Operating and Maintenance Manual For Nickel-Cadmium Aircraft Batteries MarathonNorco Aerospace, Inc. P.O. Box 8233 Waco TX. 76714-8233 Phone: (254) 776-0650 8301 Imperial Drive Waco, TX. 76712-6588 Fax: (254) 776-6558 E-Mail: marathon@mptc.com Website: www.mnaerospace.
MARATHONNORCO AEROSPACE, INC. NICKEL-CADMIUM AIRCRAFT BATTERIES RECORD OF REVISIONS Original Issue Date: JUN 23/97 Rev No. 1 2 3 4 5 6 7 8 9 10 11 12 Issue Date 10/23/97 06/30/99 09/04/01 03/28/03 11/30/03 11/19/04 04/15/06 05/10/11 06/03/11 07/25/11 11/09/12 07/11/14 Date Inserted By Rev No. Issue Date Date Inserted By Rev No.
MARATHONNORCO AEROSPACE, INC. NICKEL-CADMIUM AIRCRAFT BATTERIES RECORD OF TEMPORARY REVISIONS Temporary Rev. No.
MARATHONNORCO AEROSPACE, INC.
MARATHONNORCO AEROSPACE, INC.
MARATHONNORCO AEROSPACE, INC.
MARATHONNORCO AEROSPACE, INC.
MARATHONNORCO AEROSPACE, INC. NICKEL-CADMIUM AIRCRAFT BATTERIES INTRODUCTION This manual contains shop verified instructions for proper installation, operation and maintenance of MarathonNorco’s Nickel-Cadmium batteries. These instructions are grouped in topics shown in the Table of Contents. They are for the operation, testing, and repair of MarathonNorco’s battery products. This manual is designed to service the batteries based on the cell type within the battery.
MARATHONNORCO AEROSPACE, INC. NICKEL-CADMIUM AIRCRAFT BATTERIES DEFINITIONS OF COMMONLY USED BATTERY TERMS Ampere Hours A unit of electrical measurement used to describe the capacity of a cell or battery. The product of discharge current (in amperes) X the time of discharge (in hours). It is also used to describe the amount of electrical energy put back into a battery during the charging process. Abbreviated as Ah or Amp. hrs.
MARATHONNORCO AEROSPACE, INC. NICKEL-CADMIUM AIRCRAFT BATTERIES Deep Discharge (Cycle) A discharge in which most or all of the available capacity is withdrawn from a battery and the cells are brought individually to a zero volt condition. Reconditioning A procedure consisting of a deep discharge and a constant current charge that is used to correct cell imbalance that may occur during continual cyclic use of a rechargeable battery.
MARATHONNORCO AEROSPACE, INC.
MARATHONNORCO AEROSPACE, INC.
MARATHONNORCO AEROSPACE, INC. NICKEL-CADMIUM AIRCRAFT BATTERIES DESCRIPTION AND OPERATION DESCRIPTION General The nickel-cadmium battery cell is an electrochemical system in which the active materials contained in the plates undergo changes in oxidation state with very little change in electrolyte concentration due to the production or consumption of water. These active materials are virtually insoluble in the alkaline (potassium hydroxide) electrolyte in any oxidation state.
MARATHONNORCO AEROSPACE, INC. NICKEL-CADMIUM AIRCRAFT BATTERIES Charge Charging results in the conversion of electrical energy to stored chemical energy. The active materials, in a discharged condition, are cadmium hydroxide in the negative plates and nickel hydroxide in the positive plates. With the application of a charging current, these active materials undergo a chemical change.
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MARATHONNORCO AEROSPACE, INC. NICKEL-CADMIUM AIRCRAFT BATTERIES Capacity Capacity is measured quantitatively in ampere-hours delivered at a specified discharge rate to a specified cut-off voltage at room temperature. The cut-off voltage is 1.0 volt per cell. Battery available capacity depends upon several factors including such items as: 1. Cell design (cell geometry, plate thickness, hardware, and terminal design govern performance under specific usage conditions of temperature, discharge rate, etc.). 2.
