Attachment J.15 Excerpt from JO 6980.31A.pdf
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- Attached to
- Direct Current Back-Up System (DC BUS) Power Supply Federal contract opportunity
- Solicitation number
- 693KA8-20-R-00008
About this file
This is a screening information request (SIR) issued by the Federal Aviation Administration (FAA) for life cycle in-service support of Direct Current Back-Up System (DC BUS) uninterruptible power supplies. The FAA requires DC BUS equipment to provide conditioned, uninterruptible electrical power to support critical National Air Space (NAS) communication and electronic equipment. The anticipated contract type is an indefinite delivery indefinite quantity (IDIQ) contract with a one two-year base period and four two-year option periods, for a potential period of performance of ten years. Offerors must comply with instructions in Section L and submit proposals by 2:00pm EST on March 27, 2020. Questions are due by 2:00pm EST on March 10, 2020, with FAA responses posted by 5:00pm EST on March 18, 2020. The FAA will make a single award but reserves the right to make multiple awards or no award.
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Text version
09/21/2017 JO 6980.31A
5-25
5-19. Load Test (Capacity Test).
a. Materials and Tools:
(1) PPE, refer to Appendix O, paragraphs O-2 and O-3 as indicated in the procedure.
(2) External thermometer (e.g. infrared).
(3) Disposable rags or paper towels.
U.S. DEPARTMENT OF TRANSPORTATION
FEDERAL AVIATION ADMINISTRATION
Air Traffic Organization Policy
ORDER
JO 6980.31A
Effective Date:
09/21/2017
Implementation Date:
12/21/2017
SUBJ: Maintenance of Direct Current (DC) BUS Power System
Attachment J.15 Excerpt from
JO 6980.31A
SIR 693KA8-20-R-00008
https://employees.faa.gov/org/linebusiness/ato/operations/technical_operations/atc_facilities/power_services/operations_engineering/dcbus/documents/info/torque/ https://employees.faa.gov/org/linebusiness/ato/operations/technical_operations/atc_facilities/power_services/operations_engineering/dcbus/documents/info/torque/
5-26
(4) Lead-acid battery neutralizer (1 pound soda per 1 gallon distilled water).
(5) Distilled water.
(6) Insulated torque wrench.
(7) Insulated wrench.
(8) Appropriate insulated wrench sockets.
(9) Brass wire brush or scrub pad (e.g. Scotch-Brite).
(10) Acid-resistant grease (e.g. No-Ox grease).
(11) Non-conductive prying tool.
(12) Voltmeter or multimeter (optional: for individual cells use 2 or more meters).
(13) Ammeter (optional: for parallel strings use 2 or more ammeters).
(14) Hydrometer.
(15) Submersible thermometer.
(16) Mounted micro-ohmmeter monitoring equipment (e.g. Alber UXTM) or hand-held micro-ohmmeter (e.g. Alber Cellcorder or MidTronics Celltron).
(17) Constant current load bank.
(18) Cell jumper cable.
b. Task Instructions.
(1) For additional information about this task go to:
https://employees.faa.gov/org/linebusiness/ato/operations/technical_operations/atc_facilities/po wer_services/operations_engineering/dcbus/documents/info/load_test/. It is strongly recommended that this information is reviewed and understood prior to working this task.
warning
PPE is required for personal safety while performing certain tasks in this paragraph.
(2) Ensure that all other quarterly and annual battery maintenance tasks have been accomplished not more than 1 month prior to starting the load test. Perform maintenance if necessary.
(3) Determine the configuration of the battery system.
Note: There are several different types of battery configurations. Some of these configurations are difficult to immediately identify. Refer to Appendix E, Identifying String Configurations.
SIR 693KA8-20-R-00008
https://employees.faa.gov/org/linebusiness/ato/operations/technical_operations/atc_facilities/power_services/operations_engineering/dcbus/documents/info/load_test/ https://employees.faa.gov/org/linebusiness/ato/operations/technical_operations/atc_facilities/power_services/operations_engineering/dcbus/documents/info/load_test/
5-27
(4) Measure the charge current for each string being tested. Compare the reading to the quarterly current reading to ensure that the string is fully charged. If the battery string is not fully charged, postpone the load test until such a time as the string is charged. Refer to paragraph 5-9, Charge Current in Each Battery String.
