Manual No 4159 OPERATING INSTRUCTIONS OPERATING INSTRUCTIONS NAVY BATTERY CHARGER / ANALYZER P/N 4159 MODEL CA-1550 NSN: 4920-01-498-2543 Issued By: Lamar Technologies LLC 14900 40th Ave. NE Marysville, WA 98271 Cage Code 3C8X4 Tel: 360-651-8869 Fax: 360-651-6677 E-mail:support@lamartech.
TABLE OF CONTENTS SECTION HEADING PAGE I GENERAL / QUICK INSTRUCTIONS 3-4 II CHARGING 4-8 III DISCHARGE 8-10 IV CONDITIONING CHARGE 10-11 V SPECIFICATIONS 11-12 VI CHANGING AC LINE 12-13 VII VERIFYING METER READING 13-14 FIG. CONTROL BOX 15 FIG.
COVER MUST BE FULLY OPEN WHEN IN USE! OPERATING INSTRUCTIONS P/N 4159 Navy Battery Charger / Analyzer MODEL CA 1550 Charger Input, AC 115 V 50/60 HZ 15A Max. (For 230 V Input- See VI AC Line Change) Battery Charging Current 0-25 amperes, Discharge Current 0-50 amperes Follow NAVAIR 17-15BAD-1 for Detailed Instructions and Battery Specs Refer to Illustrations. Callouts are referred to in these instructions. e.g. (2 is the timer) I.
5. DISCHARGE / CAPACITY TEST 24 VOLT SLAB a) Set Timer to 60 minutes. b) Set low cutoff Voltage (12) to 18.0 Volts. c) Set Constant Current Discharge (15) to the C Rate (e.g. 30 amp-hr battery set to 30.0 amps). d) Accept – If the Timer times-out before the battery voltage lowers to cutoff occurs before the timer times-out. e) Fail – If cutoff occurs before the timer times-out. 24 VOLT NiCads Same as SLAB, except Set Voltage Cutoff to 1.0 Volt / Cell. 12 VOLT BATTERIES Same, except Set Cutoff to 9.
3. Plug 4159 into a 115 V outlet - max AC current draw is 15 Amps. For 230 Volt operation, internal jumper connection are changed (See VI for diagram). Do Not Connect Battery 4. Set Charge / Discharge switch (11) to Charge (center position). 5. Set Charge Current Adjust potentiometer (5) completely CCW to minimum. 6. Set Timer (2) to 180 Min (3 hrs). Time may be increased, even during operation (Also decreased, if it is not at or below the led time displayed). 7.
Note: Charging old batteries or batteries that have been in a very low state of charge 4, 6, or 8 volts and/or batteries that have been dead in excess of 24 hours to 30 days or more, should be observed for a possible temperature rise during charge. See conditioning section IV. 14. Ampere Hour Meter (16): This provides the precise ampere hours of charge into the battery, and is an indicator of acceptance of charge.
c. Switch unit off (10). d. Set Charge Current Adjust (5) to Minimum, CCW e. Switch Unit On (10) f. Set Charge / Discharge Switch (11) to “View Voltage Setting”. Hold this position while setting the Charge Voltage Adjust knob (5) to approx. 3435 Volts (or 17-18 V). g. Set Timer (2) to 120 minutes. h. Switch to On (10) and set Charge Current Adjust knob (5) to C/10 amperes (e.g.: 30 amp hr battery, set to 3.0 amperes, 10 amp hr battery set to 1.0 ampere). i. Voltage will soon rise above 28.
than C/10. For a 40 amp-hr battery C/3 would be 13.3 amperes, C/10 would be 4.0 amperes. 4) During this topping charge, check the voltage of each cell with the Fluke 77/AN meter. When every cell has reached at least 1.5 volts (1.55 optimal), the battery is charged regardless of the time. The battery is now Ready For Issue. Note 2: The ampere hour meter has a time delay of about 2 seconds. For longer time periods resetting the 4159 timer will lose the ampere hour reading.
