Acceptance Test Report
Contents
1. Does system runs without failure Fail Initials AL Board failure criteria are the same as in T001 Software failure 12C commands remain responsive throughout test Naviee ig Braille Ly Buih p Acceptance Test T003 e Cause a common failure in the system and allow a novice to utilize the User Manual in troubleshooting and solving the problem o ACMS is set up so that the fuse located on the board is one which has been burned out in a previous experiment being conducted for QA testing The novice is not aware of this fact o Tell the novice that when the board is correctly hooked up that there is no output from the power connector but that the microprocessor is still operating and can still communicate via 12C o The novice is given the User Manual for the LPRDS CMS 2011 system and asked to troubleshoot the malfunctioning board by reading the User Manual and determining that the reason the board is not working is because of the burned out fuse ROO6 4 Novice was able to solve problem CPass_ Drail Initials GE e Cause an uncommon failure in the system and allow a system expert to utilize the Maintenance Manual in troubleshooting and solving the problem Expert was able to solve problem 6S Fail Initials GE EN po Paie Adoain z Pak ATP Test T003 Expert Erik Adolfsson Witness Will Schlansker Date 5 5 11 The pack was first connected to the relays and put into the discharge state The red discha2. 2S 2P Configuration 2 serial 2 parallel Test Voltage Cables 1 4 Source Relay Pin 3 of Data Connector Test Data Cable 3 Test Data Cable Test Data Cable 1 a Ve Garnectiva_ Board 1 gt Pe Dongle p Test Procedure e Take 4 LiFePO4 cells and fully charge them individually using MPJA 9604PS Power Supply until each cell voltage reaches 3 8 V one 1 e Discharge all the cells to the following SOCs 80 50 25 10 by attaching resistor rebuaricie fieere 1 to the two terminals of the battery cell for the specified amount of time This distribution of SOCs represents a 24 9SOC standard deviation Cell SOC Time min e 1 88 100 9 O 2 23 2o 3 34 4o e Connect the OBPP to the test system shown in figure 2 o Connect wire 1 of Test Power Cable 1 to th aaki terminal of the source MPJA 9604PS Power Supply Connect wire 2 of Test Power Cable 1 to the 2 terminal of the Source Relay Connect wire 3 of Test Power Cable 1 to the 1 terminal of the Load Relay Connect wire 4 of Test Power Cable 1 to the negative terminal of the load Hrarsist6r ig 600 4 pletead resis newek tn we 1 o Connect the Te terminal of the source to terminal 1 of the Source Relay using Test Power Cable 2 o Connect the positive terminal of the load to terminal 2 of the Source Relay using Test Power Cable 3 o Connect the common ground
3. C ambient Pass J Fail Initials A SWRO01 3 GPROO5 8 ROO2 2 Pass Y Fail Initials Third Lentth Charge Discharge Cycles Monitor temperature of board once at end of every charging cycle to make sure that board does not exceed temperature requirements A gt i Cycle 3 ne Cycle 4 IY e Cycle 5 Tow C Pai i Within 70 C above 30 C ambient Pass h Fail Initials Ne 5 Following the completion of the all five 5 charge discharge cycles look at the voltage curve data which the Simulink test collected Identify that the standard deviation of the states of charge over the period of 5 charge discharge cycles decreased by the following analysis Once the cells have finished the 5 charge discharge cycles remove cells from pack and individually charge them to capacity Vmax being set at 3 8V by attaching each individual cell to the MPJA 9604PS Power Supply and setting the current to 10A Record the time required to charge each cell to its maximum voltage Cell 1 UIS hrs Cell 2 0 hrs Cell 3 1 2 hrs Cell 4 O 3 hrs Multiply the time to top off by the current used to charge the cells to get the amount of SOC still uncharged in each of the cells Subtract each of these numbers from the capacity of the cell 10 A hr and divide by the cell capacity and multiply by 100 to get the SOC of each cell at the eand of the five 5 charge discharge cycles Uncharged Capacity Cell 1 A hr Cell2
4. Clear labeling of all controls and indicators e An obvious and clearly labeled system wide power shutdown switch e Silkscreen on PCBs that includes reference designators noted power supply voltages and other critical signals Silkscreen must show a Lafayette College logo the words Made in USA a ROHS logo assembly number and revision and designated locations for serial numbers to be attached or written PCB bottom copper should have text indicating the board part number and rev e Fuses shall be socketed and at least 5 spares must be included with system delivery breakers shall be resettable All are readily accessible per maintainability requirements e Service loops on all cable harnesses e Access panels on enclosures 2 Software firmware developed must adhere to the principles and practice established in Lafayette College course CS205 Source code must be maintained under configuration control 4 Embedded computer processors shall have reset buttons These buttons must be readily acceptable for maintenance but not so easy to hit that they degrade reliability 5 Current drain analysis must be provided for all power supplies Each supply voltage must have a current rating with a 50 safety factor over the anticipated peak current 6 Allresistors or other parts dissipating more than 25 milliwatts shall be identified and analysis shall be provided that shows all such parts are properly rated for peak and average power dissipat