(5) Refer to Appendix O, para. O-2 for PPE. With the batteries connected to the DCBUS, measure and record the overall float charge voltage. Refer to paragraph 5-7, System Applied Float Voltage.
(6) Refer to Appendix O, para. O-2 for PPE. With the batteries connected to the DCBUS, measure and record individual cell voltage. Refer to paragraph 5-8, Individual Cell Voltage While on Float.
(7) With the batteries connected to the DCBUS, measure and record the battery charge current in each battery string. Refer to paragraph 5-9, Charge Current in Each Battery String.
(8) Refer to Appendix O, para. O-3 for PPE. For Flooded lead-acid batteries, measure and record the specific gravity of every 10th cell but not less than 2 measurements.
Refer to paragraph 5-20, Specific Gravity (SG).
(9) Refer to Appendix O, para. O-2 for PPE. Measure and record the temperature of every cell. Refer to paragraph 5-4, Temperature of Negative Post for VRLA and maintenance free batteries or paragraph 5-5, Electrolyte Temperature for flooded batteries.
(10) Use the manufacturer’s constant current discharge table for 77°F to determine how much current the string will sustain for 4 hours down to an end voltage of 1.75V per cell. If parallel strings are being tested, multiply the current by the number of strings in parallel. Refer to Appendix I, Battery Capacity Testing - How to Use the Manufacturers Discharge Rate Chart for more information on reading discharge charts.
Note: Do not multiply by the number of cells. In a series of batteries, the cell current is the same as the string current.
Note: A battery may be tested for less than 4 hours in order to save time, but it shall not be tested for less than 2 hours unless the NAS system was specifically designed with less than 2 hours of battery backup. Choose a test current from the manufacturers discharge rate chart according to the new test time.
Note: If the selected current is more than the maximum continuous rating of the load bank, a longer runtime, and a lower current must be selected. Multiple strings may be separated and tested independently to reduce the current.
(11) Connect the ammeter on a battery strap anywhere within the string.
Note: For multiple string tested in parallel, the ammeter will need to be moved to measure each string’s current during the test. Multiple ammeters may be used.
SIR 693KA8-20-R-00008
5-28 warning
Coordinate with Air Traffic. Discharging the battery will remove backup power for the duration of the test as well as reduce the available backup for hours or days afterwards. Depending on battery availability, any loss of commercial power may result in loss of power to all connected NAS equipment.
(12) If the DCBUS is equipped with a battery disconnect, open it.
(13) Refer to Appendix O, para. O-2 for PPE. Isolate the battery string from the DCBUS by unbolting the battery leads from the connection points or separating the connector between the system and the batteries. (Figure 5-16).
(14) If multiple strings are to be tested separately, isolate the battery string(s) from one another. Refer to Appendix O, para. O-2 for PPE. (Figure 5-17).
caution
Set all load switches and dials to zero before connecting the battery string.
(15) Refer to Appendix O, para. O-2 for PPE. Connect the battery string to the load bank. Refer to Figure 5-18 or Figure 5-19 for separated strings.
(16) The following actions need to be performed in 3 minutes or less.
(a) Set the load bank to the current selected in step (10).
Note: Use an ammeter to verify the current being drawn by the load bank. The meter on the load bank is not calibrated and may not be accurate. Adjustments during the test may be required to maintain the appropriate current.
(b) Begin timing the test.
(c) Measure and record the current of each string being tested.
(d) Refer to Appendix O, para. O-2 for PPE. Measure and record the overall string voltage.
(e) Refer to Appendix O, para. O-2 for PPE. Measure and record the individual cell voltage.
caution
Do not stop the test when a single cell reaches 1.75V.
(17) Repeat steps (16)(c) thru (16)(e) once every 10 minutes until the string voltage drops to 21V for 24V nominal systems, 42V for 48V nominal systems, or a single cell voltage approaches reversal (1.2V).
(18) If one or more cells approach reversal (1.2V), causing the load test to be aborted before the 80% mark, the test shall be considered incomplete. The weak cells must be replaced and the test performed within 6 months. To avoid aborting the test, the following procedure may be used to remove only one cell per test, and the total time the test is paused shall not exceed 6 minutes.