Note 2: Ammeter reads with a minus sign display in discharge. A. OPERATION a. Set On /Off Switch (10) to Off. b. Connect Battery (battery must be fully charged). c. Discharge Current Adjust knob (15) to min. (CCW) d. Switch Charge / Discharge switch (11) to Discharge.. e. Set Timer (2) to 60 minutes (or other time if required by special instructions). f. Switch (10) to “On”. Voltmeter reads the battery open circuit voltage. Ammeter reads zero or low decimal. g. Press Cutoff View Switch (13). h.
C. FAIL The battery fails the discharge test because of insufficient capacity if the voltage decreases to below the preset voltage cutoff (usually 0.1-0.3 volts below preset cutoff depending on the rate at which battery voltage is falling), before the timer times-out, the “Fail”(14 Red) Led illuminates, Meters and Timer Hold (Freeze), buzzer sounds. The actual ampere hour capacity of the battery is indicated by Amps x Time divided by 60. Ampere hours are also directly read on the amphour Meter (16).
a. Place the battery on the temperature plate, plug plate into thermostat jacks on the 4159 panel. b. Set the 4159 charge voltage to approximately 34-35 volts. (Max V. setting) c. Set timer to 999 minutes d. Set charge current to 1.0 ampere if the battery will accept 1 ampere. Indications: The battery voltage may rise up to the 34 volts immediately or more slowly. However, voltage may eventually begin to reduce, indicating acceptance of charge.
DIMENSIONS: 20 ½ L x 16 ¾ W x 8 ½ D WT 67 LBS *Actual Current and Voltage, charge and discharge, start at zero, but Digital Meters may not read to zero. VI. CHANGING THE AC LINE INPUT FROM 115 TO 230 VOLTS. WARNING: Before change-over, the AC line plug must be physically unplugged from any wall outlet or switch box or serious injury or death may result from AC line electrical shock. a.
VII. VERIFYING METER READING (NOT CALIBRATION) 1. GENERAL: The CA 1550 has been factory calibrated prior to shipment and the unit can be checked for verification of readings of the voltmeter and ammeter with a Fluke 77/AN multimeter. The ampere-hour meter and ammeter must be checked with a load. 2. CHECKING THE VOLTMETER WITHOUT THE BATTERY CONNECTED: a) On / Off switch OFF (10). b) Charge / Discharge switch to Charge (11). c) Charge Current Adjust Max. (5).
4. CHECKING THE AMMETER: a) In order to check the ammeter, a load is necessary in order to draw current. A battery may be used but if the battery is fully charged or is rapidly tapering, it may be difficult to check the current. A discharged battery with the 4159 unit, when set to charge, or a charged battery with the unit set to discharge is the most convenient. Also, a high wattage load resistor may be used for both voltmeter and ammeter checks.
4159 CHARGER / ANALYZER CONTROL BOX 1 4 17 3 2 16 15 5 14 13 6 12 11 7 8 10 9 ITEM NO. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17.
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CERTIFICATION OF FACTORY VERIFICATION AIRCRAFT BATTERY CHARGER / DISCHARGE TESTER MODEL: CA-1550 MIL P/N: 4159 MIL MFD. BY: Lamar Technologies LLC 14900 40th Ave NE Marysville, WA 98271 Cage Code #: 3RCD2 Tel: 415-883-6300 Fax: 415-883-6302 E-Mail: support@lamartech.com AC INPUT: 50/60 HZ 115 V 14A MAX., 230 V 7A MAX. DC OUTPUT: CHARGE 0-25A DISCHARGE: 0-50A MAX Refer to Operating Instructions for more complete specifications.
ACCESSORIES INCLUDED WITH CA-1550 UNIT: ●OPERATING INSTRUCTIONS ●TEMPERATURE SENSING PLATE ●SPARE 15A AND 40A FUSES ●ADAPTOR FOR RING TERMINALS ●ADAPTOR FOR F18 MODEL A & B BATTERY ●ADAPTOR FOR BATTERY QUICK DISCONNECT 18
