. 25'2

AMiL-80-50ANL-80-50

JX-)

FIFTY CELL TEST FACILITY

by

J. 0. Arntzen, V. M. Kolba,

W. E. Miller, and E. C. Gay

MASTEi"

p~z~ -+ t .,Ra~v++frR..N : ,. T v L v cz -: v .. .,., i r ."iym: ._ k -..'T

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AA

ARGONNE NATIONAL LABORATORY,

Prepared for the U. S. DEPARTMENTundo? Contract W-31-109-Eng-38

ARGONNE, ILLINOIS

OF ENERGY

.AnI n JF1S00 %

The facilities of Argonne National Laboratory are owned by the United States Government. Under theterms of a contract (W-31-109-Erg-38) among the U. S. Department of Energy, Argonne UniversitiesAssociation and The University of Chioago, the University employs the staff and operates the Laboratory inaccordance with policies and programs formulated, approved and reviewed by the Asscciation.

MEMBERS OF ARGONNE UNIVERSITIES ASSOCIATION

The University of ArizonaCarnegie-Mellon UniversityCase Western Reserve UniversityThe University of ChicagoUniversity of CincinnatiIllinois Institute of TechnologyUniversity of IllinoisIndiana UniversityThe University of IowaIowa State University

The University of KansasKansas State UniversityLoyola University of ChicagoMarquette UniversityThe University of MichiganMichigan State universityyUniversity of MinnesotaUniversity of MissouriNorthwestern UniversityUniversity of Notre Dame

NOTICE

The Ohio State UniversityOhio UniversityThe Pennsylvania State UniversityPurdue UniversitySaint LouAs UniversitySouthern Illinois UniversityThe University of Texas at AustinWashington UniversityWayne State UniversityThe University of Wisconsin-Madison

Printed in the United States of AmericaAvailable from

National Technical Information ServiceU. S. Department of Commerce528 Port Royal RoadSpringfield, VA 22161

NTIS price codesPrinted copy: A03Microflehe copy: A01

fit ; {;: . . '

This report was prepared as an account of work sponsored byan agency of the United States Government. Neither the UnitedStates Government or any agency thereof, nor any of theiremployees, make any warranty, express or implied, or assumeany legal liability or responsibility for the accuracy, com-pleteness, or usefulness of any information, apparatus,product, or process disclosed, or represent that its use wouldnot infringe privately owned rights. Reference herein to anyspecific commercial product, process, or service by trade name,mark, manufacturer, or otherwise, does not necessarily con-stitute or imply its endorsement, recommendation, or favoringby the United States Government or any agency thereof. Theviews and opinions of authors expressed herein do notnecessarily state or reflect those o; the United States Govern-ment or any agency thereof.

-4

w U

Distribution Category:Energy Storage-ElectrochemicaL -

Advanced Batteries (UC-94cb)

ANL-80-50

ARGONNE NATIONAL LABORATORY9700 South Cass Avenue

Argonne, Illinois 60439

FIFTY CELL TEST FACILITY

by

J. D. Arntzen, V. M. Kolba,W. E. Miller, and E. C. Gay

Chemical Engineering Division

DISCLAIMER

NO-11her ,hpUnrlraf S,.,i, (MMannrtr "nut, m 1r y f ,f xran ofher mp' M wb *l-- ny.e.L~ rrwl oaYr

July 1980

TABLE OF CONTENTS

Page

ABSTRACT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

I. INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . 1

II. TEST FACILITY DESCRIPTION . . . . . . . . . . . . . . . . . . . 2

A. Test Module . . . . . . . . . . . . . . . . . . . . . . . . 3

B. Data Acquisition System . . . . . . . . . . . . . . . . . . 8

III. FACILITY OPERATION . . . . . . . . . . . . . . . . . . . . . . . 14

ACKNOWLEDGMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

REFERENCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

APPENDIX A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

APPENDIX B . . . . . . . . . . . . . ........ ...... 0... . . 28

ii

LIST OF FIGURES

No. Title Page

1. Overall View of 50-Cell Test Facility . . . . . . . . . . . . . . 2

2. Partial View of 50-Cell Test Facility . . . . . . . . . . . . . . 3

3. Individual Cell Testing Module . . . .. . . . . . . . . . . . . 4

4. Heating Chamber for Facility Module . . . . . . . . . . . . . . . 5

5. Outside View of Side and Front Panel of 100 A-hr Cycler . . . . . 9

6. Inside View of100A-hr Cycler . . . . . . . . . . . . . . . . . 10

7. Back View ofl100A-hr Cycler . . . . . . . . . . . . . . . . . . 11

8. Data-Acquisition System for Test Facility . . . . . . . . . . . . 12

9. Local Terminals and CAMAC Portion of the Data AcquisitionSystem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

10. Computer Printout of Performance Data Initially Obtained fromData Acquisition System . . . . . . . . . . . . . . . . . . . . . 15

11. Computer Printout of Later Format for Performance Data Suppliedby Data Acquisition System . . . . . . . . . . . . . . . . . . . 16

12. Printout of Voltage, Current, and Temperature at One-MinuteIntervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

LIST OF TABLES

1. Cycler Specifications . . . . . . . . . . . . . . . . . . . . . . 7

iv

FIFTY CELL TEST FACILITY

by

J. D. Arntzen, V. M. Kolba, W. E. Miller, E. C. Gay

ABSTRACT

This report describes the design of a facility capable of thesimultaneous testing of up to 50 high-temperature (400-500*C)lithium: alloy/iron sulfide cells; this facility is located in theChemical Engineering Division of Argonne National Laboratory (ANL).The emphasis will be on the lifetime testing of cells fabricatedby ANL and industrial contractors to acquire statistical data onthe performance of cells of various designs. A computer-based'ata-acquisition system processes the cell performance data generatedfrom the cells on test. The terminals and part of the data-acquisition equipment are housed in an air-conditioned enclosureadjacent to the testing facility; the computer is located remotely.

