OPERATION and MAINTENANCE MANUAL

 

 

 

For

 

 

 

MILITARY VEHICLE MAIN BATTERIES

 

 

 

Doc No.: 9602-0749

Issue: 02

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 


 

 

 

 

 

 

 

 

 

 

 

 

 

 

APPLICABILITY LIST

This operation and maintenance manual covers the following batteries:

 

 

Battery Type

 

Battery part No.

 

NSN

 

Notes

 

 

 

 

 

 

 

 

UK6TNMF

9750N7000

Z9BAT/6140-99-219-2903

 

 

 

 

 

HASP-FT

9750N7025

6140-01-485-1472

 

 

 

 

 

NBB 248

9750N7018

6140-12-190-9027

 

 

 

 

 

BB-10N

9750N0250

6140-25-139-6183

 

 

 

 

 

Dutch MoD

9750N7032

6140-17-117-7743

 

 

 

 

 

MAN

9750N7036

 

 

 

 

 

 

12FV120

9750N7010

6140-99-690-6632

 


 

 

 

 CONTACT DETAILS

 COMMERCIAL ENQUIRIES

 

EnerSys BV
Nijverheidsweg 25

3341 LJ Hendrik-Ido-Ambacht

The Netherlands

Tel: +31 78 6810003

Fax: +31 78 6818395

TECHNICAL ENQUIRIES
EnerSys Ltd

Stephenson street

 

Newport
South Wales
NP19  4XJ
United Kingdom

Tel      +44 (0)163 327 7673

 

Fax     +44 (0)163 328 1787

 

 

 


RECORD OF REVISIONS

 

 

 

 

Revision No

 

Nature of Revision

 

Date

 

00

 

First Issue

 

JAN 2005

 

01

 

Addition of Dutch MoD & MAN variants

 

January 2008

 

02

 

Introduction of applicability list and general update of format

 

May 2010

RECORD OF AMENDMENTS

No
Incorpororated by
Date
     
     
     
     

 
No
Incorpororated by
Date
     
     
     
     

LIST OF EFFECTIVE PAGES

 

 


 

 

Any changes are shown by a vertical line along the edge of the changed page. The total number of pages in this document is 11, and it contains: -

 

Any changes are shown by a vertical line along the edge of the changed page.
The total number of pages in this document is 11, and it contains: -

SUBJECT

PAGE NO.

DATE

Title Page

T - 1

27 May 10

Applicability list

APL -1

27 May 10

Contact Details

CD -1

27 May 10

Revisions, Amendments

RR -1

27 May 10

List of Effective Pages

LEP -1

27 May 10

Table of Contents

TC - 1

27 May 10

Introduction, Health & Safety

1

27 May 10

Leading particulars

2

27 May 10

Storage and transportation

3

27 May 10

Commissioning, Maintenance

4

27 May 10

Disposal

5

27 May 10


 


TABLE OF CONTENTS


    Page
  TITLE PAGE T -1
  APPLICABILITY LIST   APL -1
  CONTACT DETAILS     CD - 1
  RECORD OF REVISIONS   RR - 1
  LIST OF EFFECTIVE PAGES  LEP - 1
  TABLE OF CONTENTS  TC - 1
1 
INTRODUCTION  1
2
HEALTH and SAFETY 1
3
LEADING PARTICULARS   2
4
STORAGE and TRANSPORTATION   3
5
COMMISSIONING     4
6
MAINTENANCE      4
7
DISPOSAL 5
   

 

 

 

 

 

1          INTRODUCTION

 

The EnerSys Newport Military Vehicle main batteries are nominal 12V approximately

120Ah valve regulated lead-acid batteries, designed and manufactured to meet the requirements of various NATO specifications.

 

The battery consists of six cells connected in series, inserted into a flame retardant

( UL94 V-2 ) polypropylene case, each cell having a safety vent. The UK6TNMF has

a venting manifold with two nozzles, one of which is supplied with a rubber cap. Case colour is “Stone grey” RAL 7030.

 

The cells incorporate materials of very high purity, giving the battery an unusually low rate of self-discharge.

 

Each battery is fitted with two handles ( type 2 of Stanag 4015), and standard tapered automotive post terminals.

 

They should not be operated in series with batteries of other types or manufacture. Note that they may be operated in parallel with batteries of different manufacture.

 

The battery is shipped from the manufacturer in approved commercial grade cardboard carton packing.

 

2       HEALTH and SAFETY

 

 

 

 

 

 

 

 

 

 

WARNINGS

 

SHORT CIRCUIT CURRENTS WILL EXCEED 2500 AMPS; ALL TOOLS MUST BE INSULATED. CARE MUST BE TAKEN WITH ALL ITEMS OF METAL IN CLOTHING AND JEWELLERY, EG. BUCKLES, ZIPS, RINGS, WATCHES, CHAINS ETC.

 

KEEP SPARKS, FLAMES AND LIGHTED CIGARETTES AWAY FROM BATTERIES.

 

DO NOT CHARGE IN A SEALED CONTAINER. DO NOT INCINERATE.


