Documente Academic
Documente Profesional
Documente Cultură
: WS- 044
TEST WORKSHEET
P/No: 40678-2
TECHNICIAN SIGNATORY
1 Name: Signature:
2 Name: Signature:
3 Name: Signature:
AUTHORISED SIGNATORY
CELL CHARGING
3 PAINT BRUSH 0.5" & 2.5" 1 3 AR
CONNECTOR
EQUILIZING RESISTORS;
4 SCREW DRIVER FLAT; 2mm, 3mm, 4mm 1 4 BS2183 AR
1 OHM, 3W
Referred Saft Battery Component and Maintenance Manual (CMM); Chapter 24-31-15; Revision-2;
Document: Dated 18 Dec 2000.
FOLLOW ALL THE CAUTIONS & WARNINGS MENTIONED IN CHAPTER DISASSEMBLY, CLEANING, CHECK,
ASSEMBLY & TEST IN CMM (As applicable).
Item
No.
Work to be Carried out Date Tech
MANUAL & S.B. STATUS:
A Check that the procedure sheet is current.
B Check that the OMM revision status is current.
Check the history card of the unit & ensure that all the relevant SB/SIL is reflected properly on
C
the history cards.
1
For the initial commissioning (new battery) carry out followings;
i) Check for any dents, distortion on battery box and cover,
ii) Visually verify the main power connector is installed and undamaged,
iii) Visually verify all cells are positioned for proper polarity.
iv) Visually verify all cells are equipped with a vent-valve and tightened
vi) Remove the main terminal shorting spring.
vii) Check the torque on upper nuts. Observed value:
PROCEED TO ITEM # 14
2 For a battery other than new, check battery case, cover, receptacle, terminal links, terminal nuts
and washers for burns, damage or electrolyte traces.
3 If presence of light dusts, carry out "light cleaning" and check torque on upper nuts.
in/lbs
4 Cell to case insulation =............... (@ 250V should be at least 250 K ohm); OR
leakage current=................micro/milli amperes.
Note: If cell to case insulation resistance or leakage current fails the test values, carry out a
general overhaul.
5 Carry out Residual Discharge. Place a fan near the battery to cool it down during Discharge.
NOTE: ENSURE ALL THE VENT VALVES ARE TIGHTENED BEFORE DISCHARGING.
6 Discharge at the rate............amp .Discharge started at.............Hrs.
Cell No..........terminal voltage reached 1 Volt at......HRS [Minimum capacity..........%]
7 Use resistors (1 Ohm 3 W) across individual, during regular/general overhaul/cell
replacemets/capacity fail, when the cell voltage falls below 1 volt. Leave the resistors in place for
12 to 16 hrs to allow each cell to completely discharge and the battery to cool.Then remove the
shorting resistors and short the battery +ve & -ve studs at receptacle using shorting clip.
The processes described in items from 8 to 14 are applicable during a general overhaul.
Item
No.
Work to be Carried Out Date Tech
9 Wash battery box, cover and cover gasket, in warm, soapy water to remove dirt and salt deposits.
Clean liner spacers in warm water. Rinse away all soap, and dry with compressed air or a dry &
clean cloth.
10 Check temperature sensor as per OMM.
11 Assemble the cells as identified during dis-assembly.
12 Torque the upper nuts and lower nuts during assembly or check torque of all upper nuts for an
assembled battery Torque applied:..............in.lbs. for upper nut & in.lbs. for lower nut.
13 Remove the vent valves O-rings from the cells and submerge them in a clean container of
distilled water. Put swab on the cell holes to keep out unwanted material. Inspect O-rings for cuts
and deformation. Clean and test vent valves with O-rings.
NOTE: THE CLEANING OF VENT VALVES MUST BE DONE WHEN THE CELLS
ARE ASSEMBLED IN THE BOX.
14 Carry out cell to case insulation test. For a new / or an in service battery following disassembly,
cleaning and drying this value should be at least 10M ohm @ 250V.
REMARKS.
