Attachment J.15 BAT SYS TEST PROC.docx

NATIONAL AIRSPACE SYSTEM (NAS)

BATTERY SYSTEM

TEST PROCEDURE

12/13/21

1.0 INTRODUCTION

This document provides testing details for battery system replacement at National Airspace System (NAS) facilities.

2.0 GENERAL REQUIREMENTS

This document applies to NAS UPS (Uninterruptible Power System), DC BUS (Direct Current Backup System) and VOR (Very High Frequency Omnidirectional Radar) equipment that utilize battery strings with more than twelve batteries per string and located at the following facilities.

1. Three Phase UPS

a. TRACONS - Terminal Radar Approach Control. The TRACON and ATCT contain electronic equipment such as ARTS, STARS, DVARS, DBRITE, FDIO, TDDS, TVS, ASDE processor and TDWR processor, and many more equipment acronyms.

b. ATCT - Air Traffic Control Tower

c. ASR - Airport Surveillance Radar ASR-8, 9, and 11

d. TDWR - Terminal Doppler Weather Radar

e. ASDE-3 & X - Airport Surface Detection Equipment

f. ARSR-3 & 4 - Air Route Surveillance Radar

g. DDH - Data Distribution Hubs. Prevalent to airports feeding voice and radar information to Southern California TRACON

h. CERAP Center Radar Approach Control. Guam, San Juan, Hawaii.

i. ARTCCs Air Route Traffic Control Center

2. Single-Phase UPS units. Satellite Communications SACOM, part of ANICS (Alaskan National Airspace System Interfaculty Communications System) and stateside facilities.

3. Direct Current Backup System (DC BUS) units. Remote Center Air/Ground (RCAG) communications facility for ARTCC voice communications with aircraft. Backup Emergency Communications (BUEC) sites. Remote Transmitter/Receiver (RTR) for ATCT/TRACON voice communications with aircraft, Radio Communications Link (RCL) is a microwave link system which relays broadband/narrowband radar and voice/data communications.

4. Very High Frequency (VHF) Omnidirectional Range (VOR) is a system radiating a VHF radio wave give the pilot a direct indication of bearing relative to the VOR facility.

3.0 TEST EQUIPMENT REQUIREMENTS

The Contractor must deliver all equipment and support items necessary to support battery testing.

4.0 TEST IMPLEMENTATION

The Contractor must be responsible for coordinating test implementation activities, perform test procedures, test personnel, briefings, contractor personnel oversight and Contractor Acceptance Inspections (CAI). All Contractor personnel must be trained and experienced in battery system installation, integration, and testing of a battery system. The project must be under the oversight of an FAA representative (Site POC) designated by the SSC. Air traffic control activity must have priority over all contractor activities. The project must not inhibit air traffic operational control or alter the status of the facility’s power system.

5.0 TESTING

After replacing each battery string, the Contractor must conduct battery tests to verify battery performance in accordance with Original Equipment Manufacturer (OEM) and Institute of Electrical and Electronics Engineers (IEEE) requirements.

After installing the new batteries:

· Place the battery back in the power system circuit and a float charge overnight at the voltage level required by the OEM. If the OEM requires the battery to be equalized, equalize in accordance with OEM requirements.

· After the float charge, measure and record the following baseline parameters: Evaluate each battery/cell against the calculated average to determine if the cell is within the manufacturers limits.

1. Float Voltage (full charge)

2. Equalize Voltage, if recommended by battery manufacturer

3. Cell internal resistances (reference section 5.1)

4. Interconnection resistances (reference section 5.1)

5. Intercell connection torque

6. String (open cell) Voltage

7. Individual Cell Voltages (under float)

8. String Current (under float)

9. AC Ripple Voltage

10. AC Ripple Current

11. Temperature of Pilot Cell

12. Ambient Temperature

13. Ground Faults

14. Specific Gravity (flooded cells only), if required

· Replace any VRLA cells that exceed the battery manufacturer’s recommendations. Replace any connections that are out of tolerance (greater than manufacturer’s recommended limits). Where the battery manufacturer’s recommendations are not available, replace a VRLA cell when its internal resistance value exceeds 120% of the average, and clean torque or replace connections that exceed 110% of the average.

