Aircraft Battery PART NUMBER 1756-1 and 1756-3tracebatteries.ru/d/476379/d/1756-1.pdfSAFT AMERICA...

SAFT AMERICA INC.COMPONENT MAINTENANCE MANUAL

1756-1 and 1756-3

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Aircraft Battery

PART NUMBER 1756-1 and1756-3

COMPONENT MAINTENANCE MANUAL

WITH

ILLUSTRATED PARTS LIST


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RECORD OF REVISIONS

REVISION No. REVISION DATE ISSUE DATE BY1 02/01/99 02/01/99 Saft


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RECORD OF TEMPORARY REVISIONS

TEMPORARYREVISION

No.

PAGENUMBER

ISSUE DATE BY DATEREMOVED

BY

NOTE: To be deleted upon issue of a formal revision


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SERVICE BULLETIN LIST

NUMBER BRIEF DESCRIPTION TYPE AFFECTED

SAI398 Conversion to 1756-3 1756-1


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LIST OF EFFECTIVE PAGES

SUBJECT PAGE DATE

Title Page T-1T-2

Feb 01/99Blank

Record of Revisions RR-1RR-2

Feb 01/99Blank

Record of TemporaryRevisions

RTR-1RTR-2

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Service Bulletin List SBL-1SBL-2

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List of EffectivePages

LEP-1LEP-2

Feb 01/99Blank

Table of Contents TC-1TC-2

Oct 24/97Oct 24/97

List of Figures LOF-1LOF-2

Oct 24/97Blank

Introduction INTRO-1INTRO-2

Oct 24/97Oct 24/97

Description andOperation

123456

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Testing and FaultIsolation

101102103104

Oct 24/97Oct 24/97Oct 24/97Oct 24/97

Disassembly 301302

Oct 24/97Oct 24/97

Cleaning 401402403404

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SUBJECT PAGE DATE

Check 501502503504505506507508509510511512

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Repair 601602

Oct 24/97Oct 24/97

Assembly 701702703704

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Fits and Clearances 801802

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Special Tools,Fixtures, andEquipment

901902903904

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Illustrated Parts List 100110021003100410051006100710081009101010111012

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TABLE OF CONTENTS

PAGESDESCRIPTION AND OPERATION

1. Description2. Operation

13

TESTING AND FAULT ISOLATION1. Testing2. Fault Isolation

101101

DISASSEMBLY1. Disassembly 301

CLEANING1. Light Cleaning2. Thorough Cleaning3. Lubrication

401401402

CHECK1. Maintenance Checks2. Maintenance Operation In Workshop3. General Overhaul

501501509

REPAIR1. Battery Condition2. Polarization Test3. Supplementary Electrical Test Before Repair

601601601

ASSEMBLY AND STORAGE1. Assembly2. Storage

701702

FITS AND CLEARANCES1. Torque Table2. Fits and Clearances Table

801802

SPECIAL TOOLS AND EQUIPMENT1. Special Tools2. Consumable Materials

901904

ILLUSTRATED PARTS LIST1. General2. How to Use Detailed Parts List3. Terms and Abbreviations Used4. Changes5. Vender Codes6. Illustrated Parts Breakdown

100110011003100410051005


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LIST OF FIGURES

PAGES

Figure 1 1756-1 and 1756-3 battery 2

Figure 501 Periodic check 502

Figure 502 Level adjustment with syringe and calibrated nozzle 504

Figure 503 Regular check 508

Figure 504 General overhaul 510

Figure 701 1756-1 and 1756-3 battery circuit 704

Figure 901 Polyamide key for vented filler caps made of polyamide 902

Figure 902 Syringe with nozzle 902

Figure 903 Cell removal tool 903

IPL Figure 1 Battery, Exploded View (4 Sheets) 1006-1009


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INTRODUCTION

1. GENERAL

A. This equipment maintenance manual with illustrated parts list has beenproduced in conformity with Air Transportation Association of Americastandard No. ATA 100. It should permit a maintainer not familiar with theequipment to determine its condition and to carry out repair.

B. The operations described may only be carried out in a specialized workshop,which has the special tooling and test benches. (See SPECIALIZED TOOLSAND EQUIPMENT)

C. The manual does not deal with current techniques or the adaptation of theoperations to ordinary methods that are available in the repair shop.

2. PRESENTATION OF THE MANUAL

A. For page numbering, a section of numbers is used for each subject. In thecase of small and simple equipment, several subjects may be treated on thesame page.

1 - 100 DESCRIPTION AND OPERATION

101 - 200 TESTING AND FAULT ISOLATION

201 - 300 (Not used)

301 - 400 DISASSEMBLY

401 - 500 CLEANING

501 - 600 CHECK

601 - 700 REPAIR

701 - 800 ASSEMBLY AND STORAGE

801 - 900 FITS AND CLEARENCES

901 - 1000 SPECIAL TOOLS AND EQUIPMENT

1001-1100 ILLUSTRATED PARTS LISTS


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B. All values are, in general, expressed in units (or multiples of the units) of thesystem international (S.I.). In certain cases, units of more common usageare employed.


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DESCRIPTION AND OPERATION

1. DESCRIPTION

A. General Description

The Saft alkaline battery has 20 semi-open, nickel-cadmium VP170KH cellswith welded polyamide cases.

It is connected to the on-board systems of the aircraft, and is used:

- For starting the engines

- On the ground before electrical ground power is applied to the aircrafton-board systems

- Airborne in case of malfunction or failure in the normal power supply

The battery is charged on the aircraft by a dedicated charger.

B. Characteristics

(1) Technical characteristics

- Nominal voltage: 24V

- Rated capacity: 17Ah at 1-hour rate

- Connector: MS 18093

- Electrolyte: Sol. KOH s.g. approximately 1.30

- Consumable volume of electrolyte 20cm3 per cell

- Maximum dimensions of battery base: L=322.6mm (12.70in)W=163.1mm (6.42in)H=199.9mm (7.87in)

- Maximum weight: 18.1kg (40lb.)

