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dan(at)familybrown.org Guest
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Posted: Mon Oct 05, 2009 8:59 am Post subject: Battery capacity testing |
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I fly a Mooney M20F which has a Concorde RG battery installed
(RG-35AXC). Concorde (as well as Bob, of course) recommend periodic
capacity testing--after 2 years, and every year thereafter.
The procedure called for in Concorde's ICA
(http://www.concordebattery.com/otherpdf/IFCA1.pdf, page is to load
the battery at the 1-hour rate (33 amps, in my case), and see how long
it takes for the voltage to drop below 10 volts. If that takes less
than 51 minutes (85% of 1 hour) on a fully-charged battery, it is to
be replaced.
So the question is, how can I uniformly (and, ideally, inexpensively)
load the battery to 33 amps? I'd think that the loading would be
fairly critical to get a valid result. Of course, I could do the math
easily enough if the load were some other constant value (say, 30 or
35 amps), but I don't think I'd get a very good result with a load
that changed over time (like using a light bulb), since it'd be hard
to integrate that into total amp-hours.
I've looked at West Mountain Radio's CBA-III
(http://www.westmountainradio.com/CBA_ham.htm), but to work for this
purpose it would also need their add-on amplifier accessory
(http://www.westmountainradio.com/CBAAmplifier.htm), bringing the
total cost to almost $900.
What other options are out there?
--
Dan Brown, KE6MKS, dan(at)familybrown.org
"Since all the world is but a story, it were well for thee to buy the
more enduring story rather than the story that is less enduring."
-- The Judgment of St. Colum Cille
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nuckolls.bob(at)aeroelect Guest
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Posted: Mon Oct 05, 2009 9:42 am Post subject: Battery capacity testing |
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At 11:55 AM 10/5/2009, you wrote:
Quote: |
I fly a Mooney M20F which has a Concorde RG battery installed
(RG-35AXC). Concorde (as well as Bob, of course) recommend periodic
capacity testing--after 2 years, and every year thereafter.
|
<snip>
Quote: | I've looked at West Mountain Radio's CBA-III
(http://www.westmountainradio.com/CBA_ham.htm), but to work for this
purpose it would also need their add-on amplifier accessory
(http://www.westmountainradio.com/CBAAmplifier.htm), bringing the
total cost to almost $900.
|
Yeah . . . lots of overkill if YOUR are interested
in endurance AS INSTALLED in YOUR airplane with YOUR
choice of equipment items operational.
The "approved" testing protocols come from a bunch
of bureaucrats who decided some years ago that
EVERYBODY's airplane should be configured and
maintained to get on the ground in 30 minutes
or less after engine driven power goes away.
How about this? YOU decide what your
alternator-out endurance target is. Wouldn't
you feel better about 1 hour? How about two
hours? Next make up a list of electro-whizzies
you plan to leave ON (and those you can't turn
off) after the LV warning light comes on.
During some CAVU cross country, deliberately
put your airplane into a failed alternator
condition and start your stop-watch. 11 volts
is a better battery depleted target. See:
http://www.aeroelectric.com/Pictures/Curves/28AH_12V_Capacity_vs_Load.gif
Note that by the time a 12 lead-acid battery
drops to 11.0 volts, the curve is VERY steep
and 10.0 volts is not far behind.
When your battery drops to 11.0 volts, note
the time it took to get down to that value.
Did that meet your design goal for battery only
endurance?
No? (1) replace battery. (2) revise electrical
load for alternator out operations or (3)
revise endurance design goals. Or some combination
of the 3.
I think it's much better that the owner/operator
craft, test and maintain personally generated
endurance goals. Your chances of understanding
and operating your airplane with confidence is
greatly improved.
After 11.0V is achieved, turn the alternator
back on. Turn on maximum number of electro-whizzies
for 10 minutes or so to mitigate the initial
inrush of battery recharge currents. After 10
minutes, reduce to minimum required for completing
the flight. If you have a battery maintainer to
hook to you battery in the hangar, it's always
a good thing whether or not you just tested
the battery.
Bob . . .