I. INTRODUCTION

Argonne National Laboratory (ANL) is developing high-performance, elec-trically rechargeable batteries for electric-vehicle propulsion and forstationary energy storage. The battery cells that are currently underdevelopment consist of a Li-Al negative electrode, an FeS or FeS2 positiveelectrode, and molten LICl-KC1 electrolyte. The melting point of theelectrolyte (352*C at the eutectic composition of 58.2 mol % LiCl) requiresa battery operating temperature in the range of 400-500 C. The majorrequirements for an electric-vehicle battery are high specific energy, highvolumetric energy density, and high specific power. Economic considerationsrequire a minimum battery lifetime of about 3 yr (about 1000 deep dischargecycles at a 4-hr discharge rate). Stationary energy-storage batteries havesomewhat less stringent specific-energy and specific-power requirements,but this application demands a lifetime of about 10 years (3000 cycles at a5 to 10-hr rate).

The successful development of the lithium alloy/iror sulfide batteryrequires a facility for the testing and evaluation of a large number ofcells. At present, the only method for lifetime testing is to cycle a cell(or group of cells) until a preselected lifetime goal is -eached or untilthe cell fails (i.e., performance drops below a specified level); thistesting method is time-consuming. To help minimize the required testing time,a facility capable of the simultaneous testing of up to 50 cells hasbeen constructed in the Chemical Engineering Division (CEN) at ANL. Thelifetime testing of a significant number of cells will provide a data basefrom which a statistical analysis of various cell designs can be made;furthermore, this statistical analysis will provide a basis for estimatingthe performance and lifetime of battery modules of many different sizes.For instance, according to the success-run theorem (Boyes' formula),1

1

2

if 10 cells of one type can be tested to a specified lifetime goal withno failures, then the reliability of this group would be 76% at the 95%confidence level, i.e., no more than 24% of 10 such cells would failwithin the specified time. Similarly, if 100 cells of one type can belifetime tested with no failures, then the reliability would be 97% at the95% confidence level; in this case, no more than 3 cells out of 100 would beexpected to fail within the specified lifetime. Discussions with some membersof industry have indicated that industrial firms will not make a largeinvestment in a pilot plant until lifetime testing of hundreds of cells hasdemonstrated the commercial potential of the lithium/iron sulfide cell.

II. TEST FA' ILITY DESCRIPTION

Figure 1 presents an overall view of the cell test facility, whichcontains 50 cell test stations (referred to as "modules") and a data

acquisition system. The desired facility area was %90 m2 (%1000 ft2);however, the available area was %82 m2 (,u880 ft 2). Power to this facilityis provided through 37.5 kVA and 45 kVA transformers.

Fig. 1. Overall View of 50-Cell Test Facility. ANL Nog, No. 308-78-463

3

The make-up of the cell-test module and data acquisition Fvstem (DAS) isdescribed below. Figure 2 shows a closeup view of a single row of testmodules.

Fig. 2. Partial View of 50-Cell Test Facility. ANL Neg. No. 308-79-42

A. Test Module

The test module design was based on the requirement for a minimum foot-print, ready access, easily replaceable components and cells, and minimalco.ts. Each module consists of an open relay rack (Bud #1364) which containsa heating chamber, furnace temperature-control panel, cell cycler, a' I powersupply. A photograph of an individual cell testing module is given in Fig. 3.

The heating chambers, shown in Fig. 4, are 87-liter (23-gal), 22-gaugesteel drums filled with an insulating material (High TemperatureBlock*) that is non-flammable, electrically non-conductive, and rigid.

*Forty Eight Insulations, Inc. Aurora, IL.

4

/POWER SUPPLY

Is

Fig. 3. Individual Cell Testing Module.ANL Neg. No. 308-78-178

0

I 0

t

-- HEATER CONTROLPANEL

1 -CYCLER

-CURRENT LEADS

VOLTAGE SENSE LEADS

THERMOCOUPLE

- PURGE GAS OUTLET

BUBBLER

RELAY RACK

DRUMHEATING CHAMBER

ARGON GAS INLET

5

INSULATION

~dJs BUBBLER

DRUM LID

7ER PLATES

CURRENT LEADS

DRUM

RADIATIONSHIELDS

SUPPORT RODS

THERMOCOUPLE

CLAMPING PLATE

Fig. 4. Heating Chamber for Facility Module. ANL Neg. No. 308-78-179

A cavity in the insulation contains two 370-W ceramic plate-type heatingelements* spaced to allow the cell and clamping plates to be inserted betweenthe elements. The heater power (115 V) is brought into the drum through aDuctorealt feedthrough mounted in the side of the drum. The cell clampingplates, two radiation shields, and two layers of rigid insulation are suspendedfrom the lid. A quick release clamp is used to fasten the lid to the drum.During testing, the cell is suspended from the lid between the clamping plates.Cell voltage and current leads enter the drum via feedthroughs (Ductoreal) inthe lid. Both the voltage leads contain a 3-A in-line fuse for cell andequipment protection. The right side of Fig. 4 shows the drum lid with attach-ments, including a clamped cell ready for insertion and testing.

*Electro-Applications, Inc., Washington, PA.

Douglas Engineering Co., Rockaway, NJ.

000ii

6

For corrosion protection, each cell is maintained under a positive-pressure argon-gas blanket while in the heating chamber. The gas is broughtto the chamber from a 101-kPa (15-psig) argon manifold; this pressure isreduced to 0.5-kPa H20 maximum pressure before the gas is piped to theindividual heating chambers. Each drum has a gas inlet with a valve near itsbottom. The gas outlet is in the cover, and a pressure-vacuum reliefbubbler is located between the outlet valve and the cover. During operation,the heating chamber is initially purged, and then the outlet valve is shutoff to maintain the argon-gas blanket when at temperatures >25*C.

As shown in Fig. 3, the heater/power control panel for the heating chamberis located near the top of the relay rack along with the cycler and powersupply. The heater/power control panel utilizes a Variac* to limit powerinput and a Love temperature controllert with thermocouple burnout protectionfor temperature control. The thermocouple is located at the center of one ofthe side faces of the cell (see Fig. 4).

The design requirements for the cyclers are given in Table 1. The cellcycler controls the charge and discharge of the cells using a programmablepower supply. The cycler contains additional features to charge and dischargecells in accordance with prescribed test procedures. The cycler can operatein the following modes: constant current discharge and charge, current-limitedconstant-voltage charge, and timed open-circuit periods (up to 999 min). Thecyclers are not computer-controlled (increased reliability), but a computeris used to monitor the cell performance. With this arrangement, the cycleris low in cost, and the equipment and programming required for data acquisitionat a remote site are minimized.

