Attachment J1 - Technical Data Package - DTBM Batteries.pdf

Version 1.0 June 2020

Specification 605: 2016

Low Self-Discharge Nickel-Metal Hydride Battery Pack

NLSBPH Spec No. 605 June 8, 2020

Revision History Revision Issue Date Change Description Rev. 1.0 November/17/2016 First Release

Table of Contents

1. Scope

2. Reference Documents

2.1. Standards

3. Requirements

3.1. Cells

3.1.1. Cell Chemistry

3.1.2. Cell size

3.1.3. Cell Weight

3.1.4. Cell Insulation

3.1.5. Cell Safety Vents

3.2. Battery Pack

3.2.1. Battery Pack Dimensions

3.2.2. Pack weight

3.2.3. Battery Pack Open Circuit Terminal Voltage

3.2.4. Battery Pack Capacity

3.2.5. Matched Cells

3.2.6. Components

3.2.7. Cable Harness

3.2.8. Battery Pack Shrink Wrap

3.2.9. Battery Pack Label

3.2.10. Operating Temperature

3.2.11. Storage Capacity Life Expectancy

3.2.12. Self-Discharge Performance

3.3. Electrical Requirements

3.3.1. Temperature Detection Monitoring Circuit

3.3.2. Fast Charge termination detection

3.3.3. Battery Pack Internal Impedance

3.3.4. Battery Pack Cycle Life

3.3.5. Battery Pack Residual Capacity Recovery

3.3.6. Short Circuit Safety Provisions

3.4. Vibration test

3.5. Pull test

3.6. Drop Test

3.7. UL compliance

3.8. Packaging Requirements

Appendix A Appendix B Appendix C

Version 1.0 June 2020

1. Scope This specification establishes the design and performance requirements for a Low Self-Discharge (LSD), rechargeable and temperature controlled Nickel- Metal Hydride battery pack produced for the National Library Service for the Blind and Physically Handicapped (NLS/BPH), Library of Congress, Digital Talking Book Machine (DTBM)

2. Reference Documents The following documents and publications form a part of this specification. In the event of conflict between the documents and publications referenced herein and the content of this specification, the content of this specification shall be considered a superseding requirement.

Standards

International Electro-Technical Commission

IEC 61951-2 3rd Edition, May 1, 2011 Specifies marking, designation, dimensions, tests and requirements for portable sealed nickel-metal hydride rechargeable single cells

IEC 61959 Specifies mechanical tests for sealed batteries IEC 62133 Specifies safety requirements for portable sealed batteries

The documents cited above are available from:

https://webstore.iec.ch/publication/6156

American National Standards Institute (ANSI)

ANSI/ASQ Z1.4-2003

Sampling Procedures and Tables for Inspection by Attributes

The document cited above is available from:

American Society for Quality 600 North Plankinton Avenue Milwaukee, WI 53203 and at http://asq.org/quality-press/ https://webstore.iec.ch/publication/6156 http://asq.org/quality-press/

ANSI C18.2M Part 1:2013 Portable Rechargeable Cells and Batteries – General and Specifications

JIS C 8708:2004

Sealed Nickel-Metal hydride rechargeable single cells

The document cited above is available from:

http://webstore.ansi.org/

UL 2054, August 2008 Standard for Household and Commercial Batteries

The document cited above is available from:

http://ulstandards.ul.com/standard/?id=2054 http://webstore.ansi.org/ http://ulstandards.ul.com/standard/?id=2054

3. Requirements Cells

Cell Chemistry

Rechargeable Nickel-Metal Hydride battery cells, optimized for low self-discharge

Cell size

Size AA shall be designated for use in the battery pack. The typical cell size shall be 14.4mm x 50.5 mm

Cell Weight

The nominal cell weight shall be 30 grams

Cell Insulation

Each individual cell shall be first insulated with heat shrink tubing made of Polyvinylchloride (PVC) of reasonable thickness, then assembled into the desired configuration.

Cell Safety Vents

Each individual cell shall contain a built-in re-sealable safety vent to maintain a pressure equilibrium within the cell. In cases of extended overcharge the safety vent should open to reduce pressure and prevent battery damage. The vent should reseal once the pressure is relieved.

