September/October 2012 www.BatteryPowerOnline.

com Volume 16, Issue 5

UPS failure is the #1*
cause of Data Center outages . . .

. . . for everyone else.

Our customers must deliver high availability and
uptime they expect nothing less and neither should
you. In fact, our customers have a perfect track
record of 100% UPS battery system uptime since
1992. Under our watch, no customer has suffered
from the far-reaching consequences of these outages.

Give us a call or visit our website to learn how you

can join the companies that have avoided becoming
another statistic.

COME SEE US AT:

Intelec 2012 in Scottsdale, AZ Visit www.intellibatt.com/uptime to learn more.
View our session on
VRLA Battery Lifetime Fingerprints
Booth# 102 1 877 422 8874 (USA)
1 415 839 7270 (Intl.)
*Source: Ponemon Institute: Addressing the Leading Root Causes of Downtime www.intellibatt.com ENSURING MISSION CRITICAL POWER

 Volume 16, Issue 5 Inside this issue of
Editor & Publisher
David Webster

Director of Content
Nick Depperschmidt

EDITORS CHOICE
Senior Editor
Shannon Given
PRBA Battery Proposals Adopted By UN Transport
Associate Editor
Heather Krier Sub-Committee . . . . . . . . . . . . . . . . . . . . . . . . . . . p 4
News Editors Jeremy Fleming,
Sue Hannebrink, Scott Webster
FEATURES
Manager of Administration The Use of Lithium-Ion Batteries in Uninterruptible
Marsha Grillo
Power Supplies . . . . . . . . . . . . . . . . . . . . . . . . . . .p 6
Advertising, Sales and Marketing
Jeremy Fleming, Monitor Your Battery Cells for Superior Reliability p 10
Director of Sales
Jennifer Graham,
Marketing Assistant Juicing Up the Battery: Cutting Edge Research
Julie Hammond,
Production Manager Delivers Battery Enhancements. . . . . . . . . . . . . . . p 13
Director of Support Services
Marc Vang
PEM Fuel Cell Systems Reliable Backup Power
Source for Remote or Extended Run
BATTERY POWER (ISSN #1092-
3616) is published bi-monthly by
Power Outages. . . . . . . . . . . . . . . . . . . . . . . . . . . . p 16
Webcom Communications Corp.,
7355 E. Orchard, #100 Greenwood Why Your Next Renewable System Should be Built
Village, CO 80111. A U.S. subscrip-
tion is $58.00/year and $72.00/year Around Energy Storage. . . . . . . . . . . . . . . . . . . . . .p 18
elsewhere. Single copies are $20
plus shipping. Back issues are avail-
able. Payment must be made in U.S.
funds to process the order. Direct NEW PRODUCTS
all subscription inquiries, orders
and address changes to Fulfillment Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .p 21
Services.
Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . p 23
Reprints/Photocopies: For requests
contact Webcom Communications ICs & Semiconductors . . . . . . . . . . . . . . . . . . . . p 24
at 720-528-3770.
Charging, Testing & Monitoring . . . . . . . . . . . . p 26
Copyright 2012 Webcom Com-
munications Corp. Material in this Power Supplies. . . . . . . . . . . . . . . . . . . . . . . . . . .p 27
publication may not be reproduced
in any form without written permis-
sion. Requests for permission should
be directed to the customer service
DEPARTMENTS
manager. Industry News. . . . . . . . . . . . . . . . . . . . . . . . . . . .p 28
Webcom Communications Corp.
7355 E. Orchard Rd., Suite 100 Marketplace. . . . . . . . . . . . . . . . . . . . . . . . . . . . p 29
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www.BatteryPowerOnline.com September/October 2012 Battery Power 3

