Lamar Technologies LLC. INSTRUCTION MANUAL MODEL D AND 24 VOLT AIRCRAFT AND GSE BATTERY DISCHARGE CURRENT CAPACITY TESTER CONTENTS

Transcription

1 Lamar Technologies LLC. INSTRUCTION MANUAL MODEL D AND 24 VOLT AIRCRAFT AND GSE BATTERY DISCHARGE CURRENT CAPACITY TESTER MEETS ALL COMMERCIAL AND MILITARY AVIATION BATTERY TESTING REQUIRMENTS MILITARY TECHNICAL BAD-1 MANUAL APPLICATIONS: SEALED (SLAB/AGM) AND LEAD ACID AIRCRAFT BATTERIES NICKEL CADIUM AIRCRAFT BATTERIES GROUND SUPPORT AND VEHICLE BATTERIES e.g.: HAWKER ARMASAFE, OPTIMA TELECOM AND SPECIAL TYPES CONTENTS I. SPECIFICATIONS II. OPERATION PREFACE III. OPERATING INSTRUCTIONS FIG. 1 IV. CALIBRATION V. MAINTENANCE VI. WARRANTY & TECH SUPPORT MFG. BY Lamar Technologies LLC th Ave. N.E. Marysville, WA Tel: (360) Fax: (360)

2 I. SPECIFICATIONS 1. Self-powered by the battery under test. No AC line cord. 2. Automatic accommodation to a 12 or 24 volt battery. 3. Discharge current range settable from 2.0 to 62.2 amperes. 4. Constant current output accurate to within +/- one tenth of preset amperes when set within the range of 5-62 amperes and within 1 to 3 tenths of an amp when set below 5A. 5. Subsequent test current setting defaults to the previous test s amperes. The setting can be set to a different ampere setting (eliminates resetting for subsequent tests on the same type of battery). 6. End-of-test battery cutoff voltage settable to 18.0 or 20.0 volts for 24V battery and 9.0 or 10.0 volts for 12V battery. Cut off voltage set point accurate to +/- one tenth of a volt. 7. Digital LED displays of battery volts, (xx.x VOLTS), amperes (xx.x AMPS), and time (xx HRS, xx MIN, xx SEC). 8. D5160 operating temperature from -10 C to 45 C (14F to 113F) Cooling: Fan cooled 9. Mounting: Weatherproof transit case Dimensions: 18 in (46cm) x 14 in (36 cm) x 7 in (18 cm) D Wt: 17 lbs (8 kg) ft DC cable AWG 8 with voltage sensing leads, and snap-in connector.

3 II. OPERATION PREFACE NOTE: RATINGS AND EXAMPLES GIVEN IN THE PREFACE BELOW MAY DIFFER FROM THE USER OR BATTERY MANUFACTURERS REQUIREMENTS. Discharge current capacity testing is the only valid method of determining the true reserve (emergency) capacity of a battery. Reserve capacity is especially important for aircraft which may have to depend on the battery for emergency power in the event of power failure. The battery must deliver usable power for one hour. This is often also important for various ground support equipment and military vehicles. Most aircraft batteries are 24 volt sealed or vented lead acid, or NiCad. Military vehicles have 12 volt lead acid batteries which may be combined for higher voltages and amperages. The 5160 accommodates both 24 and 12 volt batteries. An acceptable reserve capacity will also reflect upon the high current capability of the battery for engine starting and possible other short time high amp loads. However, the reverse is not necessarily true. An acceptable high current cold cranking amp test, whether acceptable by hand-held conductance or impedance test meters, or 15 second CCA load test, does not automatically translate into an acceptable reserve test. Both the military and FAA mandate reserve capacity testing for aircraft batteries. This may be done by removing the battery from the aircraft for testing every 600 hours of use. The test essentially loads a fully charged battery with a full ampere-hr rated load. E.g. 40 amp-hr battery drawing a 40 amp load for 1 hour. The battery must deliver full power until the voltage drops to an unusable level such as when relays and instruments drop-out. This can be at 18 or 20 V.

