Saft 4579, Component Maintenance Manual With Illustrated Parts List

Page 1: ...ns page has noted Revision No 4 dtd July 13 01 Chapter Section and Page Number Description of Change Effectivitity List of Effective Pages Pages 1 2 Revised to indicate added revised and or deleted pa...

Page 2: ......

Page 3: ...LEVARD VALDOSTA GEORGIA 31601 24 31 05 PAGE T 1 T 2 Blank July 13 01 COMPONENT MAINTENANCE MANUAL WITH ILLUSTRATED PARTS LIST Nickel Cadmium Battery 4579 BA06 ELDEC PART NUMBER S282T002 1 BOEING PART...

Page 4: ......

Page 5: ...ENANCE MANUAL 4579 24 31 05 PAGE RR 1 RR 2 Blank July 13 01 RECORD OF REVISIONS REV NO ISSUE DATE INSERT DATE BY REV NO ISSUE DATE INSERT DATE BY 1 02 28 84 03 01 84 Saft 2 06 15 91 07 01 91 Saft 3 01...

Page 6: ......

Page 7: ...SAFT AMERICA INC COMPONENT MAINTENANCE MANUAL 4579 24 31 05 PAGE RTR 1 RTR 2 Blank Jan 30 98 RECORD OF TEMPORARY REVISIONS TEMPORARY REV NO PAGE NUMBER ISSUE DATE BY DATE BY...

Page 8: ......

Page 9: ...k Jan 30 98 SERVICE BULLETIN LIST SERVICE BULLETIN NUMBER REVISION NUMBER DATE BULLETIN INCORPORATED INTO MANUAL PRODUCT IMPROVEMENTS Product Improvements have been incorporated using service bulletin...

Page 10: ......

Page 11: ...108 109 110 111 112 113 114 115 116 117 118 Jan 30 98 Jan 30 98 Jan 30 98 Jan 30 98 Jan 30 98 Jan 30 98 Jan 30 98 Jan 30 98 Jan 30 98 Jan 30 98 July 13 01 July 13 01 Jan 30 98 Jan 30 98 Jan 30 98 Jan...

Page 12: ......

Page 13: ...ONTENTS PARAGRAPH TITLE PAGE Description and Operation 1 Testing and Fault Isolation 101 Automatic Test Requirements ATLAS N A Disassembly 301 Cleaning 401 Check 501 Repair 601 Assembly Including Stor...

Page 14: ......

Page 15: ...ic instructions to be used on the equipment covered herein Most standard aerospace practices are not described herein An explanation of the use of the Illustrated Parts List IPL is provided in the Int...

Page 16: ......

Page 17: ...assembly The sensor assembly includes a thermoswitch mounted on a plate against the end of the center row of cells A charge control thermistor is located between cells 6 and 9 in the center row of ce...

Page 18: ...side brackets Width including handles 11 4 285 mm 13 0 325 mm 11 0 275 mm Cell Assembly Terminal M10 X 1 25 Number of Cell Assemblies 20 Cell Model VHP450KA 1 Rated Capacity End of Life Capacity 40 Ah...

Page 19: ...OTE All part identification numbers herein are IPL Fig 1 item numbers 2 Required Test Equipment NOTE Test equipment having equivalent specifications can be used NOMENCLATURE APPLICATION DC Power Suppl...

Page 20: ...O D NOT GOOD CHARGE LEVEL ELECTROLYTE RETURN TO SERVICE SPECIAL TESTING ALL CELLS 1 50V ANY CELL 1 50V ALL CELLS 1 50V ANY CELL 1 50V NOTES Record all discharge data in battery log book Reentry point...

Page 21: ...for a complete list of all test equipment required for proper maintenance of a Ni Cd battery C Initial Discharge Capacity Test The purpose of this discharge procedure is to determine the initial capa...

Page 22: ...ttery and all cells are considered above rated capacity Proceed to with maintenance per Fig 102 b The first cell discharged to 1 0 V in less than the minimum time listed in Figure 103 indicating that...

Page 23: ...NOTE It is not necessary to have a rest period between discharge and residual discharge 1 Continue to discharge the battery After battery voltage drops to 1 0 V connect a 1 0 ohm 3 0 watt minimum res...