5. SOC Record the amount of time that this charge cycle took to complete enter values into the following formula and calculate layg X Time AX__ hr x 100 x 100 capacity 10A h SOC from I2C and observation differ by less than 10 Pass D Initials Query 12C for the current of the pack by entering the following command into RealTerm o Read current Oh OVOOF OOO 12C Current 4 05 A 0435 Observe the current indicator on the MPJA 9604PS Power Supply Test whether the I2C current is within 10 C A of the Power Supply current SO m PS Current 5 A I2C 1A PS Com Fail Initials La Temperature Test 1 Query I2C for the temperatures of the 4 cells by entering the following commands into RealTerm o ReadTemp1 9eereeee eeeeeees 00000101 OhHOSOS FOO o Read Temp 2 00010000 00000001 00060H9 Oho OG FOSS o Read Temp 3 O hos OF FOO o Read Temp 4 00010009 00000094 00001069 O h OYOZFOSO ett 26 1 ec eta 23 ce ner AYA e ncr 29 2 c TOA GAO GDL GEH Manually measure the temperatures of areas near each of the temp sensors on the OBPP using the 16710 TE Infrared Thermometer RTL A A ec RT IAA e RT AAD e mR 223 c R002 6 R002 6 R002 6 PoT iN MANDAL Mode OnO9LLOOFF Master Device Test 1 Query I2C and set all power resistors in bypass for 5 minutes with the following commands in RealTerm o Bypass Switch 1 ONO9 OB OOOB Bypass Switch 2 ONOG Soop O hos OD 0008 o o Bypass Switch
6. SWRO01 5 In order to provide the ability to interface with the previous LPRDS system the current system does include optical isolation for high voltage protection We are not reusing previous year s safety interface RO11 1 but the redundant temperature safety system RTSS developed in this year s system is compatible with the safety loop developed by previous LPRDS projects An electrical safety plan was written by previous LPRDS teams and adopted within the first week of the project SWR001 7 We are not developing a DC potential difference greater than 30 Volts A 4 cell battery pack produces around 12 Volts GPROO5 12 We are not designing our communication cables power harnesses or connectors according to NEC ANSI NFPA 70 and ANSI C 2 GPROO5 13 We are not interfacing with the Lafayette college power grid GPROOS5 14 We are not using lasers or any RF in our design GPROO5 15 GPROO5 16 While the CMS will not operate by continually balancing a pack of cells for ECE department visitors a demo program will be developed to show that the board design and integration on a pack of four cells produces a meaningful response from the firmware programmed onto the PIC microcontroller GPRO11 2 Acceptance Test T001 This test verifies the following requirements ROO2 2 The LPRDS CMS 2011 shall re engineerthe design a new ESS to permit per cell battery management ROO2 3 The new system shall charge every cell inthe ESS in the 4 cell
7. components rated for commercial temperature range 0 70 C or better GPROO3 EMI EMC Unintentional electromagnetic radiation radiated or conducted from designs must meet US CFR Title 47 Part 15 subpart B regulations for Class A digital equipment Intentional radiators must meet subpart C regulations Exemptions from 15 103 are not allowed GPROO4 Hazmats Hazardous materials should be avoided in designs If use of a hazardous material is essential to the function of the design and there is no non hazardous alternative the use of the hazardous material must comply with the Lafayette College Chemical Hygiene Plan All materials used in electronic circuit fabrication must meet 2002 95 EC RoHS directives NiCd or Lead Acid batteries may not be used in new designs 3 Any portion of the design or prototype that is discarded must be discarded according to the Lafayette College Chemical Hygiene plan Also projects should discard the collected electronic waste in an ecological friendly manner as per the 2002 96 EC WEEE directive either by ecological disposal or by reuse refurbishment of the collected waste GPROOS Safety and Good Practice 1 All work shall comply with good industry practice that enhances reliability and maintainability These practices include such items as e Color coded wiring in accordance with applicable industry standard color codes e g NFPA 79 or UL508 for power wiring EIA TIA 568 for network wiring etc e