15 Loosen the vent caps (do not remove) and charge the battery.
16 Check individual cell voltage within 15 minutes of charge started and note it down. If any cell
indicates more than 1.7 volt immediately stop the charge. Add 10 cc of distilled water then
continue to charge and note it down. REMARKS
17 At the last 15-30 minutes of overcharge cycle at the rate of 0.1CA,adjust the electrolyte level.
Fill up all the Cell voltage and electrolyte added data in Appendix I
REMARKS...
18 Remove the vent valves O-rings from the cells and submerge them in a clean container of
distilled water. Put swab on the cell holes to keep out unwanted material. Inspect O-rings for cuts
and deformation. Clean and test vent valves with O-rings.
(NOTE: For disassembled battery this task is accomplished in item 13 of this schedule).
(CAUTION: length of time the vent-valves are removed from the cells should be kept to a
minimum.)
19 After of completion of charge, tight vent caps and complete the final assembly.
20
Perform capacity check.Discharge at the rate............amp]. -Discharge started at.............Hrs.
Cell No..........terminal voltage reached 1 Volt at......HRS
[Minimum capacity..........%]
Number of capacity checks:........................ for this shop order.
REMARKS:.
NOTE: Before replacement of any cells due to capacity failure, the further two consecutive
capacity tests shall be performed and values recorded.
Page 4 of 5
Item
No.
Work to be Carried Out Date Tech
For a charged new battery or a charged battery after a general overhaul, check cell to case
25 insulation =............. (@250V should be at least 10M Ohm); OR Leakage
current=...........micro/milli amperes.
For a charged battery after regular /or periodic check, check cell to case insulation =...........
26 (@250V should be at least 250K ohm); OR
Leakage current=........micro/milli amperes.
27 After completion of charge, tight vent caps and complete the final assembly.
Complete Ni- Cad Battery Service Record Forms and Cell Voltage Data Sheet.
28
(Refer Appendix I & Appendix II).
29 Place the shipping dust caps on main terminals and sensor harness connector.
30 Documentation completed.
DETAILS ON PARTS REPLACED
Serial No
S.No. Part Name Part Number QTY Reason For Replacement
OFF ON
Name Date
Page 5 of 5
SHEET
n-2;
ANING, CHECK,
Auth.
SHEET
Auth.
SHEET
Auth.
on For Replacement
ce with NCAR-145
SHEET
@43 RATE 0:15 ### ### ### ### ### ### ### ### ### ### ### ### ### ### ### ### ### ###
START 0:30 ### ### ### ### ### ### ### ### ### ### ### ### ### ### ### ### ### ###
TIME:10:00
22-Jan-16
0:45 ### ### ### ### ### ### ### ### ### ### ### ### ### ### ### ### ### ###
END
0:55 ### ### ### ### ### ### ### ### ### ### ### ### ### ### ### ### ### ###
TIME:11:00
TEMP:18.5
HUMIDITY:54
%
@ 21.5 AMP 0:00 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
FOR 02:10 0:15 1.39 1.40 1.40 1.40 1.40 1.40 1.40 1.40 1.40 1.40 1.40 1.39 1.40 1.40 1.40 1.40 1.40 1.40
24-Jan-16
HRS TO 0:30 1.40 1.41 1.41 1.41 1.41 1.41 1.41 1.41 1.41 1.41 1.41 1.41 1.41 1.41 1.41 1.41 1.41 1.41
MIN. 1.55V
1:00 1.42 1.42 1.43 1.42 1.43 1.42 1.43 1.43 1.43 1.43 1.42 1.42 1.42 1.43 1.43 1.42 1.43 1.42
PER CELL.
