Lamar Technologies LLC.
INSTRUCTION MANUAL
MODEL D-5160 12 AND 24 VOLT AIRCRAFT AND GSE BATTERY
DISCHARGE CURRENT CAPACITY TESTER
APPLICATIONS:
MEETS ALL COMMERCIAL AND MILITARY
AVIATION BATTERY TESTING REQUIRMENTS
MILITARY TECHNICAL BAD-1 MANUAL
SEALED (SLAB/AGM) AND
LEAD ACID AIRCRAFT
BATTERIES
NICKEL CADIUM
AIRCRAFT BATTERIES
GROUND SUPPORT AND
VEHICLE BATTERIES e.g.:
HAWKER “ARMASAFE”,
OPTIMA
TELECOM AND SPECIAL
TYPES
CONTENTS
I.
II.
III.
SPECIFICATIONS
OPERATION PREFACE
OPERATING INSTRUCTIONS
FIG. 1
IV.
V.
VI.
CALIBRATION
MAINTENANCE
WARRANTY & TECH SUPPORT
MFG. BY Lamar Technologies LLC.
14900 40th Ave. N.E.
Marysville, WA 98271
Tel: (360) 651-8869 Fax: (360)651-6677
www.lamartech.com/powerproducts
I.
SPECIFICATIONS
1. Self-powered by the battery under test. No AC line cord.
2. Automatic accommodation to a 12 or 24 volt battery.
3. Discharge current range settable from 2.0 to 62.2 amperes.
4. Constant current output accurate to within +/- one tenth of preset amperes
when set within the range of 5-62 amperes and within 1 to 3 tenths of an
amp when set below 5A.
5. Subsequent test current setting defaults to the previous test’s amperes.
The setting can be set to a different ampere setting (eliminates resetting
for subsequent tests on the same type of battery).
6. End-of-test battery cutoff voltage settable to 18.0 or 20.0 volts for 24V
battery and 9.0 or 10.0 volts for 12V battery. Cut off voltage set point
accurate to +/- one tenth of a volt.
7. Digital LED displays of battery volts, (xx.x VOLTS), amperes (xx.x AMPS),
and time (xx HRS, xx MIN, xx SEC).
8. D5160 operating temperature from -10°C to 45°C (14F to 113F)
Cooling: Fan cooled
9. Mounting: Weatherproof transit case
Dimensions: 18 in (46cm) x 14 in (36 cm) x 7 in (18 cm) D
Wt: 17 lbs (8 kg)
10. 4 ft DC cable AWG 8 with voltage sensing leads, and snap-in
connector.
II.
OPERATION PREFACE
NOTE: RATINGS AND EXAMPLES GIVEN IN THE PREFACE BELOW MAY DIFFER
FROM THE USER OR BATTERY MANUFACTURERS’ REQUIREMENTS.
Discharge current capacity testing is the only valid method of determining
the true reserve (emergency) capacity of a battery. Reserve capacity is especially
important for aircraft which may have to depend on the battery for emergency
power in the event of power failure. The battery must deliver usable power for one
hour.
This is often also important for various ground support equipment and
military vehicles. Most aircraft batteries are 24 volt sealed or vented lead acid, or
NiCad. Military vehicles have 12 volt lead acid batteries which may be combined
for higher voltages and amperages. The 5160 accommodates both 24 and 12 volt
batteries.
An acceptable reserve capacity will also reflect upon the high current
capability of the battery for engine starting and possible other short time high amp
loads. However, the reverse is not necessarily true. An acceptable high current
cold cranking amp test, whether acceptable by hand-held conductance or
impedance test meters, or 15 second CCA load test, does not automatically
translate into an acceptable reserve test.
Both the military and FAA mandate reserve capacity testing for aircraft
batteries. This may be done by removing the battery from the aircraft for testing
every 600 hours of use. The test essentially loads a fully charged battery with a
full ampere-hr rated load. E.g. 40 amp-hr battery drawing a 40 amp load for 1
hour. The battery must deliver full power until the voltage drops to an unusable
level such as when relays and instruments drop-out. This can be at 18 or 20 V.
OPERATION PREFACE CONTINUED
The only practical way to test this capability is with a constant current load.
By the end of one hour under the battery’s rated one-hour capacity
(amp-hr capacity), the battery voltage must not have dropped below the assigned
cut-off voltage which, for a 24 volt battery is usually 20 volts.
However, in normal usage over time, the actual capacity will be lower than
the rating, and both the military and FAA allows an acceptable value of 85% of the
battery’s nameplate ampere hour rating. This can be 85% of the one hour rating at
full load (e.g. 51 minutes at 40 amps for a 40 A-H battery with acceptable end
voltage of 20 V or higher), or 85% of current for 60 minutes (e.g. 34 amp for 60
minutes).