4 OPERATION PREFACE CONTINUED The only practical way to test this capability is with a constant current load. By the end of one hour under the battery s rated one-hour capacity (amp-hr capacity), the battery voltage must not have dropped below the assigned cut-off voltage which, for a 24 volt battery is usually 20 volts. However, in normal usage over time, the actual capacity will be lower than the rating, and both the military and FAA allows an acceptable value of 85% of the battery s nameplate ampere hour rating. This can be 85% of the one hour rating at full load (e.g. 51 minutes at 40 amps for a 40 A-H battery with acceptable end voltage of 20 V or higher), or 85% of current for 60 minutes (e.g. 34 amp for 60 minutes). There may be other acceptance criteria such as ½ of the AH rating for 2 hours, and battery end voltage being 18 volts. For ratings of batteries higher than the 62 amp limit of the 5160 tester, the acceptable discharge time is extended in scale with the battery rating. (e.g. For a 120 amp-hour battery, set the test current to 60 amps and run test for 2 hours).

5 III. OPERATING INSTRUCTIONS FIG. 1 ITEM # DESCRIPTION 1. ON/OFF/RESET SWITCH 2. START PUSH BUTTON 3. DISCHARGE AMP SETTING BUTTONS 4. AMMETER 5. TIME DISPLAY 6. VOLT METER 7. READY LED 8. TESTING LED 9. TEST COMPLETE LED 10. AMMETER TEST POINTS 11. VOLTAGE TEST POINTS 12. DC CABLE W/ SNAP IN CONNECTOR (NOT SHOWN) 13. AIRCRAFT BATTERY QUICK DISCONNECT CABLE CONNECTOR (NOT SHOWN) 14. RING TERMINAL CONNECTOR (NOT SHOWN) 15. REVERSED BATTERY ALERT LED 16. CUT OFF VOLTAGE SETTING SWITCH

6 III. OPERATING INSTRUCTIONS REFER TO FIG Turn On/Off switch (#1) to Off position 2. Connect battery cable (#12) to battery If polarity is reversed, LED (#15) will illuminate together with audible signal If necessary correct the reversal. 3. Set voltage cutoff set switch (#16). 9 or 10 V for 12 V batteries. 18 or 20 V for 24 V batteries. 4. Turn On/Off switch (#1) to On position All instrument displays will briefly illuminate as 8s, then as follows: a) Timing (#5) All zeros, steady. b) Amperes (#4) Flashes* *Reading depends upon last setting which may be the last factory test setting if starting with a new unit. c) Volts (#6) reads battery voltage* steady. *Reads open circuit voltage (OCV). A charged 12 V battery may read volts and 24 V batteries reads volts. d) Ready LED (#7) illuminates. 5. Preset the required discharge amperes. Use the ampere set buttons (#3); Left button is tens place, center is 1 s place, right is decimal.

7 OPERATING INSTRUCTIONS CONTINUED Current may be set below 2.0 amperes but actual discharge current and/or meter reading may be inaccurate. Actual discharge amperes may be read using the ampere test points (#10) with a digital multimeter set to the DC milli-volt scale. Subsequent amperes will default to the previous test setting. If different amperes are required from the previous test, the discharge current must be set to the new current. 6. Press Start (#2) Testing LED illuminates Cooling fan starts Ammeter reading ramps to approximately the preset level then settles to the steady preset level within +/-.1 amp. Voltmeter reading drops to battery loaded voltage level. Timer begins counting time. NOTE: CURRENT SETTING CANNOT BE CHANGED WHILE TEST IS PROCEEDING. UNIT MUST BE SHUT-OFF AND RESET WITH SWITCH (#1) 7. Test proceeds with battery voltage steadily decreasing. 8. When battery voltage lowers to the preset level (Step 3) the test is complete. The level switch may be set to the alternate level during the test. (E.g. from 20 to 18 V, or 18 to 20 V) Test complete (#9) LED illuminates All readings freeze at their final readings.

8 OPERATING INSTRUCTIONS CONTINUED 9. User will evaluate the results of the test. E.g. For a 30 amp-hour test: a) 30 amps at 48 min- FAIL b) 30 amps at 51 min (85% capacity) - PASS c) 30 amps at 60 min (100% capacity) SUPERIOR BATTERY The exact amp hr capacity of the battery is obtained as follows: a) Convert the hours and minutes to all minutes b) Divide by 60. Equals amp-hr capacity. 10. Record reading, set switch (#1) Off, remove battery.