5-29 caution
Set all load switches and dials to zero before disconnecting the battery string.
Figure 5-16. Disconnect Open and Batteries Isolated
Figure 5-17. Multiple Strings Isolated
5-30
Figure 5-18. Battery Strings Connected to Load Bank
Figure 5-19. Testing Multiple Strings Independently - String 1
5-31
(a) Refer to Appendix O, para. O-2 for PPE. Disconnect the load bank, but do not reconnect the batteries to the DCBUS.
(b) Pause the discharge timer.
(c) If a single battery string is being tested, use insulated tools to remove the battery straps and connect the jumper. Refer to Appendix O, para. O-2 for PPE. Refer to Appendix C, Building and Using a Jumper to Temporarily Replace a Battery Cell.
caution
Do not connect strings of unlike voltage together. The removed string will need to be retested once the cells are replaced.
(d) If parallel battery strings are being tested, use insulated tools to remove the entire string containing the weak cell. Refer to Appendix O, para. O-2 for PPE. The remaining string can continue the test.
(e) Refer to Appendix O, para. O-2 for PPE. Reapply the load to the battery string. Verify the discharge current is correct using an ammeter.
Note: The necessary load current for a single string will not be influenced by the removal of a cell. The necessary load current for parallel strings will be reduced when a string is removed.
(f) Resume the discharge timer.
Note: For a single string that had a cell removed, the string end voltage has changed. The recalculated voltages for common nominal system voltages are 19.25V for 24V systems and 40.25V for 48V systems. When one string is removed from a set of parallel strings, the end string voltage does not change.
(19) Stop the timer and record the actual duration of the test.
(20) Refer to Appendix O, para. O-2 for PPE. Disconnect the battery string from the load bank. (Figure 5-16).
caution
Set all load switches and dials to zero before disconnecting the battery string.
5-32
Figure 5-20. Testing Multiple Strings Independently - String 2
Figure 5-21. In-Service Configuration
5-33
(21) Refer to Appendix O, para. O-2 for PPE. Measure and Record the individual cell voltages.
(22) If other strings are to be tested, repeat this task from step (15) on each string.
(Figure 5-20).
caution
Do not connect strings of unlike voltage together.
(23) Refer to Appendix O, para. O-2 for PPE. Reconnect the operational string(s) to the DCBUS. (Figure 5-21).
Note: If a cell was jumped out of a single string system, the float voltage must be reduced.
(24) If the DCBUS is equipped with a battery disconnect, close it.
(25) Return the system to service. (Figure 5-21).
(26) Calculate the battery capacity of each individual cell by using the following equation. Replace any cell that has a calculated capacity of less than 80%. Refer to Appendix B, Battery Replacement, for more information.
Percent capacity at 77°F (25°C)
Where: Ta = actual time to 1.75V.
Ts = expected test duration from step (10).
Kt = temperature correction factor as given in Table 5-2
𝑇𝑎
𝑇𝑠∙𝐾𝑡 ∙100
5-34
Table 5-2. Recommended Time Correction Factors (KT ) for Temperatures Other Than 77°F (25°C)
Initial
Temperature
(°C)
Initial
Temperature
(°F)
Temperature
Correction
Factor KT
Initial
Temperature
(°C)
Initial
Temperature
(°F)
Temperature
Correction
Factor KT
4.4 40 0.670 26.1 79 1.007
7.2 45 0.735 26.7 80 1.011
10.0 50 0.790 27.2 81 1.017
12.8 55 0.840 27.8 82 1.023
15.6 60 0.882 28.3 83 1.030
18.3 65 0.920 28.9 84 1.035
18.9 66 0.927 29.4 85 1.040
19.4 67 0.935 30.0 86 1.045
20.0 68 0.942 30.6 87 1.050
20.6 69 0.948 31.1 88 1.055
21.1 70 0.955 31.7 89 1.060
21.7 71 0.960 32.2 90 1.065
22.2 72 0.970 35.0 95 1.090
22.8 73 0.975 37.8 100 1.112
23.3 74 0.980 40.6 105 1.140
23.9 75 0.985 43.3 110 1.162
24.4 76 0.990 46.1 115 1.187
25.0 77 1.000 48.9 120 1.210
25.6 78 1.002 - - -
Note: Battery manufacturers recommend that battery testing be performed between 65°F (18.3°C) and 90°F (32°C).