EDITORS CHOICE
Grid Storage Battery Cost to Fall to $500/kWh, Short
Of Expectations
Lithium-ion and molten-salt battery costs will approach
$500/kWh by 2022, reducing the high capital cost of emerging
grid storage technologies. However, expectations of half that
level will remain unrealistic for at least a decade, according to
Lux Research.
Technology developers make bold claims about performance
enhancements and economies of scale that will lead to dramatic
cost reductions. Lux Researchs baseline scenarios for grid-tied
systems indicate that by 2022 Li-Ion batteries will reach $506/
kWh; sodium nickel chloride, or ZEBRA, batteries will ap-
proach $473/kWh; and vanadium redox flow batteries (VRFBs)
will hit $783/kWh.
Molten-salt batteries hold the most potential to be the
cheapest large-scale systems, with manufacturing improve-
ments playing the largest role, accounting for 95 percent of the
cost reduction, said Brian Warshay, Lux Research associate
and the lead author of the report titled, Grid Storage Battery
Cost Breakdown: Exploring Paths to Accelerate Adoption.
Li-Ion batteries are dependent on cost reductions from mass
production, while molten-salt batteries and VRFBs rely on long
discharge durations to reduce costs.
To gain an understanding of the key cost components for
each technology, Lux Research analysts built production cost
models of Li-Ion, ZEBRA and VRFB systems for small- to
large-scale grid storage systems, and assessed drivers that will
facilitate cost reduction and constraints to innovative material
and manufacturing approaches. Among their findings:
Cost of Li-Ion batteries will dip 45 percent by 2022. Li-Ion
batteries may lose market share to cheaper molten-salt batteries
for large projects but will remain the system of choice for space-
constrained projects because of their high energy density.
ZEBRAs need productivity gains. ZEBRA battery manufac-
turing accounts for between 50 percent and 60 percent of the
total system costs, primarily because of the cost of processing
its key raw materials. Improved manufacturing productivity
and better capacity utilization will account for 95 percent of the
expected reduction in costs by 2022 to $473/kWh.
Vertical integration is key to VRFB costs. Vertical integration
and exclusive supply agreements will be key to managing the
cost of vanadium pentoxide, a metal with a widely variable his-
torical market price and uncertain future. Future cost estimates
for vanadium pentoxide range from $15/kg to $30/kg, from the
current $13.20/kg. At the upper end of the range, VRFB cost
will actually increase to $1,205/kWh.
PRBA Battery Proposals Adopted by UN Transport
Sub-Committee
PRBA, The Rechargeable Battery Association, announced
that the UN Sub-Committee of Experts on the Transport of Dan-
gerous Goods unanimously approved two proposals on the pack-
aging requirements for large format lithium ion batteries filed by
jointly by PRBA and its international counterpart, RECHARGE.
Large format lithium ion batteries are used as the power source
4 Battery Power September/October 2012
for electric vehicles.
The UN Sub-Committees decisions will eliminate the need
for battery manufacturers to secure approvals from transporta-
tion authorities before shipping lithium batteries in large pack-
aging as defined in UNs Model Regulations. The regulations
imposing large packing instructions for lithium batteries will
take effect in January 2015.
After numerous meetings and discussions, no consensus
was reached on the PRBA-RECHARGE proposals for shipping
waste lithium batteries and damaged/defective lithium batteries.
PRBA and RECHARGE will amend their proposals for con-
sideration at the Sub-Committees next meeting scheduled for
December 3 to 11, 2012. PRBA intends to file a proposal with
the Sub-Committee that will more clearly define the UN testing
requirements for these assemblies and provide an alternative to
the UN tests.
GE to Expand Battery Start-Up in New Yorks
Capital Region
GE will expand its new, advanced manufacturing battery
factory as part of the companys new Energy Storage busi-
ness. The Durathon battery products, which are half the size of
conventional lead acid batteries but last 10 times longer, are the
result of GEs $100 million initial investment in battery technol-
ogy developed at GEs Global Research Center in Niskayuna,
NY. The technology will provide reliable and cost-effective en-
ergy storage options for a broad range of GE customers globally,
including telecom and utility operators.
GE will invest an additional $70 million to expand the Sche-
nectady plant, effectively doubling production and adding 100
new jobs, which will bring the total factory workforce to 450
when at full capacity.
GE Chairman and CEO Jeff Immelt said, Just a few years
ago, researchers in our labs invented a new battery, one that was
simple in its ingredients but advanced in its design and science,