9 IV. CALIBRATION Preface A. The 5160 unit is microprocessor controlled with programmed functions of operation and displays. There are no user calibrations procedures, only verification of time, voltage, and current readings. Factory calibration requires battery banks, variable power supplies, oscilloscope and calibrated test instruments. Therefore, units which may be out of calibration or malfunction should be returned to the factory. East coast and west coast tech reps are available. See Tech Support on Section. VI B. In order to verify operating accuracy, there are test points for the ammeter and voltmeter, to connect to the user s multi-meter. The ammeter test points, connects to an internal shunt rated 100 amperes at 100 milli-volts. The volt meter connects to the battery by sensing leads at the snap-in connector at the end of the DC cable. For amperes, a test multi-meter such as Fluke, must be set to the DC milli-volt scale. Amperes are read as milli-volts directly. Multi-meter leads are plugged into the amperes/mv test points (Fig 1, #10) For volts, the multi-meter is set to DC volts. Leads are plugged into the volts test points or additional verification can be taken directly at the battery under test. For time readings, any quality digital timer may be used for verification. C. To verify the accuracy of the internal shunt and ammeter, a shunt rated 100 amps/ 100 milli-volts is connected in series with the DC cable and battery. The shunt may be connected in either the positive or negative leg. The milli-volt meter reads the shunt voltage which is equal to the DC amperes. This shunt connector assembly can be obtained from Power Products. See Tech Support Section.

10 V. MAINTENANCE Standard electrical/electronic equipment maintenance procedure should be observed. These include vacuum cleaning of the resistor grille and open spaces in the unit. Use only cleaners approved for plastic meter covers. Do not use harsh cleaners which may damage plastic or the silk screened or painted portions of the unit. Examine the DC cable and connectors for signs of wear, fraying, or looseness. If the connector must be replaced, the voltage sensing leads must be securely attached and well crimped or soldered to the cable in the correct polarity.

11 VI. 1 YEAR WARRANTY POWER PRODUCTS INC. warrants its products to be free from defects in workmanship and material for a one-year period from the date of shipment to the distributor, original equipment manufacturer (OEM), or original end user. If any product shall prove to be defective during the warranty period, POWER PRODUCTS INC. will repair or replace such part. There are no warranties, which extend beyond the description on the face hereof. This warranty is in lieu of all other warranties, express or implied. POWER PRODUCTS INC. excludes liability for incidental and consequential damages. An action for breach of this warranty must be commenced within one year after the breach is or should have been discovered. POWER PRODUCTS INC. specifically disclaims all other representations to the first user/purchaser, and all other obligations or liabilities. No person is authorized to give any other warranties or to assume any liabilities on POWER PRODUCTS INC. behalf.

12 POWER PRODUCTS INC. 27 PAMARON WAY, SUITE E NOVATO, CA CERTIFICATION OF CALIBRATION BATTERY DISCHARGE CAPACITY TESTER MODEL: D-5160 APPLICATION: Discharge capacity testing of 12 and 24 Volt Lead Acid and Nickel Cadmium aircraft batteries. Discharge Range: 2 62 Amperes. Amperes: XX.X Adjustable to +/- 0.1A DIGITAL DISPLAYS: Volts: XX.X Time: Hrs. XX Min. XX Sec. XX CALIBRATION PROCEDURE: SPECIFICATIONS: NOTES: 0-75 Ampere, 0-30 Volt Variable Power Supply Power Products P/N PS 7530AF used as battery substitute. Test instruments and shunt compared to the D5160 unit. Required accuracy +/- 0.2A from pre-set discharge amps. Powered by battery under test Automatic Setting to 12 or 24 Volt battery Push button adjustment for discharge amperes w/ resolution of 0.1 Amps Selectable end voltage discharge cutoff, 9/18 Volts or 10/20 Volts. Meter reading accuracy Voltmeter +/- 0.2 Volts Ammeter +/- 0.2 Amperes Timer 1 sec. Calibrating Test Instruments Used: Meters: Fluke 8010A DC MV Digital, Fluke 87 DC Volts Digital Shunt: EMPRO 100A 100MV 0.25% accuracy Traceable to NIST Calibration within one year Instrument test before each equipment test and calibration: Fluke meters with standard cell of Volts to +/ V UNIT: BATTERY DISCHARGE CAPACITY TESTER MODEL: D-5160 SERIAL #: DATE OF MANUFACTURE: PROCEDURE: D5160CAL ENVIRONMENTAL CONDITIONS: NOMINAL 70º - 80º F 35-40% R.H. SHIPPED CONDITION: CALIBRATED / IN TOLERANCE CALIBRATED BY: DATE CALIBRATED: DUE DATE OF NEXT CALIBRATION (ANNUAL): APPROVED BY TITLE: DATE: Lamar Technologies certifies that the above listed instrument meets or exceeds all published specifications. It has been calibrated using standards MIL-I whose accuracies are traceable to the National Institute of Standards and Technology.

13 MFG. by: Lamar Technologies LLC th Ave. N.E. Marysville, WA