CEMI300-12.pdf

DEPARTMENT OF THE AIR FORCE AFCEMI 300-12

Headquarters United States Air Force 11 Jan 09 Washington DC 20330-1680

Scheduled Periodic Inspection Work cards

For the Voice Network Power Subsystem

OFFICIAL

WILLIAM L. SHELTON, Lt Gen, USAF Chief of War fighting Integration and Chief Information Officer

OPR: HQ AFCA/ESMI

Headquarters United States Air Force 11 Jan 09

TABLE OF CONTENTS

TITLE PAGE NUMBER

Table of Contents…………………………………………………………………………..1

Introduction………………………………………………………………………………...2

I. Weekly Inspection

Inspection of batteries and rectifiers……………………………………………...3 A. Inspection of Batteries, all types B. Inspection of Rectifiers

II. Monthly Inspection

Battery/generator load test/power switching…………………….………………..4

Inspection of batteries and rectifiers A. Inspection of wet cell batteries………………………………………………… B. Inspection of VRLA (gel cell) batteries… C. Inspection of other battery types as applicable……………………………………5 D. Inspection of Rectifiers……………………………………………………………6

III. Quarterly Inspection

Inspection of batteries and rectifiers A. Inspection of wet cell batteries…………………………………………………...7 B. Inspection of VRLA (gel cell) batteries….………….………………………… C. Inspection of other battery types as applicable……………………………………7 D. Inspection of Rectifiers……………………………………………………………7

IV. Annual Inspection

Primary Power System Checks….…………………………… Auxiliary Power System Checks (Generator)…………………………………….9 General subsystem components………………………………………………… 10 Batteries and Rectifiers A. Inspection of wet cell batteries………………………………………………….11 B. Inspection of VRLA (gel cell) batteries…………………………………………12 C. Inspection of other battery types as applicable………………………………….13 D. Inspection of Rectifiers………………………………………………………….13

V. Appendix A

DISA Checklist

General Introduction

1. These work cards contain requirements for accomplishing system checks on the Voice Network Power Subsystem. These requirements are primarily technical in nature and the conditions listed are intended to direct attention to problem areas. These requirements are developed primarily as a standard to evaluate system performance. The interval between the accomplishment of a requirement is intended to be the longest period of time that an item or component can safely operate without an inspection or observation. These intervals are the maximum and should never be exceeded. Local conditions, (type of mission, special utilization, geographical location, etc.) may dictate more frequent inspections, therefore, commands, local commanders, and their maintenance officers have the prerogative to increase the frequency or scope of any requirement, and are expected to exercise this prerogative. This Air Force Communications-Electronics Maintenance Instruction (AFCEMI) was issued as a supplement to DISA Circular 350-195-2, MIL-HDBK-411B, and

DISA POWER, ENVIRONMENTAL, AND GROUNDING, BONDING AND

SHIELDING PERFORMANCE EVALUATION CHECKLIST dated May 2005. System specific maintenance guides for Commercial off the Shelf equipment and applicable power system TOs also apply. References are given were possible and listed in Appendix A. In the event the preventive maintenance procedures contained herein are incorporated into the technical order system, this AFCEMI will be rescinded.

3. This system check will be accomplished by Air Force activities responsible for maintenance of this equipment. Standard scheduling and documentation procedures applicable to –6 technical order inspections will be utilized for implementing this AFCEMI.

4. Maintenance supervisors will ensure that the preventive maintenance procedures contained herein are accomplished at the specified intervals. The appropriate technical manual should be consulted to obtain detailed troubleshooting and maintenance instructions as they are beyond the scope of this publication.

5. Maintenance supervisors will ensure all data is recorded and maintained electronically or on hard copy for later use in system trend analysis, troubleshooting, upgrades or other uses as required.

6. These procedures are designed to establish Preventive Maintenance Inspections (PMIs), which verify system performance, and form the basis for connection to the DISN backbone as controlled by DISA.

7. Recommended changes, additions, or deletions to this publication will be submitted through command channels to the OPR for approval/disapproval.

WARNING

Many of these procedures are above the ability of local work centers to accomplish and must be completed by a certified electrician. Coordinate with Base CE or contracting to have the tests completed and maintain certified result documents. Do not attempt to perform these tests if it is out of the scope of the work center.

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SECTION I

WEEKLY INSPECTION

Batteries contain LETHAL amperage, use care when performing any maintenance or checks. Do not short connections or busses to each other.

NOTE

The following procedure can differ by system design and component type. Refer to your systems manufacturer maintenance documents or applicable TOs as required.

Ensure eye-wash stations are present and functioning and all proper safety gear is worn when working with wet cell battery electrolytes.

