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AHR32113M1Ultra-B
A123 Systems AHR32113M1Ultra-B User Manual
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USER DOCUMENTATION
Date:
Ma
rch 6, 2014
Documen
t #:
493005
-
002
Rev
02
Battery P
ack Design,
V
alidation
,
and
Assembly Guide
using A123
Sys
te
m
s
Nanopho
sphat
e
®
Cells
Including:
APR1
8650
M1-
A
ANR26
650
M1-
B
AHR
32113
M1
Ultra
-B
AMP20
M1
HD
-A
2
Table of Contents
Default Chapter
3
Table of Contents
3
Preface
7
About this Document
7
Purpose of this Document
7
How to Use this Guide
8
Conventions Used in this Guide
8
Table 1 - A123 Systems Cell Model Numbers
8
Related Documents and Resources
9
Chapter 1
10
Possible Dangers Involved with Handling Cells and Battery Packs
10
Thermal Events
11
Short Circuits
11
Arc Flashes
11
High Voltage
11
Chapter 2
12
Transportation, Storage and Disposal
12
Transporting Batteries
13
Table 2 - Steps Required to Transport a Lithium Ion Battery
14
Table 3 - Nominal Energy and ELC of A123 Cells
16
Table 4 - US Transportation Classification of Cells
17
Table 5 - US Transportation Classification of Batteries
17
Table 6 - International Transportation Classification of Cells
18
Table 7 - International Transportation Classification of Batteries
18
Table 8 - International Air Transport Association (IATA) Packaging and Quantity Restrictions (PI-965)
19
Table 9 - International Air Transport Association (IATA) Packaging and Quantity Restrictions (PI-966 & PI-967)
21
Storing Batteries
22
Battery Disposal
22
Chapter 3
23
Nanophosphate ® Technology and Cell Characteristics
23
Nanophosphate Technology
23
Power
24
Figure 1 - AMP20 Cells Discharge Curves
24
Figure 2 - AMP20 Cells Discharge Curves at Various Temperatures
25
Safety
26
Life
27
Figure 3 - AMP20 Cells Cycle Life (1C Charge / 1C Discharge Rates)
27
Figure 4 - AMP20 Cells Capacity Loss Due to Calendar Aging
27
Chapter 4
28
Battery Pack Design
28
Design Overview
29
Configuration of Cells in a Battery Pack
30
Figure 5 - Example of AMP20 Cells Connected in Series
31
Figure 6 - Example of AMP20 Cells Connected in Parallel
32
Battery Pack Structural Design
33
Figure 7 - Effect of AMP20 Cell Life with Respect to Surface Pressure
34
Figure 8 - AMP20 Cell Thickness Variation Wrt SOC for Three Representative AMP20 Cells
35
Figure 9 - Graph of the Pressure Vs. Deflection of an Example Compliant Pad for AMP20 Cells
36
Figure 10 - Pressure on AMP20 Cell Face Without Compliant Pad (Left) and with Compliant Pad (Right)
37
Figure 11 - Pressure Map Across the Surfaces of each Cell in a Representative Stack of Cells
37
Figure 12 - AMP20 Cell Corner that will Vent under Extreme Internal Pressure
38
Figure 13 - ANR26650 End-To-End Cell Spacing
38
Figure 14 - APR18650 Cell Vents
39
Figure 15 - Diagram of Optional AMP20 Cell Cooling Concept
40
Cell Protection
41
Figure 16 - Individual Cell Fusing Strategy
41
Figure 17 - Example AMP20 Cell Fuse Pattern in Cell Terminals
42
Figure 18 - Example of a Necked-Down Connection to the Cell Which Can Act as a Fuse
42
Figure 19 - Example of Total System Fusing Strategy
43
Figure 20 - Battery Pack with Representative Short Circuit Faults
44
Battery Pack Control (Monitoring and Management)
45
Table 10 - Example of Histogram Data of Temperature Ranges and Durations
48