Page 24: ...RGE IF ANY CELL INDICATES AN IMMEDIATE VOLTAGE RISE ABOVE 1 50 VOLTS ADD ABOUT 10 CC S OF DISTILLED OR DEMINERALIZED WATER THROUGH THE VENT VALVE OPENING OF THAT CELL 3 Charge using one of the two met...

Page 25: ...rge 4 Record the time that the first cell reaches 1 0 V NOTE It is not a cause for concern if a cell goes to zero volts or reverses polarity during the battery discharge Simply short out the cell s te...

Page 26: ...analog volt ohmmeter for a measurement of 500 mA 2 Connect the negative lead to the battery container and the positive lead to the positive terminal of the battery then to the positive terminal on ea...

Page 27: ...ge the battery at 4 5A for 10 12 hours per Figure 104 3 Overcharge the battery at 4 5A for an additional 4 hours Total charge time will be approximately 18 20 hours 4 Monitor individual cell voltages...

Page 28: ...hem soak to dissolve any salts 3 Cover the cells 2 with a clean damp cloth to prevent entry of foreign matter 4 Check the liquid level in the cell a Insert the syringe P N 020915 004 into the cell ope...

Page 29: ...o achieve the correct level d At the point in step b when some excess liquid is drawn into the syringe the correct level for that cell has been reached Expel the excess liquid into a separate containe...

Page 30: ...mperature sensor assembly 22 Ohmmeter should read 1M open thermoswitch contacts at room temperature 70 F 5 F 21 1 C 2 C 2 Suspend the thermoswitch plate 23 with thermoswitch in a beaker of water with...

Page 31: ...1 00 The adapter can be made from 1 2 inch round stock with 1 4 inch I D hole 2 Screw the valve 3 with its o ring 4 into the adapter end of the pressure test fixture 3 Attach the fixture to a compress...

Page 32: ...l connector not making contact Check electrical contacts links and tightness of nuts CHECK Link loose or broken Replace if necessary torque all upper terminal nuts CHECK Zero volt with battery set to...

Page 33: ...e level TESTING and FAULT ISOLATION Disassemble and clean the battery DISASSEMBLY AND CLEANING Check electrolyte level TESTING and FAULT ISOLATION Retighten vent valve Test vent valve TESTING AND FAUL...

Page 34: ...s whose water consumption differs significantly from that of other cells in the battery more than 30 above average Leaking cell s Check sealing of cell s CHECK Disassemble and clean the battery DISASS...

Page 35: ...ut off voltage reached before minimum time or not reached at the maximum time Battery not fully discharged or strongly unbalanced Perform a regular check CHECK Cell with abnormally low voltage at end...

Page 36: ...parator and damaged plates Replace with new SAFT cell DISASSEMBLY ASSEMBLY Cell with zero voltage when battery circuit is open Short circuited cell Replace with new Saft cell DISASSEMBLY ASSEMBLY Low...

Page 37: ...TELY DISCHARGED BEFORE CELL ASSEMBLIES CAN BE REMOVED DUE TO POSSIBLITY OF ELECTRIC SHOCK WARNING USE CARE NOT TO TILT BATTERY WHILE VENT VALVES ARE LOOSENED CONTACT OF ELECTROLYTE WITH SKIN CAN CAUSE...

Page 38: ...ghtening the cell puller on cell terminals and removing cell with a steady straight up pull I Disassembly of the cell assemblies 2 is restricted to replacing defective vent valve o rings 4 and the low...

Page 39: ...are required to perform the cleaning procedures equivalent substitutes can be used Stiff bristle brush nonmetallic Dry compressed air source less than 20 psi 1 4 bar Safety goggles Lubricant non acid...

Page 40: ...N DO NOT USE A WIRE BRUSH TO CLEAN CELL TOPS CELLS MAY BE DAMAGED D Remove white deposits potassium carbonate from tops of all cell assemblies 2 using a stiff bristle nonmetallic brush WARNING TO PREV...

Page 41: ...y clean cloth CAUTION THE LENGTH OF TIME VENT VALVES ARE REMOVED FROM THE CELL ASSEMBLIES SHOULD BE KEPT TO A MINIMUM OVER EXPOSURE OF THE ELECTROLYTE TO THE ATMOSPHERE WILL AFFECT BATTERY PERFORMANCE...

Page 42: ......