1. Inspection of Batteries and Rectifiers:

A. Inspection of wet cell and VRLA batteries. The following is the minimum requirement for inspection of batteries when there is no overriding O&M guidance. Inspections should be made under normal conditions. All readings should be made under normal float conditions (not running on generator or battery power when checks are made, batteries fully charged). Readings should be taken in accordance with the manufacture's instructions. Records should be saved for future trend analysis and monitoring of overall health throughout lifecycle.

a. Measure the ambient temperature of the battery room and verify that it is between 21°C (70°F) and 27°C (80°F). If batteries are stored in COMMUNICATIONS ROOM, temperature within 68-72 degrees F (20-22 degrees C)

- Ref: MIL HDBK-411B, Vol I, Table IX

b. Check the float voltage measured at the battery string terminal.

c. Check charger output voltage and current output and record.

d. Document readings.

- Ref. TM5-684/NAVFAC MO-200/AFJMAN 32-1082, para. 14-18

B. Inspection of Rectifiers. The following is the minimum requirement for inspection of rectifiers when there is no overriding O&M guidance.

Inspections should be made under normal conditions. All readings should be made under normal float conditions (not running on generator or battery power when checks are made, batteries fully charged). Readings should be taken in accordance with the manufacture's instructions. Records should be saved for future trend analysis and monitoring of overall health throughout lifecycle.

a. Check and record panel readings as appropriate.

SECTION II

MONTHLY INSPECTION

1. Generator load test/power switching test.

- Ref: DISAC 350-195-2, Para 7.2.1; TM5-692, Para 19.2

- Ref: DISAC 350-195-2, Para 7.2.2; TM5-693, Para 4.4

The following procedure can vary by system design and component type differences. Refer to your systems manufacturer maintenance documents or applicable TOs as required.

Coordinate with Facility Chief, Civil Engineering and unit/base leadership as applicable prior to performing steps that may cause major system outages. It is highly recommended that these procedures be accomplished at times of low system volume to minimize issues if outage occurs. A master test schedule must be developed, documented and disseminated as required on a yearly basis (Ref: DISAC 350-195-2, Para 8., TM5-689, para 9.8 and

9.9).Exemptions to this test must be granted per DISAC 350-195-2, Para 9 or other competent higher authority with waiver letter authority as deemed necessary by AFCA/EC

(lead command).

Perform all weekly checks in conjunction with Monthly.

a. Remove commercial power. Allow Voice Network System to automatically switch to back-up generator. Manually switch to back-up if your facility is not setup to automatically switch.

- Ref: MIL-HDBK-411B, Vol I, Para 4.8.1

b. Ensure applicable Power Subsystem Alarms sound/light/otherwise flag to alert maintenance personnel of subsystem issue.

1. Allow Voice Network System to run on generator power for at least one hour.

c. Document Generator Load test on Voice Network System Master Station Log

(MSL). Records should be saved for future trend analysis and monitoring of overall health throughout lifecycle.

- Ref DISAC 350-195-2, Para 7.2; TM5-689, Para 9-3; TM5- 692, Para 2.2, Chap 19-23

d. (Deleted)

e. (Deleted)

f. (Deleted)

g. Return Voice Network System to commercial power.

h. (Deleted)

2. Inspection batteries and rectifiers:

A. Inspection of wet cell batteries. The following is the minimum requirement for inspection of batteries when there is no overriding O&M guidance. Inspections should be made under normal conditions. All readings should be made under normal float conditions (not running on generator or battery power when checks are made, batteries fully charged). Specific gravity readings are not meaningful during charge or following the addition of water. Readings should be taken in accordance with the manufacture's instructions and recorded. Records should be saved for future trend analysis and monitoring of overall health throughout lifecycle.

a. Check the float voltage measured at the battery terminal.

b. Check general appearance and cleanliness of the battery, the battery rack, and battery area.

c. (deleted)

d. Check electrolyte levels.

e. Check for cracks in cells or leakage of electrolyte.

f. Check for evidence of corrosion at terminals, connectors, or racks.

g. Check the ambient temperature and condition of ventilation equipment.

Compare with weekly PMI record.

h. Check the pilot cell voltage (as determined by manufacture or installation documents), specific gravity of flooded lead-acid pilot cells.

B. Inspection of VRLA batteries. The following is the minimum requirement for should be made under normal conditions. All readings should be made under normal float conditions (not running on generator or battery power when checks are made, batteries fully charged). Readings should be taken in accordance with the manufacture's instructions. Records should be saved for future trend analysis and monitoring of overall health throughout lifecycle.

a. Observe general appearance and cleanliness of the battery, the battery rack, and battery area.

b. Check the battery charger output current and voltage.

c. Check for evidence of heating and terminal damage.

d. Check for cracks or holes in cells or leakage of fluid.

e. Check overall float voltage measured at the battery terminals. For 24 cell string, float voltage should be 54 V nominal (between 53.52V and 54.45 V). For 23 cell string, voltage should be 52V nominal (between 51.29 V and 52.21 V).

f. Check DC float current (per string) with clamp-on ammeter accurate at low (less than 1 amp) currents and record for trend analysis.

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g. Check for evidence of corrosion at terminals, connectors, and racks.

h. (Deleted)

i. Check cells for bulging of covers or cases.