TEMP:18.5 C 1:30 1.43 1.44 1.44 1.44 1.45 1.44 1.44 1.44 1.44 1.44 1.44 1.44 1.44 1.44 1.44 1.44 1.44 1.44
HUMIDITY:53 2:00 1.46 1.50 1.53 1.55 1.55 1.47 1.51 1.56 1.55 1.51 1.47 1.54 1.53 1.55 1.48 1.54 1.54 1.53
% 2:10 1.55 1.56 1.57 1.57 1.58 1.56 1.57 1.58 1.59 1.56 1.56 1.57 1.57 1.58 1.55 1.57 1.57 1.57
0:15 1.48 1.49 1.49 1.50 1.51 1.50 1.50 1.51 1.52 1.49 1.49 1.50 1.49 1.52 1.48 1.50 1.50 1.49
@4.3 AMP 0:30 1.50 1.50 1.50 1.51 1.53 1.51 1.51 1.53 1.53 1.50 1.50 1.51 1.51 1.53 1.49 1.52 1.52 1.51
TOP CHARGE
FOR 4 HRS 1:00 1.52 1.54 1.54 1.56 1.56 1.53 1.54 1.56 1.56 1.54 1.53 1.55 1.54 1.57 1.53 1.56 1.55 1.55
MIN.1.50 V 1:30 1.53 1.56 1.56 1.57 1.57 1.54 1.56 1.57 1.57 1.56 1.54 1.56 1.56 1.57 1.55 1.57 1.57 1.56
(TC)
PER CELL 2:00 1.54 1.56 1.56 1.57 1.57 1.54 1.56 1.57 1.57 1.56 1.55 1.56 1.57 1.58 1.56 1.57 1.57 1.56
24-Jan-16
2:30 1.55 1.57 1.56 1.57 1.58 1.55 1.56 1.58 1.58 1.56 1.55 1.57 1.57 1.58 1.56 1.57 1.57 1.56
ELECTROLYTE
3:00 1.56 1.57 1.57 1.58 1.58 1.55 1.57 1.58 1.58 1.57 1.56 1.57 1.58 1.58 1.57 1.58 1.57 1.57
LEVEL
CHECK 3:30 1.56 1.58 1.57 1.58 1.59 1.56 1.58 1.59 1.59 1.57 1.56 1.58 1.58 1.59 1.57 1.58 1.58 1.58
FINAL WITHIN LAST
VOLT 4:00 1.57 1.58 1.58 1.59 1.59 1.57 1.58 1.59 1.59 1.58 1.57 1.59 1.59 1.60 1.58 1.59 1.58 1.59
1/2 HOUR OF
TOP CHARGE
Issue C Revision C1; Aug 2015 Page 14 of 20
Appendix - I
BUDDHA AIR (P) LTD.
TECHNICAL DEPARTMENT
@4.3 AMP
WORKSHOP DIVISION
FOR 4 HRS
MIN.1.50 V NICKEL CADMIUM BATTERY CELL VOLTAGE MONITORING
PER CELL
Shop Order No. : SWO1516-307 Part Number: 40678-2
24-Jan-16
TOP CHARGE
19 16 15 16 14 19 17 10 16 12 17 13 13 14 11 17 13 13
0:00 1.35 1.35 1.35 1.35 1.35 1.35 1.35 1.35 1.35 1.35 1.35 1.35 1.35 1.35 1.35 1.35 1.35 1.35
@43 RATE 0:15 ### ### ### ### ### ### ### ### ### ### ### ### ### ### ### ### ### ###
Capacity Check
START 0:30 ### ### ### ### ### ### ### ### ### ### ### ### ### ### ### ### ### ###
29-Jan-16
TIME:11:00 0:45 ### ### ### ### ### ### ### ### ### ### ### ### ### ### ### ### ### ###
END
0:55 ### ### ### ### ### ### ### ### ### ### ### ### ### ### ### ### ### ###
TIME:12:10
TEMP:19.1 c 1:00 ### ### ### ### ### ### ### ### ### ### ### ### ### ### ### ### ### ###
HUMIDITY:54
%
FOR 02:15 0:15 1.39 1.39 1.40 1.39 1.40 1.39 1.40 1.39 1.40 1.40 1.39 1.39 1.40 1.40 1.40 1.40 1.40 1.40
HRS TO
5-Feb-16
0:30 1.40 1.41 1.41 1.41 1.42 1.41 1.41 1.41 1.41 1.41 1.41 1.41 1.41 1.41 1.41 1.41 1.41 1.41
MIN. 1.55V
1:00 1.42 1.42 1.43 1.43 1.44 1.42 1.43 1.43 1.43 1.43 1.42 1.43 1.43 1.44 1.43 1.43 1.43 1.43
PER CELL.