| Cover |
| JO 6980.31A |
| Table of Contents |
| List of Illustrations |
| Figure 2-1. National - DCBUS System (One Line) |
| Figure 2-2. National - DCBUS System (Front) |
| Figure 2-3. National - Distribution Cabinet |
| Figure 2-4. National - Power Conversion Unit (PCU) |
| Figure 2-5. National - Converters (12V DC, -24V DC, and -48V DC) |
| Figure 2-6. National - Inverters (Front and Back) |
| Figure 2-7. National - Meter Control Alarm (MCA) Assembly (Front) |
| Figure 2-8. National - Lorain Monitoring System (LMS1000) (Front) |
| Figure 2-9. Components of a Lead-Acid Cell (1 of 2) |
| Figure 2-9. Components of a Lead-Acid Cell (2 of 2) |
| Figure 2-10. Pasted Plate |
| Figure 2-11. Planté Plate |
| Figure 2-12. Plates of Tubular Plate Lead-Acid Cell |
| Figure 3-1. C&D Technologies Battery Terminals |
| Figure 3-2. Exide/GNB Battery Terminals |
| Figure 5-1. Download Command |
| Figure 5-2. Timed-Out Screen |
| Figure 5-3. Initiate Transfer ==> Receive File |
| Figure 5-4. Save File Location and Set Protocol |
| Figure 5-5. Name the File |
| Figure 5-6. Xmodem File Receive |
| Figure 5-7. Open Main Distribution Cabinet Door |
| Figure 5-8. Remove Clear Plastic Cover |
| Figure 5-9. Fuse Alarm Holder andLMS1000 Power Fuse |
| Figure 5-10. LMS1000 Power Fuse Number 7 |
| Figure 5-11. Remove LMS1000 Power Fuse |
| Figure 5-12. Open LMS Front Panel |
| Figure 5-13. Remove Battery Using Pen Cap |
| Figure 5-14. Do Not Lose Control of the Battery |
| Figure 5-15. Do Maintain Physical Contact |
| Figure 5-16. Disconnect Open and Batteries Isolated |
| Figure 5-17. Multiple Strings Isolated |
| Figure 5-18. Battery Strings Connected to Load Bank |
| Figure 5-19. Testing Multiple Strings Independently - String 1 |
| Figure 5-20. Testing Multiple Strings Independently - String 2 |
| Figure 5-21. In-Service Configuration |
| Figure 5-22. First HyperTerminal Screen - New Connection |
| Figure 5-23. Second HyperTerminal Screen - Select COM |
| Figure 5-24. Third HyperTerminal Screen - COM Settings |
| Figure 5-25. Main HyperTerminal Screen - Blank |
| Figure 5-26. Main HyperTerminal Screen - Enter Password |
| Figure 5-27. Main HyperTerminal Screen - Communication Established |
| Figure 5-28. Distribution Cabinet with Door Open |
| Figure 5-29. Main Bay Plastic Shield Retaining Screws |
| Figure 5-30. Digital Temperature Compensator Probe Connected to MCA Main Controller Circuit Card |
| Figure 5-31. Digital Temperature Compensator Probe Unplugged from MCA Main Controller Circuit Card |
| Figure C-1. Example Battery Jumper |
| Figure C-2. Jumper Installed |
| Figure D-1. Example One of Label on Maintenance-Free Battery |
| Figure D-2. Example Two of Label on Maintenance-Free Battery |
| Figure D-3. Example of Label Hiding the Battery Caps |
| Figure D-4. Label Partially Removed to Reveal Battery Caps |
| Figure E-1. Traditional Series String |
| Figure E-2. Three Parallel Strings |
| Figure E-3. Series-Parallel String |
| Figure F-1 thru F-40 (Temperature Charts) |
| Figure G-1 thru G-26 (Temperature Charts) |
| Figure H-1. Threaded Insert Terminal |
| Figure J-1. Battery Performance Specification |
| List of Tables |
| Table 5-1. Torque Values for Rack Hardware |
| Table 5-2. Recommended Time Correction Factors (KT ) for Temperatures Other Than 77°F (25°C) |