C. Inspection of other battery types. Use applicable maintenance manuals to accomplish required monthly checks on battery systems not otherwise noted in this document and record results. Records should be saved for future trend analysis and monitoring of overall health throughout lifecycle.

D. Inspection of Rectifiers. The following is the minimum requirement for inspection of rectifiers when there is no overriding O&M guidance. Inspections should be made under normal conditions. All should be made under normal float conditions. Readings should be taken in accordance with the manufacture's instructions. Records should be saved for future trend analysis and monitoring of overall health throughout lifecycle.

a. Observe general appearance and cleanliness of rectifiers, the rectifier rack, and rectifier area.

b. Check and record panel readings as appropriate.

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SECTION III

QUARTERLY INSPECTION

Perform all Weekly and Monthly checks in conjunction with quarterly checks.

1. Inspection of wet cell batteries. The following is the minimum requirement for should be made under normal conditions and performed on a regularly scheduled basis. All readings should be made under normal float conditions (not running on generator or battery power when checks are made, batteries fully charged).

Specific gravity readings are not meaningful during charge or following the addition of water. Readings should be taken in accordance with the manufacture's instructions and recorded. Records should be saved for future trend analysis and monitoring of overall health throughout lifecycle.

a. Check all flooded lead-acid cell voltages and specific gravity.

b. Check the total battery string voltage.

c. Check 10 percent of the inter-cell connection resistances chosen at random.

d. Clean and provide corrosion protection of cells, terminals, racks, and add distilled water, as necessary to adjust electrolyte levels.

e. Provide an equalizing charge if cells are unbalanced.

f. Analyze records for trend analysis and report any issues.

2. Inspection of VRLA batteries. The following is the minimum requirement for should be made under normal conditions and performed on a regularly scheduled basis. All readings should be made under normal float conditions (not running on generator or battery power when checks are made, batteries fully charged).

Readings should be taken in accordance with the manufacture's instructions.

Records should be saved for future trend analysis and monitoring of overall health throughout lifecycle.

a. Check the negative terminal temperature of each cell/unit of batteries in the bank.

b. Check 25 percent of the inter-cell connection resistances chosen at random.

c. Check the internal impendence/conductance of all battery cells.

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d. Check voltage of each cell/unit (“unit” applies when 2, 4, or 6 cells are housed in same monoblock but are independent cells) and record.

3. Inspection of other battery types. Use applicable maintenance manuals to accomplish required monthly checks on battery systems not otherwise noted in this document and record results. Records should be saved for future trend

SECTION IV

ANNUAL INSPECTION

The following procedure can vary by system design and component type differences. Refer to your systems manufacturer maintenance documents or applicable TOs as required.

Coordinate with Facility Chief, Civil Engineering and unit/base leadership as applicable prior to performing some steps that may cause major system outages. It is highly recommended that some of these procedures be accomplished at times of low system volume to minimize issues if outage occurs. A master test schedule must be developed, documented and disseminated as required on a yearly basis. Exemptions to this test must be granted per

DISAC 350-195-2, Para 9.

Tests involving Voice Network to run off Generator and batteries should be completed in conjunction with planned Monthly Generator load test/power switching test.

Complete all Weekly, Monthly and Quarterly checks in conjunction with Yearly checks.

Many of these procedures are above the ability of local work centers to accomplish and must be completed by a certified electrician. Coordinate with Base CE or contracting to have the tests completed and maintain certified result documents. Do not attempt to perform these tests if it is out of the scope of the work center.

1. Primary Power System (as measured at power subsystem main distribution box)

a. Using appropriate calibrated test equipment, perform and record the following measurements at the main distribution panel and record. Records should be saved for future trend analysis and monitoring of overall health throughout lifecycle:

Voltage:

A∅ to Neutral ________ VAC A∅ to B∅ ________ VAC B∅ to Neutral ________ VAC A∅ to C∅ ________ VAC C∅ to Neutral ________ VAC B∅ to C∅ ________ VAC Ground to Neutral ________ VAC Current:

A∅ ________ AAC Neutral ________ AAC B∅ ________ AAC Ground ________ AAC C∅ ________ AAC Frequency: ________ Hz Total Harmonic Distortion

Washington DC 20330-1680 Voltage: Current:

A∅ to Neutral ________ % A∅ ________ % B∅ to Neutral ________ % B∅ ________ % C∅ to Neutral ________ % C∅ ________ %

b. Ensure the following conditions are met:

a. All phase to neutral and phase to voltage measurements are within +/- 2%.

- Ref: MIL-HDBK-411B, Vol I, Section 4.3

b. All phase current measurements are within +/- 10%.

- Ref: MIL-HDBK-411B, Vol I, Section 4.3

c. The ground conductor is free of current.

- Ref: MIL-STD-188-124B, Para 5.1.1.2.5.1

d. All readings recorded in step 1 vary less than +/- 3% from external commercial power

- Ref: AF-TO-33-K-100-1-1, TM 5-685/NAVFAC MO-912

e. Total voltage harmonic distortion of any three phases less than 5%.

