COMPONENT MAINTENANCE MANUAL WITH ILLUSTRATED PARTS LIST AIRCRAFT BATTERY P/N 26108

Transcription

1 (F6177) 156, Avenue de Metz Romainville - FRANCE Tel.(33-1) Telex F COMPONENT MAINTENANCE MANUAL WITH ILLUSTRATED PARTS LIST AIRCRAFT BATTERY P/N Date of issue : August 01/93 Title page - Page 1 August 01/93

2 COMPONENT MAINTENANCE

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4 RECORD OF TEMPORARY REVISIONS TEMPORARY PAGE ISSUE BY DATE BY REV. No. NUMBER DATE REMOVED RTR Pages 1/2

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6 SERVICE BULLETIN LIST NUMBER BRIEF DESCRIPTION TYPE AFFECTED SBL Pages 1/2

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8 LIST OF EFFECTIVE PAGES DATE OF DATE OF CONTENT PAGE LATEST CONTENT PAGE LATEST REVISION REVISION Title page 1 Aug 01/93 Description 1 Aug 01/93 and 2 Aug 01/93 operation 3 Aug 01/93 Record of 1 Aug 01/93 4 Aug 01/93 revisions 2 Blank Testing and 101 Aug 01/93 Record of 1 Aug 01/93 fault 102 Aug 01/93 temporary 2 Blank isolation 103 Aug 01/93 revisions 104 Aug 01/93 Service 1 Aug 01/93 Disassembly 301 Aug 01/93 bulletin 2 Blank 302 Aug 01/93 list List of 1 Aug 01/93 Cleaning 401 Aug 01/93 effective 2 Aug 01/ Aug 01/93 pages Check 501 Aug 01/93 Table of 1 Aug 01/ Aug 01/93 Contents 2 Blank 503 Aug 01/ Aug 01/ Aug 01/ Aug 01/93 List of 1 Aug 01/ Aug 01/93 illustra- 2 Blank 508 Blank tions Repair 601 Aug 01/93 Foreword 1 Aug 01/ Aug 01/93 2 Blank Assembly 701 Aug 01/93 and storage 702 Aug 01/ Aug 01/ Aug 01/93 LEP Page 1

9 LIST OF EFFECTIVE PAGES DATE OF DATE OF CONTENT PAGE LATEST CONTENT PAGE LATEST REVISION REVISION Special 901 Aug 01/93 tools and 902 Aug 01/93 equipment 903 Aug 01/ Blank Illustrated parts list TP Aug 01/93 2 Blank INTRO Aug 01/93 2 Aug 01/93 3 Aug 01/93 4 Aug 01/93 5 Aug 01/93 6 Blank VCI Aug 01/93 2 Blank NI/NUM Aug 01/93 DETAILED 1001 Aug 01/93 PARTS LIST Aug 01/ Aug 01/ Blank LEP Page 2

10 TABLE OF CONTENTS PAGE DESCRIPTION AND OPERATION 1 - Description Operation 2 TESTING AND FAULT ISOLATION 1 - Testing Fault isolation 101 DISASSEMBLY 1 - Disassembly 301 CLEANING 1 - Light cleaning Thorough cleaning Greasing 402 CHECK 1 - Periodical checks Maintenance operations in workshop General overhaul 506 REPAIR 1 - Battery condition Polarisation test Supplementary electrical test before repair 602 ASSEMBLY AND STORAGE 1 - Assembly Storage 702 SPECIAL TOOLS AND EQUIPMENT 901 ILLUSTRATED PARTS LIST Introduction INTRO Vendor code index VCI Numerical index NI/NUM Detailed parts list 1001 TC Pages 1/2

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12 LIST OF ILLUSTRATIONS PAGE Figure Level adjustment with a syringe and calibrated nozzle 502 Figure Circuit 704 Figure Polyamide key for vented filler cap made of polyamide 902 Figure Syringe with nozzle 902 Figure Cell removal tool 902 Figure 1 - Battery 20 VHP260KH-3 Type LI Pages 1/2