- One temperature sensor with: one thermistor 3k Ω ±2% @ 25°C(77°F)


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(2) Operational characteristics

- Operation temperature: -40°C to +70°C (-40°F to +158°F)

- Maximum instantaneous power:

- at +27°C (+80.6°F), 12V, 15s: 9.9Kw

- at -18°C (+05°F), 12V, 15s: 6.1Kw

1756-1 and 1756-3 BatteryFigure 1

C. Detailed Description

The battery contains 20 VP170KH (220, IPL Fig 1) cells housed in a stainlesssteel box.

The box (010) is lined with thin sheets of insulation and wedges (020). Thecells are maintained upright by means of molded silicon elastomer partfastened to the box cover that presses against the top of the cells. Cells areinterconnected by rigid nickel plated copper links (090, 120, 130). End cellsare connected by output connections (100,110) to an electrical connector(40).

Battery Cover

Battery CaseBatteryReceptacle

TemperatureSensorAssemblyConnector


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This connector connects the battery to the aircraft.

The box (010) is fitted with:

- a removable cover and pad assembly (030)

- two vent tubes

- two latches

2. OPERATION

A. Charge

(1) Flight charging

In order for the battery to be correctly charged in flight, the chargermust be functioning properly and should be checked per themanufacturer’s recommendation.

For a given voltage setting, the higher the battery temperature, thehigher the residual charge current.

The consumption of water from the electrolyte is directly proportionalto this residual charge current. It is, thus, necessary to know the exactnormal operating temperature of the batteries in order to charge themunder optimum conditions.

(2) Ground charging

All battery maintenance or overhaul operations must be carried out inthe workshop.

WARNING: GROUND CHARGING OF 1756-1 and 1756-3 BATTERIESMUST BE CARRIED OUT WITH THE COVER REMOVED TOAVOID THE ACCUMULATION OF GAS IN THE BATTERYBOX.

- Constant current charge.


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To charge a completely discharged battery, use one of the followingprocedures:

TABLE 1CONSTANT CURRENT CHARGE

Main Charge OverchargeProcedure 1: 1.7 Amps (0.1 C1A)

until battery reaches 30VTime: Minimum: 10 hours Maximum: 12 hours

+ Completion of charge 1.7Amps (0.1 C1A) for 4 hours atend of charge with all cells≥1.50V.

Procedure 2: 8.5 Amps (0.5 C1A)until battery reaches 31V

Time: Minimum: 2 hours Maximum: 2 hours 30 min.


Procedure 3: 17 Amps (1 C1A) untilbattery reaches 31.4V.

Time: Minimum: 1 hour Maximum: 1 hour 15 minutes


NOTE: If the battery voltage has not risen sufficiently during this maximumcharging time or if the battery voltage is exceeded before minimumcharge time: refer to "TESTING AND FAULT ISOLATION".

(3) Battery partially discharged and state of discharge unknown.

TABLE 2Discharge at 17 Amps (1 C1A) down to 20 V.Charge: Refer to Table 1 above, Constant Current Charge.

(4) The battery may also be charged at one of the constant current valuesgiven in section 2.A.(2) until the voltage at the battery terminalsreaches the corresponding recommended voltage (30, 31 or 31.4V).

TABLE 3Charge at 30V at ambient temperature during 4 to 5 hourAdjusted charge voltage: for a +5°C (+41°F) battery temperature: 31V for a +35°C (+95°F) battery temperature: 31.4V


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B. Discharge

The rated capacity (C1A) of the battery corresponds to a discharge time of 1hour; when completely charged, it can, therefore provide a 17A current forone hour. For short periods of time the battery can however, supply muchhigher currents than the rated discharge without being damaged. Forexample, a battery with a rated capacity of 17Ah can provide peaks of currentas much as twenty times its normal capacity.

C. Precautions

(1) Apart from providing periodic, regular, and general overhaulmaintenance, the only precautions necessary to obtain proper servicefrom the battery are as follows:

(a) Do not install the battery in an aircraft location that is overly hot.

(b) Follow ventilation instructions carefully.

(c) Check the charge level regularly.

1 Make up for any loss of charge which is not due toincorrect adjustment of the charger, by recharging on theground.

2 Any loss of charge due to incorrect adjustment of thecharger must be corrected by charger maintenance.

(2) Periodically verify:

(a) The electrolyte level, especially during hot weather.

(b) The tightness of connection nuts.

(c) The adjustment of the charger.


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TESTING AND FAULT ISOLATION

1. TESTING

Testing operations are described in the chapter entitled CHECK.

2. FAULT ISOLATION

FAULTS POSSIBLE CAUSES REMEDIESZero volt with battery set to"charge"

Defective electricalconnector (not makingcontact).

Check electrical contact andlinks and tightness of nuts(CHECK)

Link loose or broken. Examine the electrical contactsand links.

Zero volt with battery set to"discharge”

Battery fully discharged Recharge battery(DESCRIPTION ANDOPERATION)

Battery circuit open ordefective contacts.