- REF: IEEE 519; TM5-684/NAVFAC MO-200/AFJMAN 32-1082

Para 16-12

f. Total current harmonic distortion of any three phases is less than 20%.

- REF: IEEE 519; TM5-684/NAVFAC MO-200/AFJMAN 32-1082

Para 16-12

g. Neutral to ground voltage is less than 2VAC

- REF: NEC 250-51

h. AC voltage is within tolerances:

- 120 VAC nominal: 114 to 126 VAC

- 208 VAC nominal: 197 to 218 VAC

- REF: ANSI C84.1-1989

2. Auxiliary Power System:

a. Allow system to switch automatically to back-up generator power subsystem or if not setup to automatically switch, manually switch to generator power. It is best to do these checks while performing monthly generator load test.

b. Using appropriate calibrated test equipment, perform and record the following measurements at the main distribution panel. Records should be saved for future trend

Voltage:

A∅ to Neutral ________ VAC A∅ to B∅ ________ VAC B∅ to Neutral ________ VAC A∅ to C∅ ________ VAC C∅ to Neutral ________ VAC B∅ to C∅ ________ VAC Ground to Neutral ________ VAC

Current:

A∅ ________ AAC Neutral ________ AAC B∅ ________ AAC Ground ________ AAC

C∅ ________ AAC Frequency: ________ Hz

c. Ensure the generator voltage regulation is within +/- 2% for generators over 20KW and +/- 5% for generators less than 20 KW

- Ref: MIL-HDBK-411B, Vol I, Para 4.9.7 & Table A-1

d. Ensure generator can hold load for at least one hour.

- Ref: DISAC 350-195-2, Para 7.2.1, TM5-692, Para 19.2

e. Shut down generator. Allow Voice Network System to automatically switch to batteries only.

f. Ensure applicable Power Subsystem Alarms sound/light/otherwise flag to alert maintenance personnel of subsystem issue.

g. Allow Voice Network System to run on batteries only for at least one hour

- Ref: TM5-693, Para 4.4

h. Return Voice Network System to commercial power.

i. Document Battery load test on MSL. Records should be saved for future trend analysis and monitoring of overall health throughout lifecycle.

- Ref DISAC 350-195-2, Para 7.2; TM5-689, Para 9-3; TM5-692, Para 2.2, Chap 19-23

3. General Subsystem Components:

a. Ensure auxiliary power systems to include generators, batteries, rectifiers, racks, battery rooms, maintenance benches and all applicable work areas are clean, uncluttered and dust-free.

- Ref: MIL-HDBK-411B, Vol I, Para 4.9.4

b. Locate and review as-built drawings and ensure any modifications to the subsystem are properly documented and all records are up to date, always readily available for inspection.

Check equipment inventories and blueprints (electronic and paper) for accuracy.

- Ref: TM 5-684/NAVFAC MO-200/AFJMAN 32-1082, Para 1.6 and TM 5- 683/NAVFAC MO-116/AFJAN 32-1083, Para 1.5

c. Ensure all panel-boards, load centers, and distribution panels are maintained in good condition.

- Ref: MIL-HDBK-411B, Vol II, Para 5.7.4.3.

d. Ensure all AC outlets are properly installed, marked and have no open or reversed ground/neutral/hot conductors.

- Ref: Nec Article 200-11

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e. Ensure front of all equipment racks are conspicuously labeled with power panel and circuit breaker locations and numbers providing power.

- Ref: National Electrical Safety Code, C2-1997, Rule 107.

f. Ensure panel board listings correspond to equipment racks and receptacles they feed.

- Ref: MIL-HDBK-411B, Vol II, Para 5.7.4.3.

g. Battery Room:

Note Refer to applicable maintenance manuals or TOs for your exact equipment to see what applies to the type of battery your facility houses. Not all items are required for all types of batteries

a. Ensure exhaust fans are working.

- Ref: MIL-HDBK-411B, Vol I, Para 4.11.2.2.4

b. Ensure electrical items are spark proof as applicable.

- Ref: MIL-HDBK-411B, Vol II, Para 5.8.3.1.5

c. Ensure any source of radiant heat is shielded from batteries as applicable.

- Ref: MIL-HDBK-411B, Vol II, Para 5.8.3.1.8

d. Ensure appropriate safety equipment is available for maintenance techs.

Consult OSHA and AFOSH standards as applicable.

- Ref National Electric Safety Code, Section 14; OSHA 1926.441;

MIL-HDBK-411B, Vol I, Para 4.11.2.2.4

e. Ensure no-smoking/sparks/open flame signs are properly displayed.

- Ref National Electric Safety Code, Section 14; OSHA 1926.441;

MIL-HDBK-411B, Vol I, Para 4.11.2.2.4

f. Ensure acid neutralizer is available as applicable.