The voltage and current ratings specified for the cyclers were establishedto provide for most types of anticipated life testing. These criteria werebased on testing cells for a maximum discharge time of 4 hr, with a projectedmaximum cell capacity of ".400 A-hr. The precision of the voltage and currentregulation and measurement was chosen to be consistent with the desiredaccuracy of the data. The range of cut-off voltage is from 0 to 5 V for asingle cell, which will accommodate either FeS or FeS2 cells. The powersupplies chosen were SCR 7.5-100 units supplied by Electronic Measurements,Inc. (Neptune, NJ). These supplies have a 110 V ac input and a dc output of100 A at 7.5 V and are available as a standard product. The current can beregulated to 100 mA, and the voltage to 3.8 mV. Current regulation of 100 mAcorresponds to 0.1% of maximum output. These values are consistent with theresolution of the computer monitoring system. The voltage can be measuredto a precision of 1.22 mV, the current to 4.88 mV (corresponds to 48.8 mA),and the temperature to 1.22 mV (corresponds to 1.22 C).

*

General Radio, Concord, MA.

tLove Controls Corp., Wheeling, IL.

7

Table 1. Cycler Specifications

Item

Current

Voltage

Power (Discharge)

Automatic Timer

Operational Modes

Discharge

Charge

Open Circuit

Open-Circuit Switch

Cycle Changes

Discharge

Charge

Constant Current

Constant Voltage

Shutdowns (stop cycle)

Furnace Temperature

Cycler Temperature

Watch Dog

Outputs

DAS and Chart Recorder

Cell Voltage

Cell Current

Chassis Size (max.)

Value/Remarks

.' c:able to 100 Aa

At _ "'ble to 5V

2L ;

0-999 min Adjustable (automatic resetwith cycler changes, or off)

Constant Current

Constant Current or Current Limited-Constant Voltage

Adjustable to 999 minb

Manual Operation-Timed (15 sec)

Voltage or Timec Limit

Voltage Limit

Current Limit (adjustable to 99A)

Low

High

High or Low Voltage

Buffered

0-5 V

100 mV/A

47.5-cm wide, 45-cm high and 45-cm deep

aThe plus sign indicates discharge, and the minus sign indicates charge.

bSelectable at end of charge or discharge or both.

cThis is possible on cyclers whose circuits have been modified to providefor a 1- to 999-min timed discharge.

8

Each cycler contains a "watchdog" circuit that is completely independentof other cycler circuitry. This circuit has provisions to shut down the systemshould a low cell temperature or a high cycler diode temperature be reached.This circuit will also automatically shut down each cycler if presetcharge or discharge cutoff voltages are exceeded, Shutdown of any cyclerwill activate a central alarm light and audible signal in the data acquisitionroom (described later). In addition, any shutdown will be accompanied bya flashing light on the cycler affected, which indicates the condition thatinitiated the shutdown.

. Means for protecting the cell under test, the cycler itself, and theoperating personnel were of primary concern when selecting the cycler design.A fire extinguisher is provided for emergencies.

A prototype cycler was designed and built in the Electronics Divisionof ANL 'nder the guidance of John Paul. Tie Unit was debugged by CENpersonnel (W. Lark, G. Chapman, J. Hamilton, and J. Arntzen), and anoperational check-out procedure was developed (Appendix A). After the unitwas functioning properly, "as-built" art work, drawings,* and bills of materialwere prepared by the Electronics Division. A statement of work was thenprepared, bids were solicited, and a contract was awarded to a commercialvendors for the fabrication and check-out of 50 cyclers. The prototype cycler,drawings, art work, bills of materials, check-out procedure, chokes, and twopower supplies (for check-out purposes) were furnished to the contractor. Anoverall. view of a completed cycler is shown in Fig. 5. The front panel withthe operational and shutdown adjustments is shown in this view. Theinternals of the cycler are siown in Fig. 6. Figure 7 shows the location ofthe connections for the power supply, cell voltage and current leads, and thevoltage and current outputs to the DAS or recorder.

B. Data Acquisition System

The number of cells to be tested, measurements to be performed, andsimultaneous calculations to be made warrant the use of an on-line computerfor data acquisition and processing. A schematic diagram of the DAS isshown in Fig. 8. This system has the capability for real-time (i.e., con-tinuous on-line) monitoring of the cell voltage, current, and temperature;processing and storing of the data; and generating data reports as required.Data are available for the following parameters: capacity (A-hr); energy(W-hr); A-hr efficiency; W-hi efficiency; elapsed test time (hr); time ofday, average voltage (V), temperature (*C), and current (A); and maximumand minumum voltage, temperature, and current. A #1500 Powered CAMACI crateand associated equipment interface the cells to the computer (Digital 11/34)

*Numbered the CE-D7051 Series by CEN; Appendix B provides a complete list ofthese drawings.

tParaplegics Manufacturing Co., Inc., Bensenville, IL.

The CAMAC system is an international, modular data-acquisition and controlstandard which, when interfaced to a computer, allows the use of remotestations to gather data and control various types of equipment.

9

Fig. 5. Outside View of Side and Front Panel of 100 A-hr Cycler.ANL Neg. No. 308-79-823

by means of a serial highway. The DAS enclosure, which is a controlledtemperature and humidity area of %13 gn' (ti140 ft2 ), is adjacent to theroom that houses the cell-test modules. The equipment in theenclosure includes a Tektronix 4025 video terminal, a Digital Decwriter IIprinter, and the #1500 CAMAC crate. This equipment is shown in Fig. 9.These terminals provide for checking on the status of the cells and obtainingdata printouts for evaluation purposes. The test data are displayed in theDAS enclosure and the computer room on CRT terminals, and can be printedout on Decwriter terminals in either facility. In addition, hard-copy plotscan be obtained in the computer room on a Versatek printer-plotter. ThePDP 11/34 computer* is located remotely and utilizes disc and magnetic tapefor short- and long-term storage, respectively. The displays includeinformation coded to cell number, cycle number, and time of start and finishof each half cycle. The computer also stores data in the event of powerfailure, and can bootstrap up upon return of power.

