BS-6G-205-1-1995.pdf

BRITISH STANDARD AEROSPACE SERIES BS 6G 205-1: 1995 Secondary batteries for aircraft Part 1: Specification for lead-acid batteries Licensed Copy: sheffieldun sheffieldun, na, Wed Dec 06 12:20:22 GMT+00:00 2006, Uncontrolled Copy, (c) BSI BS 6G 205-1:1995 This British Standard, having been prepared under the direction of the Engineering Sector Board, was published under the authority of the Standard Board and comes into effect on 15 December 1995 © BSI 11-1999 The following BSI references relate to the work on this standard: Committee reference ACE/6 Draft for comment 91/81042 DC ISBN 0 580 24254 4 Committees responsible for this British Standard The preparation of this British Standard was entrusted to Technical Committee ACE/6, Aerospace avionic, electrical and fibre-optic technology, upon which the following bodies were represented: British Airways British Cable Makers Confederation British Rubber Manufacturers Association Civil Aviation Authority (Airworthiness Division) Federation of the Electronics Industry Ministry of Defence Society of British Aerospace Companies Ltd. Coopted members Amendments issued since publication Amd. No.DateComments Licensed Copy: sheffieldun sheffieldun, na, Wed Dec 06 12:20:22 GMT+00:00 2006, Uncontrolled Copy, (c) BSI BS 6G 205-1:1995 © BSI 11-1999i Contents Page Committees responsibleInside front cover Forewordii 1Scope1 2References1 3Definitions1 4Identification2 5Design requirements2 6Type approval3 7Quality assurance4 8Electrical tests4 9Environmental tests8 Annex A (normative) Battery group 1: engine starting and busbar support19 Annex B (normative) Battery group 2: engine starting and busbar support21 Annex C (normative) Battery group 3: engine starting and busbar support23 Figure 1 Details of battery terminals: form Q14 Figure 2 Details of battery terminals: form A (automatic coupling)16 Figure 3 Details of battery terminals: form C17 Figure 4 Details of battery terminals: form S18 Figure A.1 Battery group 120 Figure B.1 Battery group 222 Figure C.1 Battery group 324 Table 1 Type approval tests in order of application12 Table 2 Acceptance tests in order of application13 Table 3 List of test fluids13 Table A.1 Battery group 119 Table B.1 Battery group 221 Table C.1 Battery group 323 List of referencesInside back cover Licensed Copy: sheffieldun sheffieldun, na, Wed Dec 06 12:20:22 GMT+00:00 2006, Uncontrolled Copy, (c) BSI BS 6G 205-1:1995 ii © BSI 11-1999 Foreword This British Standard has been prepared by Technical Committee ACE/6 and supersedes BS 5G 205-1:1990, which is withdrawn. It introduces revised requirements for the endurance tests, gas emission tests and power rating. Editorial changes bring the specification format into line with the latest edition of BS 0. The intention to prepare a Part 2 of the standard covering nickel-cadmium batteries has been cancelled in view of the future publication of BS EN 2570 Nickel-cadmium batteries Technical specification which the Technical Committee has agreed to accept. This Part of BS 6G 205 embraces valve regulated sealed batteries. Although it is appreciated that some aircraft system designers may not always be able to employ batteries of the types included in this standard, they are encouraged to define any future battery requirement within the framework of this standard. NOTEThe latest edition of an Aerospace Series standard is indicated by a prefix number. A British Standard does not purport to include all the necessary provisions of a contract. Users of British Standards are responsible for their correct application. Compliance with a British Standard does not of itself confer immunity from legal obligations. Summary of pages This document comprises a front cover, an inside front cover, pages i and ii, pages 1 to 24, an inside back cover and a back cover. This standard has been updated (see copyright date) and may have had amendments incorporated. This will be indicated in the amendment table on the inside front cover. Licensed Copy: sheffieldun sheffieldun, na, Wed Dec 06 12:20:22 GMT+00:00 2006, Uncontrolled Copy, (c) BSI BS 6G 205-1:1995 © BSI 11-19991 1 Scope This Part of BS 6G 205 specifies the characteristics, interchangeability dimensions, performance levels, quality assurance requirements and test procedures for lead-acid batteries used on aerobatic and non-aerobatic aircraft for general purposes. Tests are included which are appropriate for the evaluation of valve regulated sealed batteries. Annex A to Annex C specify the characteristics of batteries in battery groups 1 to 3. 2 References 2.1 Normative references This Part of BS 6G 205 incorporates, by dated or undated reference, provisions from other publications. These normative references are made at the appropriate places in the text and the cited publications are listed on the inside back cover. For dated references, only the edition cited applies; any subsequent amendments to, or revisions of, the cited publication apply to this Part of BS 6G 205 only when incorporated in the reference by amendment or revision. For undated references, the latest edition of the cited publication applies, together with any amendments. 