Communications Power Sources And Vehicle Battery
Communications Power Sourcesand Vehicle Battery MaintenanceSession 7Joint Service Power Exposition25 April 2007
Session 7 Power for Manpacked Radio CommunicationsEquipment Mr. Mark Abelson- Battery Basic’s for Vehicle Lead Acid Batteries- Keeping Batteries in Service- 2nd Infantry Division Case Study
ReferenceMaterial CD BMMP for Lead Acid Batteries FY07 Primary & Secondary battery price lists POWER 1.2 and Instruction Manual Power for Manpacked Radio Systems &QP-1800 (PowerPoint) SPC Software Version E Zinc-Air battery (PowerPoint)
BENEFICIAL SUGGESTIONS
To review the primary, secondary, andalternative power devices used to energizemanpacked radio equipment.
12 VOLT RADIO SYSTEMSAN/PRC-148 (MBITR)SINCGARS RADIOSBA-5590B/UTAB BBA-5590A/U W/SOCITAB BBA-5390/UTAB BBA-5390A/U W/SOCITAB BBA-8140TAB CBA-8180TAB CBB-390B/UTAB FBB-2590/UTAB FSINCGARS SINGLE POWER ADAPTER(SSPA) AN/PAC-216TAB KMULTI-SINCGARS POWER ADAPTER(MSPA) ASAPS-6TAB KMULTI-RADIO POWER ADAPTER(MRPA) ASAPS-SC/SNAP 6CC TAB KNote: The SSPA will not work with theAN/PRC-119F. The VB-90 (TAB L) isdesigned for the AN/PRC-119F (ASIP).POWER SOURCESMBITR BatteryBA-8140/UBA-8180/UMRC-41Battery Cell HolderTAB LTAB CTAB CTAB LTAB LThe MBITR battery is a unique rechargeablebattery manufactured by Thales Inc. Wheninitially fielded the only battery charger tosupport the MBITR battery was the ThalesAC/DC commercial charger. Adapters havebeen developed to allow use of the SPCand VMC chargers (TAB I) to charge theMBITR battery.MBITR BatteryThalesAC/DC Charger
24 VOLT RADIO SYSTEMSAN/PRC-117F, AN/PSC-5, AN/PRC-113 and AN/PRC-150POWER SOURCESBA-5590B/UTAB BBA-5590A/U W/SOCITAB BBA-8180/UTAB CBB-390B/UTAB FBB-2590/UTAB FMRC-93 Single Radio Power Adapter TAB KBA-8180/U with J-6687/U24V radio adapter (TAB C)REMARKSAlthough the MRC-93 will operate fromAC or DC power, the QP-1800 (TAB M)can be used to convert VEH DC power toAC power and energize the MRC-93.The BA-5390 has not been approved for usein any 24V radio system (refer to TAB B).QP-1800
PRIMARY BATTERIES (ONE TIME USE)NEW TYPENEW NSNU/IFY07 PRICEOLD TYPEBA-5093/U6135-01-216-9771EA 111.42N/ABA-5372/U6135-01-214-6441PG (10ea) 91.05BA-5112A/U6135-01-439-6229PG (4ea)BA-5557A/U6135-01-448-4680BA-5567A/UOLD NSNOLD U/IN/AN/ABA-13726135-00-801-3493PG 196.43BA-51126135-01-235-4168EAPG (4ea) 370.35BA-55576135-01-088-2707EA6135-01-447-5082PG (12ea) 7-5082PG (12ea) 7-5083PG (5ea) 38-9450PG (4ea) 23-3037PG (4ea) 348.08N/AN/A WITH SOC LEDN/ABA-5390/U6135-01-501-0833PG (4ea) 446.03N/AN/AN/ABA-5390A/U6135-01-517-6060PG (4ea) 480.27N/AN/A WITH SOC LEDN/ABA-5598A/U6135-01-447-5081PG (4ea) 47-4001PG (4ea) 41-0402PG (8ea) -7774PG (8ea) 5-7946EA 45.07BA-5347N/AN/ABA-5368/U6135-01-455-7947PG (10ea) 5-9646PG (10ea) 7-0952EA 275.00N/AREQ ADAPTERSN/ABA-8180/U6135-01-500-0572EA 355.58N/AREQ ADAPTERSN/AWARNING – ensure personnel are using the correct NSN’s and units of issue.Many units of issue changed from EA (1) to PG (4), (5), (8), (10) or (12).TAB A