· If flooded cells are replaced, the specific gravity of each cell must be provided in lieu of the internal resistance of each cell. Replace any cell whose specific gravity is out of tolerance (outside the battery manufacturer’s recommended limits).

· After recording baseline data on test data sheet provided in Sec-J Attachment J.15 and verifying that baseline data is in accordance with OEM requirements, Contractor must setup test equipment and coordinate with the FAA POC to configure the battery system for a service test.

· When performing service tests the Contractor must utilize the runtime sheet to ensure the battery is not overloaded. Please contact the program office immediately where you suspect service test runtime and load values are too high for the battery model based on battery capacity, site load, charging or other factors.

· Begin the Service Test using the applicable test procedure (Section 5.2.1 Flooded), 5.2.2 (VRLA) or 5.2.3 (NICAD).

· The service test must be accomplished utilizing an appropriately sized (volts and amps) DC (connected to the battery) or AC load bank (connected to the UPS output). Where load bank connectivity is not practical and with facility consent and proper risk mitigation, the actual load could be utilized to service test the battery.

1. The load bank must be set to a value that matches the actual equipment load.

2. The test duration must be 10 minutes for UPS applications.

3. 30 minutes for DC Bus System and VOR sites with EGs.

4. 4 hours for VORs and DC BUS systems without EGs.

5. Upon completion of the Service Test, the Contractor must coordinate with the local FAA to place the battery back into the power system.

6. The battery string will require a recharge period before it will reach 100% capacity.

7. The FAA will ensure that float and equalize charge voltages from the rectifier/charger are adjusted to match the battery manufacturer’s specifications.

5.1 BATTERY CELL RESISTANCE READINGS

Resistance measurements must meet the requirements identified by the battery manufacturer. To ensure accuracy of future measurements (as compared to baseline measurement), the Contractor must identify the connection method used in the cellcorder manual (ex: 3-probe connection, 2-probe connection) associated with each set of resistance measurements taken so that future measurements can be made using the same method. Identify the connection method in the “Notes” section of the cellcorder report. The Contractor must use the 3-probe method to obtain separate internal and connection readings where connections are readily accessible. Where connections are not readily accessible, the contractor may utilize the 2-probe method. Utilizing the methods outlined in the OEM instruction manual, take and record the measurements for the internal resistance of all cells within the battery configuration. The Cellcorder readings must be taken after the battery string has been charge overnight but prior to the discharge (capacity) test.

When taking the battery strap resistance measurements, there will be 3 data columns. Depending upon the cell number, not all data columns will be filled in. The columns are dependent upon the Strap Type utilized to make the specific connection.

Any strap resistance 20% above the average must be re-cleaned and re-measured.

The internal resistances of the individual cells may also vary. The variations could be due to:

1) The internal resistance of the individual cells,

2) If the resistance includes the strap resistance,

3) If the resistance includes the inter-tier cable resistance.

All readings should be within +/- 20% of the average internal baseline resistance readings. Readings outside of +/- 20% indicate one of the following:

1) shorted plates (minus readings),

2) mismatched intertier cables,

3) improper torque applied to the connections,

4) bad chemical reaction within the battery.

5.2 SERVICE TESTS

5.2.1 NEW VRLA BATTERY STRING

This service test verifies a new battery string’s capability to support the equipment load for the designated runtime. The service test should be performed where capacity tests are not practical. Observe facility risk assessment and mitigation procedures.

1. Recommended Protective Equipment.

a. Goggles and face shield.

b. Acid resistant gloves.

c. Protective aprons.

d. Portable or stationary water facilities for rinsing eyes and skin in case of contact with electrolyte.

e. Class C fire extinguisher.

f. Bicarbonate of soda mixed .1 kg to 1 L (1 lb to 1 gallon) of water, to neutralize acid spillage.

g. Adequately insulated tools.

2. Recommended Test equipment.

a. RMS Voltmeter.

b. Fluke Clamp on Ammeter, or equivalent

c. Fluke mulitmeter

d. Temperature probe or infrared gun.

e. Timer

f. Load Bank

3. Pre-requisites.

a. Battery cell connections are torqued in accordance with battery manufacturer’s specifications.

b. Battery cell voltage checks are satisfactory (refer to battery manufacturer’s specifications).

c. Battery cell internal and connection resistance checks are satisfactory (refer to battery manufacturer’s specifications).

d. Battery is charged.

i) Battery charge current is minimal and stable (does not change more than 10% over a 3 hour period.