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17 (2) Operational data - Operating temperature: -40 to +71 C (-40 to +160 F) - Maximum instantaneous power : - at +23 C (+77 F): 12V 15s 12.8kW, - at -18 C (+ 0 F): 12V 15s 7kW. C. Detailed description (Refer to pages and ) The battery has 20 VHP260KH-3 (150A) cells housed in a stainless steel box which is equipped with a cover made of insulating material. The box (030A) has a lining of thin sheets of insulation (100A thru 120A). Four parts of a adhesive moss strip (060A) keep the cells vertical. Those parts are attached to the box cover which pusches down the top of the cells. Rigids links (130A and 140A), made nickel-plated copper, connect the cells together. Two supple connections connect the end cells to an electrical connector. This connector connects the battery to the aircraft. The box (030A) has: - a cover that you can remove, - and one latche. 2. Operation A. Charge (1) Flight charge Adjust the charging source to make sure the battery is correctly charged in flight. Do a charging source check as frequently as possible. At the usual temperature of +20 C (+68 F), the constant charge voltage must be 28.5 volts. If the climatic or battery operating conditions cause the cell temperature to increase to +40 C (+104 F), adjust the charging source to 27.5 to 28 volts. This is to prevent a fast loss of the electrolyte reserve and a shorter life for the cells. For a given voltage adjustment, the higher the battery temperature, the higher the remaining charge current. The consumption of water from the electrolyte is directly in proportion to the remaining charge current. Thus it is necessary to accurately know the usual operating temperature of the batteries to permit the batteries to be charged in the best conditions. Page 2

18 (2) Ground charge Do all battery maintenance or overhaul steps in a workshop. (ambient temperature: mini +5 C (+41 F), maxi +35 C (+95 F) ). Note: In addition to the constant current and constant voltage methods of charging other methods, such as combination of both or pulse charging, can be used. If the specific instructions are not given in the operating manual, SAFT should first be contacted. WARNING: REMOVE THE COVER TO CHARGE THE TYPE BATTERIES ON THE GROUND. THIS IS TO MAKE SURE THAT GAS WILL NOT COLLECT IN THE BATTERY BOX. - Constant current charge (Battery fully discharged): To charge a fully discharged battery, do one of these procedures: CONSTANT CURRENT CHARGE Main charge End of charge 2.6 amps (0.1C1A) until 30V as battery voltage mini 10h Time: maxi 12h 13 amps (0.5C1A) until 31V as battery voltage mini 2h Time: maxi 2h 30min 26 amps (1C1A) until 31.4V as battery voltage mini 1h Time: maxi 1h 15min amps (0.1C1A) for a 4h time amps (0.1C1A) for a 4h time amps (0.1C1A) for a 4h time NOTE: If the battery voltage does not increase sufficiently during the maximum charge time: Refer to "TESTING AND FAULT ISOLATION".. Page 3

19 Battery not fully discharged and discharge condition unknow. Discharge at 26 amps (1C1A) down to 20V. Charge: refer to A (2) above constant current charge. - Constant voltage charge Charge at 28.5V at ambient temperature during 4 to 5h Adjusted charge voltage: for a +5 C battery temperature: 29V for a +35 C battery temperature: 28V B. Discharge Rated capacity (C1Ah) Others rates (C1A) one hour discharge at 26 amps down to 20V 26Ah for a fully charged battery in relation temperature and time : up to 25 C1A C. Precautions - You must usually supply regular current and do regular maintenance. Thus it is only necessary to use these precautions to get correct operation of the battery: - Do not install the battery in an aircraft location which is too hot - Carefully obey the instructions that give the procedure to get a good flow of air - Do a charge level check regularly. Charge the battery on the ground when the discharge is not caused by an incorrect adjustment of the charging source. - Regularly do these checks: - Electrolyte level (specially when the weather is hot) - Tightness of the connection nuts - Adjustment of the charging source. Page 4

20 TESTING AND FAULT ISOLATION 1. Testing For the test procedures, refer to "CHECK". 2. Fault isolation FAILURES POSSIBLE CAUSES CORRECTION Zero volt with the Defective electrical Examine the electribattery set to connector (no contact cal contacts and "charge". made). links. Link loose or broken Make sure the nuts are tight (CHECK). Zero volt with the Battery fully discharged. Charge the battery battery set to (DESCRIPTION AND "discharge". OPERATION). Do an insulation check (CHECK). Battery circuit open or defective contacts. Cell fully dry Examine the contacts and links. Make sure the terminal nuts are tight (CHECK). Refer to the related subsequent steps. Leakage of electro- Incorrect adjustment of Disassemble and clean lyte. level the battery (DISAS- SEMBLY and CLEANING). Do an electrolyte level check (CHECK). Cell polarity incorrect during high-rate discharge (for example, during the engine start). Examine the aircraft circuit which charges the battery. Page 101