8. pack to its maximum recommended capacity Should some cells charge faster than others a means shail be provided to bypass the cells that become full first allowing complete charge to be delivered to cells that charge more slowly ROO2 4 On discharge every cell shall be monitored and over discharge of any individual cell must be avoided ROO2 5 The ESS shall be capable of standalone operation It shall be possible to properly charge and discharge the ESS without needing an outside computer system for control or monitoring Indicators shall be provided that give a basic display operational state charge discharge rate and charge state fuel gauge Controls shall be provided if needed to permit standalone management SWRO01 3 Surface temperatures supply current drains per GPROOS must be analytically predicted at CDR and physically measured less than 70 C over ambient 30 C and verified as compliant during ATP GPROOS 8 Components must be cooled such that the surface temperature is no greater than 40degrees C above ambient Required Materials MPJA 9604PS Power Supply e Cell Management System CMS o 4 cell pack with OBPP partially charged e 2 Gold SDP4040D DC Solid State Relay e 4 120 Watt 1 Ohm resistors o REMEE ome ter e PC running Simulink e National Instruments BNC2110 Data Acquisition Board e Test Power Cables 1 2 3 e Test Data Cables 1 2 3 e Test Voltage Cables 1 2 3 4 Festi Sahin i nc Na a ek a Se
9. 3 o Bypass Switch 4 O hog 6E cooB Red Bypass LEDs turned on for 5 min 30 sec Pass Fail Initials AD Setting the board to go into non automatic mode Observe that the yellow status LED no longer pulses but remains solid indicating non automatic mode Yellow LED solid Fail Initials AD Temperature Test 2 Query 12C for the temperatures of the 4 cells and manually measure temperatures of areas near each of the temp sensors on the OBPP as in Temperature Test 1 SH c acta 33 1 ec ncr 29 3 c ncm 39 1 c IE NE mey TOA TES RTL XH c IRT2 324 5 C IRT3 aS c IRT4 29 4 C 12C T1 Subtract temperatures from Temperatures Test 1 from Temperature Test 2 for both 12C and IR 12C pitta bl occ miz ILH vc mia ALA c miea LO ec IR Diff 1 3 5 ie Diff 2 e C Diff 3 1 8 C Diff 4 3 1 E Differences between 12C amp IR are no greater than 10 of highest of the two values Diff 1 Pass Fail Diff 1 Pass Fal Diff 3 Pass Fail Diff 1 Pass nitel ok he Master Device Test 2 Query I2C and set board back to automatic mode with the following command with RealTerm o Enter Automatic Mode 9eereceeoesseTee O O93 12 OOOO Query 12C and determine which mode the system is in automatic not with the following command in RealTerm o Get Aide Ohog12 F000 g Does RealTerm return OxOF Pass Fail Initials AL Oh coco Yellow LED setid rm Fail Initials AD blinked
10. CE211 3 All original paper documents should be scanned and stored electronically The original should be disposed of per GPRO12 4 Test reports for hardware and software must show the date time of testing name and signature of the tester and name signature of any witnesses 10 For all electronic PCB designs the following fabrication documents are required dated and numbered schematics or mechanical drawings on Lafayette College drawing format circuit net lists bills of materials artwork assembly drawings and all other files and instructions necessary for CAM or manual manufacturing The source files for fabricating PCBs and editing linked schematics shall be clearly identified and preserved Documentation must be provided both for original designs and for any subcontracted designs For purchased vendor components within the design all vendor manuals and documentation shall be retained with the system Proper mechanical drawings are required for fabricated mechanical parts Manufacturers data sheets and interface drawings are required for all purchased components For software and firmware designs Source code and executable binaries for all applications Verilog constraints and configuration bitstreams for FPGAs and ROM image files in commonly accepted JED or HEX formats for all PLDs A Users manual is required This should be a high level document that explains all operational procedures and techniques needed to ope
11. LPRDS CMS 2011 Lafayette Photovoltaic Research and Development System Cell Management System ECE 492 2011 Acceptance Test Plan Created by Erik Adolfsson Last Revision 04 20 11 by Greg Earle Requirement ROO2 2 Applicable Modification We are developing a new design for per cell battery management Confirmation Method Demonstration of convergence of a 4 cell pack as per Test T001 which will run ten 10 charge discharge cycles R002 3 R002 4 We are only charging one pack not the entire system Applicable Using resistive bypass over ten 10 charge discharge cycles measurement of voltages and SOC via Simulink will demonstrate per cell balancing as per Test T001 Using Simulink a discharge curve will be created to demonstrate that over discharge does not occur as per Test T001 R002 5 Applicable Visual demonstration of OBPP will confirm operational stand alone state via LED indicators during Test T001 amp Test T002 Achieved R002 6 12C is used to monitor in detail voltage current and SOC of battery pack including every individual cell 12C interface will be utilized during Test T002 to monitor the voltage currentf mperature and SOC of each individual cell in the pack via a PC terminal application R002 8 Applicable GPR001 1 Applicable Final Report will include photographic evidence of usage of exi