 

 

CAUTIONS

THE BATTERY IS MAINTENANCE FREE IN THE CONVENTIONAL SENSE.
UNDER NO CIRCUMSTANCES SHOULD ANY ATTEMPT BE MADE TO
INTRODUCE ANY SUBSTANCES, eg., ACID, DISTILLED WATER OR ALKALI, TO
THE BATTERY.
 

LIFT WITH CARE. USE THE HANDLES PROVIDED ( TWO PERSON LIFT ) AND
DO NOT LIFT BY THE TERMINALS.


DO NOT LEAVE IN A DISCHARGED STATE.

DO NOT STACK PACKED BATTERIES MORE THAN TWO HIGH.

NOTE
 

A dedicated lead acid battery room is not required for maintenance.
A normal electrical workshop may be used.
 

A SAFETY DATA SHEET, document reference 9602-0424, is available.

 

 

 

 

3          LEADING PARTICULARS

 

 

UK6TNMF

HASP-FT

NBB 248

BB-10N

Dutch MoD

MAN

12FV120

Design Specification

BAT264

MIL-PRF-

32143(AT)

VG 96 924 Tiel

9

FS 6140-0809

BAT 264 electrical, no venting manifold,

BAT 264 electrical, no venting manifold,

BAT 264 electrical, no venting manifold,

Nominal Voltage (V)

12

12

12

12

12

12

12

Rated Capacity to specification requirement (Ah)

 

110

 

120

 

100

 

100

 

120

 

120

 

120

Specification Test

Discharge Rate (A)

 

5.5

 

6

 

20

 

20

 

6

 

6

 

6

CCA (SAE)       (A)

1225

1225

1050

1225

1225

1225

1225

Reserve Capacity

(Minutes)

 

240

 

240

 

240

 

240

 

240

 

240

 

240

Maximum Mass (kg)

40

40

39

40

40

40

40

Maximum length (mm)

286

286

286

286

286

286

286

Maximum width (mm)

269

267

269

269

269

269

269

Maximum height (mm)

230

230

230

230

230

230

230

Case material

FR

polypropylene

FR

polypropylene

FR

polypropylene

FR

polypropylene

FR

polypropylene

FR

polypropylene

FR

polypropylene

Case colour

Stone grey

RAL 7030

Stone grey

RAL 7030

Stone grey

RAL 7030

Stone grey

RAL 7030

Stone grey

RAL 7030

Stone grey

RAL 7030

Stone grey

RAL 7030


 

4          STORAGE and TRANSPORTATION

 

4.1       Storage

 

Batteries are despatched from the manufacturer in a fully charged condition. The state of charge will decrease with storage.

 

All batteries lose their stored energy when allowed to stand open-circuit, due to parasitic chemical reactions.

 

The rate  of  self-discharge is  non-linear and  decreases with  decreasing state of charge.  It  is  also  strongly  influenced  by  temperature. High  temperatures greatly reduce storage life.

It is recommended that the fully charged battery should be stored in a cool dry place, ideally below 25°C (77°F).

 

The date of last charge at the manufacturer is marked on the battery.

 

The battery may be stored for up to 5 years without degradation of performance provided  that an open circuit voltage (OCV) check is conducted every 12 months. When stored in temperatures in excess of 30°C (86°F), the battery should be OCV checked every 6 months.

 

If the OCV falls below 12.6V the battery should be charged in accordance with para

6.2.

 

The graph below shows the relationship between temperature, storage time and

OCV.

 

 

 

4.2

Transportation

 

 

 

Shipping name - Shipping class -

 

Battery, Wet, Non-spillable

8

 

UN ID -

2800


 

 

The batteries are classified as Non-Spillable and exempt from hazardous goods requirements, in accordance with: -

 

           US Dept of Transportation - 49 CFR Section 173.159 para d.

 

           ICAO/IATA Packing Instruction 806, Special Provision A67.

 

           IMDG Class 8, UN ID 2800 exemption for Non-Spillable batteries.

 

           ADR 2003 and RID 2003 Special Provisions 238, 295 and 598

 

When securely packed and protected against short circuits.

They are air portable up to a pressure altitude of 35,000 ft (10,668m) in an unpressurised aircraft hold.

 

CAUTION        DO NOT STACK PACKED BATTERIES MORE THAN TWO HIGH.

 

5          COMMISSIONING

 

Measure the OCV. If the OCV is equal to or greater than 12.75V (approx 80% state of charge), it can normally be put into service without bench charging. Otherwise charge in accordance with para 6.2.

 

Batteries to be connected in series should be at the same state of charge.

 

6          MAINTENANCE

 

6.1       Inspection and Cleaning

 

Inspect for signs of mechanical damage, leakage or buckling of the case (due to improper charging). Scrap and replace as necessary.

 

Clean with a cloth moistened with water. Do not use detergents or solvents.

 

6.2       Charging

 

Measure the OCV. If is below 12.75V generally the battery should be charged before being re-fitted to vehicle.

 

Bench charging should be conducted with the battery at a temperature between +15°

and +30°C.

 

The preferred method of charging is constant voltage.

 

Multi-stage proprietary chargers may be suitable, but compatibility should first be established.