4. Measure and record the battery system float voltage. The battery charger must be connected during measurement.

a. Record the number of batteries in the battery string.

b. Record the battery manufacturer and model number.

c. Record ambient room temperature.

i. Battery room temperature should ideally be 77 oF.

ii. Higher room temperatures will accelerate battery aging.

iii. Lower room temperature can reduce battery performance.

5. Verify that the load is operating.

a. Record the amount of actual load in KW and Amps.

6. Turn off the ac input power to the battery charger and start the timing.

a. Read and record the battery string voltage

i. String voltage should not be less than 1.75 volts per cell multiplied by the number of cells in the string.

b. Read and record individual battery voltages.

i. Battery voltage should not be less than 1.75 volts per cell. Note: Where individual battery voltage is not monitored by a battery monitoring system and the batteries are inaccessible, measure and record only the string voltage.

c. Measure the temperature (spot check) of each battery and its associated cables and connections

i. Terminate the test if the temperature of any battery, cable or connection becomes more than 20° F higher than the average.

d. Read and record one pilot battery cell temperature.

7. Record data in accordance with step 6.a. through 6.d. periodically during the service test runtime on test data sheets provided in Section J Attachment J.15.

a. The last set of readings should be taken just before terminating the test at fifteen minutes.

i. The test may slightly exceed the designated runtime as necessary to complete the last set of measurements.

8. At approximately the end of the required runtime, terminate the test by turning on the battery charger and record the time of the test.

a. Recharge the battery and return the equipment to service.

i. The battery may not be fully recharged until after it has charged for several hours

(1) The battery is fully charged when the charging current is stable as described in 3) d).

b. The service test is satisfactory if the battery string powers actual equipment load for ten minutes without exceeding the limits identified in 6.a. through 6.c.

5.2.2 NEW FLOODED LEAD ACID BATTERY STRING

This service test verifies a new battery string’s capability to support the equipment load for the designated runtime. The service test should be performed where capacity tests are not practical. Observe facility risk assessment and mitigation procedures.

1. Recommended Protective Equipment.

a. Goggles and face shield.

b. Acid resistant gloves.

c. Protective aprons.

d. Portable or stationary water facilities for rinsing eyes and skin in case of contact with electrolyte.

e. Class C fire extinguisher.

f. Bicarbonate of soda mixed .1 kg to 1 L (1 lb to 1 gallon) of water, to neutralize acid spillage.

g. Adequately insulated tools.

2. Recommended Test equipment.

a. Voltmeter.

b. Temperature probe or infrared gun.

c. Timer

d. Hydrometer

e. Thermometer

f. Load Bank

3. Pre-requisites.

a. Battery cell connections are torqued in accordance with battery manufacturer’s specifications.

b. Battery cell voltage checks are satisfactory (refer to battery manufacturer’s specifications).

c. Battery cell internal and connection resistance checks are satisfactory (refer to battery manufacturer’s specifications).

d. Battery is charged.

i. Battery charge current is minimal and stable (does not change more than 10% over a 3-hour period.

4. Measure and record the specific gravity of each cell just prior to the test.

5. Measure and record the average temperature of the electrolyte, every 6th cell is suggested.

6. Measure and record the battery system float voltage. The battery charger must be connected during measurement.

a. Record the number of batteries in the battery string.

b. Record the battery manufacturer and model number.

c. Record ambient room temperature.

i. Battery room temperature should ideally be 77 oF.

ii. Higher room temperatures will accelerate battery aging.

iii. Lower room temperature can reduce battery performance.

7. Verify that the load is operating.

a. Record the amount of actual load in KW and Amps.

8. Turn off the ac input power to the battery charger and start the timing.

a. Read and record the battery string voltage

i. String voltage should not be less than 1.75 volts per cell multiplied by the number of cells in the string.

b. Read and record individual battery voltages.

i. Battery voltage should not be less than 1.75 volts per cell.

ii. Note: Where individual battery voltage is not monitored by a battery monitoring system and the batteries are inaccessible or the number of individual batteries exceeds 20, measure and record only the string voltage.

c. Measure the temperature (spot check) of each battery and its associated cables and connections

i. Terminate the test if the temperature of any battery, cable or connection becomes excessively higher than the average.

d. Read and record one pilot battery cell temperature.

