AMS02 Uninterruptible Power Supply

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AMS-02 Uninterruptible Power Supply
Alpha Magnetic Spectrometer NASA / DOE
Status Summary
T. J. Urban / ESCG
January 31, 2006
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AMS-02 Uninterruptible Power Supply Status Summary
Alpha Magnetic Spectrometer NASA / DOE

• Battery Pre-Delivery Acceptance Review
• Review held July 18, 2005. Review deemed
  successful.
• All battery cell qualification and acceptance
  test data reviewed
• In compliance with SOW Appendix A.
• Cells are assembled into battery bricks, and
  awaiting completion of integrated testing with
  Battery Management System (BMS) electronics prior
  to shipment.
• Shipment, via sea due to energy density (approx.
  3 weeks), following integrated testing.
• BMS has had issues, delaying cell BMS delivery
  until February 2006.

T. J. Urban / ESCG
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January 31, 2006
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AMS-02 Uninterruptible Power Supply Five Cells
Alpha Magnetic Spectrometer NASA / DOE
T. J. Urban / ESCG
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January 31, 2006
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AMS-02 Uninterruptible Power Supply Cell Details
Alpha Magnetic Spectrometer NASA / DOE
T. J. Urban / ESCG
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January 31, 2006
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AMS-02 Uninterruptible Power Supply Vibration
Testing
Alpha Magnetic Spectrometer NASA / DOE
T. J. Urban / ESCG
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January 31, 2006
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AMS-02 Uninterruptible Power Supply Cell
Destructive Testing
Alpha Magnetic Spectrometer NASA / DOE
Internal Short Test
Overvoltage Test
T. J. Urban / ESCG
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January 31, 2006
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AMS-02 Uninterruptible Power Supply Status Summary
Alpha Magnetic Spectrometer NASA / DOE

• UPS Critical Design Review
• Review held August 9, 2005. Review deemed
  successful.
• Various actions taken and closed.
• UPS housing has been redesigned with a delta 15mm
  in height.
• To facilitate battery / BMS wiring.
• Drawings complete.
• Structural Analysis all margins are positive,
  JS ESCG review of analysis report is complete.
• UPS install bracket has been split in two to ease
  installation.
• Bottom Line Approval has been given for UPS
  manufacture.

T. J. Urban / ESCG
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January 31, 2006
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AMS-02 Uninterruptible Power Supply Module
Assembly
Alpha Magnetic Spectrometer NASA / DOE
T. J. Urban / ESCG
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January 31, 2006
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AMS-02 Uninterruptible Power Supply Status Summary
Alpha Magnetic Spectrometer NASA / DOE

• Battery Management System (BMS) Testing Issue
• During BMS PCA level thermal cycle testing, 100kO
  resistors failed either open, or gt 100kO
  resistance.
• Manufacturers assessment was material corrosion
  in encapsulation material.
• Most likely candidate overheating during
  soldering.
• Resistors have been replaced.
• Thermal re-testing has been completed.
• Integrated battery / BMS testing is underway.
• PRACA (Problem Reporting and Corrective Action)
  initiated at JS ESCG, and will be reported to JSC
  PSRP.

T. J. Urban / ESCG
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January 31, 2006
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AMS-02 Uninterruptible Power Supply Status Summary
Alpha Magnetic Spectrometer NASA / DOE

• UPS SOW Revision B To be released 17 February
  2006.
• Redefine electrical interface battery safety
  signal for overvoltage.
• Work underway to determine if this is acceptable
  to CAB.
• Testing
• Update of UPS thermal testing based upon latest
  integrated thermal analysis (acceptance test _at_
  50C and qualification test _at_ 55C).
• External short circuit (72 A vs. 80 A) verifying
  with JSC/EP battery expert.

T. J. Urban / ESCG
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January 31, 2006
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AMS-02 Uninterruptible Power Supply Status Summary
Alpha Magnetic Spectrometer NASA / DOE

• Further UPS Actions
• Provide portable UPS tester CSIST to provide by
  1 April 2006.
• Locate UPS fasteners from ESCG Shipment
  delivery date to be provided by Urban to CSIST by
  10 February 2006.
• MIT procurement of UPS parts, latest EDT 28 -
  February -2006

T. J. Urban / ESCG
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January 31, 2006
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AMS-02 Uninterruptible Power Supply Battery Weight
Alpha Magnetic Spectrometer NASA / DOE

• Cell module 8.8 kg
• Battery box 3.4 kg
• BMS 0.75 kg
• Wire and connector ?
• Total est. 15 kg

T. J. Urban / ESCG
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January 31, 2006
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AMS-02 Uninterruptible Power Supply UPS Module
Weight
Alpha Magnetic Spectrometer NASA / DOE
Misc. J1J2 230g Intercell Connector
200g Screw Nut 20g Adhesive 50g Flux
100g RTV566 200g Wire 100g (6.4g8m29.3g1.4m)
Total900g X 21.8kg
T. J. Urban / ESCG
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January 31, 2006
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AMS-02 Uninterruptible Power Supply Schedule
Delay from BMS 3 Months
Alpha Magnetic Spectrometer NASA / DOE

• Shipment of batteries and BMS 17 February 2006.
• This will delay UPS delivery until mid-December
  2006.

T. J. Urban / ESCG
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January 31, 2006