containing more than 30 patents. It soon became obvious that we
werent just making a new battery; we were building a new busi-
ness, so GE teams went to work designing an advanced manufac-
turing process to build the battery efficiently and a go-to-market
strategy to ensure it can reach customers where they work.
The battery plant has received support from state and local
government in New York, where GE has done business for 130
years. New York State committed $15 million when the new
plant was announced in May 2009, and $5 million was commit-
ted by Schenectady Countys Metroplex Development Authority.
The Durathon batteries are produced using abundantly avail-
able raw materials such as salt and nickel and are non-toxic
and fully recyclable. The batteries can operate at temperatures
ranging from -4F to 140F. The batteries have received GEs
ecomagination certification from a third party for their environ-
mental and financial benefits.
The new battery plant is about the size of four football fields.
Its projected annual production capacity is approximately one
Giga-watt hour (GWh), enough energy to power 1,000 typical
American homes for one month.
www.BatteryPowerOnline.com
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FEATURE
The Use of Lithium-Ion Batteries in Uninterruptible Power Supplies
Michael A. Stout, Vice President Engineering
Falcon Electric, Inc.
Being in the UPS industry, Falcon Electric, Inc. is frequently
asked why the industry hasnt adopted the use of Lithium-ion
(Li-Ion) batteries inside more products. Li-Ion batteries have
a much higher energy density allowing them to be smaller and
weigh less than half of an equivalent Valve Regulated Sealed
Lead-Acid (VRLA) battery currently used in UPS systems. Li-
Ion batteries (Figure 1) provide much longer on-battery runtimes
and can be recharged faster than their VRLA counterparts.
Unfortunately, high energy density Li-Ion battery packs have a
number of issues that preclude them from being used in the typi-
cal commercial off-the-shelf UPSs. At the present time, with few
exceptions, their use is limited to custom UPS products specifi-
cally designed for highly specialized applications.
Figure 1. Lithium-polymer battery system containing a
Battery Management System (BMS), a charger and a
large number of lithium-polymer cells.
With the large number of cell phones, computers and power
tools now being sold with rechargeable Li-Ion batteries, it may
seem a bit odd that their use inside a UPS would be a problem.
The primary issues are cost, safety and federal regulations. Due
to Li-Ion battery chemistries having differing levels of danger,
the Department of Transportation (DOT) (in CFR 49, Sections
100 to 185) have divided the level of regulation based on pri-
mary and secondary battery types. Regulations are also based on
levels of energy density. Other applicable regulations are United
Nations UN3090 & UN3091.
A primary battery is defined as one that is shipped fully
charged and cannot be recharged. Due to their chemistry and
high level of charge available when shipped, Li-Ion batteries are
considered the most dangerous. The crash of a freight carriers
aircraft was recently suspected to be caused by a large number of
lithium primary batteries that were onboard. According to reports,
the lithium primary batteries were not declared as hazardous
materials. If lithium primary batteries become internally shorted,
due to their high amount of stored energy and chemistry, they can
6 Battery Power September/October 2012
generate enough heat to ignite the internal lithium. Once ignited,
the remaining batteries in a shipping carton or on a pallet will
ignite. The lithium fire would then burn at a high enough tem-
perature to burn through an aircrafts aluminum fuselage. Further,
most standard fire extinguishers or aircraft fire systems are use-
less against a lithium fire due to its high burning temperature.
Secondary batteries have a differing chemistry and are de-
fined as being rechargeable. They are usually shipped from their
manufacturer partially charged in an attempt to keep the energy
density as low as possible during transportation. The DOT and
UN regulations divide secondary batteries into two basic catego-
ries, which are defined by the level of energy density contained
inside the individual cells or batteries. The batteries used inside
cell phones, computers and power tools typically fall into the
lower energy density category and have much fewer transporta-
tion limitations; hence why they are allowed to fly on commer-
cial airliners with passengers.
The batteries used in a typical UPS must be capable of
supplying the high current demand of the UPS for a sustained
period of time. The period of time may be from a few min-
utes to several hours, depending on the application. For many
decades, the lead-acid battery (Figure 2) has met this demand.