TEMP:19.3 C 1:30 1.43 1.43 1.44 1.44 1.46 1.43 1.44 1.45 1.45 1.44 1.43 1.44 1.44 1.46 1.43 1.44 1.44 1.44
HUMIDITY:53 2:00 1.45 1.47 1.49 1.55 1.57 1.46 1.48 1.56 1.57 1.48 1.46 1.55 1.57 1.56 1.46 1.51 1.56 1.53
% 2:15 1.56 1.60 1.61 1.62 1.64 1.58 1.61 1.63 1.64 1.61 1.57 1.62 1.62 1.63 1.59 1.62 1.63 1.63
0:15 1.53 1.56 1.56 1.54 1.56 1.53 1.54 1.56 1.56 1.54 1.52 1.53 1.54 1.53 1.53 1.54 1.52 1.52
@4.3 AMP
0:30 1.54 1.57 1.57 1.55 1.57 1.54 1.55 1.57 1.57 1.55 1.54 1.54 1.54 1.54 1.54 1.55 1.53 1.53
OP CHARGE
FOR 4 HRS
MIN.1.50 V 1:00 1.56 1.58 1.57 1.56 1.57 1.55 1.56 1.57 1.58 1.56 1.55 1.55 1.57 1.56 1.56 1.56 1.55 1.55
(TC)
PER CELL 1:30 1.56 1.59 1.58 1.57 1.57 1.56 1.57 1.58 1.58 1.56 1.56 1.56 1.57 1.56 1.56 1.57 1.55 1.56
eb-16
PER CELL #1 #2 #3 #4 #5 #6 #7 #8 #9 #10 #11 #12 #13 #14 #15 #16 #17 #18
5-Feb-16
2:00 1.57 1.60 1.59 1.57 1.58 1.56 1.57 1.58 1.59 1.57 1.56 1.57 1.58 1.56 1.57 1.58 1.56 1.56
ELECTROLYTE 2:30 1.57 1.60 1.60 1.58 1.58 1.56 1.58 1.59 1.59 1.57 1.57 1.57 1.58 1.57 1.57 1.58 1.57 1.57
LEVEL 3:00 1.58 1.60 1.60 1.59 1.59 1.57 1.58 1.59 1.60 1.58 1.57 1.58 1.59 1.57 1.58 1.59 1.58 1.58
CHECK 3:30 1.58 1.60 1.60 1.59 1.60 1.58 1.58 1.60 1.61 1.59 1.58 1.58 1.59 1.58 1.58 1.59 1.58 1.58
FINAL WITHIN LAST
VOLT 1/2 HOUR OF 4:00 1.59 1.60 1.60 1.59 1.61 1.59 1.59 1.61 1.61 1.60 1.58 1.59 1.60 1.58 1.59 1.59 1.58 1.59
WATER TOP CHARGE
ADDED 1 2 1 1 1 3 1 1
REMARKS:
TECHNICIAN NAME: SIGNATURE:
0 0 0.0
1.40 1.39 28.0
1.41 1.41 28.2
1.42 1.42 28.5
1.44 1.44 28.8
1.53 1.50 30.4
1.57 1.56 31.4
1.49 1.49 29.9
1.51 1.50 30.2
1.55 1.54 30.9
1.56 1.56 31.2
1.56 1.57 31.3
1.57 1.57 31.3
1.58 1.58 31.5
1.59 1.58 31.6
14 13
0 0 0.0
1.40 1.39 27.9
1.41 1.41 28.2
1.43 1.42 28.6
1.44 1.43 28.8
1.53 1.48 30.3
1.62 1.61 32.2
1.54 1.55 30.8
1.56 1.56 31.0
1.56 1.56 31.2
1.57 1.57 31.4
Issue C Revision C1; Aug 2015 Page 18 of 20
Appendix - I
BATTERY DATA
Manufacturer : SAFT Rating : 43.0 A No of Cells : 20
Capacity % :
N/A
Total C.C. Water Added : 19 16 15 17 16 19 18 11 17 12 17 13 13 17 11 17 14 14 14 13
Temprature 0C/0F :
N/A
Final Voltage : : 1.59 1.60 1.60 1.59 1.61 1.59 1.59 1.61 1.61 1.60 1.58 1.59 1.60 1.58 1.59 1.59 1.58 1.59 1.61 1.60
Remarks : :
Remarks: