Battery System Equipment.docx

Battery System Equipment Characteristics

National Air Space (NAS) Battery System Equipment Characteristics

February 24, 2016 Attachment J.2 Part 1 General

1.1 This document provides specification for National Airspace System (NAS) lead calcium, Nickel- Cadmium flooded cell battery (FCB) and valve regulated lead acid (VRLA) battery systems. Battery systems include racks, monitoring equipment, support equipment and accessories. FCB and VRLA battery systems are used in the following applications:

A. Very High Frequency Omnidirectional Ranging (VOR) B. Uninterruptable Power System (UPS) C. Direct Current Back-up System (DC BUS) D. Control Power (CP)

1.2 Battery Systems shall have no less than five (5) years of proven service in the field or shall be tested by the FAA to confirm performance compliance.

1.3 Battery Systems shall be available to the FAA as a whole and at a component level.

1.4 Reference Section J Battery Exhibits/Tables for battery application information.

Part 2 Battery Systems

2.1 Flooded Cell Battery (FCB) Systems

2.1.1 FCB VOR 36VDC Application (2nd Gen)

2.1.1.1 FCB VOR (36VDC) Battery System General Requirements

A. FCBs shall be wet cell, lead calcium stationary type with 2.2 to 2.27 volts/cell float voltage. Maximum specific gravity of the electrolyte shall be 1.215 ± 10 points at 77F.

B. Constant Current Discharge Ratings – Amperes at operating temperature, Fahrenheit (F) and Celsius (C): Each battery model shall have a chart indicating discharge amperes for different Operating Time to End Point Voltages (in minutes or hours) at End Point volts/cell range from 1.75 to 1.90. 1.75V/c and 1.86V/c shall be included.

C. Operating Temperature: Between 660 F and 850 F (190 C and 300 C).

D. FCB in single-cell or multi-cell battery configuration.

E. Batteries shall be equipped with removable safety vents.

F. The batteries shall have a design life of at least 20 years and shall have a commercially competitive warranty provided by the battery manufacturer.

G. Battery terminal parts shall be copper reinforced, with lead coating uniform over copper insert with no possibility of acid contact with the copper. Copper inserted terminal posts shall be suitable for bolted connections, with no copper exposed within the bolt-holes.

H. Plate supports shall be so designed that anticipated positive plate growth will not stress the posts or the enclosing case. In addition, supports shall be so designed as to positively support the plates during shipment, handling and seismic stressing after final battery installation.

I. Positive and negative plates shall be independently supported from enclosing case and shall not rely on battery posts for support.

J. Distance from bottom of battery case to bottom of negative plates shall be adequate to accommodate shed plate material and to prevent negative plate shorting.

K. The jar shall have adequate space between plates and jar front and sides to permit plate growth from intruding into the jar material and deforming the jar.

L. Jar shall be marked on at least two sides for observing electrolyte levels.

M. Post seals design shall be such to prevent acid migration and post corrosion.

N. The following shall be furnished with the purchase of each FCB battery string:

a. Batteries.

b. Tier-to-tier and cell-to-cell connectors.

c. Terminal lugs and terminal plates.

d. Cell numbering set.

e. Flame arrestor vent caps for all cells.

f. Flame retardant and non-flame retardant cover and jar.

g. Continuous linear insulated covers over all cell posts and inter-cell connectors.

2.1.1.2 FCB VOR (36VDC) Configuration

A. Electrical Configuration (Reference Table 1/Exhibit A) B. Mechanical Configuration

a. The battery system footprint shall fit in the available space on site without exceeding NFPA 70 section 110-26 requirements

b. Where rack replacement is not required, battery strings shall be provided to fit on existing racks.

2.1.1.3 FCB VOR (36VDC) Rack and Accessories.

A. FCB Spill Containment System. Provide an electrolyte spill containment system for installation under the FCB racks that does not require floor preparation, treatment, or modification before installation. Spill containment shall be provided with flame retardant self-neutralizing pillows.

