Lamar Technologies LLC. INSTRUCTION MANUAL MODEL D-5160 12 AND 24 VOLT AIRCRAFT AND GSE BATTERY DISCHARGE CURRENT CAPACITY TESTER APPLICATIONS: MEETS ALL COMMERCIAL AND MILITARY AVIATION BATTERY TESTING REQUIRMENTS MILITARY TECHNICAL BAD-1 MANUAL SEALED (SLAB/AGM) AND LEAD ACID AIRCRAFT BATTERIES NICKEL CADIUM AIRCRAFT BATTERIES GROUND SUPPORT AND VEHICLE BATTERIES e.g.: HAWKER “ARMASAFE”, OPTIMA TELECOM AND SPECIAL TYPES CONTENTS I. II. III.
I. SPECIFICATIONS 1. Self-powered by the battery under test. No AC line cord. 2. Automatic accommodation to a 12 or 24 volt battery. 3. Discharge current range settable from 2.0 to 62.2 amperes. 4. Constant current output accurate to within +/- one tenth of preset amperes when set within the range of 5-62 amperes and within 1 to 3 tenths of an amp when set below 5A. 5. Subsequent test current setting defaults to the previous test’s amperes.
II. OPERATION PREFACE NOTE: RATINGS AND EXAMPLES GIVEN IN THE PREFACE BELOW MAY DIFFER FROM THE USER OR BATTERY MANUFACTURERS’ REQUIREMENTS. Discharge current capacity testing is the only valid method of determining the true reserve (emergency) capacity of a battery. Reserve capacity is especially important for aircraft which may have to depend on the battery for emergency power in the event of power failure. The battery must deliver usable power for one hour.
OPERATION PREFACE CONTINUED The only practical way to test this capability is with a constant current load. By the end of one hour under the battery’s rated one-hour capacity (amp-hr capacity), the battery voltage must not have dropped below the assigned cut-off voltage which, for a 24 volt battery is usually 20 volts.
III. OPERATING INSTRUCTIONS 7 8 9 6 11 5 10 4 16 3 2 15 1 FIG. 1 ITEM # DESCRIPTION 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16.
III. OPERATING INSTRUCTIONS REFER TO FIG. 1 1. Turn On/Off switch (#1) to ‘Off’ position 2. Connect battery cable (#12) to battery • If polarity is reversed, LED (#15) will illuminate together with audible signal • If necessary correct the reversal. 3. Set voltage cutoff set switch (#16). 9 or 10 V for 12 V batteries. 18 or 20 V for 24 V batteries. 4. Turn On/Off switch (#1) to ‘On’ position • All instrument displays will briefly illuminate as 8s, then as follows: a) Timing (#5) All zeros, steady.
OPERATING INSTRUCTIONS CONTINUED • Current may be set below 2.0 amperes but actual discharge current and/or meter reading may be inaccurate. Actual discharge amperes may be read using the ampere test points (#10) with a digital multimeter set to the DC milli-volt scale. • Subsequent amperes will default to the previous test setting. If different amperes are required from the previous test, the discharge current must be set to the new current. 6.
OPERATING INSTRUCTIONS CONTINUED 9. User will evaluate the results of the test. E.g. For a 30 amp-hour test: a) 30 amps at 48 min- FAIL b) 30 amps at 51 min (85% capacity) - PASS c) 30 amps at 60 min (100% capacity) – SUPERIOR BATTERY • The exact amp hr capacity of the battery is obtained as follows: a) Convert the hours and minutes to all minutes b) Divide by 60. Equals amp-hr capacity. 10. Record reading, set switch (#1) ‘Off’, remove battery.
IV. CALIBRATION Preface A. The 5160 unit is microprocessor controlled with programmed functions of operation and displays. There are no user calibrations procedures, only verification of time, voltage, and current readings. Factory calibration requires battery banks, variable power supplies, oscilloscope and calibrated test instruments. Therefore, units which may be out of calibration or malfunction should be returned to the factory. East coast and west coast tech reps are available.
V. MAINTENANCE Standard electrical/electronic equipment maintenance procedure should be observed. These include vacuum cleaning of the resistor grille and open spaces in the unit. Use only cleaners approved for plastic meter covers. Do not use harsh cleaners which may damage plastic or the silk screened or painted portions of the unit. Examine the DC cable and connectors for signs of wear, fraying, or looseness.
VI. 1 YEAR WARRANTY POWER PRODUCTS INC. warrants its products to be free from defects in workmanship and material for a one-year period from the date of shipment to the distributor, original equipment manufacturer (OEM), or original end user. If any product shall prove to be defective during the warranty period, POWER PRODUCTS INC. will repair or replace such part. There are no warranties, which extend beyond the description on the face hereof.
POWER PRODUCTS INC. 27 PAMARON WAY, SUITE E NOVATO, CA 94949 415-883-6300 CERTIFICATION OF CALIBRATION BATTERY DISCHARGE CAPACITY TESTER – MODEL: D-5160 APPLICATION: Discharge capacity testing of 12 and 24 Volt Lead Acid and Nickel Cadmium aircraft batteries. Discharge Range: 2 – 62 Amperes. DIGITAL DISPLAYS: Amperes: Volts: Time: CALIBRATION PROCEDURE: 0-75 Ampere, 0-30 Volt Variable Power Supply Power Products P/N PS 7530AF used as battery substitute.
MFG. by: Lamar Technologies LLC 14900 40th Ave. N.E. Marysville, WA 98271 www.lamartech.