Check insulation (CHECK)

Check contacts and links andtightness of terminal nuts(CHECK)

Cell completely dry Refer to the related followingsteps

Leakage of electrolyte Incorrect adjustment oflevel

Disassemble and clean thebattery (DISASSEMBLY ANDCLEANING)

Check electrolyte level (CHECK)

Cell polarity reversedduring high rate discharge(e.g. during starting)




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FAULTS POSSIBLE CAUSES REMEDIESLeakage of electrolyte (cont.) Overcharge at high

temperatures or usingexcessive current

Check the on-board chargingcircuit and if necessary adjust tonormal operating temperature(DESCRIPTION ANDOPERATION)

Disassemble and clean battery(DISASSEMBLY ANDCLEANING)


Traces of electrolyte inbattery box

Damaged cell case Check sealing of cells (CHECK)

Leakage of electrolyte Disassemble and clean thebattery (DISASSEMBLY ANDCLEANING)


Excessive waterconsumption in all batterycells

Heavy overcharge orovercharge at hightemperatures

Check the on-board chargingcircuit and adjust if necessary tonormal operating temperature(DESCRIPTION ANDOPERATION)

One or several cells whosewater consumption differssignificantly from that ofother cells in the battery:

- more than 30% aboveaverage

Leaking cell (s) Check sealing of cell (s) (CHECK)




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FAULTS POSSIBLE CAUSES REMEDIES- 25% or less of the average

valueCell (s) with damagedseparator (s)

Perform supplementary test(REPAIR) If necessary, replacewith new Saft cell(DISASSEMBLY, ASSEMBLYAND STORAGE)

Corrosion on links Operation in acidatmosphere

Make sure that battery testbench and storage areas arefree from materials which mayproduce acid fumes

Mechanical damage tonickel plating

Replace damaged links(DISASSEMBLY ANDASSEMBLY; STORAGE)

Indications of linkoverheating

Loose terminal nuts Check tightness (CHECK)

Cell with abnormally highvoltage at start of charge

Cell dry As soon as the fault is observedadd 10 cc of distilled water tothe cell. Do not adjust preciselyuntil the end of charge.

NOTE: A cell charging withinsufficient electrolyte may alsoshow considerable temperaturerise

Main charge cut off voltagereached before minimumtime or not reached at themaximum time

Battery not fullydischarged or stronglyunbalanced

Do a regular check (Refer toCheck).

Cell with abnormally lowvoltage at end of charge(Less than 1.5V at 1.7A at+20°C (+68°F))

Cell which has worked atexcessive temperaturesand charge rates andwhose separator isdamaged

Replace cell (DISASSEMBLY,ASSEMBLY AND STORAGE)


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FAULTS POSSIBLE CAUSES REMEDIESLow capacity cell (Reversedvoltage or a normal polarityvoltage of less than 1V at theend of a 1 hour discharge at17A)

Normal wear after longservice

Exceptionally heavy use(Frequent self-starting);operation at hightemperatures, with lowelectrolyte level, etc.

Replace with new Saft cell(DISASSEMBLY, ASSEMBLYAND STORAGE)

Treat appropriately (REPAIR)

Cell with swollen case. Cell operated with lowelectrolyte level;deterioration ofseparators and damagedplates.

Replace with new Saft cell(DISASSEMBLY, ASSEMBLYAND STORAGE).

Cell with zero voltage whenbattery circuit is open

Short circuited cell Replace with new Saft cell(DISASSEMBLY, ASSEMBLYAND STORAGE

Low insulation Leakage of electrolyte Disassemble and clean battery(DISASSEMBLY ANDCLEANING)



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DISASSEMBLY

1. DISASSEMBLY (refer to Section 10, Figure 1)

WARNING: ALL OPERATIONS MUST BE CARRIED OUT ON A COMPLETELYDISCHARGED BATTERY.

NOTE: See the Testing And Fault Isolation chapter to determine the condition ofcomponent and the most probable cause of its malfunction. This willindicate the extent of disassembly required and thus, avoid completelydisassembling and rebuilding the component.

A. Remove the cover (030, IPL Fig. 1).

B. Removal of vent valves:

(1) Unscrew each vent valve (230) with the special tool (fig. 901).

(2) Remove the vented filler cap (230) complete with its O-ring (240).

C. Removing a cell:

(1) Ensure vent valve is tight.

(2) Unscrew the nuts (140) that attach the links (090 to 130) to the cell. Remove the washers (150).

(3) Remove the links (090 to 130) from the cell terminals.

(4) Attach the threaded end of the special tool (fig 903) to one of the cellterminals and pull upwards.

D. Removing connector:

(1) Unscrew the nuts (070) that attach the links (100, 110) to theconnector (040). Remove the spring washers (080).

(2) Remove the links (100, 110).

(3) Remove the four screws (060) from the connector.

(4) Remove the connector (040) with its O-ring (050) from the box (010).


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E. Removing complete connector and sensor assembly

(1) Unscrew the nuts (070) that attach the links (100, 110) to theconnector (040). Remove the spring washers (080).

(2) Remove the links (100, 110).

(3) Cut the wire tie.

(4) Remove the nut (140) that attaches the sensor on the terminal (seeFigure 701) and lift off the washer (150) and sensor.

(5) Remove the jam nut (200).

(6) Remove the auxiliary connector with its gasket (210) from the box(010).


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CLEANING

1. LIGHT CLEANING

WARNING: EYE PROTECTION IS REQUIRED WHEN WORKING WITHCOMPRESSED AIR.

CAUTION: To avoid cell contamination, make sure that the vent valve is tight.

A. If a clean, filtered supply of compressed air is available, the simplest andfastest method of cleaning the cells is spraying vigorously across the tops toremove all dust and mineral salts which may have accumulated out of thebox.

B. To avoid short-circuits, use a rubber tube or an insulated nozzle.

2. THOROUGH CLEANING

CAUTION: To avoid cell contamination, make sure that the vent valve is tight.

Disassemble the battery (see DISASSEMBLY) and then clean all the components.

A. Cells:

CAUTION: To avoid cell contamination, do not direct running water on ventvalve area.

(1) The simplest method of eliminating all traces of electrolyte and mineralsalts from the terminals, covers, and sides of the cells cases is towash them in warm deionized water with a soft, non-metallic brush.

(2) To avoid cell contamination, make sure that the vent valve is tight.

(3) Do not soak the cells in water.

(4) Allow the cell dry after wiping.

B. Box:

(1) Wash with water and allow to dry after wiping.

C. Nuts, spring washers, and links:

(1) Clean by brushing in warm water .


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(2) Allow to dry.

D Packing pieces and leak proof insulator:

(1) Clean in warm water and let dry.

(E) Vented filler caps:

(1) Remove vented filler caps (see DISASSEMBLY).

