Saft 1606-1 User manual
SAFT
(F6177)
156,Avenue
de
Metz
-
93230 Romainville
-
FRANCE
TeL(33-1) 48.43.93.61
-
Telex 235W
COMPONENT
MAINTENANCE
MANUAL WITH
ILLUSTRATED PARTS LIST
AIRCRAFT BATTERY
TYPE
1606-1
Date
of
issue
:
April 01/92
24-39-06
Title
page
-
Page
1
Dec 01/92
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SAFT
COMPONENT MAINTENANCE MANUAL
1606-l
RECORD OF REVISIONS
INSERTED INSERTED
REVISION REVISION REVISION REVISION
NO DATE DATE BY NO DATE DATE BY
1 Oct.92 Oct.92 SAFT
2 Dec.92 Dec.92 SAFT
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TEMPORARY
REV. No
SAFT
COMPONENT MAINTENANCE MANUAL
1606-l
RECORD OF TEMPORARY REVISIONS
PAGE
NUMBER
ISSUE
DATE
BY DATE
REMOVED
BY
RTR Pages l/2
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NUMBER
SAFT
COMPONENT MAINTENANCE MANUAL
1606-l
SERVICE BULLETIN LIST
BRIEF DESCRIPTION TYPE AFFECTED
SBL Pages l/2
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Apr 01/92
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SAFT
COMPONENT MAINTENANCE MANUAL
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LIST OF EFFECTIVE PAGES
CONTENT
DATE OF DATE OF
PAGE LAST CONTENT PAGE LAST
REVISION REVISION
Title page
Record of
revisions
l/2 Dee 01/92 Description 1 Apr 01/92
and 2 Apr 01/92
operation 3 Apr 01/92
l/2 Dee 01/92 4 Apr 01192
Record of
temporary
revisions
Testing and 101 Apr 01192
l/2 Apr 01192 fault 102 Apr 01/92
isolation 103 Apr 01/92
104 Apr 01/92
Service
bulletin
list
List of
effective
paw
Table of
contents
Disassembly 301/302 Dee 01/92
l/2 Apr 01/92
Cleaning 401 Apr 01/92
402 Apr 01/92
1 Dee 01/92
2 Apr 01/92 Check 501 Dee 01/92
502 Apr 01/92
503 Apr 01/92
504 Dee 01/92
l/2 Apr 01/92 505 Dee 01/92
506 Apr 01/92
5071508 Dee 01/92
List of l/2 Apr 01/92 Repair 601 Apr 01/92
figures 602 Apr 01/92
Foreword
Assembly and 701 Dee 01/92
l/2 Apr 01192 storage 702 Apr 01/92
703 Dee 01/92
704 Apr 01/92
Special 901 Apr 01/92
tools, 902 Apr 01192
fixtures and 9031904 Apr 01192
equipment
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SAFT
COMPONENT MAINTENANCE MANUAL
1606-l
LIST OF EFFECTIVE PAGES
DATE OF DATE OF
CONTENT PAGE LAST CONTENT PAGE LAST
REVISION REVISION
Illustrated
parts list
TP
INTRO
VC1
1001-l Apr 01/92
1001-l Apr 01/92
1001-2 Apr 01/92
1001-3 Apr 01/92
1001-4 Apr 01/92
1001-5 Apr 01/92
1001-l Apr 01192
NIINUM 1001-l Apr 01192
Detailed part
list 1001 Apr 01192
1001-O Apr 01/92
1001-l
LEP Page 2
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SAFT
COMPONENT MAINTENANCE MANUAL
1606-l
TABLE OF CONTENTS
PAGES
DESCRIPTION AND OPERATION
1 - Description
2 - Operation
TESTING AND FAULT ISOLATION
1 - Testing
2 - Fault isolation
DISASSEMBLY
1 - Disassembly
CLEANING
1 - Light cleaning 401
2 - Full cleaning 401
3 - Lubrication 402
CHECK
1 - Regular checks 501
2 - Maintenance steps in workshop 501
3 - General overhaul 506
REPAIR
1 - Battery condition 601
2 - Polarisation test 601
3 - Added electrical test before repair 602
ASSEMBLY AND STORAGE
1 - Assembly 701
2 - Storage 702
SPECIAL TOOLS, FIXTURES AND EQUIPMENT
1 - Special tools
2 - Materials and different products
ILLUSTRATED PARTS LIST
Introduction
Vendor code index
Numerical index
Detailed parts list
24-39-06
1
2
101
101
301
901
903
1001
VC1 1001-l
NI 1001-l
1001-l
TC Pages l/2
Apr 01192
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SAFT
COMPONENT MAINTENANCE MANUAL
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LIST
OF FIGURES
PAGES
Figure 501 - Level adjustment with a syringe and a calibrated nozzle 502
Figure 701 - 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 902
Figure 1 - Battery 20 VP 160KM TYPE 1606-l 1001-O
TF pages l/2
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SAFT
COMPONENT MAINTENANCE MANUAL
1606-l
FOREWORD
1. General
This manual supplies the maintenance data and the 11
of the type 1606-l alkaline battery.
lustrated Parts List
These instructions agree with specification ATA No. 100 for the
manufacturer's technical manuals. They are included in chapters in this
sequence :
l-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 (Not used)
901-1000 Special tools, fixtures and equipment
1001-1100 Illustrated parts lists.