---------------------------------------
( . . . a long habit of not thinking )
( a thing wrong, gives it a superficial )
( appearance of being right . . . )
( )
( -Thomas Paine 1776- )
---------------------------------------
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dan(at)familybrown.org Guest
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Posted: Mon Oct 05, 2009 6:16 pm Post subject: Battery capacity testing |
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Hash: SHA1
Robert L. Nuckolls, III wrote:
Quote: | During some CAVU cross country, deliberately
put your airplane into a failed alternator
condition and start your stop-watch. 11 volts
|
Well, I've inadvertently done this (and due to the lack of active
low-voltage warning, since rectified, didn't realize it), and I lasted
about 3 hours before the GNS-430 shut down. Not realizing that the
alternator was inop, I was running ordinary daytime equipment.
Interestingly, it was my altitude encoder that was first to go (got a
number of calls from ATC that they weren't picking up my Mode C
readout). After that, the display on my engine monitor (instrument
itself kept working, but the display was dark). The KX-155 lasted the
longest before going dark.
Given my ordinary daytime system load of 10-12 amps, the battery would
have to be very far gone indeed before it would give me less than an
hour, and even 2 hours would only be about 2/3 of its rated capacity
(well below the point where I should, according to the manufacturer,
discard the battery).
With normal daytime loads, and the battery at full capacity, empirical
observation and calculations agree that I get about 3 hours. At 85%
capacity, the point where the ICAs specify battery replacement, that
would leave 2.5 hours. I'm not going to have "duration of fuel aboard"
as my battery life (and never will on the Mooney without shedding _lots_
of load--fuel capacity is 6-7 hours), but that would give plenty of time
to land. Now that I have the flashing red light for low voltage, I'll
know about a problem right away, too.
What all this doesn't tell me is the health of the battery on an ongoing
basis. I'd think there should be a better way to test this than
repeatedly failing the alternator in flight.
- --
Dan Brown, KE6MKS, dan(at)familybrown.org
"Since all the world is but a story, it were well for thee to buy the
more enduring story rather than the story that is less enduring."
-- The Judgment of St. Colum Cille
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Kellym
Joined: 10 Jan 2006 Posts: 1705 Location: Sun Lakes AZ
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Posted: Tue Oct 06, 2009 4:36 am Post subject: Battery capacity testing |
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Caution.........Unless it is a very early M20F, the gear and possibly
the flaps are electrically operated. I would not recommend running the
battery low enough to force lowering the gear by the emergency
extension. Seems like this would be an issue for all retractables that
use electric power for gear operation.
Or are you suggesting staying airborne while you reactivate the
alternator field and giving it some time to recharge the battery? Seems
like that would abuse the battery with high charging rates.
Perhaps testing by monitoring voltage and time, 30 min. with a
conservative volts cutoff(12.0?), whichever comes first might be safer,
at least for a first try.
Robert L. Nuckolls, III wrote:
Quote: | > I fly a Mooney M20F which has a Concorde RG battery installed
> (RG-35AXC). Concorde (as well as Bob, of course) recommend periodic
> capacity testing--after 2 years, and every year thereafter.
|
Quote: | Yeah . . . lots of overkill if YOUR are interested
in endurance AS INSTALLED in YOUR airplane with YOUR
choice of equipment items operational.
|
Quote: | How about this? YOU decide what your
alternator-out endurance target is. Wouldn't
you feel better about 1 hour? How about two
hours? Next make up a list of electro-whizzies
you plan to leave ON (and those you can't turn
off) after the LV warning light comes on.
During some CAVU cross country, deliberately
put your airplane into a failed alternator
condition and start your stop-watch. 11 volts
is a better battery depleted target. See:
http://www.aeroelectric.com/Pictures/Curves/28AH_12V_Capacity_vs_Load.gif
Note that by the time a 12 lead-acid battery
drops to 11.0 volts, the curve is VERY steep
and 10.0 volts is not far behind.
|
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_________________ Kelly McMullen
A&P/IA, EAA Tech Counselor # 5286
KCHD |
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mrspudandcompany(at)veriz Guest
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Posted: Tue Oct 06, 2009 5:26 am Post subject: Battery capacity testing |
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What all this doesn't tell me is the health of the battery on an ongoing
basis. I'd think there should be a better way to test this than
repeatedly failing the alternator in flight.