PRIMARY BATTERIES (ONE TIME USE)The most widely used primary battery is the BA-5590B/U Lithium Sulfur Dioxide battery.An alternative to the BA-5590B/U is the BA-5390/U Lithium Manganese battery. The BA5390/U has a 16.5/33.0 VDC maximum voltage, higher than the BA-5590B/U at 16.0/33.0VDC. This higher voltage can cause equipment damage. The BA-5390/U has beenapproved for use in SINCGARS radios (MCSC 101842Z MAR 03). The BA-5390/Uthermal switch will trip if exposed to temperatures greater than 190 Degrees Fahrenheit.The BA-5390/U provides approximately 40 percent more run time than the BA-5590B/U.DLA has recently stocked new models of the BA-5590B/U and BA-5390/U. These newmodels, shown below, have State of Charge (SOC) LED indicators.BA-5590B/U6135-01-438-9450PG (4) 293.15BA-5590A/U W/SOC6135-01-523-3037PG (4) 348.08BA-5390/U6135-01-501-0833PG (4) 446.03BA-5390A/U W/SOC6135-01-517-6060PG (4) 480.27State of Charge (SOC) indicators allow users to fully utilize battery capacity bydisplaying the remaining battery SOC in segments from 20% to 80%.TAB B
ZINC-AIR PRIMARY BATTERIESAND ADAPTERS BA-8180/UBA-8140/U12/24 VOLT800 wattsSix pounds12 VOLT400 wattsThree poundsZinc-air batteries requirespecial adapters. Theseadapters are re-usable.Zinc-air batteries must beexposed to air and willnot work if submerged.BA-8140/U with J-6686/UMBITR adapterSAMPLE PERFORMANCE 5-10 Days4-6 DaysJ-6687/USINCGARS (A-E)5-9 Days4-6 DaysSATCOM HF5-7 DaysMBITR (PRC-148)14 DaysJ-6633/UNSNPRICEU/ISATCOM/HF5940-01-516-9787 505.00EAJ-6686/UMBITR (PRC-148)5940-01-517-3990 233.00EAN/AJ-6633/UAN/PRC-119F ASIP5940-01-504-3218 113.78EA7 DaysJ-6634/USINCGARS (A-E)5940-01-504-5597 51.46EAJ-6634/UAPPLICATIONZinc-air batteries react with air andexperience continual discharge onceremoved from their packaging.TAB C
RECHARGEABLE BATTERY OPERATING & STORAGETEMPERATURE PLANNING INFORMATIONRechargeable batteries are designed to operate and accept a recharge cycle from-4 degrees F to 122 degrees F (-20 degrees C to 50 degrees C). At lowtemperatures, they may operate, but will not accept a recharge cycle. Use primarybatteries when temperatures outside these specifications are encountered.Storage temperatures for rechargeable batteries should not exceed -4 degrees F to122 degrees F. In hot climates, keep storage temperatures as low as possible.High storage temperatures will ruin a battery. Generally, the cooler the better.Charging should occur above 40 degrees F. In temperatures below 40 degrees F,the batteries will take much longer to charge and may not charge fully. Batteries leftin temperatures below -4 degrees F must be thawed before charging or they mayvent. Allow batteries to thaw for at least six hours.Stored rechargeable batteries will permanently lose capacity . . even faster in HOTenvironments . . . so . . charge them at least every six months or better yet . . USETHEM!WHEN WORKING WITH RECHARGEABLESUSE THEM OR LOSE THEMTAB D
SECONDARY BATTERIES (RECHARGEABLE)ADAPTER REQADAPTER REQBATTERY NAMEEQUIVALENTBATTERY NSNU/IFY-07 PRICEFOR SPCFOR VMCBB-2590/UBA-55906140-01-490-4316EA 295.18J-6358B/PJ-6520A/U J-6581/UBB-390B/UBA-55906140-01-490-4317EA 242.59J-6358B/PJ-6520A/U J-6581/UBB-388A/UBA-55886140-01-490-4313EA 3-7674EA EA 80.10J-6355/PBB-2847A/UBA-53476140-01-493-8092EA 070EA 87EA 0-4311EA 5372EA 117.82J-6587/PJ-6520A/UAA RechargeablesMBITR BatteryJ-6589/PEA6140-01-487-1153EAJ-6589/P 174.25J-6588/PSPC with various battery adaptersJ-6584/UTAB E
SECONDARY BATTERIES (RECHARGEABLE)The most widely used secondary (rechargeable) batteries are the BB-390B/U and the BB-2590/U.Nickel Metal Hydride.4 year warranty.Lasts 16 to 20 hoursin SINCGARS radios.Life cycle 3 – 5 years.Requires periodicconditioning.BB-390B/ULithium-Ion. Deserttan. Weighs onepound less than theBB-390B/U and hasa higher capacity.Does not requireconditioning.4 year warranty.BB-2590/UThe BB-390B/U and the BB-2590/U are warranted for four years. Check themanufacturing date (7/03) to the left of the S/N. The first digit is the month, thesecond is the year. This date starts the warranty clock.The BB-2590/U is approved for use in the AN/PRC-104, AN/PRC-113, AN/PRC117, AN/PRC-150, AN/PSC-5, KY-57, KY-99, and all SINCGARS models.Note: The BB-2590/U is NOT APPROVED for use in the Javelin CommandLaunch Unit. The higher voltage of the BB-2590/U will damage the CLUTAB Fcontrol unit.
ALTERNATIVE POWER EQUIPMENT DATA CHARTNOMENCLATUREMODELTAMCNNSNBATTERY CHARGER/ANALYZER CASP 0026130-01-527-2726 2,272.00PP-8498/UA00126130-01-495-2839 2,028.00MRC-93H77066130-01-520-8178 1,994.85SINCGARS SINGLE POWER ADAPTER (SSPA)PAC-216/UH77105985-01-465-2867 2,495.00MULTI-SINCGARS POWER ADAPTER (MSPA)ASAPS-6 / SNAP 6H77156130-01-458-4041 2,375.00ASAPS-SC / SNAP 6CCH77056130-01-473-0349 2,260.00QP-1800H0004TBA 2,555.00DISCHARGE CAPPP-8497/UN/A6130-01-490-4310 66.54SPC SLAVE CABLEJ-6362A/UN/A5940-01-501-6714 172.09CX-13560/GN/A5995-01-505-7883 65.05MRC-41N/AMcDowell Corp 1,371.46MBITR BATTERY CELL HOLDER for AN/PRC-148N/A6160-01-487-1151 157.00SCAVENGERN/A6130-01-539-0646 308.00VEHICLE MOUNTED CHARGER (VMC)SUITCASE PORTABLE CHARGER (SPC)SINGLE RADIO POWER ADAPTER 24VMULTI-RADIO POWER ADAPTER (MRPA)QP-1800 System W/NATO Slave cable and caseSPC NATO SLAVE Y-CABLEMBITR BATTERY BOX for AN/PRC-148AN/PRC-119F (ASIP) POWER ADAPTERVB-90IRIS TechnologyFY-07 PRICE 2,045.00In order to be effective on the battlefield, a unit must be able to Move, Shoot andCommunicate. Early into the invasion of Iraq, severe shortages of BA-5590/U batteriesalmost delayed combat operations. Units can mitigate future problems by trainingwith and employing alternative power. Become BATTERY INDEPENDENT.TAB G
BATTERY CHARGERSPP-8333/U CHRISTIEBATTERY CHARGER/ANALYZERPP-8498/U SUITCASEPORTABLE CHARGERPP-8481B/U VEHICLEMOUNTED CHARGERSPCVMCProgrammable.Requires periodic calibration.SL-3 cables support the BB516, BB-586, BB-557, BB-590,BB-390B/U, BB-588, and BB699. Other cables areavailable (refer to PP-8333/Udata sheet in TM-12359A-ODlocated in the Electronic ToolBox).Will not charge the BB-2590/U.Requires MI-09591A-25/1B forthe BB-390B/U.Sequentially charges up toeight batteries (two at atime) in approx. 8 hours.Operates from AC or DC.Comes with AC cable, DCcable must be ordered.Will charge the BB-2590/U.Will not charge the BB-590.Software upgradeable.Mounts in a tactical vehicle.Charges two batteries at atime and moves to the nexttwo in queue. Operates fromDC or AC. Comes with AC &DC Cable. Will charge theBB-2590/U. Will not chargethe BB-590. Softwareupgradeable.See TAB I for SPC/VMC adapter chart.See TAB J for SPC/VMC software updates.Both the SPC & VMC are equipped with VEH batterylow voltage detection & cutoff protection.TAB H
