Charge Controller (written on board and below connectors ): Supply Description:

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1 This document consists of four sections: 1. A cover sheet for the functional and thermal tests of a BARREL charge controller (CC) and DCDC converter box (DCDC), including a checklist for the thermal test of the combined system 2. The procedure for testing the DCDC and the form that this procedure fills. 3. The procedure for testing the CC and the form that this procedure fills. 4. The separate procedure for functional thermal test of a BARREL battery pack. BARREL Validation/Thermal Test for DC-DC Converters +Charge Controller CDR-Draft, John Sample, March 25, 2011 DC-DC Test Unit (written on side of box): Charge Controller (written on board and below connectors ): Batteries (not in chamber): Supply Description: Test Date: Tested by: Setup/Starting Condition: Place the DC-DC converter and Charge controller in the thermal chamber connected to each other with test harness (5 pin twistlock hex connectors on both ends) Place the combined boxes into large antistatic bag. Place ¼ tube from Nitrogen regulator through chamber port into antistatic bag. Nitrogen can remain off until First Hot-> Cold transition. Connect test loads to the DC-DC box, the loads should remain outside the chamber Connect 15pin-EDI cable and 25 pin EDI cable to CC and DCDC for monitoring outside of the chamber Run Battery cable from the Charge Controller. DO NOT CONNECT. The battery should remain outside the thermal chamber as its thermal ranges are different. Bring each of the four solar panel inputs out of the chamber, labeled. Connect SP1 to test panel or power supply [current limited at 0.0A and set at 18V]

2 Observe setup conditions as specified in the Charge Controller and DCDC functional thermal test procedures that follow. Page 2 of this document is a checklist that should act as a cover sheet for all the functional tests that this thermal test procedure calls for.

3 TEST PROCEDURE: 1. Connect Battery to Charge Controller a. Record Battery Voltage:: 2. Perform DC-DC Functional Test (DCDCFT) and Charge Controller Functional Test (CCFT) 3. Ramp the temperature up to +75C at the chamber's rate and soak for 45 min. a. Monitor battery voltage at 1min intervals 4. Repeat DCDCFT and CCFT 5. Ramp the temperature down to-30c at the chamber's rate and soak for 45 min. a. Record the ramp rate achieved in this cycle here: degrees in minutes. 6. Repeat steps 2-5 by repeating the DCDCFT and CCFT until the following table is full Test (record same number on each DCDFT and CCFT sheet that is used) DCDCFT1 (room temp) CCFT1(room temp.) DCDCFT2 (Hot) CCFT2(Hot) DCDCFT3 (Cold) CCFT3(Cold.) DCDCFT4 (Hot) CCFT4(Hot) DCDCFT5(Cold) CCFT5(Cold) DCDCFT6 (Hot) CCFT6(Hot) DCDCFT7(Cold) CCFT7(Cold) Cold Soaked Battery Startup Result

4 DC-DC CONVERTER FUNCTIONAL Set-up/Starting Condition External power connected to Charge Con at 12V, current limited to 1Amp No other connections Test Description 1. Measure the current draw of the +12V input record in table 2. Measure the voltage at each 4 pin output and record in table 3. Subsequent to the initial test, the first table should be filled out under test loads in which case nominal input current is ~500mA When under load check voltage at load 4. Connect harness loads as listed in BARREL SSD-106 to each 4 pin connector. 5. On the 25 pin connector check the following pins and record voltages in the second table THIS IS A TEST COVER SHEET/INSTRUCTIONS EACH SUBSEQUENT TEST SHOULD FOLLOW THE ABOVE PROCEDURE AND DATA TABLES SHOULD BE APPENDED WITH APPROPRIATE HEADINGS

5 Follow instructions DC-DC Converter Functional UNIT TEMPERATURE DATE Thermal Cycle # or N/A Nominal MAX MIN Measured I@+12V 75 ma 100mA 50mA N/A? V@PMT-5V -5 V -4.8V -5.2V V@PMT+5V +5V 5.3V 4.8V V@DPU-5V -5V -4.8V -5.2V V@DPU+5V +5V 5.3V (5.1) 4.8V (4.9) V@MAG+5V +5V 5.2V 3.6V V@IRI+12V +12V 15V 10.8V *The tighter range on DPU voltage is the preferred performance, wider range is acceptable, but a note should be added to any DCDC box that operates outside the preferred range. NAME +pin -pin (on DVM) (on DVM) Nominal MAX MIN Measured Vin V 15V 10V Vin CS mV 25mV 15mV DPU V 5.3V 4.8V DPU+5 CS mV 30mV 20mV DPU V -4.8V -5.2V DPU-5 CS mV 33mV 27mV IRI V 15V 10.8V IRI CS* mV 23mV 13mV Mag V 5.2V 4.8V Mag+5 CS mV 35mV 27mV PMT-5 CS mV 29mV 22mV PMT+5CS mV 33mV 27mV PMT V 5.3V 4.8V PMT V -4.8V -5.3V *the nominal values here are for the test harness resistor of 25 Ohms, actual value for the current to the resistive load varies with battery voltage, real load varies inversely with input voltage. Actual iridium currents vary widely.