- Ref: MIL-HDBK-411B, Vol I, Para 4.11.2.2; IEEE 1187-1996

g. Ensure proper drainage to center of floor or batteries have fluid catch basins as applicable.

- Ref: MIL-HDBK-411B, Vol II, Para 5.8.3.1.1; IEEE 1187-1996

h. Ensure flooring is coated with acid resistive coating as applicable.

- Ref: National Electrical Safety Code, Article 144

i. Ensure battery racks are corrosion free.

- Ref: MIL-HDBK-411B, Vol II, Para 5.8.3.1.2

j. Ensure COMMUNICATIONS ROOM (if batteries are being stored in same room) temperature reading remains between 68-72 degrees F (20-22 degrees C). Check Weekly documentation for trend analysis.

- REF: MIL-HDBK-411B, Vol I, Table IX

k. Ensure AC filters have been properly maintained and documented.

- Ref: MIL-HDBK-411B, Vol III, Para 5.5.2.1

l. Ensure there are no hot spots that may be adverse to equipment health.

- Ref: MIL-HDBK-411B, Vol III, Para 5.14.2.1

m. Ensure HVAC vents and intakes are free of obstructions

- Ref: MIL-HDBK-411B, Vol III, Para 5.5.2.1

n. Ensure automated alarms for out-of-tolerance conditions of HVAC system properly work and maintenance personnel properly respond when alarms exist

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- Ref: MIL-HDBK-411B, Vol III, Para 5.6.7

o. Check MSL to ensure any instance of power disturbances have been properly documented throughout the year (blackouts, sag, surges, impulses, distortion, HVAC issues or noises).

- Ref: MIL-HDBK-411B, Vol I, Para 4.4.

C. Batteries and Rectifiers working with wet cell battery electrolytes.

1. Inspection of wet cell batteries. The following is the minimum requirement for inspection of batteries when there is no overriding O&M guidance. Inspections should be made under normal conditions and performed on a regularly scheduled basis. All should be made under normal float conditions (not running on generator or battery power when checks are made, batteries fully charged). Readings should be taken in accordance with the manufacture's instructions. In addition to the quarterly items, record checks of the following data. Records should be saved for future trend analysis and monitoring of overall health throughout lifecycle.

a. Provide a detailed visual inspection of each cell.

b. Check all bolt connections. Re-torque to the manufacturer's specification if required.

c. Check intercell inter-tier, and battery terminal connection resistances.

d. Check integrity of the battery racks.

e. Check float charge is between 49.0 to 53.5 VDC

- Ref: MIL-HDBK-411B, Vol II, Para 5.8.2.3.c

f. Ensure rectifiers are properly charging batteries. Review weekly PMI panel readings for trend analysis.

- Ref: MIL-HDBK-411B, Vol I, Para 4.11.1

g. Check that the terminal temperatures of the battery cells do not exceed the room ambient temperature by more then 8°C (15°F). Measure the terminal temperature of at least 20 percent of the cells in the battery bank.

h. Measure the internal impedance of at least 20 percent of the cells in the battery bank. Compare the measure internal impedances with the recorded battery cell impedance at installation or the manufactures specified internal impedance. All measured impedances must be within 10% of the value of the measured impedances at installation or within the manufacture specification.

i. Check the DC power source AC ripple and wideband noise measured from DC to 20 MHz is less than 300mVp-p or less if required by equipment or battery manufactures manual. Ref: FM 11-487-4/TO 31-10-24 para B-9 or Manufactures Manual.

Note:

Measure charger buses, battery terminals, and load bus with test ground lead connected to the positive/ground site of the DC UPS

2. Inspection of VRLA batteries. The following is the minimum requirement for should be made under normal conditions and performed on a regularly scheduled basis. All should be made under normal float conditions (not running on generator or battery power when checks are made, batteries fully charged). Readings should be taken in accordance with the manufacture's instructions. In addition to the quarterly items, record checks of the following data. Records should be saved for future trend analysis and monitoring of overall health throughout lifecycle.

a. Check intercell inter-tier, and battery terminal connection resistances.

b. Check integrity of the battery racks.

c. Measure AC ripple current and/or voltage imposed on battery, see battery manufacturer data sheet for ripple limits.

d. Ensure rectifiers are properly charging batteries

- Ref: MIL-HDBK-411B, Vol I, Para 4.11.1

e. (Deleted)

f. (Deleted)

g. Check the DC power source AC ripple and wideband noise measured from

DC to 20 MHz is less than 300mVp-p or less if required by equipment or battery manufactures manual. Ref: FM 11-487-4/TO 31-10-24 para B-9 or Manufactures Manual.

Note:

Measure charger buses, battery terminals, and load bus with test ground lead connected to the positive/ground site of the DC UPS

3. Inspection of other battery types. Use applicable maintenance manuals to accomplish required monthly checks on battery systems not otherwise noted in this document and record results. Records should be saved for future trend analysis and monitoring of overall health throughout lifecycle.