MARATHONNORCO AEROSPACE, INC. NICKEL-CADMIUM AIRCRAFT BATTERIES 1.0 INSPECTION 1.1 Delivery Inspection When the battery is unpacked, a thorough inspection should be made to ensure that no damage occurred during shipment. Inspect the shipping container as well as the battery. Before putting the battery into service, check the following points carefully. 1.1.1 Damage See if any liquid has spilled into the shipping container. This may be a sign of a damaged cell. Check for dented battery container.
MARATHONNORCO AEROSPACE, INC. NICKEL-CADMIUM AIRCRAFT BATTERIES WARNING: 1.2 THE ELECTOLYTE USED IN NICKEL-CADMIUM BATTERIES IS A STRONG CAUSTIC SOLUTION OF POTASSIUM HYDROXIDE. USE RUBBER GLOVES, AN APRON AND A FACE SHIELD WHEN REPAIRING OR SERVICING THE BATTERY. IF ELECTROLYTE IS SPILLED OR SPRAYED ON CLOTHING OR OTHER MATERIALS, IT SHOULD BE BATHED IMMEDIATELY WITH LARGE QUANTITIES OF WATER NEUTRALIZED WITH A WEAK ACID SOLUTION SUCH AS VINEGAR.
MARATHONNORCO AEROSPACE, INC. NICKEL-CADMIUM AIRCRAFT BATTERIES C. Evidence of arcing of burn marks on the power contacts. This is caused when the disconnect is removed under electrical load. D. Insert the .385 inch diameter end of the inspection gauge into each power contact to a depth of .437 inches. The fit shall be snug with a force to remove greater than one (1) pound. This is to test the resiliency of the power contact to an oversized pin. E. Insert the .
MARATHONNORCO AEROSPACE, INC. NICKEL-CADMIUM AIRCRAFT BATTERIES Figure 4 Temperature vs. Charge Voltage Relationship MAXIMUM RECOMMENDED CONSTANT POTENTIAL CELL CHARGE VOLTAGE AT VARIOUS TEMPERATURES Charge Voltage, V/cell Temperature vs Charge Voltage MAXIMUM RECOMMENDED CONSTANT POTENTIAL CHARGE VOLTAGE AT VARIOUS TEMPERATURES 1.75 1.65 1.55 1.45 1.
MARATHONNORCO AEROSPACE, INC. NICKEL-CADMIUM AIRCRAFT BATTERIES 1.3 Inspection - Received in for Service When a battery is received in the shop for routine servicing, the following inspections should be performed: Visually inspect can and cover for dents, damage, epoxy coating separation, vent tube obstruction, latch function and cover seal condition. Any evidence of discrepancies, in above shall be cause for replacement of the parts.
MARATHONNORCO AEROSPACE, INC. NICKEL-CADMIUM AIRCRAFT BATTERIES 2.0 ELECTRICAL LEAKAGE To determine if external leakage is of such a magnitude as to require a complete battery cleaning set the range selector of a multimeter to the 500 milliampere range or higher. Place the positive lead of the meter on the positive terminal of the battery receptacle and touch the negative lead of the meter to any exposed metal on the battery can.
MARATHONNORCO AEROSPACE, INC. NICKEL-CADMIUM AIRCRAFT BATTERIES 3.0 TORQUING REQUIREMENTS Verify torque on every intercell connection starting with cell 1 and working sequentially through the last cell. Verify torque on cell connections to main battery connector.
MARATHONNORCO AEROSPACE, INC. NICKEL-CADMIUM AIRCRAFT BATTERIES 4.0 SENSOR ASSEMBLY INSPECTION Inspect battery for proper placement of thermostats, heaters, thermistors or other sensor elements. Inspect wiring and receptacle for insulation damage, corrosion, and crimping or other defects. At least once each calendar year, perform a functional test on the temperature sensor assembly. All functions must be within ± 10% of the values given in Table 3.
MARATHONNORCO AEROSPACE, INC. NICKEL-CADMIUM AIRCRAFT BATTERIES Table 3 (Page 1 of 8) TEMPERATURE SENSOR ASSY.
MARATHONNORCO AEROSPACE, INC. NICKEL-CADMIUM AIRCRAFT BATTERIES Table 3 (Page 2 of 8) TEMPERATURE SENSOR ASSY.
MARATHONNORCO AEROSPACE, INC. NICKEL-CADMIUM AIRCRAFT BATTERIES Table 3 (Page 3 of 8) TEMPERATURE SENSOR ASSY.