*This computer is shared with other users at CEN.

10

ii

'I

111

Fig. 6. Inside View of 100 A-hr Cycler. ANL Neg. No. 308-79-824

r c . -. .e

" wk

e

11

@6

Fig. 7. Back View of 100 A-hr Cycler. ANL Ne,. No. 308-79-825

,

w w

12

H - 126

CAMACCRATE

CRT

TERMINAL

DECWRITERTERMINAL

1

X -WING SERVICE FLOOR

MAG-TA PE

STORAGE

CAMAC DISCCRATE *STORAGE

PDP

COMPUTER

TERMINAL DECWRITER CRT

INTERFACE TERMINAL TERMINAL

VERSATECSPRINTER-

PLOTTER

Fig. 8. Data'Acquisition System for Test Facility.

SIGNALSFROM

50 CELLS

13

Fig. 9. local Terminals and CAMAC Portion of the DataAcquisition System. ANL Neg. No. 308-79-41

14

III. FACILITY OPERATION

Prior to fabrication of all test modules, one module ;as built as aprototype. The overall assembly and operation were checked out. The heatingchamber was brought from room temperature to 460*C in less than two hours;".120 W of power was required to maintain this temperature. Cool-down of theunit from 460 to 50*C required "-24 hr. The temperatures on the currentfeedthroughs on the lid were 70*C, which is well below the rated temperatureof 120*C. The surface temperature of the remainder of the exterior of theheating chamber was <35*C.

Initially, computer printouts from the DAS provided the cell performancedata in the form shown in Fig. 10. Subsequently, the data shown in theprintout given in Fig. 11 were found to be more useful. Figure 12 presentsthe voltage, current, and temperature obtained from a cycled cell at one-minute intervals. Data of this type are useful for analysis of cell perfor-mance over short time intervals.

Present operations are directed to life testing of status cells,*Mark IA celist fabricated by Eagle-Picher Industries, Inc., and developmentalcells for the Mark II program being fabricated by ANL, Gould Inc., andEagle-Picher. At present, maximum usage of the facility is "70% of availablespaces.

Fifteen cyclers have been modified to permit tied discharges, andfifteen modules will be upgraded with larger power supplies to permitdischarge currents of up to 180 A. Some of the electrical lines to themodules will be rewired to permit the loads required to support the newpower supplies, thereby allowing 100% utilization of the facility.

*These are groups of state-of-the-art cells ofin CEN.2

'1

identical design fabricated

These are multiplate cells3 fabricated by Eagle'-Picher for the Mark IA

battery program.

15

09-APR-80 14:44:11BATTERY DATA FILE ANALYSISREPORT FOR MCN '31

START CYCLE NUMBER " 8 END CYCLE NUMBER " 100

START TIME "

DATE/TIME CYC

05-APR-80 18:59 0

05-APR-80 18:18 1

06-APR-80 01:16. 1

06-APR-85 01:17 1

06-APR-La

06-APR-80

06-APR-P'

06-APR-80

06-APR-80

06-APR-80

06-APR-80

06-APR-85

07-APR-80

07-APR-80

07-APR-85

17-APR-81

07-APR-85

07-APR-85

07--APR-8

07-APR-eS

58-APR-81

58-APR-8D

0.. 11.

05:11

12:18..

12:20;.

16:14.

16:14,

23:20

23:21.

53:15

53:16,

10:22

10:23

14:16..

14:16

21:22.

21:23.

51:161

51:16,

2

2

2

2

2

3

3

3

3

4

4

4

4

5

5

5

5

6

0.0000 END TIME *

AVG I5.0

38.1

0.0

-69.5

0.0

38.1

0.0

-69.5

0.0

38.2

0.0

-69.6

0.0

38.2

0.0

-69.6

0.5

38.2

0.0

-69.5

COV

1.01

1.52

1.52

1.01

1.01

1.52

1.52

1.01

1.01

1.52

1.52

1.01

1.01

1.52

1.52

1.01

1.01

1 .52

1.52

1.01

0.5 1.51

38.8 1.52

A-HA

0.00

270.53

0.00

-270.95

0.00

271.13

0.00

-270.89

0.00

271 .23

0.00

-271.38

0.00

271.52

0.00

-270.0

0.05

270.82

5.0

-269.77

5.00

269.66

8U00.000

W-HR AVG T AVG V S-HR EL T A-EF Wo-EF

0.00

383.42

0.0

-321.60

5.00

364.32

0.00

-321.52

5.00

384.51

0.00

-321.95

5.0

384.89

0.00

-328.42

5.00

383.81

5.0

-325.05

5.55

382. 9s

0 0.00

474 1.42

0 0.00

476 1.19

0 0.00

474 1.42

0 0.00

476 1.19

0 0.00

474 1.42

0 0.00

476 1.19

0 0.00

474 1.42

0 0.00.

476 1.19

5 0.00

474 1.42

5 5.00

476 1.19

O 5.55

474 1.42

0.00

7.11

0.00

3.90

0.00

7.12

0.00

3.90

0.00

7.11

0.00

3.90

0.00

7.10

0.00

3.88

0.00

7.10

o.s05

3.88

5.58

7.59

1322.9

1330.1

1330.1

1234.0100.16%

1334.0

1341.1

1341.1

1345.099.91%

1345.0

1352.1

1352.1

1356.0100.05%

1356.0

1363.1

1363.1

1367.099.44%

1367.0

1374.1

1374.2

1378.099.61%

1378.0

1385.1

83.88x

83.66%

83.73%

83.26%

83.39%

Fig. 10. Computer Printout of Pe.rformance Data InitiallyObtained from Data Acquisition System

i

ww.*wfwfwewe**wwwww**"www*******www**w********rwwwernwwrrrwirrrrrrwrr.rwwwrwwwwrwwrr=wawrrrrwrww*ewrwr*r*rwr*w*trw+ *rwwr

10- MKI133 MCN- 31 TEST- 1 OWNER- 31 WEIGHT<KG>: 5.030 THEORETICAL CAP: 361.00CYCLE*- 355 TEST BEGAN * 18-FEB-8 15:14:22 AEFF: 1.0047 WEFF: 0.8379 UTL: 0.7010 HR/KG : 59.62