Note : The instructions in this manual cannot be used as a specification
for an acceptance test ; use these instructions for OPERATION
and CHECK of an item which is temporarily unserviceable and to
REPAIR for overhaul.
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1. Description
SAFT
COMPONENT MAINTENANCE MANUAL
1606-l
DESCRIPTION AND OPERATION
A. General
The SAFT battery has 20 semi-open nickel-cadmium VP 160KM cells with
welded polyamide cases.
The battery is connected to the aircraft systems. It is used:
- To start the APU
- On the ground, before electrical power is supplied to the aircraft
systems
- In flight, if a malfunction or a failure occurs in the power supply
system.
The 28 VDC electrical system charges the battery in the aircraft.
B. Data
(1) Technical data
- Specified voltage: 24 volts
- Specified capacity: 16Ah at a rate of lh
- Connector 3 pins: according to standard VDE OllO/S.65
- Electrolyte: Sol. KOH s.g. 1.30.
- Consumable volume of electrolyte: 20 cm3 for each cell
- Maximum dimensions of the battery base:
L=371.5 mm (14.62 in)
W=120.1 mm (4.73 in)
H=207.5 mm (8.17 in)
- Maximum weight: 17.65 kg (39.46 lb).
- 1 thermostat closes at 71"*2.8OC (160"&5"F) on temperature rise
(2) Operational data
- Operating temperature: -30 to +50°C (-22 to +122'F)
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COMPONENT MAINTENANCE MANUAL
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C. Detailed description (Refer to pages 1001-O and 1001-l)
2.
- Maximum instantaneous power:
at +23'C (+73'F): 12 V and 15 s 8.85 kW
at -18'C (+O"F): 12 V and 15 s 4.80 kW.
The battery has 20 VP 160KM (320A) cells in a stainless steel box.
The box (040A) has a lining of thin sheets of insulation and of
spacers (190A)
The cover (060A) has one insulator (070A) and 2 protectors (080A).
The cells are held in place by a hold-down bar (240A).
This hold-down bar is mounted inside box and fixed by 2 screws (1lOA)
and 2 nuts (120A).
The rigid links (290A thru 310A). made of nickel-plated copper,
connect the cells together.
Two insulated holes through the cover (060A) for the battery
terminals (250A).
These terminals (250A) connect the battery to the aircraft.
The battery has a removable cover (060A). It is fixed by 2 screws
(020A) with 2 spring washers (030A).
Operation
A. Charge
(1) Flight charge
Adjust the recharger to make sure the battery is correctly
charged in flight. Do a recharger 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 +4O"C
(+104"F), adjust the recharger 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.
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SAFT
COMPONENT MAINTENANCE MANUAL
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(2) Ground charge
Do all battery maintenance or overhaul steps in a workshop.
WARNING: REMOVE THE COVER TO CHARGE THE 1606-l 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:
- Charge at 0.1 CIA (1.6 amps) until the battery voltage is an
average of 1.5 volt for each cell (30 volts for a 20-cell
battery). Then continue to charge at this same current rate
for 4 more hours. When you do this procedure, the total
charge time must be between 14 hours (minimum) and 16 hours
(maximum).
or
- Charge at 0.5 C A (8A) for not less than 2 hours. It is
possible that t e battery voltage is not an average of 1.55il
volt for each cell (31 volts for a 20-cell battery) after
this time. Then continue to charge at this current rate
until you get the correct voltage. But do not charge at
this rate for more than 2 hours and 30 minutes (refer to
the NOTE). When you get an average of 1.55 volt, charge at
0.1 ClA (1.6 amps) for 4 more hours.
or
- Charge at ClA (16 amps) for not less than 1 hour. It is
possible that the battery voltage is not an average of 1.57
volt for each cell (31.4 volts for a 20-cell battery) after
this time. Then continue to charge at this current rate
until you get the correct voltage. But do not charge at
this rate for more than 1 hour and 15 minutes (refer to the
NOTE). When you get an average of 1.57 volt, charge at 0.1
CIA (1.6 amps) for 4 more hours.
NOTE: If the battery voltage does not increase sufficiently
during the maximum charge time: Refer to "TESTING
AND FAULT ISOLATION"..
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SAFT
COMPONENT MAINTENANCE MANUAL
1606-l
- Battery not fully discharged and discharge condition unknow.
- Discharge the remaining capacity at 1ClA (16 amps) down
to 20 volts. Then charge again as above.
- The battery can also be charged at one of the constant
current values given in section 2 (2). Do this procedure
until you get the correct voltage at the battery
terminals (30, 31, or 31.4 V).
- Constant voltage charge
You can charge the battery with a constant voltage source
(you can use an aircraft generator that has a voltage
regulator).
At the usual temperature of +20°C (+68"F), adjust the
regulator to 28.5 volts (precision 0.5%) and charge the
battery for 4 to 5 hours.
B. Discharge
The specified capacity (ClAh) of the battery gives a discharge time
of 1 hour ; when fully charged, the battery can thus supply a current
of 16 amps for one hour. But the battery can supply currents that are
much higher than the specified discharge, for short times and without
damage. For example, a battery with a specified capacity of 16Ah can
supply peaks of current that can be twenty-five times the usual
capacity.
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
recharger.
- Regularly do these checks:
- Electrolyte level (specially when the weather is hot)
- Tightness of the connection nuts
- Adjustment of the recharger.
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