Dan,
Catastrophic battery failure is rare. If you do this test one or two times
a year it will give you a good on-going test of the general battery health.
If you want to do a more quantitative test of your battery capacity then I
would suggest that you use the procedure documented on Bob N's website.
Roger
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dan(at)familybrown.org Guest
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Posted: Tue Oct 06, 2009 5:26 am Post subject: Battery capacity testing |
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Quoting Kelly McMullen <kellym(at)aviating.com>:
Quote: | Caution.........Unless it is a very early M20F, the gear and
possibly the flaps are electrically operated. I would not recommend
running
|
In my case, the plane has manual gear and flaps. That said, I think
Bob's recommendation was to reengage the alternator and let it charge
for a bit before landing.
--
Dan Brown, KE6MKS, dan(at)familybrown.org
"Since all the world is but a story, it were well for thee to buy the
more enduring story rather than the story that is less enduring."
-- The Judgment of St. Colum Cille
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nuckolls.bob(at)aeroelect Guest
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Posted: Thu Oct 08, 2009 8:57 am Post subject: Battery capacity testing |
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At 07:32 AM 10/6/2009, you wrote:
Quote: |
Caution.........Unless it is a very early M20F, the gear and
possibly the flaps are electrically operated. I would not recommend
running the battery low enough to force lowering the gear by the
emergency extension. Seems like this would be an issue for all
retractables that use electric power for gear operation.
|
I suggested that such testing be accomplished
under very low risk conditions at altitude.
As soon as the alternator is back on line, there
will be enough snort to operate the devices you
mentioned just from the alternator's output . . .
and a few minutes later, the battery will have
stored up enough to operate flaps and/or gear.
If your battery is in really good shape and still
above 11.0 volts when 20-20 minutes out, it's probably
a good idea to terminate the experiment and pay
attention to pilot business. Conducted with prudence,
this is a low-priority, low-risk experiment that
will produce a very accurate assessment of your
battery's ability to perform to YOUR design goals.
Quote: | Or are you suggesting staying airborne while you reactivate the
alternator field and giving it some time to recharge the battery?
Seems like that would abuse the battery with high charging rates.
|
The battery is subject to no more stresses than
situations where you've jump started your car
because the headlights were left on. Would the
battery last longer had it never been subjected
to the deep discharge event? Arguably yes . . . but
by so small a value as to be difficult to measure
and totally insignificant to your operational perceptions.
But it's not an undue stress on the ship's accessories.
They are all qualified to perform to nameplate ratings
when the airplane was awarded a type certificate.
Quote: | Perhaps testing by monitoring voltage and time, 30 min. with a
conservative volts cutoff(12.0?), whichever comes first might be
safer, at least for a first try.
|
So what does the cutoff of 12.0 volts tell you?
This experiment is not unlike a test in which
the whole class gets A's. Warm fuzzies abound but
you acquire no quantitative data on class knowledge.
The ideal test is just rigorous enough that nobody
gets 100%. You'll then have a top-to-bottom measure
of both individual and aggregate knowledge.
The total depletion test for measuring the total
contained energy is still the simplest and most
accurate means by which we can evaluate a battery's
ability to perform to design goals.
Bob . . .
---------------------------------------
( . . . a long habit of not thinking )
( a thing wrong, gives it a superficial )
( appearance of being right . . . )
( )
( -Thomas Paine 1776- )
---------------------------------------
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nuckolls.bob(at)aeroelect Guest
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Posted: Thu Oct 08, 2009 9:32 am Post subject: Battery capacity testing |
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At 09:11 PM 10/5/2009, you wrote:
<snip>
Quote: | What all this doesn't tell me is the health of the battery on an ongoing
basis. I'd think there should be a better way to test this than
repeatedly failing the alternator in flight.
|
If you want to use test equipment on the ground,
the simplest and least expensive system I've seen
looks like this:
http://www.aeroelectric.com/articles/battest.pdf
Adjust the number and size of lamps to product an
initial discharge current in the same neighborhood
as your anticipated alternator-out loads. This
obviously doesn't go to the 85%-replacement-benchmark.
Instead, it gives you a rough handle on performance
to your endurance goals.