(2) Replace vented filler caps with spares or cover the cell orifices toprevent the entry of foreign matter.

(3) Soak the vented filler caps for several hours (overnight, for example)in a container of distilled water (or, if not available, in very clean tapwater) to dissolve any salts which might have collected in the venthole.

WARNING: DO NOT USE PETROL, TRICHLOROETHYLENE, OR ANYOTHER SOLVENTS.

(4) Before installation back into the cells, verify operation of vented fillercaps:

(a) Attach the vented filler cap complete (230) with its O-ring (240)onto checking fixture (Saft drawing 024554-000).

(b) Connect this tube to a supply of compressed air via anadjustable reducing valve.

(c) Set the pressure to 7.25 psi (0.5 bars) and submerge thevented filler cap in a container of water. Air bubbles will escapeif the vented filler cap is in good condition. If no bubbles areobserved increase the pressure until bubbles appear and thenreduce the pressure slowly to 1.45 psi (0.1 bars) noting at whatpressure the air flow ceases.

(d) Reject all vented filler caps whose operating pressure is greaterthan 10 psi (0.7 bars) after this "freeing" operation or less than2 psi (0.14 bars).

(5) Install the vented filler caps (see ASSEMBLY).


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3. LUBRICATION

A. After cleaning the battery and with the vented filler caps in place, lightlygrease the terminals and links with neutral (non-acid) petroleum jelly or lightoil applied with a paintbrush.


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CHECK

1. MAINTENANCE CHECKS

In addition to the checks specified for airborne or ground use, in normal serviceSAFT 1756-1 and 1756-3 batteries require the following maintenance operations:

A. Periodic Check (at least every 6 months): discharge the battery, charge thebattery and adjust the electrolyte levels.

B. Regular Check (every 300 operating hours or at the needed level period): doan electrical treatment, adjust the electrolyte levels, and do a capacity test.

C. General Overhaul (every 600 operating hours or at least once a year): do anelectrical treatment, adjustment of electrolyte levels, and capacity testing.

NOTE: These periods are given as an indication; modify in accordance withoperational experience.

NOTE: Periodic and Regular Maintenance checks may be combined if operatinghours do not meet times listed.

2. MAINTENANCE OPERATIONS IN WORKSHOP

A. Periodic Check: Every 6 months or during each aircraft check (fig. 501):

(1) Physically inspect battery for obvious damage.

(2) Check cleanliness of the battery.

(a) Perform light cleaning (see CLEANING para 1) if only dust isevident.

(b) Perform thorough cleaning (see CLEANING para 2) if salt orelectrolyte traces are found.

(3) Check battery voltage.

(a) If voltage is less than 21V, perform a polarization test (seeREPAIR para 2).

(4) Perform an insulation check (see CHECK para 2.E).


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GENERALOVERHAULFIGURE 504

POLARIZATIONTEST

(REPAIR)


ADJUSTELECTROLYTE

(CHECK)

CLEANVENT CAPS

(CLEAN)

CHECK CELLNUT TORQUE

(CHECK)

RETURNBATTERY TO

SERVICE

RESIDUALDISCHARGE>43A to 20V

LIGHTCLEAN

(CLEAN)

VOLTAGECHECK

CLEANLINESSCHECK

PHYSICALCHECK

(CHECK)

PERIODIC CHECK

CHARGE(TABLE 1)

VISIBLEDEFECTS

SALT ORELECTROLYTE

TRACES

V < 21V

NO DEFECTS

DUST ONLY


INSULATIONCHECK

(REPAIR)

FAILURE

NO DEFECTS

V > 21V

Periodic Check DiagramFigure 501


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(5) Residual discharge at 17A down to a voltage of 20V at batteryterminals.

(6) Charge and adjust the electrolyte level.

(a) When the battery has reached the normal temperature range,+20°C to +25°C (+68°F to +77°F), charge the battery (seeDESCRIPTION AND OPERATION para 2.A.(2) Table 1).

(b) During the last hour of the charge, measure the voltages of theindividual cells (accuracy 0.5%). Once each cell has reached aminimum 1.50V, and with the charge current continuing to flow,adjust the level of the electrolyte in the cells. Record thequantity of the water added to each cell.

(c) The electrolyte level varies with the state of charge of thebattery and does not, therefore, attain the maximum level untilthe battery is fully charged. The level reacts as if the platesabsorbed a part of the electrolyte during the discharge andreleased it during the charge. Accurate measurements arevalid only if made near the end of charge but while the battery isstill being charged.

Any addition of liquid made without respecting these conditionswould cause overflow during normal use. The level is correctwhen the distance, measured, under these conditions, betweenthe vented filler cap seat and the electrolyte is 20mm (0.787in).

(d) If necessary, bring the level up to this value by adding distilledwater.

WARNING: NEVER USE ACID OR ACIDULATED WATER WHENADJUSTING ELECTROLYTE LEVELS IN NICKEL-CADMIUM CELLS. THE SLIGHTEST QUANTITY OFACID WILL CAUSE PERMANENT DAMAGE.

The simplest and most convenient tool for adjusting the level isa plastic syringe tube (P/N: 020915-004), similar to those usedfor medical injections, with a plastic nozzle fitted onto theconical end.

The length of the nozzle which enters the cell must be 20mm(0.787in); this length corresponds to the desired distance


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between the vented filler cap seat and the electrolyte. (See fig.502).

1 By keeping the shoulder of the syringe nozzle in contactwith the vented filler cap seat and pulling plungerupwards, the operator can monitor filling.

2 Low electrolyte levels will cause the syringe tube toremain empty when the plunger is drawn up.

3 Any excess electrolyte will be drawn into the syringe untilthe fluid level meets with the end of the nozzle.

4 If this check shows that some cells are insufficientlyfilled, inject distilled water into the cells. (As the syringeis small, it may be necessary to repeat this operationmore than once per cell).

The level is correct when, having added some water tothe cell, and with the shoulder of the syringe nozzle heldagainst the vented filler cap seat, a small amount ofliquid is drawn up by the plunger.