B. FCB rack shall be two (2) tier construction in height, with acid resistant painted vertical and horizontal structural members and with front/rear side rails and with cross bracing between each set of vertical supports. Horizontal members on whom batteries are mounted shall be provided with an insulated mat. Construction of the racks shall be suitable for zone 4 seismic.

C. Eyewash and accessories include:

a. The contractor shall provide a battery rack lifting strap and spreader block where required.

b. The contractor shall provide sealed water cartridge type (with expiration stamp) eye wash (15 minute flush) where required by the FAA

c. The contractor shall provide Arc Flash Labels in accordance with FAA and NFPA requirements.

d. Jumpers/straps

2.1.2 FCB UPS 480VDC Applications (ACEPS and TRACONS)

2.1.2.1 FCB UPS (480VDC) General Requirements

A. FCBs shall be wet cell, lead calcium stationary type with 2.2 to 2.27 volts/cell float voltage. Maximum specific gravity of the electrolyte shall be 1.215 ± 10 points at 77F.

B. Constant Power Discharge Ratings – watt/cell at operating temperature, Fahrenheit (F) and Celsius (C): Each battery model shall have a chart indicating discharge amperes for different Operating Time to End Point Voltages (in minutes or hours) at End Point volts/cell range from 1.67 to 1.85. 1.75V/c shall be included.

C. Operating Temperature: Between 660 F and 850 F (190 C and 300 C).

D. FCB in single-cell or multi-cell battery configuration.

E. Batteries shall be equipped with removable safety vents.

F. The batteries shall have a design life of at least 20 years and shall have a commercially competitive warranty available from the battery manufacturer.

G. Battery terminal parts shall be copper reinforced, with lead coating uniform over copper insert with no possibility of acid contact with the copper. Copper inserted terminal posts shall be suitable for bolted connections, with no copper exposed within the bolt-holes.

H. Plate supports shall be so designed that anticipated positive plate growth will not stress the posts or the enclosing case. In addition, supports shall be so designed as to positively support the plates during shipment, handling and seismic stressing after final battery installation.

I. Positive and negative plates shall be independently supported from enclosing case and shall not rely on battery posts for support.

J. Distance from bottom of battery case to bottom of negative plates shall be adequate to accommodate shed plate material and to prevent negative plate shorting.

K. The jar shall have adequate space between plates and jar front and sides to permit plate growth from intruding into the jar material and deforming the jar.

L. Jar shall be marked on at least two sides for observing electrolyte levels.

M. Post seals design shall be such to prevent acid migration and post corrosion.

N. The following shall be furnished with the purchase of each FCB battery string:

a. Batteries

b. Tier-to-tier and cell-to-cell connectors.

c. Terminal lugs and terminal plates.

d. Cell numbering set.

e. Flame arrestor vent caps for all cells.

f. Flame retardant and non-flame retardant cover and jar.

g. Continuous linear insulated covers over all cell posts and inter-cell connectors.

2.1.2.2 FCB UPS (480VDC) Configuration

A. Electrical Configuration (See Table 2/Exhibit B) B. Mechanical Configuration

a. The battery system footprint shall fit in the available space on site without exceeding NFPA 70 section 110-26 requirements.

b. Where rack replacement is not required, battery strings shall be provided to fit on existing racks.

2.1.2.3 FCB UPS (480VDC) Rack and Accessories.

A. FCB Spill Containment System. Provide an electrolyte spill containment system for installation under the FCB racks that does not require floor preparation, treatment, or modification before installation. Spill containment provided with flame retardant self-neutralizing pillows.

B. FCB rack shall be two (2) tier construction in height, with acid resistant painted vertical and horizontal structural members and with front/rear side rails and with cross bracing between each set of vertical supports. Horizontal members on whom batteries are mounted shall be provided with an insulated mat. Construction of the racks shall be suitable for zone 4 seismic.