4. Inspection of Rectifiers. The following is the minimum requirement for inspection of rectifiers when there is no overriding O&M guidance. Inspections should be made under normal conditions. All should be made under normal float conditions. Readings should be taken in accordance with the manufacture's instructions. Records should be saved for future trend analysis and monitoring of overall health throughout lifecycle.

b. Check and record panel readings as appropriate. Compare with other readings to verify readings are accurate and within manufacturer’s recommended tolerances.

APPENDIX A

DISA POWER, ENVIRONMENTAL, AND

GROUNDING, BONDING AND SHIELDING

PERFORMANCE EVALUATION CHECKLIST

AREAS YES

NO N/A

I. ELECTRICAL POWER

A. Administration

1. For the past 12 months, has the station been free of any instances of power disturbances (blackouts, sag, surges, impulses, distortion, or noises)?

Ref: MIL-HDBK-411B, Vol I, Para 4.4.

2. Have equipment exercise tests been recorded in the Master Station Log?

Ref: DISAC 350-195-2, Para 7.2., TM5-689, para 9-3, TM5- 692, para2.2, chap 19 – 23.

3. Have monthly power exercise tests been conducted using facility Operational load (minimum 1 hour operation) and documentation available?

Ref: DISAC 350-195-2, Para 7.2.1., TM5-692, para 19.2

4. Have quarterly power exercises been conducted using the automatic start function (minimum 1 hour) and documentation available?

Ref: DISAC 350-195-2, Para 7.2.2., TM5-693, para 4.4

5. Has a power exercise schedule been developed and disseminated?

Ref: DISAC 350-195-2, Para 8., TM5-689, para 9.8 and 9.9

6. If the exercise is not performed regularly, has an exemption been granted?

Ref: DISAC 350-195-2, Para 9.

7. Are all major equipment components accurately reflected in the facility/link database?

Ref: DISAC 300-85-1, Chap 1, Para 7, TM5-691, para 2.2, TM5-692 chap 3.

B. Primary Power

1. Using the appropriate calibrated test equipment perform and record the following measurements at the main electrical distribution panel.

Voltage:

A∅ to Neutral ________ VAC A∅ to B∅ ________

VAC

B∅ to Neutral ________ VAC A∅ to C∅ ________

VAC

C∅ to Neutral ________ VAC B∅ to C∅ ________

VAC

Ground to Neutral ________ VAC Current:

A∅ ________ AAC Neutral ________ AAC B∅ ________ AAC Ground ________ AAC C∅ ________ AAC Frequency: ________ Hz Total Harmonic Distortion Voltage: Current:

A∅ to Neutral ________ % A∅ ________ % B∅ to Neutral ________ % B∅ ________ % C∅ to Neutral ________ % C∅ ________ %

2. Are all phase to neutral voltage measurements within +/- 2% of each other?

Ref: MIL-HDBK-411B, Volume I, Section 4.3

3. Are all phase to phase voltage measurements within +/- 2% of each other?

4. Are all the phase current measurements within +/- 10% of each other?

5. Is the ground conductor free of AC current?

Ref: MIL-STD-188-124B, Para 5.1.1.2.5.1

6. The respective current, frequency and voltage measurements of the main electrical power distribution panel meters varies less than +/- 3% from the readings recorded in step B.1 ?

Ref: AF-TO-33-K-100-1-1, TM 5-685/NAVFAC MO-912.

7. The total voltage harmonic distortion of any of the three phases is less than 5 percent?

Ref: IEEE 519 and TM 5-684/NAVFAC MO-200/AFJMAN 32- 1082 para 16-12.

8. The total current harmonic distortion of any of the three phases is less than 20 percent?

Ref: IEEE 519 and TM 5-684/NAVFAC MO-200/AFJMAN 32- 1082 para 16-12.

9. Is the neutral to ground voltage less than 2VAC?

Ref: NEC 250-51

10. Is AC voltage within tolerance?

120 VAC nominal: 114 to 126 VAC 208 VAC nominal: 197 to 218 VAC Ref: ANSI C84.1-1989

C. Auxiliary Power Exercises

1. Using the appropriate calibrated test equipment perform and record the following measurements at the main electrical distribution panel while running on emergency generators.

Voltage:

A∅ to Neutral ________ VAC A∅ to B∅ ________

VAC

B∅ to Neutral ________ VAC A∅ to C∅ ________

VAC

C∅ to Neutral ________ VAC B∅ to C∅ ________

VAC

Ground to Neutral ________ VAC

Current:

A∅ ________ AAC Neutral ________ AAC B∅ ________ AAC Ground ________ AAC C∅ ________ AAC Frequency: ________ Hz

2. Does the site power transfer switch (manual or automatic) work properly?

Ref: MIL-HDBK-411B, Vol I, Para 4.8.1.

3. Are auxiliary power systems dust-free?

Ref: MIL-HDBK-411B, Vol I, Para 4.9.4.

4. Are emergency generator's output:

a. frequency regulation stable and within tolerance?