21 FAILURES POSSIBLE CAUSES CORRECTION Disassemble and clean the battery (DISAS- SEMBLY and CLEANING). Do an electrolyte level check (CHECK). Too much charge at high temperature or too much current Examine the aircraft circuit which charges the battery. If necessary, adjust to normal operating temperature (DESCRI- PTION AND OPERATION). Disassemble and clean the battery (DISAS- SEMBLY and CLEANING). Do an electrolyte level check (CHECK). Electrolyte found in Damaged cell case. Do a leak test of the the battery box. cells (CHECK). Replace the cell if necessary and refer to the related subsequent steps. Leakage of electrolyte. Disassemble and clean the battery (DISAS- SEMBLY and CLEANING). Do an electrolyte level check (CHECK). Page 102

22 FAILURES POSSIBLE CAUSES CORRECTION Too much water Charge much more than Examine the aircraft consumption for the limit or too much circuit which charges all the battery charge at high tempe- the battery. cells. rature. If necessary, adjust to normal operating temperature (DESCRI- PTION AND OPERATION). Cell(s) the water consumption of which is very different from that of the other cells in the battery: more than 30% Leaks from the cell(s). Do a leak test of more than the average the cells (CHECK). 25% (or less) of the Cell(s) with damaged Do the added test average separator(s) (REPAIR). If necessary, replace the cell(s). Corrosion on the Operation in acid air Make sure the battery links. test bench and the storage areas have no materials which can give off acid fumes. Mechanical damage to nickel plating Replace the damaged links (DISASSEMBLY, ASSEMBLY AND STORAGE). The links are too hot. Loose terminal nuts. Make sure the nuts are tight (CHECK). A cell has an unusu- Dry cell When the defect ally high voltage occurs, add 10 ml of at the start of the distilled water to charge. the cell. Do not adjust more accurately until the end of the charge. Page 103

23 FAILURES POSSIBLE CAUSES CORRECTION NOTE: If you charge a cell with a quantité of electrolyte which is not sufficient, this can cause temperature to increase very much. A cell has an unusu- The cell was operated at Replace the cell ally low voltage at temperatures and charge (DISASSEMBLY, ASSEMthe end of the charge rates that were more than BLY AND STORAGE). (Less than 1.50 V at the limits and the sepa- 2.6 amps and + 20 C rator is damaged. (+68 F) or 1.47V at) +35 C (+95 F). Low capacity cell Usual wear after long Replace the cell (The cell shows an operation. (DISASSEMBLY, ASSEMopposite voltage or BLY AND STORAGE). a correct polarity voltage of less than 1 V after a discharge of 1 hour at 26 amps). Unusual operation (Fre- Do the applicable quent engine starts with procedure (REPAIR). the battery) ; operation at high temperatures, with low electrolyte level, etc. Cell with a swollen Cell operated with low Replace the cell case. electrolyte level ; dete- (DISASSEMBLY, ASSEMrioration of separators BLY AND STORAGE) and damaged plates. Cell with zero voltage Short-circuited cell. Replace the cell. when the battery circuit is open. Low insulation. Leakage of electrolyte. Disassemble and clean the battery (DISAS- SEMBLY and CLEANING). Do an electrolyte level check (CHECK). Page 104

24 DISASSEMBLY 1. Disassembly NOTE: REFER TO "TESTING AND FAULT ISOLATION" TO FIND THE CONDITION OF THE COMPONENT OR THE POSSIBLE CAUSE OF ITS MALFUNCTION. THIS WILL GIVE THE NECESSARY LEVEL OF DISASSEMBLY. WARNING: DO ALL STEPS ON FULLY DISCHARGED BATTERIES. A. Remove a cover. B. Removal of a vented filler cap (safety cap): - Loosen the vented filler cap (160A) with the special tool (Refer to figure 901). - Remove the vented filler cap with its O-ring (170A). C. Removal of a cell: (refer to figure 1) - Remove the nuts (180A) that attach the links (130A and 140A) to the cell. Remove the spring washers (190A). - Remove the links (130A and 140A) from the cell terminals. - Fully engage the end of the special threaded tool (Refer to figure 903) on one of the cell terminals. Then pull up to remove the cell. D. Removal of the electrical connector: NOTE: In order to avoid a short-circuit, remove a link between two cells. - Remove: - the nuts (180A) that attach the positive and negative supple connections from the connector, - the spring washers (190A), - the four cells (refer to paragr. C) in front, placed just behind the connector (refer to figure 701). Page 301