PHASE BEGIN TIME A-HR V-HR AVG-I AVG-V MAXV MINV MAXI MINI MAXT MINT T-HR S-HR C-HR DWNDCPG 21-JUL-89 88:36-253.065 -299.938 -69.86 1.185 1.381 1.005 -69.71 -70.20 481.19 475.09 3884.9 3.622 3884.88 5.00GCAD 21-JUL-8N 12:13 8.008 5.500 5.05 9.000 ****** ****** -9999.00 9999.88******* 9999.00 3884.9 0.002 3884.88 0.00CHRG 21-JUL-8 12:13 251.881 357.926 37.29 1.421 1.546 1.292 39.67 9.67 479.97 473.86 3891.6 6.755 3891.64 0.00OCAC 21-JUL-89 18:58 5.595 9.599 4.80 5.090 ***** ******* -9999.00 *** 900 ***** 9999.00 3891.6 0.002 3891.64 0.00fffff!"!!lfffseffffeeflwfew**rrarr*w#***r*rr***rrw****w**w*rr********#*iw********w*w******w#*###w*********#*##*******#*#

*****t**rer***frwrrrrrreriwwr**rwrwrrrarww**r******w****#*w*******wrr#*#r#*R**#**###*srw*###«##*ww#*####*w*##w**w*w####

ID- MK11S33 MCN- 31 TEST*- 1 OWNER= 31 WEIGHT<KG>: 5.030 THEORETICAL CAP: 361.00*..ILE*- 356 TEST BEGAN N 10-FEB-80 15:14:22 AEFF: 0.9986 WEFF: 0.8327 UTL: 0.7001 WHR/KG : 59.58

PHASE BEGIN TIME A-HR V-HR AVG-I AVG-V MAXV MINV MAXI MINI MAXT MINT T-HR S-HR C-HR DWNDCHG 21-JUL-8 18:58-252.739 -299.68 -69.91 1.186 1.378 1.008 -69.76 -7.3.35 481.19 475.09 3895.3 3.615 3895.25 0.00OCAD 21-JUL-85 22:35 9.595 5.555 0.00 0.050 ****** ****** -9999.00 9999 00******* 9999.00 3895.3 0.001 3895.25 0.00CHRG 21-JUL-85 22:35 253.186 359.986 37.48 1.422 1.546 1.280 39.72 9.7 49 19 473.86 3902.0 6.752 3902.01 0.00OCAC 22-JUL-85 95:21 9.599 0.NS 0.50 0.005 «*«*** ****** -9999.00 9999.8E******* 9999.00 3902.0 0.001 3902.01 0.00fewew*eeeeen..eena.. *3* ****feseeeee**ww*w*****r*#******************w*.***************************************

**************w*****r**w-**** *0********* ************************************************************

ID- MK1333 MCN- 31 TESTS= 1 OWNER- 31 WEIGHT<KG>: 5.030 THEORETICAL CAP: 361.00CYCLED- 357 TEST BEGAN 1 19-FEB-88 15:14:22 AEFF: 0.9972 WEFF: 0.8310 UTL: 0.7036 WHR/KG : 59.86

----------------------------------------------------------------------------------------------------------------------------PHASE BEGIN TIME A-HR V-HR AVG-I AVG-V 14AXV MINV MAXI MINI MAXT MINT T-HR S-HR C-HR DWNDCHG 22-JUL-8N5 5:21-253.999 -301.589 -69.98 1.185 1.379 1.806 -69.76 -70.35 482.41 476.31 3905.6 3.629 3905.64 0.00OCAD 22-JUL-85 58:58 5.595 5.59N 9.09 0.000 ****** ****** -9999.00 9999.00**-**** 9999.00 3905.6 0.002 3905.64 0.00CHRG 22-JUL-85 98:59 254.792 362.314 37.58 1.423 1.546 1.290 39.81 9.97 481.19 475.09 3912.4 6.778 3912.42 0.00OCAC 22-JUL-8 15:45 9.089 9.05 9.59 5.555 ***** *****" -9999.0 9999.08******* 9999.00 3912.4 0.001 3912.42 0.00*=**e****oar**u****w*eoe******o ********w***##**************-^w******************************** ******** * **

f**iwieriwr****wwr**rrrrrer***iwww*wi.*rw***w****=w*w**#*w####*#w##w*www*w***w***www##w*a*########*w*x##**##*#**ww***###

ID- MKII533 MCN- 31 TEST*- 1 OWNER- 31 WEIGHTcKG>: 5.030 THEORETICAL CAP: 361.00CYCLED= 358 TEST BEGAN 1 19-FEB-8N 15:14:22 AEFF: 1.0007 WEFF: 0.8338 UTL: 0.7043 WHR/KG : 59.88

PHASE BEGIN TIME A-HR V-HR AVG-I AVG-V MAXV MINV MAX! MINI MAXT MINT T-HR S-HR C-HR DWNDCHG 22-JUL-85 15:45-254.254 -301.216 -79.51 1.185 1.379 1.005 -69.81 -70.35 481.19 476.31 3916.0 3.632 3916.05 0.00OCAD 22-JUL-88 19:23 9.889 5.0B 5.50 5.095 6***** ****** -9999.00 999988******* 9999.00 3916.1 0.001 3916.05 0.00CHRG 22-JUL-89 19:23 254.083 361.245 37.52 1.422 1.546 1.293 39.77 10.01 479.97 475.09 3922.8 6.771 3922.82 0.00OCAC 23-JUL-6 92:10 0.965 5.08 0.60 0.055 «**w*- **** -9999.00 9999.88******* 9999.80 3922.8 0.001 3922.82 0.00ff**wenw*************#ww***wwwww******we*r*********«****w**w*****-**w-******#ww**********w**#**w##w**

r** wrew**fewsfww*****wrr***irw-w*wr*#irw**i**www***w*www*#*******w***ww***********************************************ID- MK11533 MCN= 31 TEST*- 1 O'JNER- 31 WEIGHT(KG>: 5.030 THEORETICAL CAP: 361.00CYCLES= 359 TEST BEGAN 0 10-FEB-80 15:14:22 AEFF: 1.1014 WEFF: 0.9162 UTL: 0.7064 WHR/KG : 60.08