Topping-up with a syringe and calibrated nozzleFigure 502


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(e) Conclusions to be drawn from the above operations:

1 The battery is functioning properly if:

a Each individual cell voltage measured during thelast hour of charge at 1.7A is at least 1.50V.

b Each cell required approximately the samequantity of distilled water which was less than20cm3 (1.22in3).

2 If all cells required the addition of more than 20cm3

(1.22in3):

a The voltage setting of the charger in relation to thetemperature during recharging should be checked.

b The electrolyte level should be checked morefrequently.

3 Perform a complete overhaul (see "GENERALOVERHAUL") of the battery if:

a One or several cells required considerably more orless water than the other cells.

b Individual cell voltages measured at the end of a1.7A charge are less than 1.5V (see "TESTINGAND FAULT ISOLATION").

(7) Clean the vented filler caps (see CLEANING) during electrolyteleveling.

(8) Check the tightness of the cell terminal nuts.

- Check that all nuts retaining the links are torqued to 69.9 lb-in ±4 lb-in (8Nm ±1Nm).

(9) Return battery to service.

B. Regular Check: (see figure 503) every 300 operating hours or at least once ayear,


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(1) Complete steps 1 through 4 in periodic check (see CHECK para 2.A).

(2) Discharge the residual capacity at 17A down to a voltage of 20V at thebattery terminals.

(a) Measure and record the time from the start of discharge to themoment 20V is reached.

(3) Continue discharge by connecting a resistor of approximately 1Ωacross each cell. (Resistors with clips attached to their leads can beeasily attached to the cell terminals.)

(4) Leave resistors in place overnight.

(5) Remove all the resistors.

(6) Charge the battery (see DESCRIPTION AND OPERATION 2.A.(2)Table 1).

(7) Adjust the electrolyte level in the cells (see CHECK 2.A(5)(b) through(d)).

(8) Immediately after the charge and the adjustment level adjustment,perform a capacity check.

(a) Discharge the battery again at 17 Amps.

(b) Measure the terminal voltage of each cell.

(c) Record the time that is needed for the first cell to reach 1.0Vand the battery terminal voltage to reach 20.0V.

(9) Conclusions to be drawn from the above tests:

(a) The battery is functioning properly if:

1 The first discharge (section 2.B) required more than 30minutes.

2 The second discharge (section 2.B(1)) required at leastone hour for the first cell to reach 1.0V.

3 Each individual cell voltage during the last hour of chargeat 1.7A is at least 1.5V (accuracy 0.5%)


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4 The quantity of distilled water added to each cell isapproximately equal to or less than 20cm3 (1.22in3).

5 If the duration of the first discharge is less than 30minutes but the second discharge time is correct (at least1 hour) it may be concluded that the battery is in goodcondition but was not fully charged when removed fromthe aircraft. (this may be due to insufficient recharge onboard and/or discharge resulting from unexpected use ofthe battery after landing.)

(b) The battery must be given a complete overhaul (section 3) if:

1 The duration of the second discharge is less than 1 houror if any cell has a voltage of less than 1 volt or reversedpolarity before 1 hour of discharge.

2 Individual cell voltages measured during the last hour ofcharge at 1.7A are less than 1.50V.

3 One or several cells required considerably (10-25%)more or less distilled water than the other cells.

NOTE: The consumption of water by a Saft nickel-cadmiumcell is proportional to the overcharge that it hasreceived.

NOTE: The fact that one or more cells of the same batteryconsume noticeably more or less water than otherindicates a defect:

a High consumption is generally caused by leakage.

b Low consumption is caused by damagedseparator.

c Consumption is considered abnormal when it is10-25% more or less than average.

10. Charge the battery (see DESCRIPTION AND OPERATION 2.A.(2)Table 1).

11. Return battery to service.


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October 24/97


POLARIZATIONTEST

(REPAIR)



INSULATIONCHECK

(REPAIR)


(CHECK)


LIGHTCLEAN

(CLEAN)

VOLTAGECHECK

CLEANLINESSCHECK

PHYSICALCHECK

(CHECK)

REGULAR CHECK

CLEANVENT CAPS

(CLEAN)

VISIBLEDEFECTS

SALT ORELECTROLYTE

TRACES

V < 21V

NO DEFECTS

DUST ONLY

V > 21V

1 OHM CELLSHORTING

OVERNIGHT

CHARGE(TABLE 1)

ADJUSTELECTROLYTE

(REPAIR)

CAPACITYCHECK

(CHECK)

RETURNBATTERY TO

SERVICE

CHARGE(TABLE 1)

NO FAULT

NO FAULT

NO FAULT

NO FAULT

FAULT

FAULT

FAULT

FAULTFAULTISOLATION


SUPPLEMENTARYTEST

(REPAIR)

PASS

Regular Check DiagramFigure 503


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24-32-06Page 509

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C. GENERAL OVERHAUL

In addition to the electrical tests described in section 2.B this overhaulincludes a systematic disassembly and cleaning of all components of thebattery. It must be carried out once a year.

(1) Disassemble the battery (see DISASSEMBLY).

(2) Clean the battery (see CLEANING).

(3) Test the battery

(a) Cells:

1 Check that the lower terminal nuts are correctly tightenedto 43.5 lb-in. ± 8 lb-in (5 Nm ± 0.3 Nm).

(b) Box:

1 Straighten the box sides and flatten out any minor dents.

(c) Nuts, links, and spring washers:

2 Discard and replace any corroded or damagedcomponents.

(d) Spacers:

1 Discard and replace all defective components.

(e) Connector:

1 Ensure that the connector is in good condition, both innerand outer surfaces. Replace if the contacts show anysigns of corrosion, burning, or arcing.