Battery Pack

Battery Pack Dimensions

See Appendix A for details (DWG. 20160622)

a. Width: 88mm (max)

b. Height: 54mm (max)

c. Depth:15.5 (max)

Pack weight

The battery pack shall weigh no more than 200 grams.

Battery Pack Open Circuit Terminal Voltage

The battery pack nominal Open Circuit terminal voltage shall be

7.2 volt.

Battery Pack Capacity

Six matched and safety vented AA cells shall be used.

a. Nominal capacity at 23 +/-5˚C shall be 2,000 mAh +/-2.5% when charged at 200 mA (0.1C) for 16 hours, and discharged at 400 mA (0.2C) to 1.0 volt per cell.

b. The battery pack shall not be deformed when over-charged at 0.1C for 48 hours at an ambient temperature of 23+/-5 ˚C

Matched Cells

Individual cells in any given battery pack must have matched capacities. The capacity tolerance shall be +/- 2.5%.

Components

Battery pack shall incorporate the following components

a. Self resetting positive temperature coefficient (PTC) fuse, (see

Bourns P/N MF-S350 or equivalent, http://www.bourns.com/data/global/pdfs/mfs.pdf ). The fuse shall allow no more than 2.5 Amps to flow at 60 ˚C.

Electrical characteristics:

i. Maximum on current (hold current)

I(hold) = 3.5A at 23˚C

ii. Trip current

I(trip) = 6.3A at 23˚C

iii. Maximum device surface temp in trip state

T(max) = 125 ˚C

b. Precision Thermistor , ( see Semitec, P/N 104AT- 2 or equivalent, http://www.mouser.com/ds/2/362/semitec_atthermistor- 371460.pdf) Beta β25˚C/85˚C=4665+ 1% at 25˚C and 85˚C, R25˚C =100K Ω+ 1% at 25 ˚C.

c. Thermal Switch (see ACCU THERM, P/N AT100PN 70C27L or equivalent, http://www.microtech-hk.com/product_details.php?id=PR01233) http://www.mouser.com/ds/2/362/semitec_atthermistor-371460.pdf http://www.mouser.com/ds/2/362/semitec_atthermistor-371460.pdf http://www.microtech-hk.com/product_details.php?id=PR01233 http://www.microtech-hk.com/product_details.php?id=PR01233 triggered at 70°C + 5 °C

Cable Harness

The battery pack cable harness wiring length and segments shall be fabricated as specified in Appendix A( DWG. 20160622)

i. 22AWG 7x30 Red (Battery +), Black (Battery -), white thermistor(-), white thermistor(+)

ii. Connector JST: PAP-04V-S (LF)(SN)

Battery Pack Shrink Wrap

The battery pack insulation shrink wrap sleeve shall be white.

When subjected to a temperature of 45˚C for a period of 48 hours, shrink wrap shall remain consistent in thickness

Battery Pack Label

All markings shall be in permanent black ink, legible and smudge resistant.

Label shall contain the following information:

a. Ni-MH Low Self Discharge Battery Pack

b. Voltage and ampere-hours as specified by vendor (e.g. 7.2 V

2000mAh)

c. Part number (e.g. P/N: 040-1310901)

d. The manufacturer shall identify the date code using a traceable coding scheme, e.g. A16 (Jan 2016).

e. The manufacturer shall include the appropriate recycle logo.

f. Warning statement cautioning against disassembly, improper disposal.

Operating Temperature

The battery pack shall be designated to operate over the following temperature ranges and under the conditions described

a. 0 to 50 ˚C while discharging at 0.2C rate

b. 10 to 35 ˚C while charging at 0.5C rate

c. -45 to +60 ˚C after storage for 24 hours at each temperature extreme

Storage Capacity Life Expectancy

The capacity retention after a storage period of 24 months shall be greater than 80% from full charge at room temperature (20 ˚C) when measured according to the discharge parameters defined in section 3.2.4 part a.

Self-Discharge Performance

The self-discharge capacity performance of a fully charged battery (0.1Cx16hrs) at the storage temperatures

a. 0˚C

b. 25˚C

c. 40˚C spanning over a period of five years, relative humidity RH 65%+20% shall meet or exceed the following performance curves.

Electrical Requirements

Temperature Detection Monitoring Circuit

The battery pack shall be compatible with the temperature detection circuit of the NLS digital talking book machine (DTBM). The DTBM monitoring circuit is designed according to the temperature/voltage profile below. The DTBM uses Linear Technology LTC4011 for battery charge control.