----------------------------------------------------------------------------------------------------------------------------PHASE BEGIN TIME A-HR V-HR AVG-I AVG-V MAXV MINV MAXI MINI MAXT MINT T-HR S-HR C-HR DWNDCHG 23-JUL-8 91:18-254.99G -392.198 -69.96 1.185 '.378 1.005 -69.76 -70.44 482.41 476.31 3926.5 3.645 3926.47 0.00OCAD 23-JUL-89 05:48 9.00 .0E 0.50 0.00 ****** *w***" -9999.05 9999.88******* 9999.00 3926.5 0.001 3926.47 0.00CHRG 23-JUL-80 05:48 231.523 329.855 34.59 1.425 1.546 1.290 39.72 10.01 481.19 475.09 3933.3 6.792 3933.26 0.E8OCAC 23-JUL-89 12:36 0.00 9.090 0.05 0.000 ***w ***-* -9999.00 9999.0******* 9999.00 3933.3 0.001 3933.26 0.00r**e--rrrrw-irew-rr*ri*r*w-----ww*www**x*wr*#*ww-****#*www#*w*#w*w-w*w*******#***w*w***#******#*********"*******"********

Fig. 11. Computer Printout of Later Format for Performance

Data Supplied by Data Acquisition System

N-0'

17

09-APR-80 15:23:19BATTERY DATA FILE ANALYSISREPORT FOR MCN 74

START CYCLE NUMBER * 0 END CYCLE NUMBER " 1005

START TIME 5.500 END TIME " 2.0000

CYCLE BATTERY BATTERY TIME AMP-HRS WATT-HRS DATENO. VOLTS AMPS HOURS

1 1.381 9.428 0.002 0.016 0.022 08-APR-80 13:08:421 1.383 10.650 0.018 0.193 0.267 08-APR-80 13:09:421 1.389 10.161 0.035 0.363 0.507 08-APR-80 13:10:421 1.387 10.161 0.052 0.532 0.73.' 08-APR-80 13:11:421 1.387 15.845 0.568 0.713 0.987 08-APR-80 13:12:421 1.389 9.770 0.085 0.878 1.217 08-APR-80 13:13:431 1.389 10.454 0.102 1.052 1.459 08-APR-80 13:14:431 1.390 9.917 0.119 1.218 1.689 08-APR-80 13:15:431 1.391 10.454 0.135 1.392 1.931 08-APR-80 13:16:431 1.390 10.992 0.15: 1.575 2.186 08-APR-80 13:17:431 1.390 15.161 0.169 1.745 2.421 089-APR-80 13:18:431 1.391 10.943 0.185 1.927 2.675 0-APR-80 13:19:431 1.392 10.259 0.202 2.098 2.913 '8-APR-80 13:20:431 1.391 10.69Q 0.219 2.276 3.161 08-APR-80 13:21:431 1.391 9.819 0.235 2.440 3.389 08-APR-80 13:22:431 1.391 9.868 0.252 2.607 3.621 08-APR-80 13:23:441 1.392 9.819 0.269 2.771 3.849 08-APR-80 13:24:441 1.391 9.819 0.286 2.934 4.077 08-APR-80 13:25:441 1.394 10.796 0.303 3.117 4.332 08-APR-80 13:26:451 1.394 10.601 0.319 3.294 4.578 08-APR-80 13:27:451 1.392 10.747 0.336 3.473 4.827 08-APR-80 13:28:451 1.395 10.601 0.352 3.650 5.074 08-APR-C8 '3:29:451 1.394 10.601 0.369 3.829 5.324 08-APR-80 1 :30:461 1.395 10.357 0.386 4.002 5.565 08-APR-80 13:31:461 1.395 10.747 0.403 4.181 5.815 08-APR-80 13:32:461 1.395 10.210 0.419 4.351 6.052 08-APR-80 13:33:461 1.397 10.064 0.436 4.522 6.290 08-APR-80 13:34:471 1.395 10.259 0.453 4.696 6.533 08-APR-80 13:35:481 1.397 9.868 2.470 4.860 6.762 08-APR-80 13:36:481 1.397 18.112 0.487 5.029 6.998 08-APR-80 13:37:481 1.397 10.064 0.504 5.199 7.236 08-APR-80 13:38:491 1.398 10.064 0.520 5.367 7.471 08-APR-80 13:39:491 1.398 9.819 0.537 5.631 7.700 08-APR-80 13:40:491 1.397 10.660 0.554 5.708 7.948 08-APR-80 13:41:491 1.398 10.699 0.570 5.886 8.197 08-APR-80 13:42:491 1.396 10.112 0.687 6.055 8.432 08-APR-80 13:43:491 1.400 10.357 0.604 6.228 8.674 08-APR-80 13:44:491 1.400 10.601 0.620 6.404 8.921 08-APR-80 13:45:491 1.400 10.161 0.637 6.574 9.150 08-APR-80 13:46:491 1.401 10.603 0.654 6.749 9.403 08-APR-80 13:47:491 1.402 9.233 0.670 6.903 9.619 08-APR-80 13:48:49

Fig. 12. Printout of Voltage, Current, and Temperatureat One-Minute Intervals

18

REFERENCES

1. C. Lipson and N. J. Sheth, Statistical Design and Analysis of EngineeringExperiments, McGraw Hill Co., New York, NY (1973).

2. D. L. Barney et al., High Perfornance Batteries for Electric VehiclePropulsion and Stationary Energy Storage: Progress Report for the Period

October 1978-September 1979, Argonne National Laboratory ReportANL-79-94, p. 97 (March 1980).

3. ibid., p. 22.

ACKNOWLEDGMENT

We wish to express our appreciation of L. Burris, D. Webster, D. L. Barney,R. K. Steunenberg, and P. A. Nelson for their administrative support.Special thanks to Wayne Lark for his design assistance on the cycler and toGlenn Chapman for his assistance in the design and check-out of the cyclers.