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24-32-06Page 510

October 24/97

ASSEMBLEBATTERY

(ASSEMBLY)

THOROUGHCLEAN

(CLEAN)

BATTERY TEST(CHECK)

INSULATIONCHECK

(REPAIR)


(CHECK)

CLEANVENT CAPS

(CLEAN)

1 OHM CELLSHORTING

OVERNIGHT

CHARGE(TABLE 1)

ADJUSTELECTROLYTE

(REPAIR)

CAPACITYCHECK

(CHECK)

RETURNBATTERY TO

SERVICE

CHARGE(TABLE 1)

NO FAULT

NO FAULT

NO FAULT

FAULT

FAULT

FAULTFAULTISOLATION

SUPPLEMENTARYTEST

(REPAIR)

PASS

GENERALOVERHAUL

POLARIZATIONTEST

(REPAIR)

VOLTAGECHECK

V < 21V

V > 21V

ON FAULT SCHEDULED



FAIL

IF 3 CELLS FAIL DURINGSERVICE CYCLE, OR 5 CELLS OVER LIFE OF

BATTERY THEN REPLACEALL CELLS

General OverhaulFigure 504


1756-1 and 1756-3


October 24/97

D. Checking of temperature sensor:

NOTE: Checking of the temperature sensor can only be carried out while thebattery is dismantled.

(1) Temperature sensor (P/N 022836-000) for the 1756-1 battery:

(a) Check that the test resistance value between the sensor lugand pin A is 0Ω at 25°C (77°F).

(b) Check that the resistance value between pins B and C is 3k Ω±2% at 25°C (77°F).

(2) Temperature sensor (P/N 024639-000) for the 1756-3 battery:

(a) Check that the test resistance value between the sensor lugand pin A is 4990Ω ±1% at 25°C ±2°C (77°F).

(b) Check that the resistance value between pins B and C is 3kΩ±1.4% at 25°C ±2°C (77°F).

E. Insulation resistance:

(1) After completely reassembling the battery, measure the insulationresistance between the block of cells and the metal box. The valuemeasured must be at least 10MΩ under 250V continuous using aMegohmmeter.


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REPAIR

1. BATTERY CONDITION

A. Carry out a polarization test (see REPAIR), if following an unscheduledremoval or before maintenance, a battery shows such abnormal features as:

(1) Any cells with reversed polarity.

(2) The battery open voltage is below 21.0V.

B Carry out a supplementary test (see REPAIR) if during periodic maintenanceoperations, or during a general overhaul, the battery shows such abnormalfeatures as:

(1) End of charge voltage too low.

(2) Voltage during charge too high.

(3) Insufficient capacity.

(4) Abnormal water consumption.

2. POLARIZATION TEST

A. Charge the battery at 1.7A for 1.5 hour.

B. Leave the battery in open circuit condition for 1 hour.

C. Measure the open voltage of each cell

(1) If the cell open voltage is 0V or reversed, carry out a supplementarytest and proceed to repair. (see REPAIR)

(2) If every cell presents an open voltage above 0V, charge the battery(see DESCRIPTION AND OPERATION Table 1).

3. SUPPLEMENTARY ELECTRICAL TEST BEFORE REPAIR

A. The first test charge may be unsatisfactory if the electrolyte level is too low insome cells (the level is not adjusted until the end of this charge). If faultshave been observed, carry out a second test as follows:

(1) Charge the battery (see DESCRIPTION AND OPERATION Table 1).


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(a) After the total charging time, continue to charge at 1.7Afor 5 additional hours.

(b) Record the voltage of the cells at regular intervals.

(c) Cells with damaged separators will show significant,continuous temperature increases, and their voltages willprogressively decrease to less than 1.50V.

NOTE: Overcharging reduces the service life of cells. Thisparticular test should, therefore, only be used when thebattery has malfunctioned on board the aircraft or ifabnormal behavior has been noticed during in-shopmaintenance.

(d) Adjust the level of electrolyte during the last half-hour ofovercharge.

(e) Discharge at 17A down to 20V. The cells with thefollowing characteristics should be considered defectiveand should be replaced:

1 Final overcharge voltages of less than 1.50V(accuracy 0.5%).

2 Voltage below 1V before one hour of dischargeduring the final test discharge.

3 Short-circuited cell (zero volt).

NOTE: If 3 cells during a service cycle or 5 cells over thelife of the battery are replaced, it isrecommended to replace all cells of the battery.


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ASSEMBLY AND STORAGE

1. ASSEMBLY

NOTE: Tooling and equipment are identified in the list of "SPECIAL TOOLS ANDEQUIPMENT".

A. Installation of the vent valves

(1) Ensure that the O-ring (240) is in good condition; replace if it showssigns of wear.

(2) Install the vent valve (230) with its O-ring (240) using the vent valvewrench from the special tool kit (fig 901).

B. Installation of a cell

(1) Using a paintbrush, put a thin layer of neutral petrolatum (petrolatumthat is not acid) or light oil on the cell terminals and the links.

(2) Place a discharged cell in its position, making sure that it is correctlypositioned with respect to polarity.

(3) Push in gently with a piece of softwood placed against the terminals.

CAUTION: To avoid cell damage, never use a hammer or strike the wood.

(4) Install the links, washers, and nuts in the following order:

(a) Links (090, 100, 110, 120, 130)

(b) Washers (080, 150)

(c) Nuts (070, 140), torque to 69.9 701-in ±4 lb-in (8 Nm ±1Nm).

C. Installation of the complete temperature sensor (Figure 701)

(1) Position the temperature sensor harness assembly connector withgasket (210).

(2) Position the sensor lug in place on the positive terminal of cell 11 (seefig 701).


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October 24/97

(3) Install the sensor with the nut and torque to 69.9 lb-in ±4 lb-in (8 Nm±1Nm).

(4) Fix the cable of the sensor along the links with wire ties (see fig 701).

(5) Install the connector (040) as described below (ASSEMBLY ANDSTORAGE 1.D.).

D. Installation of the electrical connector

(1) Install the electrical connector (040) with its gasket (050) and secure itwith the four Sems screws (060).

(2) Install the links (090, 100, 110, 120, and 130) on the terminalsfollowing the order given in para. B (Installation of a Cell).

E. Assembly of a battery

(1) Insert all spacers (020) as shown in detailed parts list, fig. 1 page1006.

(2) Insert the connector of the temperature sensor with its gasket (210)into the case (010), secure with the jam nut (200) (ASSEMBLY ANDSTORAGE 2.C.). Torque the jam nuts to 20 lb-in ±2 lb-in (2.26Nm±0.2Nm).

(3) Insert twenty VP170KH cells, being careful to position them correctlyfor polarity.

(4) Install the complete connector as described in para. D.

(5) Lightly grease terminals and links using a neutral petroleum jelly orlight oil applied with a paintbrush.

(6) Install the links (090 to 130) to the cells and connector terminals,install the washers (150) and nuts (140). Torque the nuts to 69.6 lb-in±4 lb-in (8Nm ±1Nm).

(7) Install the cover (030) and close the battery with the two toggle typefasteners.


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2. STORAGE

A. Preparation of battery before storage

(1) After adjusting the electrolyte levels (see CHECKS), discharge thebattery (see CHECKS Table 1).

(2) Install shorting spring across connector (40).

(3) Lightly grease with a neutral petroleum jelly or light oil the nuts, links,connector contact and all components that might be susceptible toatmospheric corrosion.

(4) Refit the cover and place the battery in the normal upright position.

B. Storage facilities

(1) Saft 1756-1 and 1756-3 batteries must be stored in a dry, dust freelocation.

C. Temperature conditions

(1) Batteries may be stored between -60°C and +60°C (-76°F and+140°F). However, the best temperature range is between 0°C and+30°C (+32°F to +86°F).

D. Packing

(1) Saft 1756-1 and 1756-3 batteries are normally packed in a cardboardbox. For prolonged storage or for shipment overseas, packing in awelded plastic container is recommended. In this type of containerand under optimal storage conditions, shelf life should be 10 years.

E. Transport

(1) It is important that nickel-cadmium 1756-1 and 1756-3 batteries betransported in the upright position. For this reason, packages must beclearly marked "TOP" and "BOTTOM".


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F. Service after storage:Storage Time Servicing ProcedureLess than 3 months Charge the battery (see DESCRIPTION AND

OPERATION Table 1).3 months to 1 year Complete the periodic check (see CHECK).

More than 1 year Complete the regular check (see CHECK).

1756-1 and 1756-3 Battery CircuitFIGURE 701

Installtemperaturesensor lugon thisterminal


1756-1 and 1756-3


October 24/97

FITS AND CLEARANCES

1. Torque Table

Figure / Item Number Torque Value Name, LocationIPL Fig 1 140 69.9 ± 4 lb-in (8 ± 1 Nm) Nut, Terminal, UpperIPL Fig 1 200 20 ± 2 lb-in (2.26 ± 0.2 Nm) Nut, JamIPL Fig 1 250 43.5 ± 2.5 lb-in (5 ± 0.3Nm) Nut, Terminal, Lower

2. Fits and Clearances Table

No fits and clearances required.


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SPECIAL TOOLS AND EQUIPMENT

APPLICATION

PART NUMBER NOMENCLATURE

TEST/FAULT

DISASSEMBLY

CLEANING

CHECK

REPAIR

ASSEM./STORE

093382-000 Wrench, Vent Valve (fig. 901) X X X X X X

018327-000 Syringe, 20cm3 (1.22in3) (fig. 902) X X X

017556-000 Wrench, Cell Extraction (fig. 903) X X

024554-000 Check Fixture, Vent Valve X

Equalizing resistors (1Ω 3W) X X

Megohmmeter (10MΩ 250Vcontinuous)

X X

Precision Multimeter (volt, Ω, mA) X X X X

0-60 Amp. DC Power Supply X X X

0-60 Amp DC Load Bank X X X X


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October 24/97

Wrench, Vent ValveFIGURE 901

Syringe, 20cm3

FIGURE 902


1756-1 and 1756-3

24-32-06903

October 24/97

Wrench, Cell Extraction(Dimensions in inches)

FIGURE 903


1756-1 and 1756-3

24-32-06904

October 24/97

List of Consumable Materials

DESIGNATIONSPECIFICATION 1-OTAN 2-F 3-US 4-UK

SUPPLIER REFERENCE

Mineral Vaseline 1-S.743 2-AIR 3565 3-VLP 2364-DEF 2333

ESSOIndustrial Vaselinen.2ELFAviation Vaseline

Grease 1-G.3923-MIL-G43434-DTD 5610

Dow CorningMolykote 55M

Glue 3 M FranceEC1236

Distilled Water Physical: Clear, colorless,and odorless on boiling.

Resistance at +20°C >30,000 ohm. centimeter.

Limit: 15,000ohm.centimeterin storage.

Chemical: 5 < pH < 7Lack of organic matters andreducing substances:oxidizable carbon as KMnO4

consumption < 30milligram/literTotal SO42- + CI- ions < 10milligram/literTotal dissolved solids < 15milligram/literSilica as SiO2 < 20milligram/liter

Local Supply


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1. INTRODUCTION

A. The Illustrated Part List (IPL) is prepared in compliance with ATA 100. TheIPL is intended to identify all the components of the unit.

(1) The Illustrated Parts List contains the following sections:

(a) Introduction

(b) Vendors Code Index

(c) List of Circuit Symbols (if applicable)

(d) Alphanumeric Index of Manufacturer’s Part Numbers

(e) Detailed Parts List

2. HOW TO USE DETAILED PARTS LIST

A. The Detailed Parts List includes the nomenclature and illustrations of the unitcomponents.

(1) The Detailed Part List columns are arranged as follows

(a) 1st column: Figure and Item Number

(b) 2nd column: Manufacturer’s Part Number

(c) 3rd column: Airline Part Number

(d) 4th column: Nomenclature

(e) 5th column: Usage Code- (Applicability)

(f) 6th column: Units per Assy. (Quantity per next higherassembly)

(2) Figure and item numbers

(a) The figure number, covering items listed, is indicated on the firstline at the top of each page.