6 CHARGE CONTROLLER FUNCTIONAL TEST Set-up/Starting Condition Connect a functional, loaded DCDC to charge controller load output Connect scope to output of Charge Controller Helpful to have a fully charged battery and a largely discharged battery, for verification of both full charge cutoff and Low voltage disconnect Connect 1 st DMM to battery to be used 2 nd DMM will be used to measure output on load and EDI connector outputs Scope should be set to trigger off of charge controller load transitions rising or falling as appropriate, 0-16V viewable, for load turnoff a time window of 100ms is appropriate, for load turn on a time window of 10ms is appropriate Set power supply to 18V and max current limit to ~1.5A Test Description 6. Five scenarios need to be tested: i. Connecting a depleted battery, letting it charge to the Low Voltage Reconnect (LVR), turning the load on. Measure the battery voltage before connecting, make sure that the scope is set to trigger on rising load voltage with a 10ms time window, turn on power supply at limited at 0A and raise current limit to 1A. ii. Connecting a sufficiently charged battery, turning the load on at connection Measure the battery voltage, make sure that the scope is set to trigger on rising load voltage as in i. iii. Any situation following one or the other of the above in which the load is on, the battery is then allowed to drain to the low voltage cutoff (LVC), and the charge controller disconnects the load. Set the scope to trigger on a falling load voltage around 10V. Increase the time window on the scope to ~100ms. Reduce power supply current limit to zero. The load voltage will drop quickly from the LVC to ~9V and then slowly as the capacitors in the DC-DC converters discharge. iv. A nearly full battery is further charged until it reaches the Full Charge Cutoff (FCC) Charge the battery until the Full Charge Cutoff is reached by exposing panel to full sun or increasing current limit of power supply. The FCC is recognized by a reduction in the supply current and a small drop in the battery voltage (from 15V to ~14V). The battery voltage may oscillate a few hundred millivolts below the FCC. v. A battery that would otherwise be charging needs to have its thermistor raised above 46C to observe the high temp. charging cutoff. This does not involve actually raising battery temperature. only a thermistor or potentiometer connected as a sense input to the charge controller across pins 14 and 15. For testing purposes: Put a battery into a gradual charge that is well below the Full Charge Cutoff of 14.5V. Using a potentiometer or resistor potentiometer combo that can range between 10kΩ and 20kΩ, record the resistances at which the charging cutoff occurred and where the resistance where charging recommenced.

7 7. If appropriate for the scenario being tested, record open circuit battery voltage 8. Connect Battery to Charge Controller, monitor load output and battery voltage on scope THIS IS A TEST COVER SHEET-INSTRUCTIONS EACH SUBSEQUENT TEST SHOULD FOLLOW THE ABOVE PROCEDURE AND DATA TABLES SHOULD BE APPENDED WITH APPROPRIATE HEADINGS

8 Unit # Temperature Date Thermal Cycle # Record Battery Open Circuit Voltage: Scenario i: Charging under voltage battery, load initially off Nominal MAX MIN Measured Initial Battery Voltage N/A 13.2 N/A Approximate charging 1A 3A N/A current Approximate time until N/A N/A N/A battery reaches LVR Load turn on time to 9V 500us 1.5ms N/A after LVR Battery voltage at load turn on Lowest Battery voltage found after LVR N/A 15V 10.8V Scenario ii: Battery is sufficiently charged, load will turn on when Battery is connected. Nominal MAX MIN Measured Battery voltage before 13.5 NA 13 connection Rise time to 9V 500us 1.5ms N/A Lowest Battery voltage after turn on N/A 13.6V 10.5V Scenario iii: LVC exercise. Nominal MAX MIN Measured Battery Voltage at LVC 10.3V 10.6V 10.1V Battery Voltage after LVC Scenario iv. Charge the battery until the Full Charge Cutoff is reached. Nominal MAX MIN Measured Supplied Current 1A 2A N/A Battery Voltage at FCC 14.5V 14.8V 14.3V Battery Voltage when 13.6V 13.8V 13.4V charge current resumes (if oscillation, report Vmin of oscillation) IF Oscillation: frequency N/A N/A N/A Scenario v: checking the thermal cutoff Min T deg. C Max T deg. C Temperature cutoff Temperature reconnected Measured Resistance Converted to temperature

9 NAME The EDI output cable should be checked with the supply or Solar Panel connected to SP1. Describe the state of the battery: Charging? Current? +pin -pin (on DVM) Nominal (on DVM) MAX MIN Measured Batt CS mV 50mV 0mV* Batt V 15V 10.8V SP1 CS mV 50mV 0mV* SP V 12V SP V 12V** SP V 12V** SP V 12V** CCM V 5.1V 4.9V * The voltage measured here should be (0.025*I) if current is being supplied, 0mV is not an acceptable min. ** SP2,3,4 will only show voltage if the Supply/Panel is connected to these charge controller inputs, this can be done in the following section SP2 SP3 SP4 9. Check the 2 nd through 4 th Solar Panel inputs to the charge controller Batt CS in Range? Battery Charging?

10 BARREL Battery Functional thermal Introduction: Because the BARREL battery pack has a different operating temperature range than the CC and DCDC it is kept out of the thermal chamber for the previously described functional thermal test, it is important however for the packs to be tested. The most accurate test of a pack that does not subject it to any potential damage is to do 2 cycles of a complete room temperature discharge to 10.5V at ~1.8A load followed by a charge at constant 900mA current to a ΔV of -20 mv. This latter condition should occur at ~14.75 V (temperature dependent, use ONLY ΔV of -20 mv at fixed current as charge termination). If possible the complete V vs. time curve for both discharge and charge should be recorded. At minimum: 1. Record battery initial voltage: 2. Record time to discharge to 10.5V: 3. Record time to charge to Full charge: 4. Record full charge voltage (while charging): 5. Record full charge voltage after removing charging current: Repeat the above sequence a second time. A form for recording this information will be available in the BARREL dropbox file exchange. Each battery should undergo the above functional test at: 1. Room temperature Capacity: deg. C Capacity: 3. 0 deg. C. Capacity: 4. Room temperature Capacity: