Technical Procedure Manual

Avionics Shop

Issue: Initial Revision: 1 REGULAR CHECK ATS/ATCL/BS/004-B

Responsible Quality Manager SAFT NI-CD BATTERY Part No. 2758 Rev. Date: Nov/2015
Aerospace Technical Services, Airport Authority of India, Juhu Airport, Mumbai-400 056.India.

Procedure review change following revision in – OMM Reference 24-38-51

The following amendments carried out in accordance with OMM Reference 24-38-51

S/N REVISION NO DESCRIPTION OF CHANGES PAGE NO. SIGNATURE.

PREPARED BY CHECKED BY (WM) APPROVED BY (QM) APPROVED BY (AM)

NAME
POSITION
DATE

SIGN

STAMP

ATS/ATCL/BS/004-B A division of Aerospace Technical Consultancy Limited, U.K. PAGE 1 of 8

 Technical Procedure Manual
Avionics Shop

Issue: Initial Revision: 1 REGULAR CHECK ATS/ATCL/BS/004-B

Responsible Quality Manager SAFT NI-CD BATTERY Part No. 2758 Rev. Date: Nov/2015
Aerospace Technical Services, Airport Authority of India, Juhu Airport, Mumbai-400 056.India.

1. PURPOSE:

1.1 These procedure details step by step instructions for REGULAR CHECK OF NI-CD
BATTERY "SAFT" Part No. 2758 limited to Aerospace Technical Services Avionic
shop (Battery shop).

1.2 This Procedure also meets the requirements for ATS’S External Customers.

2. SCOPE AND APPLICABLE:

2.1 This procedure defines the REGULAR CHECK OF NI-CD BATTERY "SAFT" Part No.
2758 limited to Aerospace Technical Services Avionic shop (Battery shop).

2.2 This procedure is also applicable to ATS’S Customers Battery Services carried out
at ATS’S battery shop.

2.3 Responsibilities:

2.3.1 Responsible to all Avionics personnel approved/Authorised to carry out job within
the scope as mentioned in the approval card issued by Quality Department.

2.3.2 Only personnel authorised within the scope of authorisation shall carry our above
Task.

2.4 Health, Safety and Environment:

2.4.1 Responsible of all Avionic personnel to maintain appropriate Health, Safety and
Environment all time.

2.4.2 Health and Safety precaution are to adhered and proper use of Personnel Protective
Equipment (PPE) to be used during work in progress.

2.4.3 There is statutory obligation to provide and maintain safe working environments and
process operations. Further information on the requirement and responsibilities is
provided in ATS Health and Safety precautions, Material Safety Data Sheets
(MSDS) and ATS Health Safety & Environment Manual.

ATS/ATCL/BS/004-B A division of Aerospace Technical Consultancy Limited, U.K. PAGE 2 of 8

 Technical Procedure Manual
Avionics Shop

Issue: Initial Revision: 1 REGULAR CHECK ATS/ATCL/BS/004-B

Responsible Quality Manager SAFT NI-CD BATTERY Part No. 2758 Rev. Date: Nov/2015
Aerospace Technical Services, Airport Authority of India, Juhu Airport, Mumbai-400 056.India.

Works Order No:

. REGULAR CHECK SAFT NI-CD BATTERY Part No. 2758

Start Date:
Completed Date:
Revision: 0
BATTERY P/N: BATTERY A/H:
BATTERY S/N: CELL TYPE:
BATTERY TYPE: FORM TRACKING NO.
A/C REGN: Reference Chapter No: 24-38-51
START TIME: COMPLETE TIME:
A/C MSN:
Ops DETAILS OF WORK DONE Tech Approved Date:
No. Engineer
10 Special Tools/Equipments:
1.Cell extraction wrench
2. Vent valve wrench
3.Syringe assembly
4.Shorting clips
5.Equalising resistors (1Ω, 3W min)
6.Insulated Ratchet & Socket
7.Constant current power unit (0-45V, 0-60A)
8.Constant current load bank (0-60A)
9. Precision multi-meter (Range 2V & 50V, Accuracy 1%))
10.Mega-ohmmeter (Analog) 250 V dc, 0-50 MΩ)
11. Torque wrench
12. Thermometer (Immersion)
13.Hygrometer
20 Consumables:
1. DM/Distilled/De-ionized water
2. Lubricant (Non acidic petroleum jelly)
3. Neoprene glue
4. Soap
5. Dry compressed air
30 Spares: If Required
40 VISUAL INSPECTION:
(a) Remove the cover assembly.
(b)Visually check the battery for any dents, cracks. Visually check each cell for any
evidence of electrolyte leakage & clean if necessary.
(c)Check the hardware for bends, tarnish, corrosion, burns & any loss of NI
plating. Minor tarnish can be polished off with fine non metallic brush. Defective
hardware should be replaced.
(d) Check the main power connector for evidence of arcing, corrosion, cracks or
cross threaded terminals.
(e) Check the Temp. Sensor & connector for obvious damage.