Page 43: ...ry 2 Remove the battery cover 8 pad 9 and formed insulator 10 3 Visually verify the connector receptacle 16 is present and undamaged 4 Visually verify all cells 2 are positioned for proper polarity 5...

Page 44: ...if leakage is evident B Visually check each cell vent valve assembly 3 for defective o rings cracks or other physical damage Replace defective o rings 4 Vent valves that visually appear damaged shoul...

Page 45: ...ks dents or other physical defects Any evidence of the above conditions however minor is cause for replacement Discard the damaged unit and replace with factory new 3 Visually check all wiring for dam...

Page 46: ......

Page 47: ...ed 3 Attach cell removal tool P N 017556 000 to the cell s terminal and remove cell from the case using a steady upward pull 4 Replace cell with factory new by inserting the new cell into the case and...

Page 48: ...particles from falling into the cell 3 Remove the defective O ring 4 from the vent valve 3 and install a new O ring 4 onto the vent valve 3 4 Remove the cloth from the cell and insert the vent valve...

Page 49: ...align the holes in the liner with the hole in the partition 3 Insert the thermoswitch plate 23 IPL Fig 1 in back of liner assembly 27 11 so that the liner assembly 27 11 Fig 702 is between the thermos...

Page 50: ...L Fig 1 in the left and right hand side of the battery case 7 IPL Fig 1 Be sure to maintain the proper cell arrangement and polarity orientation per Fig 703 3 Install the left and right end liners 27...

Page 51: ...e defective nickel plating 2 Using a small brush lightly coat cell terminals and intercell links with neutral nonacid petroleum jelly NOTE Excessive use of petroleum jelly on the terminals and connect...

Page 52: ...3 No corrosive liquids or gases stored in the same room 4 After 90 days the battery must be charged and the water level checked in accordance with procedures found in TESTING and FAULT ISOLATION C In...

Page 53: ...rge and delivers its rated capacity STORAGE TIME SERVICE PROCEDURE Less than 3 months Charge the battery TESTING and FAULT ISOLATION More than 3 months Perform electrical tests and charge the battery...

Page 54: ...SAFT AMERICA INC COMPONENT MAINTENANCE MANUAL 4579 24 31 05 PAGE 706 Jan 30 98 Battery Liners Figure 702...

Page 55: ...SAFT AMERICA INC COMPONENT MAINTENANCE MANUAL 4579 24 31 05 PAGE 707 708 Blank Jan 30 98 Cell Polarity Figure 703...

Page 56: ......

Page 57: ...OTE The values listed in Fig 801 are lube torque values The threads should be lightly greased prior to installation and applying torque Figure Item Number Torque Value Name Location IPL Fig 1 IPL Fig...

Page 58: ......

Page 59: ...004 is used in the electrolyte level adjustment and the cell puller P N 017556 is used in cell removal Spare hardware vent valves and O rings are provided 2 The following items in Figure 901 are the...

Page 60: ...A I R A S S E M S T O R E 093382 000 Wrench Vent Valve X X X X X X 020915 004 Syringe 20cm3 1 22in3 fig 111 X X X 017556 000 Wrench Cell Extraction X X Constant Current Power Unit 0 60 Amp X X X Const...

Page 61: ...ned in the EFF CODE column to each top assembly The reference letter of the applicable top assembly is also shown in the EFF CODE column for each detail part and subassembly except that no reference l...

Page 62: ...tion differences 4 Optional parts 5 Product improvement parts non service bulletin b Alpha variant item numbers are not shown on the exploded view when the appearance and location of the alpha variant...

Page 63: ...SAFT AMERICA INC COMPONENT MAINTENANCE MANUAL 4579 24 31 05 PAGE 1003 Jan 30 98 Figure 1 1 of 3...

Page 64: ...SAFT AMERICA INC COMPONENT MAINTENANCE MANUAL 4579 24 31 05 PAGE 1004 Jan 30 98 Figure 1 2 of 3 Figure 1 3 of 3...

Page 65: ...EA 1 9 018553 000 Pad Hold Down EA 1 10 018559 000 Insulator Formed EA 1 11 015575 000 Link Flat Terminal EA 5 12 018569 000 Link Curved Terminal EA 3 13 015577 000 Link Flat Terminal EA 2 14 018567...

Page 66: ......