MARATHONNORCO AEROSPACE, INC. NICKEL-CADMIUM AIRCRAFT BATTERIES Table 3 (Page 4 of 8) TEMPERATURE SENSOR ASSY. SPEC Part Number Connector Type Active Pins Action Battery Type 29432-029 MIL-C-38999 MIL-C-38999 29529-001/-002 MS3102R-14S-6P 30K Ohms @ Room Temp Open @ Room Temp / Close @160°F 30K Ohms @ Room Temp Open @ Room Temp / Close @160°F Heater Element-appx. 100 Ohms 36K Ohms at 70°F Heater element-appx.
MARATHONNORCO AEROSPACE, INC. NICKEL-CADMIUM AIRCRAFT BATTERIES Table 3 (Page 5 of 8) TEMPERATURE SENSOR ASSY. SPEC Part Number Connector Type Active Pins Action Battery Type 30320-001 A-B A-C 1-3 Close at 160°F Close at 160°F Close at 160°F TCA-14, TSP-380, TSP-440 30400-001 Bendix PTS06DRL10-6S 31279-001 30465-002 MS-3114P10-6P 30727-001 PT07P-8-4P B – Connector D – Connector A-D A-C N.O. Closes 140°F N.O.
MARATHONNORCO AEROSPACE, INC. NICKEL-CADMIUM AIRCRAFT BATTERIES Table 3 (Page 6 of 8) TEMPERATURE SENSOR ASSY.
MARATHONNORCO AEROSPACE, INC. NICKEL-CADMIUM AIRCRAFT BATTERIES Table 3 (Page 7 of 8) TEMPERATURE SENSOR ASSY. SPEC Part Number Connector Type Active Pins Action Battery Type 31810-001 MS-3102R-14S-6P MS3114P12-8P 31920-002 MS-3474W106P Heater Element-appx. 100 Ohms 36K Ohms at 70°F Heater element-appx. 100 Ohms 36K Ohms at 70°F 10.45V to 10.
MARATHONNORCO AEROSPACE, INC. NICKEL-CADMIUM AIRCRAFT BATTERIES Table 3 (Page 8 of 8) TEMPERATURE SENSOR ASSY.
MARATHONNORCO AEROSPACE, INC. NICKEL-CADMIUM AIRCRAFT BATTERIES 5.0 CHARGE (CONSTANT CURRENT) For batteries that are partially discharged, i.e., batteries received in for service, begin with STEP I For batteries that are completely discharged, i.e., new batteries, batteries following capacity test, or deep cycle, begin with STEP IA. CELL VENTS SHOULD BE UNLOCKED DURING CHARGE. STEP I Connect battery to charging source and charge at the main charge rate until all cells are 1.55 volts or greater.
MARATHONNORCO AEROSPACE, INC. NICKEL-CADMIUM AIRCRAFT BATTERIES STEP IA Connect battery to charging source and charge at the main charge rate a MINIMUM of two and one-half (2½) hours and until all cells are 1.55 volts minimum. IF CELL(S) ARE DRY, HIGH CELL VOLTAGE MAY OCCUR (1.76 VOLTS OR GREATER). FIVE TO TEN CC’s OF DISTILLED OR DEMINERALIZED WATER MAY BE ADDED TO EACH CELL. After completion of the main charge with all cells at 1.
MARATHONNORCO AEROSPACE, INC. NICKEL-CADMIUM AIRCRAFT BATTERIES Reflex and Constant Current Charging Rates CELL REFLEX CHARGING CONSTANT CURRENT CHARGING TYPE 1 HOUR REFLEX MODE AMPS MAIN CHARGE AMPS TOPPING CHARGE AMPS TRICKLE CHARGE RATE MILLIAMPS 3H120 6 1.8 0.8 6 5H120 10 3.2 1.3 10 10H120 20 6.5 2.6 20 12H120 24 7.5 3.0 24 12M220 24 7.5 3.0 24 14M220 28 8.5 3.4 28 15M220 26 8.5 3.4 26 15SP100 26 8.5 3.4 26 17H100 34 9.0 3.6 34 17SP100 34 9.0 3.