12. Project Website All files to be delivered are in GPR001 10 Applicabl pplicable standard and portable document 7 formats SWRO01 1 Environmental Memo in the Final Report will analyze that the system meets the Operational and storage temperatures In addition ROHS compliance will be analyzed GPROO2 1 Applicable SWRO01 2 EMI EMC Memo in the Final Report will analyze the unintentional electromagnetic radiation concerns of the system GPROO3 1 Applicable Environmental Memo will analyze if the system has any hazardous materials and if they comply with V GPR004 1 Applicable LC Chemical Hygiene Plan Environmental Memo will make sure all materials used in electronic circuit fabrication are RoHS compliant GPR004 2 Applicable Environmental Memo will GPR004 3 Applicable consider disposal of design or prototypes GPR005 1 Applicable Inspection h GPROOS5 2 Applicable Firmware will be peer reviewed to ensure that it complies with all principles and practices established in LC s course CS205 Archived revision histories zip files and final version of PIC firmware will be located on the project website under Resources gt PIC Firmware tab Testing software Simulink files for ATP ATR will be located on the project website under Resources gt Test Software tab A Software Readme file will be located on
13. actical to store with the bulk of the project materials these separate parts must be clearly labeled so their association with the stored project is obvious Projects placed on display may have portions not on display The undisplayed portions shall be either stored or discarded as described herein 3 Portions of projects or complete projects that are discarded must be discarded in accordance with Hazmat procedures described herein 4 Test equipment moved from labs shall be replaced in its original location 5 Trash loose wires scattered components and other detritus resulting from frenzied development and testing shall be cleaned up 6 Paper documents that have been scanned per GPROO1 shall be placed in a paper recycling bin 7 The project web site must be updated with all final documents The documents on the final web site must match the delivered system Obsolete documents on the web site shall be removed In addition the following special waivers and restrictions are applicable to the project Special Waivers and Restrictions SWR001 1 Analysis must show the system is compliant to GPROO2 however no formal environmental testing or empirical data is required 2 Analysis can be used to show the system is compliant to GPROO3 no formal EMI EMC certification testing or empirical data is required 3 Surface temperatures supply current drains per GPROOS must be analytically predicted at CDR and physically measured and ve
14. amp l A hr Cell3 MS A hr cell4 138 Ahr Ending State of Charge 10 Amp hrs x lam ep SE Cell 1 x v1 56 Cell 2 x 1 4 21 Cell 3 x3 l gt 1D Cell 4 x4 NG Lado Compute the average SOCs of the four cells x Ole Compute the standard deviation of the cells in the pack by the following formula s eDit eee Ti 3 7 SOC Is the final standard deviation of the cells within the pack less than the standard deviation at the beginning of the test 27 GPROO06 4 After the last charge discharge cycle allow the pack to sit without balancing overnight If there is more time left in the 24 hour period of the test continue to observe the board and look for failure conditions rf rai Does system runs without failure Kas A y Fail Initials AN Failure is defined as the following conditions for board and software Board failure overheating beyond specified threshold temperature discoloration combustion or other obvious component failure Software failure relays cease to function and charging discharging indicators fail to update over the expected duration of a cycle Further software failure can occur in 12C communication which will be tested in T002 ATP T001 Verification of Operation of Bypass Cell Voltage vs Time ATP T001 T T T 3 5 Goes out of bypass now that it is within 50mV of other cells 3 4 S 3 37 oO D gt g 3 2 More than 50mV higher th
15. an cell 3 14 3 enters bypass Morg than 50mV More than 50mV 3 higher than cells 2 or 3 higher than cells 2 or 3 enters bypass enters bypass 100 SOC 95 SOC H 80 SOC 70 SOC LE 1 2 Time hours Cell Voltage vs Time ATP T001 or E 100 SOC 3 4 95 SOC ji 80 SOC 70 SOC 3 3 4 a 3 2 D S o gt 3 3 1 4 O 3 4 2 9 5 Time hours Cells 1 3 and 4 are 300mV 325mV and 125mVhigher than cell 2 Enters bypass Acceptance Test T002 This test verifies the following requirements R002 6 In addition to local controls and indicators a remote SCADA I C system shall be able to monitor in detail the voltage and current of andstate of charge of the aggregate ESS batteryand every individual cell in the CMS ESS as well as the overall state of charge of the pack SS parameters R002 5 The ESS shall be capable of standalone operation It shall be possible to properly charge and discharge the ESS without needing an outside computer system for control or monitoring Indicators shall be provided that give a basic display operational state charge discharge rate and charge state fuel gauge Controls shall be provided if needed to permit standalone management Required Materials e MPJA 9604PS Power Supply e Cell Management System CMS o 4 cell pack with OBPP partially charged e 2 Gol