Of course, you've already discovered that knowing
battery capacity is not terribly useful if you
don't have timely notification of alternator
failure. Sounds like you've got a handle on it.
Bob . . .
---------------------------------------
( . . . a long habit of not thinking )
( a thing wrong, gives it a superficial )
( appearance of being right . . . )
( )
( -Thomas Paine 1776- )
---------------------------------------
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mrspudandcompany(at)veriz Guest
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Posted: Thu Oct 08, 2009 9:48 am Post subject: Battery capacity testing |
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Quote: |
Caution.........Unless it is a very early M20F, the gear and
possibly the flaps are electrically operated. I would not recommend
running the battery low enough to force lowering the gear by the
emergency extension. Seems like this would be an issue for all
retractables that use electric power for gear operation.
|
I suggested that such testing be accomplished
under very low risk conditions at altitude.
As soon as the alternator is back on line, there
will be enough snort to operate the devices you
mentioned just from the alternator's output . . .
and a few minutes later, the battery will have
stored up enough to operate flaps and/or gear.
If your battery is in really good shape and still
above 11.0 volts when 20-20 minutes out, it's probably
a good idea to terminate the experiment and pay
attention to pilot business. Conducted with prudence,
this is a low-priority, low-risk experiment that
will produce a very accurate assessment of your
battery's ability to perform to YOUR design goals.
Quote: | Or are you suggesting staying airborne while you reactivate the
alternator field and giving it some time to recharge the battery?
Seems like that would abuse the battery with high charging rates.
|
The battery is subject to no more stresses than
situations where you've jump started your car
because the headlights were left on. Would the
battery last longer had it never been subjected
to the deep discharge event? Arguably yes . . . but
by so small a value as to be difficult to measure
and totally insignificant to your operational perceptions.
But it's not an undue stress on the ship's accessories.
They are all qualified to perform to nameplate ratings
when the airplane was awarded a type certificate.
Quote: | Perhaps testing by monitoring voltage and time, 30 min. with a
conservative volts cutoff(12.0?), whichever comes first might be
safer, at least for a first try.
|
So what does the cutoff of 12.0 volts tell you?
This experiment is not unlike a test in which
the whole class gets A's. Warm fuzzies abound but
you acquire no quantitative data on class knowledge.
The ideal test is just rigorous enough that nobody
gets 100%. You'll then have a top-to-bottom measure
of both individual and aggregate knowledge.
The total depletion test for measuring the total
contained energy is still the simplest and most
accurate means by which we can evaluate a battery's
ability to perform to design goals.
Bob . . .
One further **** CAUTION **** Be very careful doing this test on
your "ALL ELECTRIC AIRPLANE" (ONE HAVING BATTERY OPERATED ELECTRONIC
IGNITION) You may, unintentionally, end up in a glider.
Roger
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Kellym
Joined: 10 Jan 2006 Posts: 1705 Location: Sun Lakes AZ
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Posted: Thu Oct 08, 2009 7:13 pm Post subject: Battery capacity testing |
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For safety you need to know the minimum excitation voltage for your
specific alternator. Otherwise you could easily drop the battery voltage
to a point where turning on the alternator field would get you exactly
zero output. IIRC for some of the older alternators that value isn't
much below 11.0.
Robert L. Nuckolls, III wrote:
Quote: | So what does the cutoff of 12.0 volts tell you?
This experiment is not unlike a test in which
the whole class gets A's. Warm fuzzies abound but
you acquire no quantitative data on class knowledge.
The ideal test is just rigorous enough that nobody
gets 100%. You'll then have a top-to-bottom measure
of both individual and aggregate knowledge.
The total depletion test for measuring the total
contained energy is still the simplest and most
accurate means by which we can evaluate a battery's
ability to perform to design goals.
Bob . . .