| Table I-1. Performance Specifications - Constant Current |
| Table N-1. Meter Control Assembly (MCA) Settings |
| Table N-1. Meter Control Assembly (MCA) Settings (Continued) |
| Table N-2. UXTM Battery Monitoring System Settings |
| Chapter 1. General Information and Requirements |
| 1-1. Purpose |
| 1-2. Audience |
| 1-3. Where Can I Find This Order |
| 1-4. Cancellation |
| 1-5. Explanation of Policy Changes |
| 1-6.Certification |
| 1-7.Aircraft Accidents |
| 1-8.Maintenance Procedure |
| 1-9.Risks |
| 1-10. Implementation Date |
| 1-11. Related Publications |
| 1-12. Scope |
| 1-13. Applicability |
| 1-14. Safety |
| 1-15. thru 1-99. Reserved |
| Chapter 2. Technical Characteristics |
| 2-1. Purpose or Function |
| Section 1. DC BUS |
| 2-2. Description |
| 2-3. Theory |
| 2-4. National DCBUS Images |
| 2-5. thru 2-19. Reserved |
| Section 2. Batteries |
| 2-20. Description |
| 2-21. Theory |
| 2-22. thru 2-99. Reserved |
| Chapter 3. Standards and Tolerances |
| 3-1. General |
| Section 1. National DCBUS |
| 3-2. Converter Output Voltage |
| 3-3. Inverters |
| 3-4. thru 3-9. Reserved |
| Section 2. Other DCBUS |
| 3-10. Converter Output Voltage |
| 3-11. Inverters |
| 3-12. thru 3-19. Reserved |
| Section 3. Battery |
| Subsection 1. Valve Regulated Lead-Acid (VRLA) Batteries |
| 3-20. Temperature of Negative Post |
| 3-21. Overall Float Charge Voltage |
| 3-22. Ambient Temperature |
| 3-23. Individual Cell Voltage Whileon Float |
| 3-24. Battery Charger Current Output |
| 3-25. Internal Battery Resistance (Conductance) |
| 3-26. Intercell Connection Resistance (Conductance) |
| 3-27. Intercell Connection Torque |
| 3-28. Load Test (Capacity Test) and Service Test, Battery on Discharge |
| 3-29. Load Test (Capacity Test) and Service Test, Battery after Discharge |
| 3-30. Equalize Voltage |
| 3-31. Ripple Voltage |
| 3-32. Ripple Current |
| 3-33. thru 3-49. Reserved |
| Subsection 2. Flooded Lead-Acid Batteries |
| 3-50. Battery Cell Temperature |
| 3-51. Overall Float Charge Voltage |
| 3-52. Ambient Temperature |
| 3-53. Individual Cell Voltage While on Float |
| 3-54. Battery Charger Current Output |
| 3-55. Internal Battery Resistance (Conductance) |
| 3-56. Intercell Connection Resistance (Conductance) |
| 3-57. Intercell Connection Torque |
| 3-58. Specific Gravity (SG) @ 77°F |
| 3-59. Load Test (Capacity Test) and Service Test, Battery on Discharge |
| 3-60. Load Test (Capacity Test) and Service Test, Battery after Discharge |
| 3-61. Equalize Voltage |
| 3-62. Ripple Voltage |
| 3-63. Ripple Current |
| 3-64. thru 3-79. Reserved |
| Chapter 4. Maintenance Requirements |
| 4-1. General |
| 4-2. FAA Form 6000 Series and eTPR Workbooks |
| Section 1. Performance Checks |
| 4-3. Monthly. Reserved |
| 4-4. Quarterly |
| 4-5. Semi-Annually. Reserved |
| 4-6. Annually |
| 4-7. Every 7 Years |
| 4-8. Every 12 Years |
| 4-9. thru 4-19. Reserved |
| Section 2. Other Maintenance Tasks |
| 4-20. thru 4-39. Reserved |
| Section 3. Condition Based Maintenance Tasks |
| 4-40. As Required. Equalize Charge (Boost Charge) |
| 4-41. As Required. Measure and Record Specific .Gravity |
| 4-42. As Required. Baseline New Battery String Requirements |
| 4-43. As Required. Testing Battery Cell Replacement |
