HANDLING AND STORAGE PRACTICE

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1 PREFERRED RELIABILITY PRACTICES Practice N. PD-ED-1109 Page 1 f 5 Ni-H SPACECRAFT BATTERY HANDLING AND STORAGE PRACTICE Practice: Develp and implement handling and strage prcedures t ensure reliable peratin, minimize deteriratin, and prevent irreversible effects n the flight perfrmance f Ni-H flight batteries due t imprper handling and strage. Benefit: Ni-H batteries will significantly deterirate, principally due t capacity fading, if the prper strage and handling prcedures are nt fllwed in a number f stages in the cell/battery lifetime. A set f prven guidelines is fllwed by flight prjects in the preparatin and utilizatin f prject unique handling and strage prcedures in rder t minimize these deteriratin effects and ensure the reliable perfrmance f Ni-H batteries. GSFC Prgrams That Used Practice: Hubble Space Telescpe (HST) - (NASA's first flight use f Ni-H batteries in lw Earth rbit applicatin Earth Observing System AM, (EOS AM) LANDSAT Center T Cntact Fr Mre Infrmatin: Gddard Space Flight Center Implementatin: A sealed Ni-H secndary cell is a hybrid, cmbining battery and fuel-cell technlgies. The nickel psitive electrde cmes frm the nickel-cadmium cell and the negative platinum electrde frm the hydrgen-xygen fuel cell. The cell is cntained in a pressure vessel designed t perate up t 1,00 p.s.i. f hydrgen gas when the cell is fully charged. Pressure measurements can be used t determine the "state f charge" f batteries in flight. Salient features f the Ni-H battery are a lng cycle life that exceeds any ther maintenance-free secndary battery system, high specific energy (gravimetic energy density), high pwer density (pulse r peak pwer capability), and a tlerance t vercharge and reversal. It is these features that make the Ni-H battery system the prime candidate fr the energy strage subsystem in many GODDARD SPACE FLIGHT CENTER

2 Practice N. PD-ED-1109 Page f 5 aerspace applicatins, such as gesychrnus-earth-rbit (GEO), cmmercial cmmunicatins satellites, and lw-earth-rbit (LEO) satellites. The GEO and the LEO applicatins have tw different requirements fr batteries. The LEO applicatins require charge/discharge cycles f 18,000 t 30,000 cycles with depth f discharges (DOD) up t 40% and up t a 5 year lifetime in rbit. The GEO applicatins require lifetimes in rbit f 5 t 10 years and abut 100 cycles per year with maximum DODs f 60% fr a ttal f 500 t 1,000 cycles. T meet these missin requirements, a number f different design appraches are used by a variety f Ni-H battery manufacturers. Generally, tw r mre batteries are used per spacecraft t meet the pwer requirements. The majr advantage f using multiple batteries is reliability. If ne battery fails, the ther battery r batteries can maintain all r at least the mst significant functins f the spacecraft. The strage and handling f Ni-H cells and batteries can significantly alter perfrmance during bth prelaunch and missin lifetimes. The develpment f a lw-vltage plateau in the discharge mde r capacity fading (lss f capacity t 1.0 vlts) is the majr cncern. Under mst circumstances, capacity can be recvered. Hwever, if a cell r battery is verheated, it can be permanently damaged. The fllwing strage and handling prcedures cver the three stages in the cell/battery lifetime: Stage 1 - Strage f cells after manufacture and befre assembly int batteries: Strage perids can range frm a few weeks t several years depending upn the launch schedule. The fllwing three methds are used t stre and maintain capacity f cells fr perids f time frm several weeks up t three years. (a) Stre fully charged cells pen-circuited at temperatures belw 0 C. These cells must be recharged, (tpped ff), every 7 t 14 days. (b) Stre fully charged cells at temperatures belw 0 C with a trickle charge rate f C/100. (c) Stre discharged cells pen-circuited at 0 C fr up t three years. Stage - Strage f batteries after assembly: Once the flight batteries are assembled, they are generally stred until they are shipped t the launch site fr integratin int the spacecraft. Fr flight batteries, the strage perid can range frm a few mnths t three years. The lnger perids represent prgram delays that affect launch schedules. The same methds fr the strage f batteries can be used as defined abve fr cells. Regardless f the methd f strage used, the capacity f batteries is measured bth befre and after strage t determine if any capacity fading has ccurred during strage.