Ref: MIL-HDBK-411B, Vol II, Para 5.4.4.8.

b. Voltage regulation within +/- 2 percent for generators over 20KW and +/-5 percent for generators less than 20KW?

Ref: MIL-HDBK-411B, Vol I, Para 4.9.7. & Table A-1 Note: ((No Load - Full Load Voltage)/Full Load Voltage)X100

5. Can the generator maintain the station load (minimum 1 hr)?

Ref: DISAC 350-195-2, Para 7.2.1., TM5-692, para 19.2

D. Distribution Wiring

1. Are the as-built drawings of the facility's distribution wiring system readily available and up to date?

Ref: TM 5-684/NAVFAC MO-200/AFJMAN 32-1082, Para 1.6 and TM 5-683/NAVFAC MO-116/AFJAN 32-1083, Para 1.5 Note: This includes a single line power (system) diagram that details the electrical distribution from the input to the facility to the feeder power panels. This document should be readily available to all operation and maintenance personnel.

2. Are all panel-boards, load centers, and distribution panels maintained in good condition?

Ref: MIL-HDBK-411B, Vol II, Para 5.7.4.3.

3. Are all AC outlets properly installed?

Ref: NEC Article 200-11.

Note: No open or reversed ground/neutral/hot conductors

4. Are the front of all equipment racks conspicuously labeled with the power panel and circuit breaker providing power to that rack?

Ref: National Electrical Safety Code, C2-1997, Rule 107.

5. Are all circuits correctly identified in the panel board listing?

Ref: MIL-HDBK-411B, Vol II, Para 5.7.4.3.

E. Batteries/Rectifiers

1. Inspection of wet cell batteries. The following is the minimum requirement for inspection of batteries when there is no overriding O&M guidance. Inspections should be made under normal conditions and performed on a regularly scheduled basis. All should be made under normal float conditions. Specific gravity readings are not meaningful during charge or following the addition of water. Readings should be taken in accordance with the manufacture's instructions.

a. Monthly. Provide recorded checks of the following data:

(1) Check the float voltage measured at the battery terminal.

(2) Observe general appearance and cleanliness of the battery, the battery rack, and battery area.

(3) Check the battery charger output current and voltage.

(4) Check electrolyte levels.

(5) Check for cracks in cells or leakage of electrolyte.

(6) Check for evidence of corrosion at terminals, connectors, or racks.

(7) Check the ambient temperature and condition of ventilation equipment.

(8) Check the pilot cell voltage, specific gravity of flooded lead-acid pilot cells and terminal temperature of valve-regulated cells.

b. Quarterly. In addition to the monthly items, provide recorded checks of the following data:

(1) Check all cells voltages, specific gravity of all flooded lead-acid cells.

(2) Check the total battery terminal voltage.

(3) Check 10 percent of the inter-cell connection resistances chosen at random.

(4) Clean and provide corrosion protection of cells, terminals, racks, and add water, as necessary to adjust electrolyte levels.

(5) Provide an equalizing charge if cells are unbalanced.

E. Batteries/Rectifiers

(6) Analyze records and report any recommendations.

c. Annually. In addition to the quarterly items, provide recorded checks of the following data.

(1) Provide a detailed visual inspection of each cell.

(2) Check all bolt connections. Retorque to the manufacturer's specification if required.

(3) Check intercell inter-tier, and battery terminal connection resistances.

(4) Check integrity of the battery racks.

d. Special inspections. A special inspection should be made whenever a battery experiences an abnormal condition (such as a severe discharge or overcharge) to ensure that the battery has not been damaged. This inspection should include all of the quarterly tests.

Ref: TM 5-684/NAVFAC MO-200/AFJMAN 32-1082, Para 14-

2. Inspection of VRLA batteries. The following is the minimum requirement for inspection of batteries when there is no overriding O&M guidance. Inspections should be made under normal conditions and performed on a regularly scheduled basis. All should be made under normal float conditions. Specific gravity readings are not meaningful during charge or following the addition of water. Readings should be taken in accordance with the manufacture's instructions.

a. Weekly. Provide recorded checks of the following data:

(1) Measure the ambient temperature of the battery room and verify that it is between 21°C (70°F) and 27°C (80°F).

(2) Check the float voltage measured at the battery terminal.

b. Monthly. In addition to the weekly items, provide recorded checks of the following data:

(1) Observe general appearance and cleanliness of the battery, the battery rack, and battery area.

(2) Check the battery charger output current and voltage.

(3) Check for evidence of heating and terminal damage.

(4) Check for cracks or holes in cells or leakage of electrolyte.

(5) Check the AC ripple voltage.

(6) Check the pilot cell voltage and terminal temperature of the pilot cell(s).

c. Quarterly. In addition to the monthly items, provide recorded checks of the following data:

(1) Check the terminal temperature of each cell in the bank.

(2) Check 25 percent of the inter-cell connection resistances chosen at random.

(2) Check the internal impendence of all battery cells.

d. Semiannually. In addition to the quarterly items, provide recorded checks of the following data.