We gratefully acknowlege the efforts of G. Redding and J. Hamilton onassembly and check-out of the modules and system. Thanks also to SteveGabelnick, Joe Thomas, Carl Swoboda and Glenn Chapman for their efforts inthe selection and installation of the DAS equipment and preparations of thesoftware for the system, and to Mike Slauecki for the electrical design efforts,

and to Joe Harmon for his editorial efforts,

19

APPENDIX A

CHECK-OUT PROCEDURE FOR75-A CELL CYCLER

20

ARGONNE NATIONAL LABORATORY TM-02167801A Technical MemorandumTitle: Operational Check to be Performed by Rev. Approved Dateew e Vendor of 75 Amp Cell Cycler

Uof CAUA USAEC 50 Cell Test Facility Pagej_. of._2

1.0 SCOPE

This technical memorandum describes the in-house testing required of the

contractor on the 75-amp cell cyclers to be built for the Laboratory.

2.0 MATERIALS

These tests of completed cell cyclers will be conducted in conjunction

with a model SCR 7.5-100 Electronic Measurements, Inc. power supply provided

by the Laboratory. Testing will be accomplished using a lead acid cell

as the load. This cell will be provided by the Laboratory. Two 3 1/2 digit

DVM's will be required to monitor voltages during testing. Testing should

be performed with the lead acid cell fully charged.

3.0 PROCEDURE

The individual cyclers will be tested according to the following procedure.

3.1 Interconnections

3.1.1 Make solid current lead connections while observing proper

polarity between the power supply and the cycler, and the

cycler and the cell with cable capable of handling 100 amps,

in the order stated so that connections to cell terminals

are made last.

3.1.2 Connect separate voltage sensing leads from the cell to the cycler.

3.1.3 Connect both the cycler and the power supply to 115 VAC circuits.

ANL-242 (1/70)

21

A R G O N N E N A T I O N A L L A B O R A T O R Y

Technical Memorandum TM-02167801Title: Operational Check to be Performed by Rev. Approved Date

Vendor of 75 Amp Cell CyclerumoaAUSEC 50 Cell Test Facility Page2 of8

3.1.4 Place a jumper wire across the furnace temperature input

jack on the upper back panel of the cycler.

3.1 .b Connect a DVM to the current output jacks on the front

panel of the cycler.

3.2 preliminary Set Point Adjustments

3.2.1 Set "charge current adjust" fully counter clock wise (CC

3.2.2 Set "maximum cLarge voltage" adjust fully CCW.

3.2.3 Set "minimum charge current" adjust fully CCW.

3.2.4 Set "discharge voltage cutoff" adjust fully CCW.

3.. .5 Set "discharge current adjust" fully CCW.

3.2.6 Set "high level" (watchdog) fully clock wise (CW).

3.2.7 Set "low level" (watchdog) fully CCW.

3.3 Set Limits

3.3.1 Turn on cycler control power. Built in light in switch

should come on. Set "cc-cv" switch in cc mode.

3.3.2 "Maximum charge voltage" trip light should come on.

3.3.3 Measure cell voltage at jacks on front cycler panel with

(.VM. Measure actual cell voltage at cell terminals with

EVM. Readsnys should agree within 10 mV.

3.3.4 Cell current measured with DVM connected to front panel

should read less than 10 mV.

3.3.5 Connect DVM to "charge current adjust " and "common" and

adjust to +1.0 volts (10 amps).

w).

ANL-242 (1/70)

22

A RGO0N NE N A TI O NAL L ABO0R A TOR YTechnical Memorandum TM-02.67801

Title: Operational Check to be Performed by Rev. Approved DateVendor of 75 Amp Cell Cycler

Uo*CAUAUAE 50 Cell Test Facility Pages.of.

3.3.6 Connect DVM to "maximum charge voltage" and "common" and

adjust to +2.35 volts.

3.3.7 Connect DVM to "minimum charge current" and "common" and

adjust to +0.5 volts (5 amps).

3.3.8 Connect DVM to "discharge voltage cutoff" arnd "common" and

adjust to +1.7 volts.

3.3.9 Connect DVM to "discharge current" and "common" and adjust

to +1.0 volts (10 amps).

3.4 Watchdog Circuit Adjustments

3.4.1 Connect DVM to "high level trip" and "common" and adjust

to +2.5 volts.

3.4.2 Connect DVM to "low level trip" and "common" and adjust

to +1.5 volts.

3.5 Check Basic Functions

3.5.1 Connect DVM's to voltage and current jacks on front panel.

3.5.2 Turn "open circuit timer" switch to off.

3.5.3 Be sure "cell power" indicator light is off. If light is

on, press "cell power off" button.

3.5.4 Remove jumper wire on furnace temperature jacks at rear

of cycler. "Furnace temperature low" light on front panel

should flash. Replace jumper wire and press reset button.

3.5.5 Place "charge-discharge" switch in discharge mode. Discharge

light should be on.

.ANL-242 (1/70)

23

A R G O N N E N A T I O N A L L A B O R A T O R Y

ATechnical MemorandiTni?67nTitle: Operational Check to be Performed by Rev. Approved Date

Vendor of 75 Amp Cell Cycler

U* CALJAEC 50 cell Test Facility Pagei._ of....

3.5.6 Place "CC-CV" switch in CC mode.

3.5.7 Turn on power supply. Light in switch should come on.

3.5.8 Press "cell power on" button. "Cell power" light should

come on.

3.5.9 Observe power supply meters and DVM's. Respective readings

should agree.

3.5.10 Press "open circuit" button momentarily. Cell should drop

out of circuit indicated by current reading returning

to zero and "cell power" light going off. After 15 seconds

cell should come back on.

3.5.11 Press "cell power off" button. "Cell power" light should

go out.

3.5.12 Place "charge-discharge" switch in charge position. Charge

light should come on.

3.6 Check Limit Circuits

Connect one DVM to appropriate panel function and common for each

adjustment.

3.6.1 Press "cell power on" button. Light should come on.

3.6.2 Observe DVM's and power supply meters for agreement.

3.6.3 Reduce "maximum charge voltage" to equal cell voltage as

monitored at cell voltage jacks on front panel. Circuit

should trip within 10 mV. Return setting to +2.35 V.