2.2 Informative references This Part of BS 6G 205 refers to other publications that provide information or guidance. Editions of these publications current at the time of issue of this standard are listed on the inside back cover, but reference should be made to the latest editions. 3 Definitions For the purposes of this Part of BS 6G 205, the following definitions apply. 3.1 rechargeable battery (hereinafter referred to as a battery) an assembly consisting of one or more rechargeable cells or multicell blocks 3.2 rechargeable cell (hereinafter referred to as a cell) a voltaic cell that, after discharge, can be brought back to its initial (charged) chemical state by passing a current through it in a reverse direction to that of discharge 3.3 manufacturers instructions those service instructions in the manual provided by the battery manufacturer and approved by the appropriate Approving Authority1) 3.4 nominal battery voltage nominal cell voltage multiplied by the number of cells in series in the battery NOTENominal cell voltage is 2 V. 3.5 rated capacity capacity expressed in ampere hours (A·h), equivalent to the 1C1 rate 3.6 1C1 rate the current specified by the manufacturer that the battery is to deliver for 1 h when it is discharged down to a battery voltage corresponding to a mean voltage per cell of 1.67 V at an ambient temperature of (23 ± 2) °C 3.7 charged battery a battery that has been fully charged in accordance with the battery manufacturers instructions (3.3) 3.8 normal servicing battery servicing including cleaning, electrolyte topping-up and charging, as specified by the manufacturers instructions (3.3), but not including overhaul 3.9 serviceable battery a battery that in all respects meets the requirements stated in the manufacturers instructions (3.3) for continued use on aircraft 3.10 battery runaway a battery condition that is characterized by increasing cell temperature and charging current during constant potential charging and that, if not controlled, can result in the destruction of the battery 1) The Approving Authorities for batteries in British civil aircraft and British military aircraft are, respectively, the Airworthiness Division of the Civil Aviation Authority (or through a Design Authority approved by them) and the Ministry of Defence. Licensed Copy: sheffieldun sheffieldun, na, Wed Dec 06 12:20:22 GMT+00:00 2006, Uncontrolled Copy, (c) BSI BS 6G 205-1:1995 2 © BSI 11-1999 3.11 valve regulated sealed battery a battery that contains cells or cell blocks which are sealed and do not freely emit gases under normal operating conditions. The cells or cell blocks are fitted with a resealing pressure relief valve and the design does not permit the addition of water or electrolyte 4 Identification 4.1 The following information shall be clearly and indelibly marked on the battery casing. a) Type of battery (i.e. lead-acid; aerobatic or non-aerobatic; vented or valve regulated sealed). b) Manufacturers name or identification. c) Manufacturers type or part number. d) Manufacturers serial number. e) Date of manufacture, and initial charge if appropriate. f) Modifications incorporated. g) Positive terminal polarity (see 5.1.5). h) Nominal battery voltage and number of cells. i) Rated capacity. j) Diagram of any internal ancillary circuits. 4.2 Provisions shall be made on the battery casing for the entry of servicing records. 4.3 Batteries shall not be coloured in any manner that may cause confusion between types and therefore no blue colour shall be displayed on lead-acid batteries. NOTEThe normally accepted colour for lead-acid batteries is pink. 5 Design requirements 5.1 General construction requirements 5.1.1 The battery shall satisfy the topple test requirements of 9.5. NOTEIt is essential that the battery be constructed such that the risk of failure due to rough handling in workshops or on aircraft is minimized. 5.1.2 If a carrying handle (or handles) is provided, it shall be so arranged that, when the battery is carried in the appropriate manner, the electrolyte will not be spilled and the battery cannot be accidentally detached from its handle. 5.1.3 All parts susceptible to attack by the electrolyte shall be protected. 5.1.4 The external connections of the battery shall be protected against the risk of accidental short circuit. All internal live parts that may be exposed during installed servicing shall be protected. NOTEIt is essential that protection be such as to minimize the risk of accidental short circuit. 5.1.5 A positive symbol on each cell or multicell block shall be provided adjacent to the positive terminal in the form of a raised or indented polarity symbol. NOTEA suitable red identification mark may also be added. The negative terminal shall not be identified. 