There may be other acceptance criteria such as ½ of the AH rating for 2
hours, and battery end voltage being 18 volts.
For ratings of batteries higher than the 62 amp limit of the 5160 tester, the
acceptable discharge time is extended in scale with the battery rating. (e.g. For a
120 amp-hour battery, set the test current to 60 amps and run test for 2 hours).
III.
OPERATING INSTRUCTIONS
7
8
9
6
11
5
10
4
16
3
2
15
1
FIG. 1
ITEM # DESCRIPTION
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
ON/OFF/RESET SWITCH
‘START’ PUSH BUTTON
DISCHARGE AMP SETTING BUTTONS
AMMETER
TIME DISPLAY
VOLT METER
‘READY’ LED
‘TESTING’ LED
‘TEST COMPLETE’ LED
AMMETER TEST POINTS
VOLTAGE TEST POINTS
DC CABLE W/ SNAP IN CONNECTOR (NOT SHOWN)
AIRCRAFT BATTERY QUICK DISCONNECT CABLE CONNECTOR (NOT SHOWN)
RING TERMINAL CONNECTOR (NOT SHOWN)
REVERSED BATTERY ALERT LED
CUT OFF VOLTAGE SETTING SWITCH
III.
OPERATING INSTRUCTIONS
REFER TO FIG. 1
1. Turn On/Off switch (#1) to ‘Off’ position
2. Connect battery cable (#12) to battery
• If polarity is reversed, LED (#15) will illuminate together with
audible signal
• If necessary correct the reversal.
3. Set voltage cutoff set switch (#16). 9 or 10 V for 12 V batteries.
18 or 20 V for 24 V batteries.
4. Turn On/Off switch (#1) to ‘On’ position
• All instrument displays will briefly illuminate as 8s, then as follows:
a) Timing (#5) All zeros, steady.
b) Amperes (#4) Flashes*
*Reading depends upon last setting which may be the last factory test
setting if starting with a new unit.
c) Volts (#6) reads battery voltage* steady.
*Reads open circuit voltage (OCV). A charged 12 V battery may read
12.5-13.0 volts and 24 V batteries reads 25.0-26 volts.
d) ‘Ready’ LED (#7) illuminates.
5. Preset the required discharge amperes.
• Use the ampere set buttons (#3); Left button is tens place, center is 1’s
place, right is decimal.
OPERATING INSTRUCTIONS CONTINUED
• Current may be set below 2.0 amperes but actual discharge current
and/or meter reading may be inaccurate. Actual discharge amperes
may be read using the ampere test points (#10) with a digital multimeter set to the DC milli-volt scale.
• Subsequent amperes will default to the previous test setting. If
different amperes are required from the previous test, the discharge
current must be set to the new current.
6. Press ‘Start’ (#2)
• ‘Testing’ LED illuminates
• Cooling fan starts
• Ammeter reading ramps to approximately the preset level then settles
to the steady preset level within +/- .1 amp.
• Voltmeter reading drops to battery loaded voltage level.
• Timer begins counting time.
NOTE: CURRENT SETTING CANNOT BE CHANGED WHILE TEST IS PROCEEDING.
UNIT MUST BE SHUT-OFF AND RESET WITH SWITCH (#1)
7. Test proceeds with battery voltage steadily decreasing.
8. When battery voltage lowers to the preset level (Step 3) the test is
complete.
• The level switch may be set to the alternate level during the test.
(E.g. from 20 to 18 V, or 18 to 20 V)
• Test complete (#9) LED illuminates
• All readings freeze at their final readings.
OPERATING INSTRUCTIONS CONTINUED
9. User will evaluate the results of the test.
E.g. For a 30 amp-hour test:
a) 30 amps at 48 min- FAIL
b) 30 amps at 51 min (85% capacity) - PASS
c) 30 amps at 60 min (100% capacity) – SUPERIOR BATTERY
• The exact amp hr capacity of the battery is obtained as follows:
a) Convert the hours and minutes to all minutes
b) Divide by 60. Equals amp-hr capacity.
10. Record reading, set switch (#1) ‘Off’, remove battery.
IV.
CALIBRATION
Preface
A. The 5160 unit is microprocessor controlled with programmed functions
of operation and displays. There are no user calibrations procedures, only
verification of time, voltage, and current readings. Factory calibration requires
battery banks, variable power supplies, oscilloscope and calibrated test
instruments. Therefore, units which may be out of calibration or malfunction
should be returned to the factory. East coast and west coast tech reps are
available. See Tech Support on Section. VI
B. In order to verify operating accuracy, there are test points for the ammeter
and voltmeter, to connect to the user’s multi-meter. The ammeter test points,
connects to an internal shunt rated 100 amperes at 100 milli-volts. The volt
meter connects to the battery by sensing leads at the snap-in connector at the
end of the DC cable.