ANL-242 (1/70)

24

A R G O N N E N A T I O N A L L A B O R A T O R YTechnical Memorandum TM-02167801

Title: Operational Check to be Performed by Rev. Approved DateVendor of 75 Amp cell Cycler

udo~wUCU C50 Cell Test Facility Page._5_ o.8

3.6.4 Raise "discharge cutoff voltage" to equal cell voltage.

Circuit should trip with 10 mV of cell voltage. Return

setting to +1.7 V.

3.6.5 Reduce "high level trip" (watchdog) to equal cell voltage.

Circuit should trip within 10 mV of cell voltage. Return

setting to +2.5 V. Push reset. Push "cell power on."

3.6.6 Raise "low level trip" (watchdog) to equal cell voltage.

Circuit should trip within 10 mV of cell voltage. Return

setting to +1.5 V. Push reset. Be sure cell is in charge mode.

3.6.7 Place "CV-CC" switch in CV mode.

3.6.8 Push "cell power on" button.

3.6.9 While monitoring cell voltage at front panel, raise "charge

current adjust" until voltage mode light on power supply comes on.

Cell voltage should not exceed +2.35 V by more than 10 'nV.

3.6.10 While monitoring cell current at front panel raise "minimum

charge current" adjustment until the circuit trips. The

trip should occur within 10 mV of cell current. Return

"minimum charge current" adjustment to +0.5 V (5 amps).

3.6.11 Place "CC-CV" switch in "CC" mode.

3.6.12 Reset "charge current" adjustment to +1.0 V (10 amps).

aNL-242 (1/70)

25

A R G O N N E N A T I O N A L L A B O R A T O R YTechnical Memorandum TM-02167801

Title: Operational Check to be Performed by Rev. Approved DateVendor of 75 Amp Cell Cycler

U C 'AU'50 Cell Test Facility Pageiof A..JL..

3.7 Check Open Circuit Timer Functions

3.7.1 Set open circuit switch to "both."

3.7.2 Set thumbwheel to 1 minute.

3.7.3 Turn timer switch to "on."

3.7.4 Raise "discharge voltage cutoff" setting to equal cell

voltage and allow to trip. Return setti;ig to +1.7 V.

3.7.5 "Open circuit timer" light should come on when circuit

activates. After one minute elapses cell power should come

back on. The LED timer display should indicate one minute,

and will remain on until the timer circuit is activated

again.

3.7.6 Lower "maximum charge voltage" adjustment to equal cell

voltage to cause circuit to trip. "Open circuit timer"

should come on. Return "maximum charge voltage" to +2.35 V.

3.7.7 Select "after discharge" mode on open circuit timer and

repeat steps 3.7.4 through 3.7.6 above, determining that there

is no open circuit period after charge mode.

3.7.8 Select "after charge" mode on open circuit timer and repeat

steps 3.7.4 through 3.7.6 above, determining that there is

no open circuit period after discharge. Turn cell power off.

An-242 (1/70)

26

A R G O N N E N A T I O N A L L A B O R A T O R Y

Technical Memorandum TM-02167801

Title: Operational Check to be Performed by Rev. Approved Date

& Wa Vendor of 75 Amp Cell CyclerUd*"AUAU9C 50 Cell Test Facility PageL.._ of_8

3.8 Loi1g Term Cycling

3.8.1 Attach current and voltage output on front of panel to a two pen

strip chart recorder.

3.8.2 Set charge and discharge current at 80 amps.

3.8.3 Set "CC-CV" switch to CV mode.

3.8.4 Turn cell power on. Allow to cycle for 24 hours.

3.9.5 Set "CC-CV" switch to "CC" mode. Allow to cycle for 24 hours.

3.8.6 Turn cell power off.

3.8.7 Turn cycler power off.

3.8.8 Turn power supply off.

3.9 Check Output Diode Temperature and Stability

3.9.1 Remove the positive current lead from the cell terminal and

attach it to the negative current lead at the cell so both

current leads go to the cell negative terminal. Do not disturb

the voltage sense leads. Leave them connected to the cell.

3.9.2 Turn power supply on.

3.9.3 Turn cycler power on.

3.9.4 Place "charge-discharge" switch in discharge mode.

3.9.5 Turn cell power on.

3.9.6 Operate at 80 amps for 4 hours.

3.9.7 Connect an oscilliscope to current output Jacks on front

panel and check to see that ripple does not exceed 1 amp (100 mV).

AIL-242 (1/70)

27

I V

A R G O N N E N A T I O N A L L A BO R A T O R Y

Technical MemorandumOperational Check to be Performed byVendor of 75 Amp Cell Cycler

b ell Test Facility

TM-02l 67801Rev. Approved Date

Page. of._

Title:

U of CAUA USAEC

Turn cell power off.

Turn cycler power off.

Turn power supply off.

Remove current leads from cell

Remove voltage sense leads from cell.

A

3.9.8

3.9.9

3.9.10

39.11

3.9.12

ANL-242 (1/70)

28

APPENDIX B

Drawings List

Number Given Numberby Electronics Given by

Division CEN Sheets Title

L3555-7702-DC-00

L3555-7702-DD-00

L3555-7701-DB-00

L3555-7703-DA-00

L3555-7703-DA-00

CE-D7051

CE-D7051

1 of 2

2 of 2

CE-B7051 1 of 7through7 of 7

CE-A7051

CE-A7051

CE-A-7051

CE-A-7051

CE-A-7051

CE-A-7051

CE-A-7051

CE-A-7051

CE-A-7051

CE-A-7051

CE-A-7051

Front Panel

Cell CyclerTemp late

Template

75 - Rear Apron

Cell Cycler 75

1 of 11 Cell

2 of 11 Cell

3 of 11 Cell

4 of 11 Cell

5 of 11 Cell

6 of 11 Cell

7 of 11 CellWrap

8 of 11 CellWrap

9 of 11 CellWrap

10 of 11

11 of 11

Cycler

Cycler

Cycler

Cycler

Cycler

Cycler

CyclerBoard

CyclerBoard

CyclerBoard

75

75

75

73

75

75

75

Front Panel

Front Panel

Rear Panel

Chasis Components

Chasis Components

Watchdog Assy.

Logic Wire

75 Logic Wire

75 Logic Wire

Cell Cycler 75 Analog PrintedCircuit Board

Cell Cycler 75 Analog PrintedCircuit Board