Ats 004-C

Technical Procedure Manual
Avionics Shop
Issue: Initial Revision: 1 GENERAL OVERHAUL (ANNUAL) ATS/ATCL/BS/004-C

Responsible Quality Manager SAFT NI-CD BATTERY- P/N :2758 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-C A division of Aerospace Technical Consultancy Limited, U.K. PAGE 1 of 8

Avionics Shop

1 PURPOSE:
1.1 These procedure details step by step instructions for GENERAL OVERHAUL SAFT
NI-CD BATTERY- P/N: 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 GENERAL OVERHAUL SAFT NI-CD BATTERY- P/N: 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.

Avionics Shop

Works Order No:

. GENERAL OVERHAUL SAFT NI-CD BATTERY-
P/N : 2758 Start Time
Complete Time:
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 date Completed Date
Ops DETAILS OF WORK DONE Tech Approved Date:
. Engineer
No.
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.

Avionics Shop

Any defects observed:
50 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.
60 NUT TIGHTNESS: Tighten And Check The Torque Of All Upper Cell Nut.
 Upper Nut Actual Torque Value:_______________________
 Upper Nut Set Torque Value:__________________________
70 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.
80 DISASSEMBLY AND THROUGHOUT CLEANING:
a) Remove the shorting clips
b) Disassemble the battery as per OMM page 3001, 3002
c) Thoroughly clean and inspect all the parts as per OMM page 4001, 4002
90 COMPONENT INSPECTION: Carryout the component inspection as follows:
a) Verify that cell box show no leakage
b) Make the side of box straight and remove dents if any:
c) Check the main power connector for evidence or arcing, corrosion cracks
or cross threaded terminals.
Any defects observed:
100 SENSOR CHECK: Carry out the sensor check as follows:
a) Insulation check: Verify that the insulation between each point of
connector and all metal parts of the sensor is > 10MΩ @250 VDC
b) Sensor Check: Check the temperature sensor, if applicable referring to
the table given on page 5009 - 5016
110 VENT VALVE TEST:
A. Test the vent valves to ensure that the valves closed when pressure is
less than 2psi (0.14 bar)
B. Test the vent valves to ensure that the valves open between 2-10 psi
(0.14 - 0.7 bar)
Actual Value
120 ASSEMBLY:
a) Make sure the components are clean and dry before assembly.
b) Torque the lower nut on each cell terminal as per OMM
c) Install the cells maintaining correct polarity
d) Install the connector receptacle and tighten the screws.
e) Install inter cell connecting hardware and attach temperature sensor
f) Lightly coat cell terminals and links with neutral petroleum jelly.
g) Mount the washers and torque upper terminal nuts.

Avionics Shop

140 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.
150 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
160 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.
170 If the battery passes the 1st Capacity Test then proceed to point 70, 150 and
220.
If the battery fails the capacity test then carryout 2nd CT and repeat the
procedure to point 70, 150 and 180.
NOTE: IT MIGHT BE NECESSARY TO CARRY OUT DEEP CYCLE OF A BATTERY
UPTO THREE TIMES TO CORREC T SERVICE IMBALANCE.

Avionics Shop

180 2nd CAPCITY TEST: Discharge the battery at the rate of 1C1A. Record the time that
the first cell reaches 1 volt.
______________mins.
190 If the battery passes the 2nd Capacity Test then proceed to point 70, 150 and
220.
If the battery fails the capacity test then carryout 3rd CT and repeat the
procedure to point 70, 150 and 200.
200 3rd CAPACITY TEST: Discharge the battery at the rate of 1C1A. Record the time
that the first cell reaches 1 volt.
______________mins.
210 If the battery passes the 3rd Capacity Test then proceed to point 70, 150 and
220.
If the battery fails the capacity test then the battery is Rejected.
220 VENT VALVE CLEANING: After the Capcity test is carried out carry out light
cleaning of Vent Valves externally.
240 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.
250 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.
260 Notify the customers/operator.
270 Make an entry in Battery Shop Incoming/Outgoing Register.
280 DISPOSAL: NI-CD batteries contain: *Nickel * Cadmium * Potassium Hydroxide.
They must therefore be discarded or used again, in agreement with local
legislation. For more information, contact your local SAFT supplier.

Avionics Shop

Technician Approved Engineer
Name: ______________________________ Name: ______________________________
Signature: __________________________ Signature: __________________________
Date: _______________________________ Date: _______________________________
REMARKS:
WORKS ORDER CLOSURE:

NAME SIGNATURE DATE:
TIME:

Avionics Shop

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
VOLTAG
E

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Technical Procedure Manual

Issue: Initial Revision: 1 GENERAL OVERHAUL (ANNUAL) ATS/ATCL/BS/004-C

Procedure review change following revision in – 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)

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

Issue: Initial Revision: 1 GENERAL OVERHAUL (ANNUAL) ATS/ATCL/BS/004-C

2. SCOPE AND APPLICABLE:

2.4 Health, Safety and Environment:

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

Issue: Initial Revision: 1 GENERAL OVERHAUL (ANNUAL) ATS/ATCL/BS/004-C

Works Order No:

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

Issue: Initial Revision: 1 GENERAL OVERHAUL (ANNUAL) ATS/ATCL/BS/004-C

Any defects observed:

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

Issue: Initial Revision: 1 GENERAL OVERHAUL (ANNUAL) ATS/ATCL/BS/004-C

150 Note: Remove all the shorting resistors before charging.

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

Issue: Initial Revision: 1 GENERAL OVERHAUL (ANNUAL) ATS/ATCL/BS/004-C

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

Issue: Initial Revision: 1 GENERAL OVERHAUL (ANNUAL) ATS/ATCL/BS/004-C

Technician Approved Engineer

Name: ______________________________ Name: ______________________________

Signature: __________________________ Signature: __________________________

Date: _______________________________ Date: _______________________________

WORKS ORDER CLOSURE:

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

Issue: Initial Revision: 1 GENERAL OVERHAUL (ANNUAL) ATS/ATCL/BS/004-C

NI-CD BATTERY CHARGING SHEET

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

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

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Name: Name:

Signature: Signature:

Date: _ Date: _

Date:_/_/ BATTERY TYPE/PART NO._______