THM_MINT_PROC_054d Battery Handling Plan
Contents
1. SPACE SCIENCE LABORATORY THEMIS MINT THEMIS UNIVERSITY OF CALIFORNIA PLANS gt BERKELEY TITLE THEMIS PLAN for BATTERY DOC THM MINT PROC 054 MAINTENANCE and OPERATIONS Rev D REVISION DATE May 24 2006 REVISIONS APPROVALS ENG DATE QA DATE MSE DATE PM DATE 1 0 INTRODUCTION 2 0 BATTERY HANDLING DURING INTEGRATION AND TEST 3 0 SHIPMENT 4 0 STORAGE 5 0 POWER SYSTEM EGSE 6 0 EGSE PROBE CONFIGURATION 7 0 FINAL CHECKOUT AND PREPARATION FOR LAUNCH APPENDIX A BATTERY CHARGING SCHEMATIC 1 Introduction This document describes the plan for operating and maintaining the Lithium Ion batteries used on the THEMIS probes The first Probe is delivered to UCB from Swales with an Engineering Model EM battery which is swapped with a flight battery after environmental testing The subsequent four Probes are all delivered to UCB with flight batteries integrated This battery plan is based on information obtained from the following documents as well as direct consultations with the battery manufacturer AEA Technology 2 Reference Documents e THEMIS Li Ion Design Description AEA Technology THMIS AEA RP 0005 THEMIS Li Ion Battery User Manual and Design Description AEA Technology THMIS AEA MA 0039 THEMIS Li Ion Electrical Analysis Report AEA Technology THMIS AEA RP 0014 THEMIS Battery Interim Charge Discharge Procedure Swales Aerospace SAI PROC 1558 THEMIS Battery Hand2. Prior to integration of the Probe Bus with the Instruments the battery shall be placed in controlled storage at Swales for an estimated time period of 5 months The batteries are stored in a refrigerator at approximately 4 C with monitored temperature The AEA fade calculation assumes storage of up to a year at 25 C 4 1 Charging Methods Charging of the batteries may be accomplished via the DPC or the SAS in the EGSE rack or via the battery rack 4 2 Discharging Methods The discharging of the batteries may be accomplished using the EGSE Rack only and running the probe without charging it 5 0 Probe Power System EGSE The Power System EGSE consists of the following e 4 Solar Array Simulators Agilent 6633B power supplies driven by labview programmed I V curves If setting the parameters manually the nominal settings are 0 33A and 38V with the over voltage protection set to 39V and the current limit set to 0 500A e 1 Direct Power Supply DPC Agilent 6633B used for initial power of the probe prior to commanding the battery enable relay closed The current limit is generally set at 1 75A and the over voltage protection set to 39V e Solar Panel Set Simulator SPSS Allows SAS power routing to be switched between the Solar Panel connector interfaces and the umbilical interface The SPSS also contains resistors to simulate the solar panel PRTs and linear shunt resistors 6 0 EGSE Probe Configuration There are three possib
3. measured battery voltage 3 Closes battery relay once voltages are matched and current is not flowing through the battery relay If running in SAS Battery configuration each of the four SAS power supplies representing the four Solar Array strings shall be set to 0 33A in constant current mode when the battery is below 70 SoC lt 32V This simulates the current expected to be provided by the Solar Arrays on orbit When the battery is above 32V the SAS current shall be set lower than 0 33A or operations should be switched to use the battery only If running in DPC Battery configuration the DPC shall be set to 32V plus the voltage drop determined approx 4V typ when bringing up the system The goal is to keep the battery at approximately 31 32V throughout the Integration and Test Phase This will keep the battery SoC at 50 70 keep the shunts off minimize time at high SoC minimize high charge discharge rates and minimize high DoD Finally it is similar to expected flight bus voltage which is predicted to be at the full charge voltage of 33 6V most of the time For most I amp T activities the SAS Battery configuration is desired as it most closely represents the on orbit configuration 2 3 Operations During Environmental Test During all Environmental testing batteries will be kept at a constant state of charge around 31 32V as stated above During thermal vacuum testing the battery temperature will stay within the vendor approv