C. Eyewash and accessories:

a. The contractor shall provide a battery rack lifting strap and spreader block where required.

b. The contractor shall provide sealed water cartridge type (with expiration stamp) eye wash (15 minute flush) where required by the FAA

c. The contractor shall provide Arc Flash Labels in accordance with FAA and NFPA requirements when directed by the FAA

d. Jumpers/straps

2.1.3 FCB DC BUS (24&48VDC) Applications (Legacy)

2.1.3.1 FCB DC BUS (28 and 48VDC) General Requirements

A. FCBs shall be wet cell, lead calcium stationary type with 2.2 to 2.27 volts/cell float voltage. Maximum specific gravity of the electrolyte shall be 1.215 ± 10 points at 77F.

B. Constant Current Discharge Ratings – Amperes at operating temperature, Fahrenheit (F) and Celsius (C): Each battery model shall have a chart indicating discharge amperes for different Operating Time to End Point Voltages (in minutes or hours) at End Point volts/cell range from 1.75 to 1.90. 1.75V/c shall be included.

C. Operating Temperature: Between 660 F and 850 F (190 C and 300 C).

D. FCB in single-cell or multi-cell battery configuration.

E. Batteries shall be equipped with removable safety vents.

F. The batteries shall have a design life of at least 20 years and shall have a commercially competitive warranty provided by the battery manufacturer.

G. Battery terminal parts shall be copper reinforced, with lead coating uniform over copper insert with no possibility of acid contact with the copper. Copper inserted terminal posts shall be suitable for bolted connections, with no copper exposed within the bolt-holes.

H. Plate supports shall be so designed that anticipated positive plate growth will not stress the posts or the enclosing case. In addition, supports shall be so designed as to positively support the plates during shipment, handling and seismic stressing after final battery installation.

I. Positive and negative plates shall be independently supported from enclosing case and shall not rely on battery posts for support.

J. Distance from bottom of battery case to bottom of negative plates shall be adequate to accommodate shed plate material and to prevent negative plate shorting.

K. The jar shall have adequate space between plates and jar front and sides to permit plate growth from intruding into the jar material and deforming the jar.

L. Jar shall be marked on at least two sides for observing electrolyte levels.

M. Post seals design shall be such to prevent acid migration and post corrosion.

N. The following shall be furnished with the purchase of each FCB battery string:

a. Batteries.

b. Tier-to-tier and cell-to-cell connectors.

c. Terminal lugs and terminal plates.

d. Cell numbering set.

e. Flame arrestor vent caps for all cells.

f. Flame retardant and non-flame retardant cover and jar.

g. Provide continuous linear insulated covers over all cell posts and inter-cell connectors.

2.1.3.2 FCB DC BUS (24 and 48VDC) Configurations

A. Electrical Configuration (Reference Table 3/Exhibit C) B. Mechanical Configuration

a. The battery system footprint shall fit in the available space on site without exceeding NFPA 70 section 110-26 requirements.

b. Where rack replacement is not required, battery strings shall be provided to fit on existing racks.

2.1.3.3 FCB DC BUS (24 and 48VDC) Rack, and Accessories.

A. FCB Spill Containment System. Provide an electrolyte spill containment system for installation under the FCB racks that does not require floor preparation, treatment, or modification before installation. Spill containment provided with flame retardant self-neutralizing pillows.

B. FCB rack shall be two (2) tier construction in height, with acid resistant painted vertical and horizontal structural members and with front/rear side rails and with cross bracing between each set of vertical supports. Horizontal members on whom batteries are mounted shall be provided with an insulated mat. Construction of the racks shall be suitable for zone 4 seismic.

A. Eyewash and accessories:

a. The contractor shall provide a battery rack lifting strap and spreader block where required.

b. The contractor shall provide sealed water cartridge type (with expiration stamp) eye wash (15 minute flush) where required by the FAA

c. The contractor shall provide Arc Flash Labels in accordance with FAA and NFPA requirements when directed by the FAA

d. Jumpers/straps

2.1.4 FCB CP (120VDC) Applications (CRPDS/DRPDS)

2.1.4.1 FCB CP (120VDC) General Requirements

A. FCBs shall be Nickel- Cadmium stationary type with 1.2 volts/cell float voltage.

B. Constant Current Discharge Ratings – Amperes at operating temperature, Fahrenheit (F) and Celsius (C): Each battery model shall have a chart indicating discharge amperes for different Operating Time to End Point Voltages (in minutes or hours) at End Point volts/cell.