16. d SDP4040D DC Solid State Relay e 4 120 Watt 1 Ohm resistors e PC running Simulink amp RealTerm e National Instruments BNC2110 Data Acquisition Board e Test Power Cables 1 2 3 e Test Data Cables 1 2 3 e Test Voltage Cables 1 2 3 4 e Test Bypass Cables 1 2 3 4 e PCto 12C Adaptor utilizing USB e Agilent Digital Multimeter 34401A e 16710 TE Infrared Thermometer To National Instruments DAQ to PC N Test Data Cable 1 Test Procedure ROO2 6 Maintain the same connection configuration as shown in figure 2 with the following exception o Connect the red connector of Test Data Cable 1 to the PC to 12C Adaptor as displayed in Figure 3 to enable I2C communication Begin the program RealTerm on the PC click on the tab which says 12C in order to test the functionality of the communication The OBPP will begin charging the pack of cells as an initialization cycle 12C commands are formed by three bytes of information 12C Command Format 7 bits 8 bits 8 bits amp bits OhS4 Hem Addcess 8 wits Acgument 16 bubs Initial tests Change the 12C address of the board currently connected to the 12C interface to be board Ox08 with the following command in RealTerm Ohoees o Write 12C Address Oh 5410 0003 Query the 12C for the Board Number and Firmware Version ID with the following command in RealTerm to confirm that the change of I2C address was successful o Read Board Number oseteses c
17. from the National Instruments DAQ board to terminal 4 of the Source Relay and Load Relay using wires 2 of Test Data Cable 2 and Test Data Cable 3 respectively o Connect wire 1 of Test Data Cable 2 from an output port of the DAQ to terminal 3 of the Source Relay and wire 1 of Test Data Cable 3 from an output port of the DAQ to terminal 3 of the Load Relay 4 OK fe Connect wire 1 SPs data connector on the OBPP Kage M port on the DAQ with 45k resistor O using Pest Data Cable 1 E A Sameeinputport o Connect the positive terminals of each of the cells to analog inputs 0 3 of the DAQ using Test Voltage Cables 1 4 e Using Simulink and the prexdeus setup the test will run for 5 charge discharge cycles and record the voltage of the individual cells demonstrating per cell balancing within one pack The Simulink file is named 7 and is located on the project website under the tab Resources gt Test Software testSetup md sth Ne zie Le er e Set the MPJA 9604PS Power Supply to supply a 10A current to the CMS e Connect the 10 Resistors in a 2S 2P configuration as shown in figure 1 as the Load le Zip Me SWRO01 3 GPROO05 8 SWRO01 3 GPROO5 8 SWRO001 3 GPR005 8 First Charge Discharge Cycle The OBPP will initially charge the cells Observe that the yellow LED blinks to indicate that the OBPP is on N _ r Initials A Yell
18. hese tests will verify the various functions of the cell management system CMS The Acceptance Test Plan ATP gives step by step instructions on how to test the system to the fullest extent and make sure the CMS meets all the system requirements System Requirements The project was originally presented with over 80 requirements These were reviewed and several were not achievable applicable within the scope of the ECE 492 14 week term The following are the agreed upon and altered requirements adapted from the LPRDS CMS 2011 statement of work R002 Energy Storage 2 The existing ESS design does not allow any automated per cell or aggregate battery management There is no way to charge the cells individually taking into account their individual characteristics The LPRDS CMS 2011 shall re engineer design the ESS to permit per cell battery management 3 The new system shall charge every cell he SS in the 4 cell pack to its maximum recommended capacity Should some cells charge faster than others a means shall be provided to bypass the cells that become full first allowing complete charge to be delivered to cells that charge more slowly 4 On discharge every cell shall be monitored and over discharge of any individual cell must be avoided 5 The ESS shall be capable of standalone operation It shall be possible to properly charge and discharge the ESS without needing an outside computer system for control or monitoring Indicators
19. ion and have a proper heat sink and fan if necessary that provides adequate cooling over the ambient temperature range 8 Components must be cooled such that the surface temperature is no greater than 40 70 degrees C above ambient 9 Power dissipation rating of parts shall be 50 overrated over the required temperature range 10 Working voltage of capacitors shall be 25 overrated above the peak voltage anticipated including all expected glitches spikes and tolerance limits 11 Project activities must adhere to the general Lafayette College safety policy possibly augmented by any ECE Department or ECE Laboratory safety rules Applicable rules are those in effect on the date of ATP GPRO0O6 Reliability The system wide Mean Time Between Failures MTBF must be greater than 1000 hours over the system lifetime Reliability requirements must be demonstrated in the ATP both by analysis and by Inspection The use of MIL HDBK 217 Bellcore TR 332 or other equivalent techniques are encouraged for the analysis Every part and subsystem in the full BOM must be explicitly considered in the MTBF analysis Parts with power dissipation over 25 milliwatts shall be identified and the reliability analysis shall include reliability derating of these components based on the expected dissipation In addition to the analysis a reliability inspection shall be conducted during ATP where the system is shown to operate for 24 hours without any obvi