SPC/VMC CHARGER TO ADAPTER REF TABLERedindicatesUNIVERSALADAPTERSwhich aredesigned tohold variousdifferenttypes ofbatteries atthe sametime.ADAPTERADAPTER NSNFY-07 PRICEU/IRECHARGEABLE BATTERYJ-6358B/P5940-01-501-3312 79.62EABB-2590/UJ-6357A/P5940-01-493-6388 28.14EABB-388A/UXJ-6356/P5940-01-427-9183 28.14EABB-326/U (old BB-516A/U)XJ-6355/P5940-04-427-9247 44.96EABB-503A/UXJ-5354/P5940-01-427-9278 60.47EABB-2847A/UXJ-6523A/P5940-01-492-7238 46.25EABB-557/UJ-6521/P5940-01-467-8813 44.96EABB-2600A/UXJ-6587/P5940-01-493-6750 43.66EABB-2800/UXJ-6589/P5940-01-493-7622 84.39EAAA BATTERIESXJ-6588/P5940-01-493-6751 68.88EAMBITR BATTERY (PRC-148)XJ-6520A/U5940-01-493-8744 44 44 331.64EABB-516A/UBB-326XJ-6520A/U5940-01-493-8744 331.64EABB-2847A/UJ-6581/U5940-01-494-7116 0 0 -6584/U Universal Adapter for the VMC.TAB I
BATTERY CHARGERANCILLARY DEVICESDISREGARDJ-6362A/U DC slave cablefor the PP-8498A/U (SPC).Disregard the smaller cable CX-13560/G connectstwo SPC’s to one DC(attached), it is only usedwith the legacy PP-8444A/U. slave cable (J-6362A/U).PP-8497/U Self-Discharge Device(CAP), black, tan or dual colored, isused to discharge (condition) theBB-390B/U or “Quick Check” thatboth 12-volt sections of the batteryare working. When used with theBB-2590/U, it is only used to providea “Quick Check”. The BB-2590/Udoes not require conditioning.SPC/VMC SOFTWARE UPDATESThe current version of software for the SPC is 3 30 .00.exeprogram E. Software updates can be downloaded from theU.S. Army rechargeable battery web site (TAB N) or callyour supporting FSR (TAB Q). As new SPC adapters aredeveloped supporting software updates will be published.The VMC, although software upgradeable, does not requirea software upgrade at this time.TAB J
12/24V RADIO POWER ADAPTERS24VPOWER ADAPTER,SINCGARS SINGLE POWER24V MRC-93ADAPTER (SSPA) or AN/PAC-216Replaces batteryReplaces batterybox. Energizes one box. Energizes one24V radio using ACSINCGARS radioor DC input.using AC input.Built in UPS. DoesThe MRC-93 is UPS capable when any BAnot operate off DC5590 equivalent battery is inserted into thepower.adapter. Will not charge batteries used in12Vthis configuration. Warranted for 4-years.MULTI-SINCGARS POWER ADAPTER(MSPA) or ASAPS-6Energizes up to sixSINCGARS radiosusing AC or DCpower.12VMULTI-RADIO POWER ADAPTER(MRPA) or ASAPS-SC/SNAP 6CCEnergizes up to six 12Vradios using AC or DCpower. Supplied with six12-foot radio powercables.12VThe MSPA & MRPA are more effective when connected to both AC &VEH DC. While operating from the AC source, the VEH battery acts asan UPS. The AC power also maintains the VEH battery SOC.TAB K