9. Record data in accordance with step 8) a) through 8) d) periodically during the service test runtime on test data sheets provided in Section J Attachment J.15.

a. The last set of readings should be taken just before terminating the test at thirty minutes.

i. The test may slightly exceed the listed runtime as necessary to complete the last set of measurements.

10. At approximately the end of the required runtime, terminate the test by turning on the battery charger and record the time of the test.

a. Recharge the battery and return the equipment to service.

i. The battery may not be fully recharged until after it has charged for several hours

(1) The battery is fully charged when the charging current is stable as described in 3) d).

b. The service test is satisfactory if the battery string powers actual equipment load for thirty minutes without exceeding the limits identified in 8)a) through 8)c).

5.2.3 NEW NICKEL-CADMIUM BATTERY STRING

This service test verifies a new Nickel-Cadmium Alkaline battery string’s capability to support the equipment load for the designated runtime. The service test should be performed where capacity tests are not practical. Observe facility risk assessment and mitigation procedures.

1. Recommended Protective Equipment.

a. Goggles and face shield.

b. Acid resistant gloves.

c. Protective aprons.

d. Portable or stationary water facilities for rinsing eyes and skin in case of contact with electrolyte.

e. Class C fire extinguisher.

f. 3-percent boric acid solution or vinegar to neutralize electrolyte spillage.

g. Adequately insulated tools.

2. Recommended Test equipment.

a. Voltmeter

b. Temperature probe or infrared gun

c. Timer

d. Thermometer

e. Load Bank

3. Pre-requisites.

a. Battery cell connections are torqued in accordance with battery manufacturer’s specifications.

b. Battery cell voltage checks are satisfactory (refer to battery manufacturer’s specifications).

c. Battery cell internal and connection resistance checks are satisfactory (refer to battery manufacturer’s specifications).

d. Battery is charged.

i. Battery charge current is minimal and stable (does not change more than 10% over a 3 hour period.

4. Measure and record the battery system float voltage. The battery charger must be connected during measurement.

a. Record the number of batteries in the battery string.

b. Record the battery manufacturer and model number.

c. Record ambient room temperature.

i. Battery room temperature range should ideally be 60º F to 80º F.

ii. Random variations in temperature from about 40 F to 85 F will have no significant effect on the battery charging.

iii. At low temperature, increase the float voltage 1 percent per 8 ºF below the lower limit of the range in i.

iv. At high temperature, decrease the float voltage 1 percent per 8 ºF above the higher limit of the range in i.

5. Verify that the load is operating.

a. Record the amount of actual load in KW and Amps.

6. Turn off the ac input power to the battery charger and start the timing.

a. Read and record the battery string voltage

i. String voltage should not be less than 1.10 volts per cell multiplied by the number of cells in the string.

b. Read and record individual battery voltages.

i. Battery voltage should not be less than 1.10 volts per cell.

c. Note: Where individual battery voltage is not monitored by a battery monitoring system and the batteries are inaccessible or the number of individual batteries exceeds 20, measure and record only the string voltage.

d. Measure the temperature (spot check) of each battery and its associated cables and connections

i. Terminate the test if the temperature of any battery, cable or connection becomes excessively higher than the average.

e. Read and record one pilot battery cell temperature.

7. Record data in accordance with step 6) a) through 6) d) periodically during the service test runtime on test data sheets provided in Section J Attachment J.15.

a. The last set of readings should be taken just before terminating the test at fifteen minutes.

i. The test may slightly exceed 15 minutes as necessary to complete the last set of measurements.

8. At approximately the end of the required runtime, terminate the test by turning on the battery charger and record the time of the test.

a. Recharge the battery and return the equipment to service.

i. The battery may not be fully recharged until after it has charged for several hours

(1) The battery is fully charged when the charging current is stable as described in 3) d).

b. The service test is satisfactory if the battery string powers actual equipment load for fifteen minutes without exceeding the limits identified in 6)a) through 6)c).

5.3 BASELINE READINGS AND SERVICE TEST DATA

Upon successful completion of all Baseline and Service Tests, the Contractor must provide copies of the CAI Checklist, baseline battery and service test data to the site Environmental Service Unit (ESU) Personnel (1 ea.) and Battery Program Office (1 ea.).