20. oogecetesetteet OF OB 1B Foco o Read Version ID postrecoe ceoesest 00012880 Onhos 1A F000 Version ID 0x40 Cos Fail Initials AL 6hOO10 Board Number Oxt5 Pass Fail Initials x D Oh 600 Voltage Tests Query via 12C for the voltages of the 4 cells by typing in the following commands into RealTerm Read Voltage 1 00010000 00000001 090060041 OhOROTF OOO Read Voltage 2 0094060006006006160000940 9 HOR ORF OO o Read Voltage3 0001090000000066400990014 O 08 03 FOES o Read Voltage 4 p9e199ee eeeeeee c0000100 O HOS O4 Foco O revi 33H v cv2 236 v nev 3 38 v new 336G v 8a ACL ACFE ASE Manually measure the voltages across the terminals of each cell in the CMS DMM V1 _3 35 v DMMV2 3H _ v pMMv3 _3 24 v DMMV4 H v SOC amp Current Tests Query 12C for the integrated current of the pack and time step by entering the following commands into RealTerm o Because the system was originally designed for the master device to do the calculations for aggregate battery pack SOC the number which is returned by this query is not the actual SOC of the pack The number returned is the average current which passed through the cell for the duration of the charge discharge cycle o Read Iwr 0001 0000 00000001 00001004 Oh 0904 FOOG lint Z ALO A is xT 340 Ax 60 hr 166 SS 100 Ss capacity 10A h Observe the current indicator on the MPJA 9604PS Power Supply Record the value this will be used as average current to calculate
21. ous failure Failures are defined as anything that causes system requirements to be missed Failures include but are not limited to computer software lock ups shutdowns caused by overheating automatic operations stalled by exceptions or requests for human intervention as well as random component failure GPROO7 Maintainability The system wide Mean Time To Repair MTTR must be less than 1 week over the system lifetime Maintainability requirements must be demonstrated in the ATP both by analysis and by Inspection The use of MIL HDBK 472 N1 and MIL STD 470B ISO IEC 25000 2005 or other equivalent techniques are encouraged for the analysis In the maintainability analysis you should assume a stock of recommended spare parts The list of these spare parts should be included in the ATP The Users Manual should include a section giving simple troubleshooting procedures The Maintenance Manual should have more elaborate diagnosis and troubleshooting resources In addition a maintainability inspection shall be conducted during ATP where a novice using procedures included in the User Manual demonstrates the diagnosis and repair of a likely failure and an expert using resources included in the Maintenance Manual demonstrates the diagnosis and repair of an UN likely failure GPR008 Manufacturability A production design is a project design that could reasonably be manufactured in large quantity e g greater than 1000 units yr All produc
22. ow LED Flashes Pass y Fail Set up scopes in Simulink to monitor the voltages from the four cells the bypass LEDs and the done signal These severscopes will be used to analyze the operation of the pack Following completion of the test analysis of the data from the first charge discharge cycle will be completed in ATR to demonstrate the operation of the bypass circuits Criteria for demonstrating operation of bypass is to show that if a cell is greater than 50mV from nig p the lowest cell the scope of the LeB forthat cell will show a jep in voltage for a 20 min period Full analysis for all cells for the full charge cycle will be completed in the ATR Second Charge Discharge Cycle Observe when the cells are charging when a bypass LED is turned on indicating partial resistive bypass Using the IR heat gun amp laser crosshairs aim as close as possible towards the underside of the keardwhere the power resistors are located and find the maximum temperature Nitatsinks 7 a I YI y Temp 1 dl C Temp 2 C Temp3 _ gt C Temp4 C Within 70 C above 30 C ambient Pass y Fail Initials Z JA ew Wait 15 minutes and repeat previous step again es E aK Temp1 C Temp2 C Temp3 C Temp4 C SNN y Within 70 C above 30 C ambient Pass Fail Initials a Wait 15 minutes and repeat step a third time oN Mer 20 9 JDS 2 Temp 1 2 C Temp2 2 C Temp3 C Temp 4 e Within 70 C above 30