| 4-44. As Required. Testing Increased Internal Resistance (or Decreased Conductance) or Other Re-test Condition |
| 4-45. thru 4-49. Reserved |
| Chapter 5. Maintenance Procedures |
| 5-1. General |
| 5-2. Remote Maintenance Monitoring (RMM) |
| Section 1. Performance Checks |
| 5-3. Battery Inspection |
| 5-4. Temperature of Negative Post |
| 5-5. Electrolyte Temperature |
| 5-6. Electrolyte Level |
| 5-7. System Applied Float Voltage |
| 5-8. Individual Cell Voltage While on Float |
| 5-9. Charge Current in Each Battery String |
| 5-11. Download LMS1000 Configuration File (National Only) |
| 5-12. Replace LMS1000 CPU Battery (National Only) |
| 5-13. Converter Output Voltage |
| 5-14. Inverter Output Voltage and Frequency |
| 5-15. Battery Rack |
| 5-16. UXTM Alarm Reporting |
| 5-17. Intercell Connection Resistance (Conductance) |
| 5-18. Intercell Connection Torque |
| 5-19. Load Test (Capacity Test) |
| 5-20. Specific Gravity (SG) |
| 5-21. thru 5-29. Reserved. |
| Section 2. Other Maintenance Tasks |
| 5-30. thru 5-49. Reserved |
| Section 3. Condition Based Maintenance |
| 5-50. Equalize Charge (Boost Charge) |
| 5-51. Confirm Delivery Shipment |
| 5-52. Battery Startup and Initial Charge |
| 5-53. Ripple Voltage and Current |
| 5-54. Service Test |
| 5-55. thru 5-69. Reserved |
| Section 4. Special Maintenance and Troubleshooting Procedures |
| 5-70. National DCBUS Serial Communications |
| 5-71. National DCBUS Startup |
| 5-72. National DCBUS Shutdown |
| 5-73. National Temperature Compensator Probe |
| 5-74. Strap Removal and Cleaning |
| 5-75. thru 5-99. Reserved |
| Appendix A. Reserved |
| Appendix B. Battery Replacement |
| B-1. Battery Replacement Procedure |
| B-2. thru B-9. Reserved |
| Appendix C. Building and Using a Jumper to Temporarily Replace a Battery Cell |
| Appendix D. Maintenance Free Batteries (Flooded Cell) |
| Section 1. General |
| Section 2. Examples |
| Appendix E. Identifying String Configurations |
| E-1. General |
| E-2. String |
| E-3. Parallel Strings |
| E-4. Combination Strings |
| Appendix F: Float Voltage Temperature Compensation Charts |
| F-1. General |
| F-2. Engineering Notes |
| F-3. Temperature Compensation Charts |
| Appendix G. Individual Cell Voltage Temperature Compensation Charts |
| G-1. General |
| G-2. Engineering Notes |
| G-3. Temperature Compensation Charts |
| Appendix H. Position of Measurement Probes |
| Section 1. General |
| Section 2. Preferred Position |
| Section 3. Alternate Position |
| Section 4. Examples of Battery Terminal Configurations |
| Appendix I. Battery Capacity Testing - How to Use the Manufacturer’s Discharge Rate Chart |
| Section 1. General |
| Section 2. Selecting Appropriate Values of Test Parameters |
| Section 3. Illustrative Examples |
| Section 4. Examples of Manufacturer’s Performance Specifications |
| Appendix J. Interpolation |
| Section 1. General |
| Section 2. Illustrative Examples |
| Appendix K. Open Circuit Voltage and Critical Cell Voltage |
| Section 1. General |
| Section 2. Open-Circuit Voltage (OCV) |
| Section 3. Critical Cell Voltage (CCV) |
| Appendix L. Definitions |
| Appendix M. Glossary |
| Appendix N. Settings for Vortex Power System and UXTM Battery Monitor |
| Appendix O. Maintenance Task PPE Requirements |
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