3 Practice N. PD-ED-1109 Page 3 f 5 Stage 3 - Strage f cells/batteries during shipment: Stage 4 - Strage f batteries at the launch site: Cells/batteries are fully discharged and shrt circuited during shipment. Each cell/battery is wrapped separately with its wn packaging material t exclude humidity and cntrl temperatures t 5 C (+/- 5 C). Five t 10 cells can be packed within the same cntainer and shipped air express t minimize shipping time. The shipping cntainer shuld be equipped with temperature recrders t prvide assurance that flight cells/batteries have nt been expsed t temperatures exceeding 5 C. The capacity f cells/batteries is measured bth befre and after shipment t determine if any capacity fading has ccurred during shipping. Batteries shuld be in the fully discharged state during handling peratins at the launch site. Batteries can then be maintained during shrt term strage in the charged state at rm temperatures but must be recharged every 7 t 14 days. Als, flight batteries can be maintained n trickle charge prir t launch. The final recnditining f flight batteries shuld be perfrmed 14 days prir t spacecraft launch. Upn cmpletin f the recnditining, flight batteries shuld be kept n lw rate trickle charge until launch r recnditined every 30 days if the launch is delayed. The batteries shuld be kept in cld strage if the launch is delayed beynd 90 days. The fllwing additinal general guidelines and prcedures are used in the handling and peratin f Ni-H batteries. 1) A battery shuld be "recnditined" if it has been n pen circuit, subjected t intermittent use, i.e., pen circuit, trickle charge, ccasinal discharge, etc., fr a cumulative perid f 30 days. Recnditining is effected by perfrming the fllwing sequence at 0 C. (a) Discharge at C/ cnstant current rate until the first cell reaches 1.0 v/c. (b) Drain each cell with a 1 hm resistr until each cell's vltage is less than.03 V/C. (c) Recharge battery at C/0 cnstant current rate fr 40 hurs (+/- 4 hurs). (d) Repeat steps a and b. (e) Charge battery at C/10 cnstant current rate fr 16 hurs ( +/- 4 hurs). (f) Repeat steps a, b, and e. ) Batteries are nt charged r discharged in parallel. Islatin is prvided in spacecraft pwer systems t ensure that a failure f ne battery des nt affect anther battery. 3) Batteries are charged and all functins and cells are checked ut thrughly prir t installatin in a flight spacecraft. Batteries are installed int a spacecraft in a discharged state. 4) "Tap"s are never installed n any prtin f a string f cells in series that can cause unbalanced lading f prtins f a battery.

4 Practice N. PD-ED-1109 Page 4 f 5 5) Shrting resistrs are nrmally placed acrss individual cells t prevent cell reversal which culd damage individual cells when flight Ni-H batteries are stred shrt circuited. 6) Pwer system designs include circuitry t prevent vercharging f batteries and the generatin f excessive heat which can damage batteries. 7) The temperatures f Ni-H batteries are mnitred during peratin and strage. Operating temperatures are nt permitted beynd 18 C and nn-perating expsures are nt permitted beynd 5 C. Expsure t temperatures beynd 30 C results in permanent lss f capacity. 8) Heaters are used as required t insure that the temperature f Ni-H batteries d nt g belw -5 C at any time in rder t prevent freezing f the electrlyte. 9) Flight batteries shuld nt be subjected t extended spacecraft integratin and test activities. The pen circuit and intermittent use f Ni-H batteries during extended spacecraft integratin and testing activities are knwn t significantly accelerate the degradatin f batteries. Results frm cntrlled tests have shwn permanent and irreversible changes. 10) The design f flight batteries shuld include the fllwing prvisins fr grund cnsle interfacing with the batteries while integrated int the spacecraft. (a) (b) (c) Signal lines fr mnitring ttal battery vltage, charge and discharge currents, battery temperatures, and individual cell vltages. Capabilities t charge and discharge the battery frm the grund test cnsle. Capability t place a resister and a shrting plug acrss each individual cell. 11) A lg bk shall be maintained n each flight battery including the cmplete test histries f each cell, f the assembled battery, and f all integratin and test and launch site activities. Each lg bk shall identify the prject and battery and individual cell serial numbers. Chrnlgical (date and time) entries fr all test sequences, summary f bservatins, identificatins f related cmputer stred recrds, malfunctins, names f respnsible test persnnel, and references t test prcedures cntrlling all tests shall be recrded. Since Ni-H batteries are perishable, their ability t satisfactrily cmplete their missin life is directly related t their strage, their grund use, and handling. Histrical perfrmance infrmatin is required t ensure their flight wrthiness at launch time.

5 Practice N. PD-ED-1109 Page 5 f 5 Technical Ratinale: Ni-H batteries can deterirate due t imprper strage and handling. This practice which avids this deteriratin is based n a lng perid f battery develpment, testing, and flight experience. Impact f Nnpractice: The impact f nt fllwing this practice is that batteries may be damaged during handling and strage and may exhibit degraded perfrmance during the missin including early life failure. Additinally, batteries may nt be prperly charged prir t launch and therefre may nt meet their missin perfrmance requirements r may require a lengthy recharging prcedure befre the satellite can be fully activated. Reference: 1. NASA Handbk fr Nickel-Hydrgen Batteries: NASA Reference Publicatin 1314, September 1993

PREFERRED RELIABILITY PRACTICES. Practice:

PREFERRED RELIABILITY PRACTICES. Practice: PREFERRED RELIABILITY PRACTICES PRACTICE NO. PD-EC-1103 PAGE 1 f 6 Octber 1995 Ni-Cd CONVENTIONAL SPACECRAFT BATTERY HANDLING AND STORAGE Practice: Flight prjects develp and implement handling and strage

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