23. parts list User s Manual for troubleshooting procedures and Maintenance Manual for more elaborate GPR007 3 Applicabl ppiisable diagnosis and troubleshooting Y resources All docs are located on Project Website under Project Documents Test T003 will check the GPROO7 4 Applicable usefulness of the User and Maintenance Manuals S ili i GPROO8 1 Applicable ee Manufactwrability Memo in Y Final Report f ey Fa ail GPROO8 2 Applicable See Manu acturability Memo in Final Report Final Project demonstration will GPR011 1 Applicable take place on 5 6 11 for ECE p l Faculty i GPRO12 Applicable Inspection seer Acceptance Testing Approved WEAK Acceptance Test Report Deliverables Due Date Completed Initials Date D001 CDR as Materials 3 2 2011 FO Dy Sf tt D002 User s l kei 5 6 2011 L LAr S Ag J D003 Final Report and Maintenance Manual 5 6 2011 D004 Acceptance Test Plan 4 15 2011 D005 Acceptance Test Report oe 7 CLA Spe ea a E D006 QA Audit Report D007 Project Website D008 LPRDS CMS 2011 Integrated System D009 Conference 4 8 2011 i fy Paper D010 Project Poster 5 3 2011 Periodically 5 6 2011 5 6 2011 Intr ion In order to ensure the project can meet the requirements of the LPRDS CMS 2011 Statement of Work it must successfully pass acceptance testing T
24. rate the system is a safe and effective manner including getting started FAQ detailed explanations of all functions and controls and user level calibration and maintenance A technical Maintenance manual is required This should be a low level document that explains the unique technical principles and details of system operation The maintenance manual includes information on any advanced maintenance or calibration techniques that could be applied by an expert maintainer A set of schematics pinouts of all connectors the signal assignments of all cables and the semantics of all interfaces hardware and software must be documented within this manual All documentation must be provided and delivered in electronic form Emailing a description of a document along with a URL into the project web site is an acceptable and desirable form of delivery The use of standard and portable document formats e g PDF TXT must be used so that the documentation can be viewed on any computer without the need for proprietary applications The documentation must be arranged in an organized and professional manner on the project web site GPROO2 Environmental All projects must demonstrate reliable and normal functional operation in ambient lab temperatures of 15 C to 30 C 10 to 80 RH non condensing The overall system must tolerate a storage environment of 0 C to 60 C 5 to 95 RH non condensing Designs should use electronic
25. rging LED blinked a few times and then went solid to indicate the pack was empty The resistive load was removed from the pack and used a multi meter to measure the voltage of the pack and concluded that it was in fact not empty Next the expert measured the voltage of each cell and compared each of these values to the corresponding I2C value It was immediately apparent that the 12C value for cell 1 did not match the multi meter The expert used the Maintenance Manual to find the appropriate pin for cell 1 voltage and checked the input pin to the A2D for cell 1 and saw that it matched the 12C but not the multi meter The expert then narrowed his focus to the differential amplifier between the voltage for cell 1 and the PIC He removed the OBPP from the battery pack and pulled up the schematic for the differential amplifier He located the differential amplifier for cell 1 and inspected the chip It looked burnt out but to be sure he inspected the resistor values All 4 resistors in the circuit are 100K The expert used the multi meter to confirm this and then deduced the TLC 2252 chip was faulty and needed replacement Once the chip was replaced the cell 1 voltage input to the A2D was restored to the proper value
26. rified as compliant during ATP 6 The system life for the purpose of requirements analysis other than for GPROOS shall be 5 years The first requirement of the LPRDS CMS 2011 is to develop a new Energy Storage Subsystem ESS to replace the existing ESS The main function of the ESS is to act as an Energy Accumulator to store the excess electrical energy available from the PC array and later deliver that stored energy to the Energy Delivery Subsystem ROO2 1 The scope of this project is limited to a cell balancing PCB that is attached to each 4 cell pack The system is scalable and can be used within the current ESS but will not be implemented or tested at this time For this system the SCADA interface is not used ROO2 7 Instead an I C interface which uses a USB adapter to communicate with a PC Since we are reducing the scope of our project we cannot conform to ESS requirements inherited from previous years ROO2 9 ROO2b 1 through ROO2b 13 Our project is not sophisticated enough for us to write a software application for interfacing with the pack ROO6 1 ROO6 2 We also cannot write a demonstration application on such a simple circuit ROO8 1 through ROO8 5 however the OBPP board does demonstrate operation through the implementation of 4 LEDs demonstrating bypass and 3 LEDs indicating charging discharging and board status We are not interfacing with any high voltage or photovoltaics ROO9 1 through ROO9 3 RO10 1 RO10 2 SWR001 4