4. switches SW1 2 3 4 are set to ON Probe with some side solar array panels installed With some of the side panels installed the probe can be powered through the umbilical and the linear shunt function still preserved through the C3038 harness In this configuration the C3038 Octopus harness is connected to the uninstalled probe solar array connectors and the SAS power routed via the Umbilical The SAS Power Router Switch SW 5 is set to PUD and all of the SAS switches SW1 2 3 4 are set to OFF When DPC only is used to power the probe not typically recommended power available for the bus will be limited The over voltage protection circuit is designed to turn all shunts on if the battery relay is disabled and power is applied to the probe Therefore the DPC will need to provide excess current above the expected bus current due to the linear shunt The current provided is dependent upon the bus voltage 7 0 Final Checkout and Preparation for Launch Configuration The Flight batteries will receive final preparations for launch at Astrotech s Hazardous Operations Building just prior to shipment of the full payload including Delta 3rd Stage This final launch preparation will consist of charging the batteries to full SofC while monitoring using the umbilical rack not the battery charging rack Transportation to the Pad and Pad Activities Except for launch pad charging no battery processing of any type will occur during transport
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6. below as described in the normal operations section below For transportation the battery shall be discharged to lt 50 SoC The AEA fade calculation assumes a non op 100 SoC and 50 cycles to a 50 SoC Battery SoC is constantly monitored via the ITOS system and a file log is maintained throughout all activities Note AEA Technology recommends e Battery should not remain at high SoC for more than 6 days and e Batteries should be stored with lt 5 SoC Prior to integration of the Probe with the Instruments the batteries are stored at lt 5 SoC at Swales The AEA fade calculation assumes storage at 10 SoC 2 1 3 Protection Against Over Voltage and Short Circuit Protection 100 SoC for the THEMIS battery is 33 6 Volts The first line mechanism for not overcharging the battery is ensuring that the power systems shunts are always installed whenever the probe is powered by following the guidelines for Power EGSE configuration above Specifically when a side solar panel is not installed the C3038 Octopus harness must be connected In addition the battery has built in over voltage protection Each cell contains a disconnect mechanism if that disconnects a cell should it charge beyond 4 8V and the cells are matched to inhibit voltage imbalance between cells or overcharging of one cell Over discharging is not hazardous operation for this battery contrary to other battery chemistries Over discharge tests show that this form of abuse may
7. ed operating limits of 15C to 40C There are three thermistors on the battery for temperature monitoring During all I amp T activities yellow temperature limits shall be set to 10 C and 30 C and red temperature limits set to 15 C and 40 C in ITOS Operators continually monitor the Probe whenever powered and will be alerted immediately if the battery goes outside of these limits If conditions are such that the battery is run for an extended time gt 15 minutes above the yellow limits or if the red limits are reached the test shall be stopped and the conditions changed The AEA fade calculation assumes a typical operating temperature of 25 C AEA has also stated that temporary lt 48 hours thermal excursions to 50 C are acceptable Note AEA Technology recommends e Operating Battery temperature 10 C and 30 C preferred 15 C and 40 C acceptable e Storage Battery temperature Refrigerator storage is recommended 2 4 Battery Charging Not Allowed Due to safety concerns no battery charging is allowed during RCS pressure testing and Probe fueling 3 0 Shipment of Batteries The flight batteries shall be discharged to lt 20 SoC for shipment durations longer than 10 days The temperature of the environment will be monitored Following shipment if the batteries are discharged they shall recharged using the Battery Rack EGSE See Swales Battery Rack Users Guide for charge rates and procedure 4 0 Battery Storage
8. harge DoD Whenever possible the battery will be kept at 20 C or lower 2 Non Operational Non Operational 2 5 00 Test operational Storage 6 months Figure 1 1 AEA Technology Fade Estimate for Ground Operations 2 Battery Handling During Integration and Test 2 1 Charging Safeguards and Procedure 2 1 1 Charging and Discharging Charging discharging the battery is done routinely during when the Probe is set to Battery SAS Solar Array Simulator or Battery DPC umbilical operation See normal operations section below The typical probe load with all instruments on is 0 9A close to the C 10 1 2A desired The maximum probe load with transponder on is approximately 1 7A Additional current draw from the heaters is possible only during Thermal Vacuum testing During all Probe level I amp T activities the linear shunt circuit is automatically activated whenever the battery voltage reaches the target voltage of 33 6V sinking current not used by the loads away from the bus Safe spacecraft operating voltage of approximately 25V not the battery limit sets the lower battery voltage used during I amp T Note AEA Technology recommends e Charge discharge rate of C 10 1 2A although up to 12 is acceptable and Charge discharge should be limited to between 33 6V and 20 0V 2 1 2 State of Charge During I amp T activities the battery will typically be between 50 70 SoC 31V to 32V see Figure 3 1