For amperes, a test multi-meter such as Fluke, must be set to the DC
milli-volt scale. Amperes are read as milli-volts directly. Multi-meter leads are
plugged into the amperes/MV test points (Fig 1, #10)
For volts, the multi-meter is set to DC volts. Leads are plugged into the
volts test points or additional verification can be taken directly at the battery
under test. For time readings, any quality digital timer may be used for
verification.
C. To verify the accuracy of the internal shunt and ammeter, a shunt rated
100 amps/ 100 milli-volts is connected in series with the DC cable and battery.
The shunt may be connected in either the positive or negative leg. The
milli-volt meter reads the shunt voltage which is equal to the DC amperes. This
shunt connector assembly can be obtained from Power Products. See Tech
Support Section.
V.
MAINTENANCE
Standard electrical/electronic equipment maintenance procedure should be
observed. These include vacuum cleaning of the resistor grille and open spaces in
the unit.
Use only cleaners approved for plastic meter covers. Do not use harsh
cleaners which may damage plastic or the silk screened or painted portions of the
unit.
Examine the DC cable and connectors for signs of wear, fraying, or
looseness. If the connector must be replaced, the voltage sensing leads must be
securely attached and well crimped or soldered to the cable in the correct polarity.
VI. 1 YEAR WARRANTY
POWER PRODUCTS INC. warrants its products to be free from defects in
workmanship and material for a one-year period from the date of shipment to the
distributor, original equipment manufacturer (OEM), or original end user. If any
product shall prove to be defective during the warranty period, POWER
PRODUCTS INC. will repair or replace such part.
There are no warranties, which extend beyond the description on the face hereof.
This warranty is in lieu of all other warranties, express or implied. POWER
PRODUCTS INC. excludes liability for incidental and consequential damages.
An action for breach of this warranty must be commenced within one year after the
breach is or should have been discovered.
POWER PRODUCTS INC. specifically disclaims all other representations to the
first user/purchaser, and all other obligations or liabilities. No person is authorized
to give any other warranties or to assume any liabilities on POWER PRODUCTS
INC. behalf.
POWER PRODUCTS INC.
27 PAMARON WAY, SUITE E
NOVATO, CA 94949
415-883-6300
CERTIFICATION OF CALIBRATION
BATTERY DISCHARGE CAPACITY TESTER – MODEL: D-5160
APPLICATION:
Discharge capacity testing of 12 and 24 Volt Lead Acid and Nickel Cadmium
aircraft batteries. Discharge Range: 2 – 62 Amperes.
DIGITAL DISPLAYS:
Amperes:
Volts:
Time:
CALIBRATION
PROCEDURE:
0-75 Ampere, 0-30 Volt Variable Power Supply
Power Products P/N PS 7530AF used as battery substitute.
Test instruments and shunt compared to the D5160 unit.
Required accuracy +/- 0.2A from pre-set discharge amps.
SPECIFICATIONS:
▪
▪
▪
▪
▪
NOTES:
XX.X Adjustable to +/- 0.1A
XX.X
Hrs. XX Min. XX Sec. XX
Powered by battery under test
Automatic Setting to 12 or 24 Volt battery
Push button adjustment for discharge amperes w/ resolution of 0.1 Amps
Selectable end voltage discharge cutoff, 9/18 Volts or 10/20 Volts.
Meter reading accuracy – Voltmeter +/- 0.2 Volts
Ammeter +/- 0.2 Amperes
Timer 1 sec.
Calibrating Test Instruments Used:
Meters: Fluke 8010A DC MV Digital, Fluke 87 DC Volts Digital
▪ Shunt: EMPRO 100A 100MV 0.25% accuracy
Traceable to NIST Calibration within one year
Instrument test before each equipment test and calibration:
Fluke meters with standard cell of 1.019 Volts to +/- 1.02 V
UNIT:
BATTERY DISCHARGE CAPACITY TESTER
MODEL:
D-5160
SERIAL #:
_____________________
DATE OF MANUFACTURE:
_____________________
PROCEDURE:
D5160CAL- 62-01
ENVIRONMENTAL CONDITIONS:
NOMINAL 70º - 80º F 35 - 40% R.H.
SHIPPED CONDITION:
CALIBRATED / IN TOLERANCE_____________________
CALIBRATED BY:
________________ DATE CALIBRATED: _______________
DUE DATE OF NEXT CALIBRATION (ANNUAL):
________________________________________
APPROVED BY_______________________ TITLE:______________________ DATE:_______________
Lamar Technologies certifies that the above listed instrument meets or exceeds all published specifications. It has been calibrated
using standards MIL-I-45208 whose accuracies are traceable to the National Institute of Standards and Technology.
MFG. by: Lamar Technologies LLC
14900 40th Ave. N.E.
Marysville, WA 98271
www.lamartech.com