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(b) Assemblies, sub-assemblies and parts listed, but not illustrated,are identified by a dash (-) preceding the corresponding itemnumbers.

(c) A "lettered index" appearing before the item number is a cross-reference to the illustration of the variant called out from thecorresponding main figure.

B. Manufacturer’s part number

(1) Each of the assemblies, sub assemblies, and detailed parts, illustratedor not, is assigned a manufacturer’s part number.

(2) When the manufacturer’s actual part number exceeds 15 characters,an equivalent assigned part number is listed in the "Part Number"column preceded by the following annotation: "ORDEROVERLGTH....MADE BY V....” Both part numbers are listed in theAlphanumeric Index in their logical order; the actual part number iscross-referenced to the assigned part number preceded by theannotation "SEE>>>".

C. Nomenclature

(1) The nomenclature is indented to show the relationship between theparts listed, as follows:

1 2 3 4 5 6 7Assembly. Detail parts for assembly. Sub assembly. Attaching parts and/or storage for sub-assembly ***

. . Detail parts for sub-assembly

. . Sub-sub-assembly

. . Attaching parts and/or storage parts for sub-sub-assembly ****

. . . Detail parts for sub-sub-assembly

(2) This vendor code or the abbreviation "NP" (non-procurable) is placedat the extreme right-hand side of the 1st line of the nomenclature.


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D. Applicability (Usage Code)

(1) An alphanumeric usage code indicates the applicability of sub-assemblies and detail parts to the next higher assembly(ies) or sub-assembly(ies).

(2) When the applicability is general, the "usage code" column is leftblank.

(3) The usage code corresponds to the figure/item number of the nexthigher assembly(ies) or sub-assembly(ies), i.e. applicability 1A, 1B, 1Cis written 1ABC.

E. Units per assembly

(1) The units per Assy column show the number of units required for the nexthigher assembly. In some cases, this information is replaced by the lettersREF (reference) or AR (as required).

3. TERMS AND ABBREVIATIONS USED

AR: as required

ATTACHING PARTS

DELETED

DET: Detail

LH and RH: Left and Right

MADE BY

MADE FROM

MATCHED PARTS

MODIFIED FROM

NHA: Next higher assembly

NP: Non procurable

Old PN: Old reference


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OPT TO: Optional parts

ORDER OVERLGHT MPN: Actual part number exceeding 15 characters

OVERSIZE: Oversize repair parts

POST SB: After applying Service Bulletin instructions

R: Revised

RF: For memories

REF: For reference

SAME AS

SEE

SEL FROM: Select from parts

STORAGE PARTS

SUPSDS by: Superseded by

UNDERSIZE: Undersize repair parts

T: tera 10E12 G: giga 10E9

M: mega 10E6 k: kilo 10E3

m: milli 10E-3 F: micro 10E-6

n: nano 10E-9 p: pico 10E-12

4. CHANGES

A. When an item is revised, added, or deleted, the letter "R" is shown in theright margin (the page date of issue changes).

B. The letter "R" appears in the right margin opposite the page number when allthe item numbers are changed.


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5. Vendor Code Index

VENDORCODE

NAME - ADDRESS

V09052 Saft America Inc.711 Industrial Blvd.Valdosta, GA 31601Tel: (912) 247-2331Fax: (912) 247-8486


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Battery, Exploded ViewFigure 1 (Sheet 1 of 4)

030

020

010

060050

040

080

070


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110

100130

090

140

150

230

240

120


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210

200

160160A


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250

260

270

280

290

230

240

220


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Fig Item Manufacturer’sPart Number

AirlinePart Number

Description1 2 3 4 5 6 7

UsageCode

Qty

1 1756-11756-3

20 VP170KH Battery Assembly20 VP170KH Battery Assembly

AB

RFRF

010 023048-000 . Case, Marked 1756-1(V09052) 1011 NP . . Modification Label (V09052) B 1020 XX-000 . . Kit, Spacer (V09052) 1030 018248-000 . Cover & Pad (V09052) 1040 021741-000 . Connector, Complete (V09052) 1050 009384-000 . . Gasket (V09052) 1060 093616-000 . . Screws, Sems (V09052) 4070 015995-000 . . Nut (V09052) 2080 018124-000 . . Washer, Curved Spring (V09052) 2090 015734-000 . Link (V09052) 13100 015735-000 . Link (V09052) 1110 015736-000 . Link (V09052) 1120 015737-000 . Link (V09052) 5130 019728-000 . Link (V09052) 1140 015995-000 . Nut (V09052) 40150 018124-000 . Washer, Curved Spring (V09052) 40160 093445-000 . Connector & Sensor Assembly

(V09052)A 1

160A 024639-000 . Connector & Sensor Assembly(V09052)

B 1

200 NP . . Nut, Jam (V09052) 1210 NP . . O-Ring (V09052) 1220 017460-000 . Cell, VP170KH (V09052) 20230 015990-000 . . Valve, Vent (V09052) 1240 091180-008 . . . O-Ring (.301ID X .070THK)

(V09052)1

250 015995-000 . . Nut (V09052) 2260 023935-001 . . Polarity Washer, Red (V09052) 1

023935-002 . . Polarity Washer, Blue (V09052) 1270 018124-000 . . Washer, Curved Spring (V09052) 4280 021870-000 . . Washer, Flat (V09052) 2290 091180-008 . . O-Ring (V09052) 2

Aircraft Battery PART NUMBER 1756-1 and 1756-3tracebatteries.ru/d/476379/d/1756-1.pdfSAFT AMERICA...

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Transcript of Aircraft Battery PART NUMBER 1756-1 and 1756-3tracebatteries.ru/d/476379/d/1756-1.pdfSAFT AMERICA...