---------------------------------------
( . . . a long habit of not thinking )
( a thing wrong, gives it a superficial )
( appearance of being right . . . )
( )
( -Thomas Paine 1776- )
---------------------------------------
|
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http://www.matronics.com/Navigator?AeroElectric-List |
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_________________ Kelly McMullen
A&P/IA, EAA Tech Counselor # 5286
KCHD |
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nuckolls.bob(at)aeroelect Guest
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Posted: Thu Oct 08, 2009 8:16 pm Post subject: Battery capacity testing |
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At 10:10 PM 10/8/2009, you wrote:
Quote: |
For safety you need to know the minimum excitation voltage for your
specific alternator. Otherwise you could easily drop the battery
voltage to a point where turning on the alternator field would get
you exactly zero output. IIRC for some of the older alternators that
value isn't much below 11.0.
|
Not true. All the externally regulated alternators
for which I've designed regulators will come on line
with less than 1 volt of b-terminal voltage. Everything
else will light up with 2 volts. Some alternators
spun at over 10KRPM on the front of a Lycoming will
self-excite. The gear driven 100A machines on Barons
and Bonanzas will also self-excite.
If you can get the battery contactor to close (about
5 volts) then your alternator will come on line.
Bob . . .
---------------------------------------
( . . . a long habit of not thinking )
( a thing wrong, gives it a superficial )
( appearance of being right . . . )
( )
( -Thomas Paine 1776- )
---------------------------------------
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bicyclop(at)pacbell.net Guest
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Posted: Tue Oct 13, 2009 8:40 am Post subject: Battery capacity testing |
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Howdy,
I recently subjected the Concord RG-25XC in our RV to an unscheduled
deep discharge test by way of leaving the E-buss switch on for a couple
of days on the ramp at West Yellowstone. We jump started the airplane
with a car, but as soon as the cables were removed, there was nothing on
the panel. Apparently the battery was so dead that the alternator didn't
kick in. I failed to notice if the alternator was running with the
jumper cables connected, but I think it must have been. All the normal
lights and gages were working prior to disconnection.
We called National Aircraft Parts Association and had them send over a
"snowmobile battery", a Yaesu 18ah sized like a PC680 and that got us
going. We hauled the dead Concorde RG-25XC home and I charged it up. I
did a capacity check on it with a West Mountain Radio CBA II tester down
to 10.5 volts, just as I do at annual, and it did pretty well. It
produced 28 ampere hours at a 4amp draw. Not bad for a 24AH battery!
When tested at the most recent annual inspection, it put out just over
30, so it may be slightly degraded, but still very good. We only need
about 16AH to be able to keep the electronic ignition and some of the
more important bits of avionics working 'till we run out of gas, so this
battery still has a ways to go before replacement. I'll save the 18AH
Yaesu for other uses.
Pax,
Ed Holyoke
Quote: | The battery is subject to no more stresses than
situations where you've jump started your car
because the headlights were left on. Would the
battery last longer had it never been subjected
to the deep discharge event? Arguably yes . . . but
by so small a value as to be difficult to measure
and totally insignificant to your operational perceptions.
But it's not an undue stress on the ship's accessories.
They are all qualified to perform to nameplate ratings
when the airplane was awarded a type certificate.
|
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rhdudley1(at)bellsouth.ne Guest
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Posted: Tue Oct 13, 2009 9:43 am Post subject: Battery Capacity Testing |
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For what it is worth, here are my battery endurance procedure experiences.
For the first and second annual condition inspections of my RV-6A, I decided to follow the procedure of replacing my 17/18 AH RG battery rather than do an endurance check. The battery had cost only $50 and I treated it as expendable.
Meanwhile, after the second condition inspection, I conducted experiments on the replaced battery. Based on measured current draw of the avionics and instruments that I considered necessary in the event of an alternator failure I used automobile lights in parallel to simulate a load equivalent to the expected current drain.. I confirmed the current drawn with that load. Then I monitored the voltage and the time until the battery reached 11 volts. It turned out that with a current of about 9 amps, I had 1.5 hours endurance on a battery that had been used for a year. This pretty much agreed with the published endurance curves for that battery.
For the third condition inspection, I decided to test the year-old battery in place in the aircraft. To accomplish this, I switched on the "endurance" bus, turned on the avionics and instruments that I considered essential after alternator failure. I then monitored voltage, the avionics and time. The result was similar to the earlier simulation with the auto lamps: the avionics went out at about 1.5 hours.
Since this test was over in an hour and a half, only a voltmeter and clock were needed to gather data and the battery was re-charged in a reasonable time via my external power jack. This convinced me that the battery could be used until the next condition inspection.