(1) Check the DC float charging voltage of all cells within the battery bank.

(2) Verification of performing a load capacity test.

e. Annually. In addition to the Semiannually items, provide recorded checks of the following data.

(1) Check intercell inter-tier, and battery terminal connection resistances.

(2) Check integrity of the battery racks.

d. Special inspections. A special inspection should be made every whenever a battery experiences an abnormal condition (such as a severe discharge or overcharge) to ensure that the battery has not been damaged. This inspection should include all of the quarterly tests.

Ref: TM 5-684/NAVFAC MO-200/AFJMAN 32-1082, Para 14-

3. Are site personnel proficient in maintaining station power systems (i.e. batteries, rectifiers, etc.)?

Ref: Technical Order/Manual specifications

4. Can the battery bank maintain the station load (1 hr manned/1- 4 hrs partial manned/ 4 hrs unmanned)?

Ref: TM5-693, para 4.4

5. Is the float-charge for the batteries between 49.0 - 53.5 VDC?

Ref: MIL-HDBK-411B, Vol II, Para 5.8.2.3.c.

6. Do the DC rectifiers keep the batteries properly charged?

Ref: MIL-HDBK-411B, Vol I, Para 4.11.1.

7. Is the DC power source AC ripple and wideband noise measured from DC to 20 MHz less than 300mVp-p or less if required by equipment or battery manufactures manual.

Ref: FM 11-487-4/TO 31-10-24 para B-9 or Manufactures Manual.

Note: Measure charger buses, battery terminals, and load bus with test ground lead connected to the positive/ground site of the DC

UPS

7. The terminal temperature of the battery cells check does not exceed the room ambient temperature by more then 8°C (15°F).

Measure the terminal temperature of at least 20 percent of the cells in the battery bank.

9. Measure the internal impedance of at least 20 percent of the cells in the battery bank. Compare the measure internal impedances with the recorded battery cell impedance at installation or the manufactures specified internal impedance.

All measured impedances are within 10% of the value of the measured impedances at installation or within the manufacture specification?

F. Battery Room

1. Is there an exhaust fan installed and in good working order in the battery?

Ref: MIL-HDBK-411B, Vol I, Para 4.11.2.2.4.

2. Are all electrical devices such as fans, heating and cooling units, lights, switches, and convenience outlets spark-proof?

Ref: MIL-HDBK-411B, Vol II, Para 5.8.3.1.5.

3. Are all sources of radiant heat in the room shielded?

Ref: MIL-HDBK-411B, Vol II, Para 5.8.3.1.8.

4. Is the following protective equipment available to personnel who perform battery maintenance work?

a. Goggles and face shields.

b. Acid-resistant gloves.

c. Protective aprons.

d. Portable or stationary water facilities shall be located within 25 feet (7.62 m) of the battery area for rinsing eyes and skin in case of contact with the electrolyte. Sealed water rinse or neutralizing packs may be substituted for the quick drenching or flushing.

Ref: National Electric Safety Code, Section 14 and OSHA 1926.441

5. Are there safety signs inside and outside of the battery room or in the vicinity of a battery area prohibiting smoking, sparks, or flame?

Ref: National Electric Safety Code, Section 14

6. Are battery racks free of corrosion?

Ref: MIL-HDBK-411B, Vol II, Para 5.8.3.1.2.

7. Are the floors of battery areas of an acid-resistive material, or painted with acid-resistive paint, or otherwise protected?

Ref: National Electrical Safety Code, Article 144

8. Is neutralizer available in the battery room? Does each spill barrier contain a sufficient quantity of spill absorption and neutralization mats to cover the area inside the barrier?

Ref: MIL-HDBK-411B, Vol I, Para 4.11.2.2 and: IEEE 1187-

9. Does the battery room floor slope to a central drain or have an electrolyte catch basin or is each battery rack equipped with a liquid-tight barrier resistant to electrolyte?

Ref: MIL-HDBK-411B, Vol II, Para 5.8.3.1.1. and IEEE 1187-

II. ENVIRONMENTAL CONTROL SYSTEMS

1. Is the communications room temperature within 20-22 degrees C (68-72 degrees F)?

Ref: MIL-HDBK-411B, Vol I, TABLE IX

2. Are all areas free of adverse conditions which may inhibit the effectiveness of the filtration system?

Ref: MIL-HDBK-411B, Vol III, Para 5.5.2.1.

3. Are all areas being supplied filtered air?

4. Are new/clean filters replaced when they become unserviceable?

5. Does the visual and audible (ZETTLER) alarm system activate when out-of-tolerance operating conditions occur?

Ref: MIL-HDBK-411B, Vol III, Para 5.6.7.

6. Are personnel able to read, understand, and properly respond to alarms on TRAMCON?

Ref: MIL-HDBK-411B, Vol III, Para 5.6.7.

7. Is the facility free of hot spots that could be caused by poor air circulation?

Ref: MIL-HDBK-411B, Vol III, Para 5.14.2.1.