C. Operating Temperature: Between 660 F and 850 F (190 C and 300 C).

D. FCB in single cell or multi-cell battery configuration.

E. Batteries shall be equipped with safety vents.

F. The batteries shall have a design life of at least 20 years and shall have a commercially competitive warranty available from the battery manufacturer.

G. Jar shall be marked for observing electrolyte levels.

H. Flame retardant or non-flame retardant cover and jar shall be provided based on FAA requirements.

I. The following shall be furnished with the purchase of each FCB battery string:

a. Batteries

b. Tier-to-tier and cell-to-cell connectors.

c. Terminal lugs and terminal plates.

d. Cell numbering set.

e. Flame arrestor vent caps for all cells.

f. Continuous linear insulated covers over all cell posts and inter-cell connectors.

2.1.4.2 FCB CP (120VDC) Battery Configuration

A. Electrical (Reference Table 4/Exhibit D) B. Mechanical

a. The battery system footprint shall fit in the available space on site without exceeding NFPA 70 section 110-26 requirements.

b. Where existing rack replacement is not required, the contractor shall provide batteries to fit on existing rack.

2.1.4.3 FCB CP (120VDC) Rack and Accessories.

A. FCB Spill Containment System. Provide an electrolyte spill containment system for installation under the FCB racks that does not require floor preparation, treatment, or modification before installation. Spill containment provided with flame retardant self-neutralizing pillows.

B. FCB rack shall be two (2) tier construction in height, with acid resistant painted vertical and horizontal structural members and with front/rear side rails and with cross bracing between each set of vertical supports. Horizontal members on whom batteries are mounted shall be provided with an insulated mat. Construction of the racks shall be suitable for zone 4 seismic at locations required by FAA.

C. Eyewash and Accessories:

a. The contractor shall provide sealed water cartridge type (with expiration stamp) eye wash (15 minute flush) where required by the FAA

b. The contractor shall provide Arc Flash Labels in accordance with FAA and NFPA requirements when directed by the FAA

c. Straps/jumpers

2.2 Valve Regulated Lead Acid (VRLA) Battery Systems

2.2.1 VRLA VOR (36 and 48VDC) Applications (2nd and 3rd Gen)

2.2.1.1 VRLA VOR (36 and 48VDC) General Requirements:

A. Constant Current Discharge Ratings – Amperes at (operating temperature, float and charge): Each battery model shall have a chart indicating discharge amperes for different Operating Times to End Point Voltages (in minutes or hours) at End Point volts/cell range from 1.75 to 1.90. 1.75V/c and 1.86V/c shall be included.

B. Battery shall be provided with commercially competitive manufacture’s battery warranty.

C. Battery shall have a twenty year design life D. Battery shall have front facing terminals E. Battery racks shall be provided with seismic ratings and shaker test reports at locations required by the FAA.

F. Battery shall be provided with case and cover that are flame retardant compliant with UL 1778 at locations required by the FAA.

G. Operating Temperature: Between 660 F and 770 F (190 C and 250 C).

H. The following shall be furnished with the VRLA battery:

a. Tier-to-tier and cell-to-cell connectors.

b. Terminal lugs and terminal plates.

c. Battery or cell numbering.

d. Electrical safety shields covering battery terminals and energized parts

2.2.1.2 VRLA VOR (36 and 48VDC) Battery Configurations

A. Electrical (Reference Table 5/Exhibit E)

a. The battery system footprint shall fit in the available space on site without exceeding NFPA 70 section 110-26 requirements.

2.2.1.3 VRLA VOR (36 and 48VDC) Automated Battery Monitor (ABM) and Battery Accessories A. Battery systems shall include an ABM where directed by the FAA. The ABM shall provide voltage, resistance, current and temperature monitoring. BMS shall monitor and record discharges. BMS shall provide alarm contacts for remote reporting. The ABM shall have network connectivity to support remote report analysis.