MARATHONNORCO AEROSPACE, INC. NICKEL-CADMIUM AIRCRAFT BATTERIES 6.0 ELECTROLYTE LEVEL ADJUSTMENT During the last 15 minutes of the topping charge, and while the current is still flowing, the cells are at their most uniform electrolyte level, and it is at this time that the electrolyte level can be most accurately adjusted. The electrolyte level should be adjusted using the syringe and appropriate nozzle (available in kit P/N 32480-001).
MARATHONNORCO AEROSPACE, INC. NICKEL-CADMIUM AIRCRAFT BATTERIES 6.1 Electrolyte Level Adjustment Procedure Insert the syringe with the appropriate nozzle into the cell opening until the shoulder of the nozzle rests firmly on the “O” ring seat. Withdraw the plunger and check for any electrolyte in the syringe. If the level is too low the syringe will remain empty.
MARATHONNORCO AEROSPACE, INC. NICKEL-CADMIUM AIRCRAFT BATTERIES TABLE 6 MAXIMUM ALLOWABLE WATER CONSUMPTION CELL TYPE VOLUME (cc) 3H120 5H120 10H120 12M220 12H120 3.5 4.5 8.0 31.0 31.0 14M220 15M220 15SP100 17H100 17SP100 18H120 25.0 25.0 25.0 16.0 16.0 10.0 20SPE100 20H120 24M220 24H120 24ME220 24SP100 20.0 20.0 30.0 30.0 96.0 30.0 25SP100 28SP100 36M220 36H120 38H100 38SP100 30.0 24.0 37.0 37.0 78.0 78.0 40SP100 40SP100L 44SP100 44SP100L 46SPE100 34.0 75.0 34.0 34.0 85.0 52H120C 65H132 142.
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MARATHONNORCO AEROSPACE, INC. NICKEL-CADMIUM AIRCRAFT BATTERIES 7.0 CAPACITY TEST If following a charge, a noticeable rise in battery temperature has occurred (warm to the hand) allow the battery to cool prior to proceeding with capacity test. When battery is cool proceed with capacity test (measure discharge versus time) using one of the following discharge rates: − − C-rate for 51 minutes - 85% capacity requirement to minimum acceptable end voltage of 1.0 volts per cell for in-service batteries.
MARATHONNORCO AEROSPACE, INC. NICKEL-CADMIUM AIRCRAFT BATTERIES Table 7 CAPACITY TEST AMPERES Cell Type 3H120 5H120 10H120 12M220 12H120 14M220 15M220 15SP100 17H100 17SP100 18H120 20SPE100 20H120 24M220CR 24ME220 24H120 24SP100 25SP100 28SP100 36H120 38H100 38SP100 40SP100 40SP100L 44SP100 44SP100L 46SPE100 52H120C 65H132 81H120 “C” Rate 3 5 10 12 12 14 13 15 17 17 17 20 20 24 24 24 24 25 28 40 38 38 40 40 44 44 46 52 60 80 C/2 Rate 1.5 2.5 5.0 6.0 6.0 7.0 6.5 7.5 8.5 8.5 8.5 10.0 10.0 12.0 12.0 12.
MARATHONNORCO AEROSPACE, INC. NICKEL-CADMIUM AIRCRAFT BATTERIES 8.0 RECONDITIONING 8.1 When reconditioning is required discharge the battery until cells reach 0.5 volts or less. Place a short-out clip across each cell once it has reached 0.5 volts or less. When all cells have a short-out clip attached, turn off discharge unit. For reconditioning, allow battery to stand in a shorted condition for a minimum of 4 hours, preferably overnight. See 8.2 below.
MARATHONNORCO AEROSPACE, INC. NICKEL-CADMIUM AIRCRAFT BATTERIES 9.0 CLEANING CAUTION: Exercise extreme care when working around the battery. Do not use metal brushes or metal brush supports. Remove rings and other metal jewelry from the hands. Any of these may cause an electrical short which may result in skin burns and damage to the battery. The battery should be kept in a clean, dry state for optimum performance. The extent of the cleaning process depends upon the condition of the battery.
MARATHONNORCO AEROSPACE, INC. NICKEL-CADMIUM AIRCRAFT BATTERIES If the battery has liquid electrolyte on the top of the cells, drain off as much as possible, wash with water, and air dry. If the electrolyte has overflowed to the extent that it has run down between the cells, the battery should be completely discharged, disassembled, and completely cleaned before reassembling. 1. Disassembly -- Disassemble the battery as described in 11.0. 2.