25 - Loosen the four screws which attach the connector and remove them, - Remove the connector. E. Removal of the battery. - Remove: - the electrical connector (refer to paragr. D), - the cells ( refer to paragr. C), Page 302

26 CLEANING 1. Light cleaning - If a clean filtered supply of compressed air is available, do this procedure to easily and quickly clean the cells: blow with much force across the tops of the cells to remove all dust and mineral salts from the box. - To prevent short-circuits, use a rubber tube or an insulating nozzle. 2. Full cleaning Disassemble the battery (Refer to "DISASSEMBLY") and then clean all the components. A. Cells: - To easily remove all the electrolyte and mineral salts from the terminals, the covers and the sides of the cell cases: clean in warm water with a soft brush. - Make sure that the vented filler cap (safety cap) is tight. - Do not soak the cells in water. - Rub the cell with a cloth and let dry. B. Box: - Clean with water, rub with a cloth and let dry. C. Nuts, spring washers and links: - Clean in warm water with a brush and let dry. D. Packing parts and sealed insulating liner: - Clean in warm water and let dry. E. vented filler caps: - Remove the vented filler caps (Refer to "DISASSEMBLY"). - Put covers on the cell holes to keep out unwanted material. - Soak the vented filler caps for some time (during the night, for example) in a container of distilled water (or, if not available, in very clean tap water). Do this to remove all salts from the vent hole. Page 401

27 WARNING: DO NOT USE PETROL, TRICHLOROETHYLENE OR OTHER SOLVENTS. - Before you put the vented filler caps back into the cells, make sure that they operate correctly. Do these steps: - Install the vented filler cap (160A) with its O-ring (170A) on the end of a metal tube that has a correct end-piece. - Connect this tube to a supply of compressed air through a vented filler cap of the adjustable reducing type. - Adjust the pressure to 0.5 bar (7.25 psi) and put the vented filler cap into a container of water. Air bubbles come out if the vented filler cap is in good condition. If there are no bubbles, increase the pressure until you see bubbles. Then decrease the pressure slowly to 0.1 bar (1.45 psi) and monitor the pressure at which the air flow stops. - Reject all vented filler caps that have an operating pressure of more than 0.7 bar (10 psi) (after the check done before to make sure that the related cap operates correctly) or less than 0.14 bar (2 psi). - Install the vented filler caps (Refer to "ASSEMBLY"). 3. Lubrication When the battery is clean (and after installation of the vented filler caps), put a thin layer of neutral petrolatum (petrolatum that is not acid) or light oil on the terminals and the links. Use a paintbrush. Page 402

28 CHECK 1. Regular checks You must do the checks which are necessary to use the SAFT batteries in flight and on the ground. But you must also do these maintenance steps during operation: - Periodical check (in a workshop): adjustment of electrolyte levels - Regular check (in a workshop): electrical treatment, adjustment of electrolyte levels, and capacity test. A. Periodical check 2. Maintenance steps in workshop Periodically (at flight hour intervals such that the allowable water consumption is not exceeded): - Clean the battery (See "CLEANING") - Adjust the electrolyte level (Refer to (1)). (1) Charge of the battery and adjustment of the electrolyte level: - Discharge the remaining capacity at 26 amps down to a voltage of 20 volts at the battery terminals. - When the battery temperature is +20 C to +25 C (+68 F to +77 F) (usual temperature range), charge the battery (Refer to one of the procedures given in "DESCRIPTION AND OPERATION" for a fully discharged battery). - During the last hour of the charge (while the charge current continues to flow), adjust the level of the electrolyte in the cells. Then measure the voltages of each cell. Write the quantity of water that is added to each cell. - The electrolyte level changes with the battery charge. Thus you do not get the maximum level until the battery is fully charged. The level changes as if the plates absorbed a part of the electrolyte during the discharge and released it during the charge. Page 501