B. Eye Wash (1 gallon flush) shall be mounted container type with expiration stamp.

C. The contractor shall provide Arc Flash Labels in accordance with FAA and NFPA requirements when required by the FAA

2.2.2 VRLA UPS (360, 384, 432 and 480VDC) High Rate Front Facing Applications

2.2.2.1 VRLA UPS (360 to 480VDC) General Requirements:

A. Constant Power Discharge Ratings –Watts per Cell at (operating temperature, float and charge): Each battery model shall have a chart indicating watts/cell for different Operating Times to End Point Voltages (in minutes) at End Point volts/cell range from 1.67 to 1.85. 1.75V/c shall be included.

B. Batteries shall have a front facing terminal design C. Batteries shall have 10 year design life.

D. Battery racks shall be front facing.

E. Battery racks shall be seismically rated with shaker test report at locations where required by the FAA.

F. Battery shall be provided with commercially competitive manufacture’s battery warranty G. Battery case and cover shall be flame retardant compliant with UL 1778 when directed by the FAA.

H. Battery shall be able to operating between 660 F and 770 F (190 C and 250 C).

I. The following shall be furnished with the VRLA battery:

a. Tier-to-tier and cell-to-cell connectors.

b. Terminal lugs and terminal plates.

c. Battery or cell numbering.

d. Electrical safety shields covering battery terminals and energized parts

2.2.2.2 VRLA UPS (360 to 480VDC) Configuration

A. Electrical (Reference Table 6/Exhibit F) B. Mechanical

a. The battery system footprint shall fit in the available space on site without exceeding NFPA 70 section 110-26 requirements

b. Where rack replacement is not required, battery strings shall fit on existing racks

2.2.2.3 VRLA UPS (360 to 480VDC) Automated Battery Monitor and Battery Accessories A. Battery systems shall include an ABM where directed by the FAA. The ABM shall provide voltage, resistance, current and temperature monitoring. The ABM shall monitor and record discharges. ABM shall provide alarm contacts for remote reporting. The ABM shall have network connectivity to support remote report analysis. The ABM shall have a maintenance data terminal that supports all ABM software requirements and allows viewing data.

B. Eye Wash (1 gallon flush) shall be mounted container type with expiration stamp.

C. The contractor shall provide Arc Flash Labels in accordance with FAA and NFPA requirements when required by the FAA.

2.2.2a VRLA UPS (360 to 480VDC) High Rate Top Terminal Application (pop up requirements)

2.2.2a.1 VRLA UPS (360 to 480 VDC) General Requirements:

A. VRLA with capacity range from 100 watts/Cell to 400 watts/cell, at 15-minutes and with end voltage of 1.67 volts per cell, with 10-year design life.

B. Battery String configuration is 30 (360 volt) and 40 (480 volt) batteries per string C. Batteries shall have top terminal design D. Battery shall be provided with commercially competitive manufacture’s battery warranty E. Battery case and cover shall be flame retardant compliant with UL 1778 when directed by the FAA.

F. Battery shall be able to operating between 660 F and 770 F (190 C and 250 C).

G. The following shall be furnished with the VRLA battery:

a. Tier-to-tier and cell-to-cell connectors.

b. Terminal lugs and terminal plates.

c. Battery or cell numbering.

d. Electrical safety shields covering battery terminals and energized parts

2.2.2a.2 VRLA UPS (360 to 480VDC) Configuration A. Electrical (Reference Table 6/Exhibit F) B. Mechanical

a. Battery strings shall fit on existing racks

2.2.2a.3 VRLA UPS (360 to 480VDC) Accessories A. Eye Wash (1 gallon flush) shall be mounted container type with expiration stamp.

2.2.3 VRLA DC BUS (24&48 VDC) Long Duration Battery Applications

2.2.3.1 VRLA DC BUS (24 & 48) General Requirements:

A. Constant Current Discharge Ratings – Amperes at (operating temperature, float and charge): Each battery model shall have a chart indicating discharge amperes for different Operating Times to End Point Voltages (in minutes and hours) at End Point volts/cell range from 1.75 to 1.90. 1.75V/c shall be included.