9. increase the internal resistance of the cells but does not result in a hazardous event The first line mechanism against short circuiting the battery is installation of a Battery Fuse Plug which is used at UCB during preliminary Instrument Integration The Fuse Plug is removed during final close out after the Instruments have been integrated and prior to environmental test In addition the battery has built in short circuit protection Each cell has a Positive Temperature Coefficient PTC polymer current limit device fitted to the top cap This protects against over current by temporarily increasing the in line resistance as it expands thermally Battery discharge Battery charge Figure 3 1 Battery Voltage versus SoC 2 2 Operations During Integration THM MINT PROC 010 Probe Power On Off Procedure provides the normal power on procedure for the THEMIS Probe Unless otherwise noted for a specific test the Probe shall always be run in the SAS Battery or DPC Battery configuration as opposed to being run off of the DPC without the battery connected An ITOS script baupoweron proc has been created to bring the Probe up in a safe power configuration The script steps through the following sequence 1 Brings up the system on DPC with the battery disconnected Operator input for initial conditions of the DPC should be Battery Voltage plus approximately 4V and 1750mA 2 Runs script dpeadjust proc to match the DPC voltage and
10. le power configurations used during various stages of Probe Integration and Test Each requires a different EGSE configuration which must be in place to power on the Probe without risk to the Battery e Probe with all solar array panels installed e Probe with no side solar array panels installed e Probe with some of side solar array panels installed For a complete power system the linear shunt resistor function must be included in the EGSE Probe configuration However the probe may be powered using only the DPC with careful consideration for the shunt configuration battery state of charge and power required Probe with all solar array panels installed When the probe is completely assembled the EGSE is not required to supply shunt resistors In this configuration the SAS power is routed to the probe via the umbilical harness and the linear shunt resistors and PRTs are located on the solar array panels The SAS Power Router Switch SW 5 is set to PUD and all of the SAS switches SW1 2 3 4 set to OFF Probe with no side solar array panels installed Without the all of the side panels the probe power system does not contain the linear shunt resistors required for battery charge regulation In this configuration the C3038 Octopus harness is connected to the probe solar array connectors and the SAS power may be routed via the C3038 harness or the Umbilical The SAS Power Router Switch SW 5 is set to SPSS or PUD and all of the SAS
11. ling Memo Swales Aerospace SAI TM 2647 THEMIS Launch Site Battery Processing Swales Aerospace SAI TM 2827 THEMIS Power Up Power Down Procedure Swales Aerospace SAI PROC 1557 THEMIS Battery Rack Users Guide Swales Aerospace Joint 45 SW SE and 30 SW SE Interim Policy Letter Regarding EWR 127 1 Requirements for Li Ion Batteries 3 Objective The purpose of this plan is to ensure safe operation of the battery and to preserve battery capacity prior to launch Worst case conditions during storage shipping integration and test and launch site processing have been used in the Battery Electrical Analysis Software Tool BEAST to determine a battery fade estimate This fade estimate was used to validate the battery capability over the mission lifetime Following this plan will ensure that the fade analysis assumptions remain valid for the ground operations phase The fade estimate from THMIS AEA RP 0014 for Integration and Test and Ground Operations is shown in Figure 1 1 below with assumptions provided in the corresponding table In addition it should be noted that the existing capacity fade estimate of 7 is conservative and could be reduced by controlling the battery storage and testing thermal environment limiting long periods of storage over 4 days at high SoC and minimizing the quantity and severity of test on the ground i e minimize time at high State of Charge SoC minimize charge discharge rates and minimize Depth of Disc
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