(http://cds.linear.com/docs/en/datasheet/4011fb.pdf ).

Data sheet 104AT Semitec Thermistor Resistance kΩ– Temperature °C

TE

M

P

0˚C 5°C 10°C 15°C 20°C 25°C 30°C 35°C 40°C 45°C 50°C 55°C 60°C

Re s

K Ω

390.3 292.5 221.5 168.6 129.5 100 77.81 60.94 48.10 38.13 30.44 24.42 19.72

V t em p 1.94 1.86 1.77 1.67 1.55 1.42 1.29 1.16 1.03 0.90 0.78 0.67 0.58

Fast Charge termination detection

Using the circuit provided in section 3.3.1 and a charging current of 950-1000mA, the battery pack shall be capable of being fully charged by the DTBM. The controlling parameters used are:

a. dT/dt : 0.8°C to 1°C per minute

b. -∆V: 0 to 5mV/cell typical (2 to 3mV/cell at 0.5C)

c. Temperature 20°C - 45°C

R1 82.3k

R2 169k

R3

0 Rth 100k

Vrt (Pin 6)

External NTC Thermistor Network LTC4011

Vtemp (pin 7) R4

51k C1 10nF http://cds.linear.com/docs/en/datasheet/4011fb.pdf

Battery Pack Internal Impedance

The battery pack internal impedance shall not exceed 300 mΩ when measured between battery terminal (B+) and (B-) at 1 kHz.

Battery Pack Cycle Life

The battery pack capacity after 500 cycles shall be at least 80% of its initial capacity when testes as described in IEC 61951-2 section 7.5.

Battery Pack Residual Capacity Recovery

A discharged battery (remaining capacity of less than 2%) shall be capable to recover its full capacity after a storage period of 24 hours at 23°C + 5°C

Short Circuit Safety Provisions

Battery pack shall be capable to sustain a short circuit between battery pack terminals (B+) and (B-).

Vibration test

The battery pack shall meet capacity requirements, mechanical dimensions, and operating performance requirements after exposure to the vibration test described below.

The direction of vibration is vertical, and the severity is:

• Duration 30 minutes

• Amplitude 0.35mm

• Frequency range 10Hz - 50Hz t- 10Hz

• Sweep range is approximately 1 octave/minute

Pull test

The battery pack cable assembly shall resist being pulled out of the battery pack and shall not separate from the battery pack when being pulled with a force that gradually increases from 0 to 20 pounds over 5 to 10 seconds and maintained for 1 minute.

Note: The connector shall not be used to grasp the cable for this test.

Drop Test

The battery pack shall meet capacity requirements, mechanical dimensions, and operating performance requirements after exposure to the drop test described below.

The battery pack shall be subjected to a drop test from a height of 50cm onto a wooden surface having a thickness of 30mm for a total of three times.

UL compliance

The battery pack shall comply with the following tests described in UL standard 2054.

• Short-Circuit Test – section 9

• Abnormal Charging Test – section 10

• Abusive Overcharge Test – section 11

• Forced-Discharge Test – section 12

Packaging Requirements

Battery packs are to be protected from electrical and mechanical contact during shipment. Packaging shall be constructed of material of sufficient strength to meet the following requirements:

a. Battery packs shall be packaged into shipping cartons that hold 10 battery packs.

b. Shipping cartons shall be packaged into a master “over-pack” box that will hold 6 shipping cartons.

c. Both shipping cartons and over-pack boxes must be of sufficient strength to be separately mailed through the USPS.

d. Over-pack boxes must be of sufficient strength to contain the shipping cartons during shipping via USPS

e. Over-pack boxes must be strong enough to be stacked at least 3 levels high

f. The batteries shall be evenly distributed within boxes, acceptable for safe transit through the U.S. Postal System, and subject to the approval of the Library of Congress Contracting Officer (COR)

g. Both over-pack boxes and shipping cartons shall have markings similar to the example packaging drawings provided in the Appendix B and Appendix C to facilitate address labelling.

Note: Drawings are provided for reference only and do not represent the proper dimensions for battery pack packaging materials.

Appendix A Battery Pack Drawing

Appendix B Example Shipping Carton Drawing

Appendix C Example Overpack Drawing