ATS/ATCL/BS/004-B A division of Aerospace Technical Consultancy Limited, U.K. PAGE 3 of 8

 Technical Procedure Manual
Avionics Shop

Issue: Initial Revision: 1 REGULAR CHECK ATS/ATCL/BS/004-B

Responsible Quality Manager SAFT NI-CD BATTERY Part No. 2758 Rev. Date: Nov/2015
Aerospace Technical Services, Airport Authority of India, Juhu Airport, Mumbai-400 056.India.

Any defects observed:

50 INSULATION CHECK: Check cell to case insulation using a meghometer, set to
250vdc and check the insulation resistance between positive terminal of each cell
and battery box.

60 NUT TIGHTNESS: Tighten And Check The Torque Of All Upper Cell Nut.
 Upper Nut Actual Torque Value:_______________________
 Upper Nut Set Torque Value:__________________________
70 POLARIZATION: The Individual Cell Voltage Of Each Cell Should Be U > 1.05V.
•If it is greater than 1.05V then there is no cell with reverse polarity.
•If it is less than 1.05v then carry out polarization test as per OMM 24-38-51 page
5004.
80 Residual Discharge: Discharge the battery at 1C1A or 0.5C1A rate until each cell in
the battery is discharged to 1.0V or below.
CELL SHORTING: As each cell voltages drops below 1.0V connect equalizing
resistors of 1Ω 3W across each terminal. Leave the resistors in place for 12 to 16
hours. Allow each cell to completely discharge & battery to cool.
90 Note: Remove all the shorting resistors before charging.
CHARGE: charge the battery according to any one method given in following
table.

METHOD USED:___________
NOTE: CHECK THE CELL VOLATAGE AT THE BEGINNING OF CHARGE.IF ANY CELL
INDICATES AN IMMEDIATE RISE ABOVE 1.5V ADD 5cc OF DISTILLED OR DEIONIZED
WATER TO THAT CELL.
•ADJUST ELECTROLYTE LEVEL: During The Last 15-30 Minutes Of overcharge cycle
adjust the electrolyte level.
 Maximum consumable quantity of water is ______cc
 The average quantity of water added in each cell ________cc

ATS/ATCL/BS/004-B A division of Aerospace Technical Consultancy Limited, U.K. PAGE 4 of 8

 Technical Procedure Manual
Avionics Shop

Issue: Initial Revision: 1 REGULAR CHECK ATS/ATCL/BS/004-B

Responsible Quality Manager SAFT NI-CD BATTERY Part No. 2758 Rev. Date: Nov/2015
Aerospace Technical Services, Airport Authority of India, Juhu Airport, Mumbai-400 056.India.