29 Thus the level checks are only satisfactory if they are done almost at the end of the charge (but during the charge). Leakage can occur during operation if you do not obey these instructions when you add liquid. The level is correct when the distance between the seat of the vented filler cap and the electrolyte is 20 mm (0.787 in) (distance measured in the conditions given before). - If necessary, add distilled water to adjust the level to this value. WARNING: DO NOT USE ACID OR ACIDULATED WATER to adjust the electrolyte levels in nickel-cadmium cells. A very small quantity of acid is sufficient to cause permanent damage. The easiest tool to adjust the level is a plastic syringe tube (equivalent to that used for medical injections, with a plastic nozzle on the conical end). The length of the nozzle which goes into the cell must be 20 mm (0.787 in) ; this is the distance necessary between the seat of the vented filler cap and the electrolyte (Refer to figure 501). To adjust the level, keep the shoulder of the syringe nozzle against the seat of the vented filler cap and pull the plunger up: 20 mm in Level adjustment with a syringe and a calibrated nozzle Figure 501 Page 502

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31 - If the level is not sufficient, the syringe tube stays empty when you pull the plunger. - If there is too much liquid, this liquid is removed by the syringe until the level aligns with the end of the nozzle. If this check shows that the level is not sufficient in some cells, add distilled water to these cells. (The syringe is small ; it can thus be necessary to do this step more than one time for each cell). The level is correct when only a small quantity of liquid goes into the syringe when you pull the plunger. To do this check (after water is added to the cell), keep the shoulder of the syringe nozzle against the seat of the vented filler cap. - Results of the above procedure: - The battery operates correctly if: - The voltage of each cell measured during the last hour of charge at 2.6 amps is not less than 1.50 volt (1.47 volt at +35 C (+95 F)). - Approximately the same quantity of distilled water was added to each cell. This quantity must be less than 21cm 3 (1.28in 3 ). - If the quantity of water added to all cells is more than 21cm 3 (1.28in 3 ): make sure that the voltage adjustment in relation to the temperature during the charge is correct. Also do the electrolyte level check more frequently. - Do a full overhaul of the battery (Refer to paragraph 3 "General overhaul"): - If the quantity of water necessary for one or more cell(s) is much higher or smaller than for the other cells. - If the voltage of each cell measured at the end of a 2.6 amps charge is less than 1.50 volt (1.47 volt at +35 C (+95 F)) (Refer to "TESTING AND FAULT ISOLATION"). (2) Clean the vented filler caps (Refer to "CLEANING") when you adjust the electrolyte levels. (3) Make sure the cell terminal nuts are tight. Make sure that all the nuts that attach the links are torqued to 8 ± 2 N.m (5.90 ± 1.47 ft.lbf). (4) Do an insulation check (Refer to paragraph 3.D). Page 503

32 B. Regular check 1) At the time of a second periodical check OR AFTER A MAXIMUM OF SIX MONTHS, do this battery test (also do the steps given in paragraph 2.A): - Discharge the remaining capacity at 26 amps down to a voltage of 20 volts at the battery terminals. - Measure the time from the start of discharge to the time when the voltage is 20 volts. - Connect a resistor of approximately 1Û 3W across each cell and continue to discharge. Resistors with crocodile clips attached to their leads can be easily attached to the cell terminals. - Let the resistors stay in position for the night. 2) Remove all resistors, charge the battery (Refer to "DESCRIPTION AND OPERATION" for a fully discharged battery). - Adjust the electrolyte level in the cells (Refer to paragraph 2.A (1)). Then measure the voltage of each cell during the last hour of the charge. Also write the quantity of distilled water added to each cell. - Immediately after the charge and the level adjustment, discharge the battery again at 26 amps down to 20 volts ; measure the terminal voltage of each cell. Write the time that is necessary for this second discharge. - Results of the above tests: The battery operates correctly if: - The time necessary for the first discharge (paragraph 2.B (1) is more than 30 minutes, - The time necessary for the second discharge (paragraph 2.B (2)) is not less than one hour, - The voltage of each cell measured during the last hour of the charge at 2.6 amps is not less than 1.50 volt (1.47 volt at +35 C (+95 F)), - The quantity of distilled water added to each cell is approximately equal to or less than 21cm 3 (1.28in 3 ). Page 504

33 - If the first discharge time is less than 30 minutes but the second discharge time is correct: the battery is in good condition but was not fully charged when removed from the aircraft. This condition can be caused by: - An incorrect charge in the aircraft. - And/or a discharge caused by an unusual operation of the battery after landing. Do a full overhaul of the battery (paragraph 3) if: - The second discharge time is less the correct one or one cell has a voltage of less than 1 volt (or incorrect polarity before 1 hour of discharge). - The voltage of each cell measured during the last hour of charge at 2.6 amps is less than 1.50 volt (1.47 volt at +35 C (+95 F)). - The quantity of distilled water necessary for one or more cell(s) is much higher or smaller than for the other cells. NOTE: The consumption of water by a SAFT nickel-cadmium cell is in proportion to the unwanted charge. Thus, the consumption must be the same for all the 20 cells in the battery. The quantity of water necessary for one or more cell(s) (in the same battery) can be much higher (or smaller) than the other cells. Then there is a defect: - High consumption is usually caused by a leakage. - Low consumption is caused by a damaged separator. - The consumption is incorrect when it is 25 % more or less than the average. Page 505