Figure 21 - AMP20 Cell Voltage Vs. SOC at 23 °C
51
Figure 22 - AMP20 Cell Vsoc Sensitivity to OCV Error
51
Figure 23 - AMP20 Cell Temperature Effects on OCV with Respect to (Wrt) SOC
52
Figure 24 - AMP20 Cell 60S, 20A DCR Measurements Wrt SOC at Various Temperatures
53
Battery Pack Use
54
Figure 25 - Battery Voltage and Current During Recharge
55
Table 11 - Charge Current and Voltage Calculation Examples
55
Figure 26 - AMP20 Cell* Capacity Degradation Vs. Time for Various Recharge Rates
56
Chapter 5
59
Summary of Battery Pack Validation
59
Performance Testing
60
Table 12 - Performance Tests
60
Abuse Testing
61
Table 13 - Abuse Tests
61
Compliance Testing
62
Table 14 - Useful Battery Pack Standards and Their Relevant Applications
62
Chapter 6
63
Battery Pack Assembly
63
Incoming Cell Inspection
63
Material Handling and Storage
63
Cell Welding
64
Figure 27 - Bus Bar Concept Diagram and Resulting Welded Cross Sections
64
Figure 28 - Two Types of Bus Bars Ultrasonically Bonded in the Center to each Other
65
Figure 29 - Schematic of Cylindrical Cell Welding Process
65
Cell Specifications
67
Appendix A
67
Amp20M1Hd-A
68
Table 15 - AMP20M1HD-A Cell Specifications
68
Table 16 - AMP20M1HD-A Max Continuous Charge Currents Wrt Temperature and SOC
71
Table 17 - AMP20M1HD-A Max 10S Pulse Charge Currents Wrt Temperature and SOC
71
Table 18 - AMP20M1HD-A Max Continuous Discharge Currents Wrt Temperature and SOC
71
Table 19 - AMP20M1HD-A Max 10S Pulse Discharge Currents Wrt Temperature and SOC
71
Figure 30 - AMP20M1HD-A Cell Dimensions
76
Figure 31 - Notes for AMP20M1HD-A Cell Dimensions Drawing
77
Anr26650M1-B
78
Table 20 - ANR26650M1-B Cell Specifications
78
Table 21 - ANR26650M1-B Max Continuous Charge Currents Wrt Temperature and SOC
80
Table 23 - ANR26650M1-B Max Continuous Discharge Currents Wrt Temperature and SOC
80
Table 24 - ANR26650M1-B Max 10S Pulse Discharge Currents Wrt Temperature and SOC
80
Table 22 - ANR26650M1-B Max 10S Pulse Charge Currents Wrt Temperature and SOC
80
Figure 32 - ANR26650M1-B Cell Diagram and Dimensions
84
Apr18650M1-A
85
Table 25 - APR18650M1-A Cell Specifications
85
Table 26 - APR18650M1-A Max Continuous Charge Currents Wrt Temperature and SOC
87
Table 27 - APR18650M1-A Max 10S Pulse Charge Currents Wrt Temperature and SOC
87
Table 28 - APR18650M1-A Max Continuous Discharge Currents Wrt Temperature and SOC
87
Table 29 - APR18650M1-A Max 10S Pulse Discharge Currents Wrt Temperature and SOC
87
Figure 33 - APR18650M1-A Cell Diagram and Dimensions
88
Ahr32113M1Ultra-B
89
Table 30 - Ahr32113M1Ultra-B Cell Specifications
89
Table 31 - Ahr32113M1Ultra-B Max Continuous Charge Currents Wrt Temperature and SOC
91
Table 32 - Ahr32113M1Ultra-B Max 10S Pulse Charge Currents Wrt Temperature and SOC
91
Table 33 - Ahr32113M1Ultra-B Max Continuous Discharge Currents Wrt Temperature and SOC
91
Table 34 - Ahr32113M1Ultra-B Max 10S Pulse Discharge Currents Wrt Temperature and SOC
91
Figure 34 - Ahr32113M1Ultra-B Cell Diagram and Dimensions
95
Acronyms and Terminology
96
Table 35 - Acronyms and Terminology Descriptions
96
Appendix B
96
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A123 Systems AHR32113M1Ultra-B Specifications
General
Brand
A123 Systems
Model
AHR32113M1Ultra-B
Category
Battery Pack
Language
English
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