100 CAPACITY TEST: Discharge the battery at the rate of 1C1A. Record the time that
the first cell reaches 1 volt.
 The time must be greater than or equal to 51 mins for VO & VP cells
______________mins.
 The time must be greater than or equal to 1 hr/60 mins for VHP,VXP,CVH,CVD
& CVK cells _______________hr/mins.
110 If the battery passes the 1st Capacity Test then proceed to point 80, 90 and
160.
If the battery fails the capacity test then carryout 2nd CT and repeat the
procedure to point 80, 90 and 120.
NOTE: IT MIGHT BE NECESSARY TO CARRY OUT DEEP CYCLE OF A BATTERY UPTO
THREE TIMES TO CORREC T SERVICE IMBALANCE.
120 2ND CAPCITY TEST: Discharge the battery at the rate of 1C1A. Record the time
that the first cell reaches 1 volt.
 The time must be greater than or equal to 51 mins for VO & VP cells
______________mins.
 The time must be greater than or equal to 1 hr/60 mins for VHP,VXP,CVH,CVD
& CVK cells _______________hr/mins.
130 If the battery passes the 2nd Capacity Test then proceed to point 80, 90 and
160.
If the battery fails the capacity test then carryout 3rd CT and repeat the
procedure to point 80, 90 and 140.
140 3rd CAPACITY TEST: Discharge the battery at the rate of 1C1A. Record the time
that the first cell reaches 1 volt.
 The time must be greater than or equal to 51 mins for VO & VP cells
______________mins.
 The time must be greater than or equal to 1 hr/60 mins for VHP,VXP,CVH,CVD
& CVK cells _______________hr/mins.
150 If the battery passes the 3rd Capacity Test then proceed to point 80, 90 and
160.
If the battery fails the capacity test then the battery is Rejected.
160 VENT VALVE CLEANING: After the Capcity test is carried out carry out light
cleaning of Vent Valves externally.
170 NUT TIGHTNESS: Tighten And Check The Torque Of All Upper Cell Nut.
 Upper Nut Actual Torque Value:_______________________
 Upper Nut Set Torque Value:__________________________
180 Return the Battery/component(s)/Part(s) to stores with Serviceable Tag, along
with DGCA CA Form-1/EASA FORM 1 issued by Approved/ Authorized Engineer,
the Works Order and other relevant Technical documents.
190 Failed/Rejected items: Return to Quarantine stores with Unserviceable Tag,
along with the detailed report. Cause of Failure/Reject along with all relevant
Technical documents.
200 Notify the customers/operator.
210 Make an entry in Battery Shop Incoming/Outgoing Register.
220 DISPOSAL: NI-CD batteries contain: *Nickel * Cadmium * Potassium Hydroxide.

ATS/ATCL/BS/004-B A division of Aerospace Technical Consultancy Limited, U.K. PAGE 5 of 8

 Technical Procedure Manual
Avionics Shop

Issue: Initial Revision: 1 REGULAR CHECK ATS/ATCL/BS/004-B

Responsible Quality Manager SAFT NI-CD BATTERY Part No. 2758 Rev. Date: Nov/2015
Aerospace Technical Services, Airport Authority of India, Juhu Airport, Mumbai-400 056.India.

They must therefore be discarded or used again, in agreement with local

legislation. For more information, contact your local SAFT supplier.

Technician Approved Engineer

Name: ______________________________ Name: ______________________________

Signature: __________________________ Signature: __________________________

Date: _______________________________ Date: _______________________________

REMARKS:

WORKS ORDER CLOSURE:

NAME SIGNATURE DATE:
TIME:

ATS/ATCL/BS/004-B A division of Aerospace Technical Consultancy Limited, U.K. PAGE 6 of 8

 Technical Procedure Manual
Avionics Shop

Issue: Initial Revision: 1 REGULAR CHECK ATS/ATCL/BS/004-B

Responsible Quality Manager SAFT NI-CD BATTERY Part No. 2758 Rev. Date: Nov/2015
Aerospace Technical Services, Airport Authority of India, Juhu Airport, Mumbai-400 056.India.

NI-CD BATTERY CHARGING SHEET

Date:___/___/____ BATTERY TYPE/PART NO.___________

TIME:_____:_____ BATTERY SERIEL NO._______________
CAPACITY(C₁):____________AH NO. OF CELLS:____________CELLS
CHARGING CURRENT:
Main Charge______× (C₁) =_________Amps.
Overcharge 0.1× (c₁) =________Amps.

CELL NO. MAIN CHARGE DURATION OVERCHARGE READING H20 ADDED REMARKS
1 Hrs 2 Hrs. 3 Hrs. 4 Hrs. IN CC

TIME
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
TOTAL
VOLTAGE

ATS/ATCL/BS/004-B A division of Aerospace Technical Consultancy Limited, U.K. PAGE 7 of 8

 Technical Procedure Manual
Avionics Shop

Issue: Initial Revision: 1 REGULAR CHECK ATS/ATCL/BS/004-B

Responsible Quality Manager SAFT NI-CD BATTERY Part No. 2758 Rev. Date: Nov/2015
Aerospace Technical Services, Airport Authority of India, Juhu Airport, Mumbai-400 056.India.

NI-CD BATTERY DISCHARGING SHEET

Date:___/___/____ BATTERY TYPE/PART NO.___________

TIME:_____:_____ BATTERY SERIEL NO._______________
CAPACITY(C₁):____________AH NO. OF CELLS:____________CELLS
DISCHARGING CURRENT:____________

Cell No. Open 10 20 30 40 50 FINAL REMARKS

Circuit MINS MINS MINIS MINIS MINIS READING
Voltage
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
TOTAL
VOLTAG
E

ATS/ATCL/BS/004-B A division of Aerospace Technical Consultancy Limited, U.K. PAGE 8 of 8