Should anyone wonder during the second year about the battery endurance, the test could be conducted at any time with the expenditure of a couple of hours.
Regards,
Richard Dudley
[quote][b]
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trigo(at)mail.telepac.pt Guest
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Posted: Tue Oct 13, 2009 10:52 am Post subject: Battery Capacity Testing |
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Perhaps a dumb question about a small detail, but to conduct these capacity tests, how did you measure the time, were you one and a half hours looking at the voltmeter to see when it reached the 11V?
Carlos
From: owner-aeroelectric-list-server(at)matronics.com [mailto:owner-aeroelectric-list-server(at)matronics.com] On Behalf Of Richard Dudley
Sent: terça-feira, 13 de Outubro de 2009 18:36
To: aeroelectric-list(at)matronics.com
Subject: Re:Battery Capacity Testing
For what it is worth, here are my battery endurance procedure experiences.
For the first and second annual condition inspections of my RV-6A, I decided to follow the procedure of replacing my 17/18 AH RG battery rather than do an endurance check. The battery had cost only $50 and I treated it as expendable.
Meanwhile, after the second condition inspection, I conducted experiments on the replaced battery. Based on measured current draw of the avionics and instruments that I considered necessary in the event of an alternator failure I used automobile lights in parallel to simulate a load equivalent to the expected current drain.. I confirmed the current drawn with that load. Then I monitored the voltage and the time until the battery reached 11 volts. It turned out that with a current of about 9 amps, I had 1.5 hours endurance on a battery that had been used for a year. This pretty much agreed with the published endurance curves for that battery.
For the third condition inspection, I decided to test the year-old battery in place in the aircraft. To accomplish this, I switched on the "endurance" bus, turned on the avionics and instruments that I considered essential after alternator failure. I then monitored voltage, the avionics and time. The result was similar to the earlier simulation with the auto lamps: the avionics went out at about 1.5 hours.
Since this test was over in an hour and a half, only a voltmeter and clock were needed to gather data and the battery was re-charged in a reasonable time via my external power jack. This convinced me that the battery could be used until the next condition inspection.
Should anyone wonder during the second year about the battery endurance, the test could be conducted at any time with the expenditure of a couple of hours.
Regards,
Richard Dudley
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rhdudley1(at)bellsouth.ne Guest
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Posted: Tue Oct 13, 2009 12:27 pm Post subject: Battery Capacity Testing |
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Hi Carlos,
The short answer is: yes. I used a stop watch function on my wristwatch. In the first capacity tests with the dummy load of auto lamps, I checked the voltage at convenient intervals like 10 minutes until it approched 11 volts because I was unsure what to expect. I even plotted the data. When it started to change more rapidly I checked more often. From fully charged, around 12.7 volts to near 11 volts, the change is very slow. Near 11 volts, the decline is quite rapid.
After I knew better what to expect, during the actual tests in the plane in the hangar, I just checked the voltage periodically and noted when the avionics failed. It was part of my condition inspection tests so, I had other things to do on the plane.
There are plenty of fancier automated ways to test without personally monitoring. (Bob Nuckolls has published a timer that will count until the battery voltage drops to a predetermined voltage.) However, I felt that I could "squander" an hour and a half once a year looking at a voltmeter and my watch, and even multitasking with other tasks I had in the hangar.
Regards,
Richard
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nuckolls.bob(at)aeroelect Guest
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Posted: Tue Oct 13, 2009 12:33 pm Post subject: Battery capacity testing |
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Ed and Richard,
Good job gentlemen! A fine thinker and craftsman of repeatable
experiments once opined:
"When you can measure what you are speaking about, and express
it in numbers, you know something about it; but when you cannot
measure it, when you cannot express it in numbers, your knowledge
is of a meagre and unsatisfactory kind; it may be the beginning
of knowledge, but you have scarcely in your thoughts advanced
to the state of Science." -Lord Kelvin-
Bob . . .
---------------------------------------
( . . . a long habit of not thinking )
( a thing wrong, gives it a superficial )
( appearance of being right . . . )
( )
( -Thomas Paine 1776- )
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