />
ITEM<br />
1-001<br />
010<br />
020<br />
030<br />
-040<br />
-050<br />
-060<br />
-070<br />
-080<br />
-090<br />
100<br />
110<br />
120<br />
130<br />
140<br />
150<br />
160<br />
170<br />
180<br />
190<br />
200<br />
210<br />
220<br />
230<br />
240<br />
-250<br />
-260<br />
-270<br />
-280<br />
-290<br />
300<br />
PART<br />
NUMBER<br />
5317CH-1<br />
23837<br />
23840<br />
23456<br />
91180-2<br />
21870<br />
21971<br />
23382-1<br />
23382-2<br />
15579<br />
22228<br />
15579<br />
23619<br />
12536-2<br />
18567<br />
15575<br />
23904<br />
22078<br />
9384<br />
93616<br />
15579<br />
22228<br />
23850<br />
92178-8<br />
90064<br />
23870<br />
90064<br />
92830-4<br />
90063<br />
23872<br />
TBD<br />
-ITEM NOT ILLUSTRATED<br />
<strong>SAFT</strong> AMERICA INC.<br />
Component Maintenance Manual<br />
1159SCAV519-1<br />
1234567<br />
NOMENCLATURE<br />
<strong>BATTERY</strong>, <strong>STORAGE</strong><br />
.CASE, MARKED<br />
.COVER & PAD MARKED<br />
.CELL, <strong>BATTERY</strong>, <strong>STORAGE</strong><br />
..PACKING, PREFORMED<br />
..WASHER, FLAT<br />
..WASHER, BELLEVILLE<br />
..WASHER, POLARITY, (+) (Red)<br />
..WASHER, POLARITY, (-) (Blue)<br />
..NUT, HEX<br />
..WASHER, BELLEVILLE<br />
..NUT, HEX<br />
..VALVE, VENT, ASSY<br />
...PACKING, PREFORMED<br />
.INTERCELL CONNECTOR<br />
.INTERCELL CONNECTOR<br />
.INTERCELL CONNECTOR W/HOLE<br />
.CONNECTOR RECEPTACLE<br />
..GASKET, PREFORMED<br />
ATTACHING PARTS<br />
.SCREW, SEMS<br />
* * *<br />
.NUT, HEX, (17mm)<br />
.WASHER, BELLEVILLE<br />
.CONNECTOR & HARNESS ASSY<br />
ATTACHING PARTS<br />
.SCREW, BINDING HEAD<br />
.NUT, LOCKING<br />
* * *<br />
.PLATE & STUD ASSY<br />
..NUT, LOCKING<br />
.SCREW, FLAT<br />
.NUT, LOCKING<br />
.LINER, THERMOSTAT MOUNTING<br />
.KIT, LINER/SPACER<br />
USAGE<br />
CODE<br />
UNITS<br />
PER<br />
ASSY<br />
RF<br />
1<br />
1<br />
20<br />
2<br />
2<br />
4<br />
1<br />
1<br />
2<br />
2<br />
1<br />
1<br />
14<br />
6<br />
2<br />
1<br />
1<br />
4<br />
2<br />
2<br />
1<br />
4<br />
4<br />
1<br />
4<br />
2<br />
2<br />
1<br />
1<br />
24-34-01<br />
PAGE 1002-0<br />
AUG 30/96