34 3. General overhaul This overhaul includes the electrical tests given in paragraph (2.B). Do an added electrical test before repair (Refer to REPAIR paragr. 3) if the voltage of each cell measured during the last hour of charge at 2.6 amps is less than 1.50 volt (1.47 volt at +35 C (95 F)). It also includes the disassembly and cleaning procedures to be done systematically for all the battery components. Do an overhaul one time each year or during each most important servicing of the aircraft. Do these steps: - Disassemble the battery - Clean the battery - Do a battery test - Do an insulation test. A. Disassemble the battery (Refer to "DISASSEMBLY"). B. Clean the battery (Refer to "CLEANING"). C. Do a battery test: (1) Cells: (2) Box: - Make sure that the lower terminal nuts are tight: - Tightening torque: 5 ± 0.5 N.m (3.69 ± ft.lbf). - Verify that cell boxes show no leakage. Make the sides of the box straight and remove the dents. (3) Nuts, links and spring washers: - Discard the components that show signs of corrosion or damage. (4) Packing parts: - Discard all defective components. (5) Connector: - Make sure that the connector is in good condition (inner and outer surfaces); replace it if the contacts are burned. Page 506

35 D. Insulation resistance : - Fully assemble the battery. Then measure the insulation resistance between the block of cells and the metal box. The resistance must not be less than 10 MÛ at 250 V continuous. Page 507/508

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37 REPAIR 1. Battery condition Do a polarisation test (Refer to paragraph 2) if you find these defects on the battery (after a removal that was not scheduled or before regular maintenance): - The polarity of the cells is incorrect - The battery open voltage is less than 21 V. Do an added test (Refer to paragraph 3) if you find these defects on the battery (during regular maintenance or general overhaul): - The voltages at the end of the charge are too low - The voltage during the charge is too high - The capacity is not sufficient - The water consumption is incorrect. 2. Polarisation test - Charge the battery at 2.6 amps for 1.5 hour. - Keep the battery in the "open circuit" condition for 1 hour. - Measure the open voltage of every cell. If the cell open voltage is 0 volt (or opposite), do an added test (refer to paragraph 3). Then repair. If each cell has an open voltage that is more than 0 volt, charge the battery (Refer to one of the procedures given in "DESCRIPTION AND OPERATION", paragraph 2.A (2), for a fully discharged battery). Page 601

38 3. Added electrical test before repair The first test charge can be unsatisfactory if the electrolyte level is too low in some cells (the level is not adjusted until the end of this charge). If you find defects, do a second test: - Charge the battery (Refer to one of the procedures given in "DESCRIPTION AND OPERATION", paragraph 2.A (2), for a fully discharged battery). At the end of the total charge time, continue to charge at 2.6 amps for 5 more hours. Regularly write the voltage and temperature of the cells. The temperature of the cells that have damaged separators increases very much and continuously. The voltage of these cells continuously decreases to less than 1.50 volt (1.47 volt at +35 C (+95 F)). NOTE: When you charge the battery more than necessary, you decrease the life of the cells. Thus, do this special test only if: - A battery malfunction occurred in the aircraft - Defects were found during shop maintenance. - Adjust the electrolyte level during the last one of the 5 last hours of charge. - Discharge at 26 amps down to 20 volts. After this test, discard the defective cells: - Cells with a voltage of less than 1.50 volt at the end of the charge. - Cells with a voltage that decreases to less than 1 volt before one hour of discharge (during the last test discharge). - Short-circuited cells (zero volt). Page 602