B. Batteries shall have front facing terminal.

C. Battery racks shall be front facing.

D. Battery racks shall be seismically rated with shaker test reports at location required by the FAA.

E. The battery shall have a 20 year design life and a commercially competitive manufacture’s battery warranty.

F. Case and Cover: Provide non-flame retardant batteries. Flame retardant case and cover compliant with UL 1778 where required by FAA.

G. Operating Temperature: Between 660 F and 770 F (190 C and 250 C).

H. The following shall be furnished with the VRLA battery:

a. Tier to tier and cell to cell connectors

b. Terminal lugs and terminal plates

c. Battery cell numbering

d. Electrical safety shields covering battery terminals and energized parts

2.2.3.2 VRLA DC BUS (24 and 48VDC) Configuration:

A. Electrical: (reference Table 7/Exhibit G) B. Mechanical: Battery string footprint shall be no larger than

a. 500 to 625 Amp-Hour Range: Length 26-inches; Height 26-inches; and depth: 30-inches.

b. 1200 to 1600 Amp-Hour Range: Length 88-inches; Height 38-inches; and depth: 30-inches.

2.2.3.3 VRLA DC BUS (24 and 48VDC ABM and Battery Accessories A. Battery systems shall include an ABM where directed by the FAA. The ABM shall provide voltage, resistance, current and temperature monitoring. The ABM shall monitor and record discharges. The ABM shall provide alarm contacts for remote reporting. The ABM shall have network connectivity to support remote report analysis. The ABM shall have a maintenance data terminal that supports all ABM software requirements and allows viewing data.

B. Eye Wash (1 gallon flush) shall be mounted container type with expiration stamp.

C. The contractor shall provide Arc Flash Labels in accordance with FAA and NFPA requirements when required by the FAA

2.2.4 VRLA CP (48VDC) Long Duration Battery Applications (ACEPS)

2.2.4.1 VRLA CP (48VDC) General Requirements:

A. Constant Power Discharge Ratings – Amps at (operating temperature, float and charge): Each battery model shall have a chart indicating watts/cell for different Operating Times to End Point Voltages (in minutes) at End Point volts/cell range from 1.67 to 1.90.

B. Constant Current Discharge Ratings – Amperes at (operating temperature, float and charge): Each battery model shall have a chart indicating discharge amperes for different Operating Times to End Point Voltages (in minutes or hours) at End Point volts/cell range from 1.67 to 1.90. 1.67V/c shall be included.

C. Batteries shall have front facing terminal D. Battery racks shall be front facing.

E. Battery racks shall be seismically rated with shaker test reports at locations required by the FAA.

F. The battery shall have a 20 year design life and a commercially competitive manufacture’s battery warranty.

G. Case and Cover: Provide non-flame retardant batteries. Flame retardant case and cover compliant with UL 1778 where required by FAA.

H. Operating Temperature: Between 660 F and 770 F (190 C and 250 C).

I. The following shall be furnished with the VRLA battery:

a. Tier to tier and cell to cell connectors

b. Terminal lugs and terminal plates

c. Battery cell numbering

d. Electrical safety shields covering battery terminals and energized parts

2.2.4.2 VRLA CP (48VDC) Configuration:

A. Electrical: (reference Table 8/Exhibit H) B. Mechanical

a. Battery rack footprint shall fit in available space on site without exceeding NFPA 70 section 110-26 requirements

b. Where rack replacement is not required, battery shall fit in existing racks

2.2.4.3 VRLA CP (48VDC) ABM and Battery Accessories

A. Battery systems shall include an ABM where directed by the FAA. The ABM shall provide voltage, resistance, current and temperature monitoring. ABM shall monitor and record discharges. BMS shall provide alarm contacts for remote reporting. The ABM shall have network connectivity to support remote report analysis. The ABM shall have a maintenance data terminal that supports all ABM software requirements and allows viewing data.

B. Eye Wash (1 gallon flush) shall be mounted container type with expiration stamp.

C. The contractor shall provide Arc Flash Labels in accordance with FAA and NFPA requirements when required by the FAA.

2.3 Support Equipment Candidate List (SECL)

2.3.1 The contractor shall provide battery system support equipment (reference Table 9) where required by the FAA.

Attachment J.2