5.1.6 Where the battery can be lifted by the connector, vent tubes or other natural hand holds, these shall be so designed that they can carry the load without derangement. 5.2 External electrical connections The main and auxiliary terminations shall be of the type specified for the group number of the battery in the appropriate annex of this standard, and shall be in accordance with Figure 1 to Figure 4, as appropriate, where these forms apply. 5.3 Physical characteristics The dimensions, mass and other main characteristics shall be as specified for the group number of the battery in the appropriate annex of this standard. 5.4 Venting 5.4.1 General If the battery contains cells that are designed to liberate gas in normal service, it shall be provided with means of ventilation, which shall be either natural (5.4.2) or assisted (5.4.3). In either method, the design of battery case or lid shall ensure that pockets of gas are not entrapped. 5.4.2 Naturally ventilated The battery container and/or cover shall have sufficient holes or louvres to allow any liberated gases to be dispersed. Such holes or louvres shall be protected against the ingress of solid objects. 5.4.3 Assisted ventilation The cells shall pass the liberated gases into a sealed venting chamber having ports for the scavenging air. The position and type of port shall be as specified for the group number of the battery in the appropriate annex of this standard. The chamber and ports shall satisfy the performance requirements of 9.3. NOTEThe preferred methods of achieving a scavenging air flow are as follows. Method 1. This method assumes gas removal by exhausting from a single outlet port. The entry of air into the battery should be via a single entry housing a non-return valve that will accept air from the surrounding atmosphere. It should not be possible to connect a pipe to the inlet side of this valve and the valve should be completely contained within the venting chamber. Method 2. This method assumes that air is taken to and from the battery by pipe connections and that the battery will not be operated without both connections being made. The direction of ventilation is immaterial. Licensed Copy: sheffieldun sheffieldun, na, Wed Dec 06 12:20:22 GMT+00:00 2006, Uncontrolled Copy, (c) BSI BS 6G 205-1:1995 © BSI 11-19993 5.5 Environmental conditions 5.5.1 Temperature The battery shall be suitable for operation in the temperature range 30 °C to + 50 °C and shall not be deranged by exposure (non-operation) to the temperature 40 °C to + 70 °C. 5.5.2 Altitude The battery shall be suitable for operation over the altitude/pressure range 457 m ( 1 500 ft), 106.94 kPa to + 16 764 m (+ 55 000 ft), 9.12 kPa. 5.5.3 Acceleration The battery shall conform to 9.7. 5.5.4 Vibration The battery shall conform to 9.6. 5.5.5 Fluid contamination The battery shall conform to 9.11. 5.6 Aerobatic operation In accordance with Annex A to Annex C, batteries designed to operate in aerobatic aircraft shall be designated as “aerobatic”, and other batteries shall be designated as “non-aerobatic”. Each battery designated as “aerobatic” shall conform to 9.2.1, and each battery designated as “non-aerobatic” shall conform to 9.2.2. 5.7 Electrical performance The battery shall conform to clause 8 as further defined for the group number of the battery in the appropriate annex of this standard. NOTEThis standard does not include batteries that require specific charge regimes or batteries that are not charged in situ on the aircraft. Neither does it include batteries designated as “not for engine starting”. Such batteries may be introduced in the future by the issue of an amendment(s) to this standard; in which case those requiring specific charge regimes, or those not charged in situ on the aircraft will not be required to satisfy 8.11, 8.12 and 8.13. In addition, charging conditions and appropriate test procedures will be required from the manufacturer, and will be substituted for those specified in 8.11, 8.12 and 8.13 for the purposes of type testing, and batteries designated as “not for engine starting” will be exempted from meeting the requirements of the short circuit test (8.14). 5.8 Condition monitoring Condition monitoring sensors, where used, shall be so installed that they may be removed for calibration purposes. NOTEIt is essential that the sensors be readily removable. The operating characteristics of the sensors shall be as specified for the group number of the battery in the appropriate annex of this standard. The sensors shall be monitored continuously throughout all tests, and it shall be demonstrated that no spurious or erroneous operation occurs. Sensors that are intended to indicate an overheat condition as specified in 8.13.2, may operate during the short circuit current test of 8.14, but shall not be deranged. The sensors shall retain their calibration throughout the type approval test program. This shall be proved on completion of the test programme for eac