39 ASSEMBLY AND STORAGE 1. Assembly NOTE : Tooling and equipment are identified in the list of "SPECIAL TOOLS AND EQUIPMENT". A. Installation of the vented filler caps: - Make sure the O-ring (170A) is in good condition; replace the O-ring if it is worn. - Install the safety vented filler cap (160A) with the special tool (Refer to figure 901); hold the special tool by its upper ribbed part. B. Installation of à cell: - Install the discharged cell and make sure its polarity is correct (refer to figure 701). - Carefully position the cell (150A) and push on the terminals with a piece of soft wood. Install: - the links (Refer to figure 1 for their locations), - the spring washers (190A), - the nuts (180A) and torque them to 8 ± 2 N.m (5.90 ± 1.47 ft.lbf). C. Installation of the electrical connector: - Install the connector in the box, - install the four screws with their four lock washers and their four flat washers, - install the cells (refer to paragr. B), - attach the two supple connections from the connector and the links (130A) to the cells, - put the spring washers (190A) on the cells, - install the nuts (180A) and torque them to 8 ± 2 N.m (5.90 ± 1.47 ft.lbf). Page 701

40 D. Assembly of the battery Install these components in the box: - the spacers below (090A thru 120A) (refer. to figure 1 for their location). Units Item Designation per Dimensions assy 090A Bottom spacer 1 292x160x1 *100A Spacer x 77x1 110A Slotted insulator 1 280x210x A Insulator 2 280x189x0.5 * Caution, put only that number is necessary to wedge each cell row. Install: - Twenty VHP260KH-3 cells (150A) (refer to paragr. B), and make sure their polarities are correct as shown in figure The electrical connector (Refer. to paragr. C) - All links (130A and 140A) on the cell terminals with the spring washers (190A) and the nuts (180A). Torque the nuts to 8 ± 2 N.m (5.90 ± 1.47 ft.lbf). Lightly lubricate the terminals and the links with neutral petrolatum or light oil (use a paintbrush). - Install the cover and affix it with the latcher of the box. 2. Storage A. Preparation of the battery before storage - Adjust the electrolyte levels (Refer to "CHECK", paragraph 2.A. Then discharge at a constant current of 26 amps down to a terminal voltage of 20 volts. - Lightly lubricate these components with neutral petrolatum or light oil: the nuts, the links, the connector contacts and all the components that can be damaged by atmospheric corrosion. - Put the battery in its usual vertical position. Page 702

41 B. Storage room: Keep the SAFT batteries in a dry and clean room. C. Temperature conditions: Keep the batteries at a temperature of -60 C to +60 C (-76 F to +140 F). But the best temperature range is between 0 and +30 C (+32 F and +86 F). D. Packing The SAFT batteries are usually put in cardboard boxes. For long storage or sea transportation, we recommend that you put the batteries in a welded plastic container. In this type of container, the batteries can be kept for 10 years in the best storage conditions. E. Transportation It is important that you move the nickel-cadmium SAFT batteries in the vertical position. Thus, the containers must be identified with "TOP" and "BOTTOM" marks that can be read easily. F. Servicing after storage Storage time Servicing procedure Less than 3 Charge the battery (Do one of months the procedures given in "DESCRIPTION AND OPERATION", paragraph 2.A (2)) for a fully discharged battery) 3 months to Do the Periodicalcheck 1 year (Refer to "CHECK" 2.A). More than Do the Regular check 1 year (Refer to "CHECK" 2.B). Page 703

42 Circuit Figure 701 Page 704

43 SPECIAL TOOLS, FIXTURES AND EQUIPMENT 1. Special tools. USE Manufact. DESIGNATION T D C C R P/N E I L H E S S E E P T A A C A / S N K I F S I R A E N U M G Polyamide key for vented filler caps made of polyamide (Refer to figure 901) X X X X X Syringe nozzle (Refer to figure 501 and 902) X X X Syringe: 20 cm 3 (1.22in 3 ) (Refer to figure 902) X X X Cell removal tool (Refer to figure. 903) X X L T B L Y Equalizing resistors (1Û 3W) X X NOTE: Equivalent tools can be used as alternatives to the ones above. Page 901

44 Polyamide key for vented filler caps made of polyamide Figure 901 Syringe with nozzle Figure 902 Cell removal tool Figure 903 Page 902

45 2. Materials and different products. SPECIFICATION DESIGNATION 1-NATO 2-F SUPPLIER 3-US 4-UK REFERENCE Mineral 1- S.743 ESSO petrolatum 2- AIR 3565 Industrial 3- VLP 2336 n.2 4- DEF 2333 ELF Aviation vaseline Grease 1- G.392 DOW CORNING 3- MIL-G4343 Molykote 55M 4- DTD 5610 Glue 3 M FRANCE EC1236 Distilled water Local supply Page 903/904

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