1. Battery Safety and Design Manual for Payloads presented by Jerri S. Ling September 13, 2004 presented by Jerri S. Ling September 13, 2004

2. Battery community suggests that the JSC battery handbook needs to be updated (June 2001). RMO submits a Code Q RTOP proposal to update the JSC battery handbook (Sept. 2001). RTOP is approved Oct. 2002, however payload community recommendations for updates differ from PSRP recommendations (Jan. 2003 to March 2003). Decision to make document internal to GRC (March 2003). Initial information gathering (Best Practices, Lessons Learned, text books, graphics, vendor sites, etc) (March 2003 to Sept. 2003). GRC-M8100-006 Battery Safety and Design Manual for Payloads completed (July 2004). Background

3. Overview DOCUMENT PURPOSE - Provides a compendium of quality and safety- related best practices and reference information for design, and testing of cells and batteries used in space flight applications. DOCUMENT SCOPE - Intended to provide project managers and design engineers with key elements of battery selection, factors to consider during the design/development phases, and clarification of the safety review process for batteries. Used by payload designers in conjunction with the JSC Battery Handbook (JSC 20793). Allows Project Management to more accurately map out required resources based on battery-related tasks that need to be performed.

4. Contents CHAPTER 2 - REFERENCES Applicable Documents NSTS 1700.7B and it’s ISS Addendum - Safety Policy and Requirements for Payloads NSTS/ISS 13830 - Payload Safety Review and Data Submittal Requirements JSC 20793 - Manned Space Vehicle Battery Safety Handbook GRC-0510-002 Space Assurance Requirements and Guidelines (SARG) Others

5. Contents CHAPTER 3 - CELL/BATTERY DESIGN CONSIDERATIONS Charging Batteries Preventing Battery Short Circuits Voltage Reversal Thermal Preventing Leakage Preventing Improper Insertion

6. Contents CHAPTER 4.0 - FACTORS AFFECTING BATTERY PERFORMANCE Voltage Level Discharge load Discharge mode (constant current, constant power, constant load, etc.) Temperature during discharge Service Life Voltage Regulation Charging Voltage Battery Age/Storage Conditions Battery Design

7. Contents CHAPTER 5.0 - BATTERY SELECTION AND APPLICATIONS CHAPTER 6.0 - CELL/BATTERY TEST PLANS Purpose of Test Plan Test Plan Outline Test Plan Checklist

8. Contents CHAPTER 7.0 - GROUND TEST CONSIDERATIONS Hazards and Precautions for Battery usage Battery Test Facility Checklist Safe Handling Requirements Lead-Acid Batteries Nickel-Cadmium Batteries Lithium Batteries Emergency Procedures Exposure to Electrolyte Leakage/Venting/Temperature increase Cell Rupture Lithium Cell Fires Disposal Procedures

9. Contents CHAPTER 8.0 - FLIGHT SAFETY REQUIREMENTS Overview of Flight Safety Review Process/Requirements Summary General Hazards and Controls Structural Gas Evolution Elevated Pressure Electrolyte Leakage Short Circuits Circulating Currents High Temperature Overcharging Safety of Specific Battery Types Lithium Ion, Nickel-Cadmium, Nickel Hydrogen, Silver-Zinc, et al.

10. Contents CHAPTER 9.0 - CELL SCREENING TESTS Automated Testing Equipment Coulombic Efficiency Polarization Testing Open Circuit Decay Test Tailoring Screening Tests for Specific Cells Thermal Tests

11. Contents CHAPTER 10.0 - BATTERY TEST PROGRAM Engineering/Certification Tests Battery Level Performance Testing Abuse Tests Qualification Testing Flight Acceptance Testing Payload vs. GSE Usage and Testing Recommendations

12. Contents CHAPTER 11.0 - OTHER ENERGY STORAGE DEVICES Fuel Cells (description of various types), Flywheels APPENDIX A - LESSONS LEARNED APPENDIX B - THEORETICAL VOLTAGE/CAPACITY TABLE APPENDIX C - SUMMARY OF BATTERY BEST PRACTICES Glossary of Terms/Acronym List

13. 8100/Risk Management Office Document available from GRC BMS