MARATHONNORCO AEROSPACE, INC. NICKEL-CADMIUM AIRCRAFT BATTERIES 10.0 REPLACEMENT OF CELLS AND BATTERY REPAIR 10.1 Replacement of Damaged or Defective Cells If a cell becomes contaminated, physically damaged, or is defective and must be replaced, proceed as follows: 1. Discharge the entire battery as per Paragraphs 7.0 / 8.0, remove the shorting clips. 2. Clean the battery (Paragraph 9.0) 3. Remove enough intercell connectors to permit the cell to be withdrawn from the battery can. 4.
MARATHONNORCO AEROSPACE, INC. NICKEL-CADMIUM AIRCRAFT BATTERIES 10.2 Replacement of Damaged Power Connectors In some battery types, the battery is provided with a special quick disconnect receptacle, such as a type manufactured by Elcon or Cannon, or any of a number of MS type receptacles. Should one of these become damaged, it will be necessary to replace it with a replacement part obtained from your local MarathonNorco authorized distributor.
MARATHONNORCO AEROSPACE, INC. NICKEL-CADMIUM AIRCRAFT BATTERIES 11.0 BATTERY DISASSEMBLY AND REASSEMBLY CAUTION: Exercise care when working around the battery. Avoid the use of uninsulated tools - severe arcing may result with possible harm to personnel and damage to the tools and a cell or cells in the battery. Rings, metal watchbands and identification bracelets should be removed.
MARATHONNORCO AEROSPACE, INC. NICKEL-CADMIUM AIRCRAFT BATTERIES Starting at the positive terminal of the battery, tighten each terminal screw to the torque specified in Table 2. CARE SHOULD BE TAKEN TO INSURE THAT THE TERMINAL SCREW IS NOT BINDING, DUE TO THREAD DAMAGE, OR BOTTOMING, BUT IS ACTUALLY TIGHTENING THE CONNECTOR. IMPROPER TORQUE MAY RESULT IN DAMAGE TO THE BATTERY. Some batteries contain flat-sided washers as part of the terminal hardware.
MARATHONNORCO AEROSPACE, INC. NICKEL-CADMIUM AIRCRAFT BATTERIES 12.0 Battery Maintenance Flow Chart BATTERY MAINTENANCE FLOW CHART New in Service or 100% Discharged Received In for Service Inspect Sect 1.3 Inspect Sect 1.3 Electrical Leakage Torque Check Sensor Inspection Sect 2.0 Sect 3.0 Sect 4.0 Electrical Leakage Torque Check Sensor Inspection Sect 2.0 Sect 3.0 Sect 4.0 Charge Sect 5.0 Step 1 Step 1A Cells > 1.75 V Cells < 1.55 V Cells > 1.55 V Recondition Replace Per Sect 10.
MARATHONNORCO AEROSPACE, INC. NICKEL-CADMIUM AIRCRAFT BATTERIES BATTERY RECONDITIONING FLOW CHART Reconditioning Cells < 1.50V Charge See Note 1 Cycle 2 and 3 Sect. 8 Cells > 1.75V Sect. 5 Step 1A Replace per Sect 10 Replace per Sect 10 Capacity Test < Minimum Capacity Sect. 7 NOTES: Charge Sect. 5 Step 1A 1. A severely unbalanced battery may need to be reconditioned as many as three times to restore its capacity.
MARATHONNORCO AEROSPACE, INC. NICKEL-CADMIUM AIRCRAFT BATTERIES 13.0 TROUBLE-SHOOTING TROUBLE-SHOOTING HINTS TROUBLE APPARENT LOSS OF CAPACITY COMPLETE FAILURE TO OPERATE EXCESSIVE SPEWAGE OF ELECTROLYTE PROBABLE CAUSE CORRECTIVE ACTION Very common when recharging on a constant potential bus, as in aircraft. Usually indicates imbalance between cells because of difference in temperature, charge efficiency, selfdischarge rate, etc., in the cells. RECONDITIONING WILL ALLEVIATE THIS CONDITION.