COMMERCIAL-OFF-THE-SHELF (COTS)PrototypeVB-90 Power Adapter forthe AN/PRC-119F (ASIP).SCAVENGER – rechargeAAs in 100 minutesscavenging unused energyfrom BA-5590 equivalentbatteries.Products pictured (TAB L) have not been tested to MIL SPECstandards.MRC-41 – holds primaryor rechargeable battery,powers the AN/PRC-148.Buyer beware, many vendors will attempt to sell products they claimto meet military specifications. They may or may not fail at high orlow operating temperatures or in field environments.Any product containing Lithium must be tested and approved forMarine Corps use under the Navy Lithium Battery Safety Program.AN/PRC-148 (MBITR) Battery Cell Holder, holdsDL2/3A, provides ten hours of operation.TAB L
DC TO AC INVERTERSThe QP-1800 is a semi-ruggedized 1800W DC toAC (True Sine Wave) inverter that enablesoperation of 115 VAC powered devices fromvehicle power (24 VDC). The QP-1800 connectsto the vehicle using a supplied NATO SLAVEcable.BATTERY SAFETYWhen used incorrectly or mishandled, batteriescan be hazardous. Be familiar with the materialsafety data sheets for all battery types.TAB M
WEB SITE’SU.S. Marine CorpsProgram ManagerExpeditionary Power SystemsMarine Corps Systems Commandwww.marcorsyscom.usmc.mil/sites/pmepsU.S. ArmyRechargeable q/power/rechargebat.htmlIntroduction, NSNs and PricesDA Rechargeable Battery Policy . . .It's Time to get all "Charged upTAB N
TRAININGBattery Maintenance and SustainmentSystems (CD is available from FSR’s)Power Management forCommunication Equipment Operators(available at www.marinenet.usmc.mil,course 0612AO)12 Volt and 24 Volt Radio Adapter andPower Supply (CD is available from FSR’s)PP-8333/U, Christie Casp 2000HBattery Charger, operator’sinteractive CD (available fromFSR’s)TAB O
BATTERY PLANNING TOOLSMaster BatteryRequirementsModel Battery planning tool Standard record of T/E equipment that usesbatteries Have exercise specific records Standard reports and back-up Run scenario’s MUST BE TRAINED in use prior to issue Available from your supporting FSRPOWER 1.1 Battery Calculator isan excel data base applicationdeveloped by the U.S. Army toestimate communications equipmentbattery requirements. It is availablefrom your FSR or by contactingWebPubEPS@mcsc.usmc.mil.TAB P
POINTS OF CONTACTPM EPS FIELD SERVICE REPRESENTATIVESI MEF CAMP PENDELTONMr. Talmadge Jacksontalmadge.d.jackson.ctr@usmc.mil(760) 725-4923III MEF CAMP KINSERMr. John 3 (DSN 637-5023)II MEF CAMP LEJUENEMr. Ken Copelandken.copeland@usmc.mil(910) 451-1902MEF FORWARDMr. Daryl WilsonWilsonDK@cssemnf-wiraq.usmc.milDSN 302-3640-220 (Iraq)PM EPS MARINE CORPS SYSTEMS COMMANDADVANCED POWERSend questions to PM EPS MCSC atTEAM LEADERMs. Joanne l(703) 432-3584 (DSN 378-3584)U.S. ARMY RECHARGEABLE BATTERY PROGRAMMr. Don Brockeldonald.brockel@us.army.mil(732) 532-4948TAB Q
WebPubEPS@mcsc.usmc.mil
QUESTIONSmbissonnette@mkisystems.com
MRC-93 . Single Radio Power Adapter . REMARKS . Although the MRC-93 will operate from AC or DC power, the QP-1800 (TAB M) can be used to convert VEH DC power to AC power and energize the MRC-93. BA-8180/U with J-6687/U 24V radio adapter (TAB C) The BA-5390 has not been approved for use in
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