27. shall be provided that give a basic display operational state charge discharge rate and charge state fuel gauge Controls shall be provided if needed to permit standalone management 8 In addition to local controls and indicators a remote SEADA C system shall be able to monitor in detail the voltage and current of and state ef charge of the aggregate ESS battery and every individual cell in the CMS ESS as well as the overall state of charge of the pack ESS parameters 9 Although a new charge management system must be developed the LPRDS CMS 2011shall re use the existing LiFePO4 cells incorporated in the existing ESS system Also to the largest extent possible the existing mechanical enclosure cabling controls and safety interfaces for the old ESS should be re used GPROO1 Documentation 1 Complete and accurate documentation must be provided with all projects These documents shall include documents for mechanical and electrical fabrication test results software development kits maintenance manual user manual and specification compliance matrices and technical papers All documentation shall be accumulated in electronic form centralized in a project web site and thoroughly indexed The web site represents the primary point of delivery for document data items 2 Text documents shall be written in a professional style commensurate with quality standards established by Lafayette College ECE writing courses e g ES225 and E
28. sting LiFePO4 cells SFEER R Oport oF HST OT documentation ane eeeeons GPR001 2 GPR001 3 Applicable rised a Standards pae a hil is loca project website Another member of the team will edit each individual s work to ensure adherence to group standards compliant with those of Lafayette College writing courses Applicable Inspection GPROO1 5 GPROO1 4 Applicable Inspection of QA Audit Report and low level test reports Applicable manufacturing are located on the All schematics mechanical drawings circuit net lists BOMs artwork assembly drawings and other files necessary for Project Website under the tab Resources gt OBPP Design Documents __ 4 All datasheets of components used in the system design are J GPROO1 6 Applicable located on the project website wes under the tab Resources gt Datasheets The final report will include a section entitled Firmware Development which will include documentation of the design V decisions implementation and issues with the current firmware GPR001 7 Applicable See User s Manual located on GPR001 8 Applicable Project Website under the tab Project Documents See Maintenance Manual on GPR001 9 Applicable Project Website under the tab Project Documents Inspection of
29. the project website under the Resources tab GPROOS 4 Applicable A jumper connection on the board Ref Des will reset the board when the contacts are bridged GPROOS5 5 Applicable See Voltage Analysis Memo in Final Report GPROOS5 6 Applicable GPROO5 8 Surface temperature rise no greater than 70 degrees C above ambient GPROOS 9 oo Applicable See Power Dissipation Memo in Final Report Test T001 demonstrates that the components used do not have a surface temp gt 70 C above ambient 30 C See Power Dissipation Memo in Final Report ee Applicable See Voltage Analysis Memo in Final Report GPROOS 11 L Applicable See Maintenance Manual on Project Website under Project Documents GPR006 1 Applicable GPR006 2 Applicable See Reliability Memo in Final Report See Reliability Memo in Final Report GPR006 3 GPR006 4 Applicable A See Reliability Memo in Final Report Applicable Tests T001 will be conducted within a 24 hour period of continuous system operation See Reliability Memo in Final a GPR006 5 Applicable A ppsa Report GPR007 1 Applicable See Maintainability Memo in L Final Report GPR007 2 Apolicakie See Maintainability Memo in Final Report See ATP for spare
30. tion designs must be built from components and subassemblies that have a sustainable source of supply over the system lifetime To demonstrate that this requirement is met it must be shown that each item in the Bill of Materials BOM for the design is available from a minimum of two independent suppliers In addition industry trends shall be considered when selecting 24 implementation options Designs should choose options most aligned with future industry trends The tolerances of components shall be considered in the design Any component with a value that determines a critical voltage time constant frequency or other parameter shall have a tolerance such that system requirements are met with 99 yield in manufacturing An analysis shall be provided that identifies any tolerance critical components and proves that the tolerances are adequate to meet system requirements at that yield GPRO11 Project Demonstration Completed projects must be demonstrated for review by ECE faculty GPRO12 Final Disposal of Projects 1 Projects may be stored for future work placed on display or discarded Time must be included in project schedules for final disposal 2 Ifa project is to be stored all its materials must be collected together in a single location If possible these materials should be enclosed in a sealed container locked cabinet or secure room that contains only these materials from one project and no other If certain parts are impr
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