MARATHONNORCO AEROSPACE, INC. NICKEL-CADMIUM AIRCRAFT BATTERIES TROUBLE PROBABLE CAUSE CORRECTIVE ACTION FAILURE OF ONE OR MORE CELLS TO RISE TO THE REQUIRED 1.55 VOLTS AT THE END OF CHARGE. Negative Electrode not fully charged. Cellophane separator damage. DISTORTION OF CELL CASE TO COVER. Overcharged, overdischarged, or overheated cell with internal short. DISCHARGE BATTERY AND RECHARGE. IF THE CELL STILL FAILS TO RISE TO 1.55 VOLTS OR IF THE CELL'S VOLTAGE RISES TO 1.
MARATHONNORCO AEROSPACE, INC. NICKEL-CADMIUM AIRCRAFT BATTERIES TROUBLE CELL TO BATTERY CAN LEAKAGE TO GROUND DETECTED BY TESTING FOAMING OF ELECTROLYTE DURING CHARGE FALSE OR NO BATTERY HIGH TEMPERATURE INDICATION PROBABLE CAUSE CORRECTIVE ACTION Excessive spewage CLEAN BATTERY, CHARGE AND ADJUST ELECTROLYTE LEVEL. RECHECK FOR ELECTRICAL LEAKAGE. Damaged cell case to cover seal. DISCHARGE BATTERY AND DISASSEMBLE, REPLACE DEFECTIVE CELL, RECONDITION BATTERY.
MARATHONNORCO AEROSPACE, INC. NICKEL-CADMIUM AIRCRAFT BATTERIES 14.0 STORAGE 14.1 Inactive Storage Inactive storage is where the battery is stored for long periods of time. The battery should be stored in a completely discharged, shorted out condition. (See Section 8.1). Nickel-cadmium batteries may be stored in a non-corrosive atmosphere for an unlimited period at temperatures ranging from -65° to + 120°F; the upper limit may be extended to + 160°F for up to two weeks. 14.
MARATHONNORCO AEROSPACE, INC. NICKEL-CADMIUM AIRCRAFT BATTERIES 15.0 SHIPPING Shipments must conform to current IATA regulations (UN2795 or UN2800 as applicable). See the MSDS for further information. Current MSDS can be downloaded off the MarathonNorco Aerospace Website: www.mnaerospace.com.
MARATHONNORCO AEROSPACE, INC. NICKEL-CADMIUM AIRCRAFT BATTERIES 16.0 WARRANTY INFORMATION 16.1 Product Warranty Registration MarathonNorco Aerospace, Inc. includes a warranty registration card with the shipment of each new vented nickel-cadmium battery. The warranty registration card must be validated by a MarathonNorco Aerospace, Inc. authorized distributor/dealer, then filled out and mailed within 30 days of the date of purchase to MarathonNorco Aerospace, Inc.
MARATHONNORCO AEROSPACE, INC. NICKEL-CADMIUM AIRCRAFT BATTERIES 17.0 SPECIAL TOOLS/RECOMMENDED EQUIPMENT 17.1 Nickel-cadmium Battery Maintenance Kit MarathonNorco Aerospace, Inc. has made available through distributors, a battery maintenance kit (P/N 32480-001). Items contained within the kit are listed as follows: QTY REQUIRED 1 5 1 22 1 1 1 1 1 1 1 1 17.2 DESCRIPTION PART NO.
MARATHONNORCO AEROSPACE, INC. NICKEL-CADMIUM AIRCRAFT BATTERIES 18.0 Record Keeping Associated with good maintenance practices is the keeping of accurate records. These records serve as a verification of the maintenance procedure and provide information for establishing optimum servicing schedules in keeping with individual usage of the battery. Documentation of battery servicing is not only required for warranty consideration, it is vital to the proper diagnosis of problems.
MARATHONNORCO AEROSPACE, INC. NICKEL-CADMIUM AIRCRAFT BATTERIES BATTERY SERVICE DATA SHEET Work Order Date ___________ ___________ Page _______ of _______ __________ __________ Battery S/N Battery Type Aircraft Type Aircraft No __________ __________ ___________ ___________ Hours in Service Service Performed by SPECIFICATIONS Cap. Test Amps ___________ ___________ Main Chg. Amps Top Chg. Amps Sensor ___________ ___________ Torque in Lbs.
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