 

If the battery will not accept current and the OCV was 10V or less, Deep Discharge

Recovery (para 6.2.3) may recover the battery

 

The battery temperature should not be allowed to exceed 45 degrees Celsius.


 

6.2.1    Constant Voltage

 

Charge with a constant voltage of 14.4V per battery series. There is no need to limit the current. The higher the maximum current available is, the faster the charge will be completed.

 

Charge until the current has remained stable for three consecutive hourly readings, or until the current has reduced to 0.75A.

 

6.2.2    Constant Current

 

Constant current charging is not recommended, but if it is the only form of charging available, charge at 8A until the on load voltage rises to 14.4V or 16 hours charging have elapsed, whichever occurs sooner.

 

Monitor the temperature of the battery. It must not exceed 45 degrees Celsius. If necessary, halt the charge and allow the battery to cool.

 

This procedure will bring the battery to about 75% to 80% state-of-charge.

 

6.2.3    Deep Discharge Recovery

 

This procedure is applied to product that has been left in a deeply discharged state

for a long time. Product requiring this procedure will have a very low OCV and will not accept normal charge. A constant current charger capable of applying up to 35V will be necessary.

 

Attempt to charge at 6A. At first the current drawn may be lower.

 

Monitor the temperature of the battery. It must not exceed 45 degrees Celsius. If necessary, halt the charge and allow the battery to cool.

 

If after 2 hours of charge a current of 6A has not been achieved, stop the charge and reject the battery.

 

After a maximum of 4 hours charge return the battery to one of the standard charge regimes.

 

7          DISPOSAL

Regulatory phrases are: - Contains Lead.

Disposal controlled.

Recyclable.

 

Dispose of in a discharged state, and in accordance with local regulations. The product is recyclable by licensed facilities.

 

If the battery is damaged such that internal materials could escape, transport will require a registered hazardous waste carrier.

 

TIPS
       
Battery Maintenance Tips        
by Waseem Ahmad        
         
Poorly maintained and used industrial batteries can not perform to their full potential. Proper maintenance is critical.
Industrial batteries, like all pieces of industrial equipment, require proper maintenance to prolong their service life. Battery life is always extended when proper maintenance regimens are observed. On the other hand, poorly maintained and improperly used industrial batteries cannot perform to their full potential for the duration of the warranty period.

Here are some "do's and don'ts" of battery care for motive power battery users:

• Do maintain the proper electrolyte (acid) level by frequent additions of water. In general, normal city water will suffice, but if the end user has any doubts about purity of the local water supply, contact the battery supplier who will be happy to do a chemical analysis of the water. If in doubt, use distilled water.

• Don't—that is NEVER—add sulfuric acid to the battery. If an acid spillage occurs, contact a qualified battery repair service.

• Do read the instructions provided with the battery on proper recharging of the battery. Automatic, voltage-controlled chargers will take the guesswork out of charging and there are several types available in the marketplace.

• Don't try to save money by buying a charger which is smaller than required. This will result in an undercharged battery with significant reduction in operating life. Your battery vendor has all the information to ensure the battery and charger are precisely matched.

• Do check the charger settings and meters on a regular basis. This can be done by an in-house electrician, but should be performed every quarter by the battery service technician.

  • Don't overcharge the battery. More is not necessarily better when it comes to recharging batteries. The best way to ensure batteries are not being overcharged is to periodically (once a month) check the temperature of the center cell on a battery at the end of regular charge. If the temperature of the electrolyte is more than 36° F above the ambient temperature, call your battery technician— there is a problem.

• Do keep regular records on the maintenance of batteries. For instance, keep a log of every time the battery is watered; temperature checks at the end of charge, etc. These records will be invaluable when it comes to predicting when battery replacement is going to be necessary.

• Don't overdischarge batteries. Most battery manufacturers warranty their batteries for up to 1.500 cycles of charge and discharge provided, among other things, that the battery is never discharged beyond 80%. This normally coincides with an eight hour shift. But trucks fitted with extra equipment such as clamps, high speed lifts, etc. will need a higher capacity battery to ensure the battery is not discharged beyond 80%. Lift truck interrupts are available to detect the correct discharge level and are recommended by battery manufacturers as a means of ensuring batteries are not overdischarged.

• Do replace a battery with capacity that has fallen below 80% of its rated capacity. Continuing to operate the battery can be false economy since costly damage can be done to a truck's electric motor and electronics.

• Don't place metal objects on a battery. Such objects can cause a short circuit between adjacent cells and result in possible injury to those close to the battery. Similarly, people charged with caring for or operating batteries should not wear any metal jewelry.

  • Do make regular inspections of every battery in the fleet and address problems of acid spillage and resulting corrosion immediately. Periodic (every three months) measurement and recording of the voltage and specific gravity of each cell in the battery will give early warnings of impending problems.

• Don't underestimate the money a trained battery repair service can save you. They are the key to long, uninterrupted battery life and successful electric truck operation.
Waseem Ahmad is Vice President of Engineering for Hawker Powersource, Inc. and has worked in the motive power industry for more than 27 years.

© copyright 1999 - 2010 Hawker, © copyright 1999 - 2010 Hawker, an EnerSys company. All rights reserved.