Its capability to supply the high current demands of the UPS is
very good. However, its energy density to weight ratio leaves a
lot to be desired. High power UPS systems capable of provid-
ing several hours of battery backup can have lead-acid battery
banks weighing tons. The energy density of a lead-acid battery
ranges from 30 to 50
Watt/Hours per Kg,
while it is 110 to 160
Watt/Hours per Kg for
Li-Ion chemistry bat-
teries. This represents
a weight reduction
of two to three times
that of an equivalent
lead-acid battery. This
makes Li-Ion batteries
viable for use in elec-
tric vehicles as well Figure 2. Valve-regulated lead-acid
(VRLA) battery
as UPS products.
Unfortunately, all
shipments of UPS
units containing high energy density Li-Ion batteries, battery
banks or batteries packaged inside a UPS must be shipped as
class 9 hazardous materials and cannot be shipped on com-
mercial airliners. They must ship by ground cargo only. This
becomes very impractical and drives the costs associated with
the incorporation of lithium batteries up even further.
There are substantial additional costs associated with the
implementation of Li-Ion batteries in a UPS. First, there is the
cost differential between lead-acid and Li-Ion batteries. Good
quality Absorbed Glass Mat (AGM) VRLA batteries are very
www.BatteryPowerOnline.com
FEATURE
inexpensive and readily available. Their low cost is one of the
reasons UPS manufacturers use them in their products. A typi-
cal 12 volt, 7 Ah VRLA battery designed to provide a five-year
service life costs UPS manufacturers about $9.00. The same 12
volt Lithium-Phosphate battery costs more than $100, ten times
the price. If a typical 6 kVA on-line UPS had a 240 VDC battery
bus voltage, it would require 20 individual 12 VDC batteries to
be installed. The cost to the manufacturer for lead-acid batter-
ies maybe as low as $180, while the cost for equivalent Li-Ion
batteries would be $2,000. This example is very conservative. A
custom lithium-battery system for the same 6 kVA UPS might
cost more than $10,000.
However, the cost of the Li-Ion batteries alone is not the total
cost associated with proper implementation. In order to meet
UN and DOT transportation regulations, one needs to incorpo-
rate adequate over-current protection and properly recharge the
Li-Ion batteries. A specialized intelligent battery management
system (BMS) must be incorporated into the UPS design. The
BMS typically consists of a circuit board assembly or assem-
blies containing microprocessor battery monitoring, battery pro-
tection, recharge control and battery cell equalization circuits.
The primary function of the BMS is battery short circuit
protection. Lithium cells have a very low cell resistance and a
high energy storage capacity. A short circuited string of cells or
batteries could be catastrophic and result in an explosion or very
high temperature lithium fire. A typical BMS processor monitors
the battery current and has a large semiconductor switch circuit
that can be opened to prevent an excessive over-current condi-
tion. The second function of the BMS is to assure the proper
recharging of the lithium cells. Cells can receive an initial
high-rate charge current to reduce recharge time, followed by
a long cell equalization charger to balance the cell voltages to
within a few millivolts. The equalization charge is followed by
the charge voltage being turned off to prevent cell overcharg-
ing and possible cell damage. The BMS also monitors to assure
the charger voltage does not run away to the point of causing
the cells to overheat and catch fire. The cost of the BMS board
is substantial and has to be added to the cost of the Lithium-ion
batteries and UPS. As the UPS market is very competitive, these
added costs would price most UPS products out of most markets
except military and specialized scientific applications. The cost
of adding a BMS board to a UPS can range from $100 to more
than $1,000.
To assure continuous protection of the batteries, the BMS
must be powered and monitor the batteries continuously whether
the UPS is turned on, turned off, during shipment and storage.
This presents storage and non-use issues. Li-Ion batteries have a
very low self-discharge rate. However, when the UPS is not be-
ing powered from utility power, the BMS must be powered from
the batteries it is protecting. This accelerates the discharge rate,
requiring the batteries be recharged far more frequently. With
some BMS designs, recharging occurs every few months even
while in storage. Like lead-acid batteries, should Li-Ion batteries
be allowed to become too discharged, they can suffer internal
damage, requiring their costly replacement. Their replacement
8 Battery Power September/October 2012
can become even more costly due to the dangers associated with
handling high-capacity Li-Ion batteries. They typically must be
replaced by trained factory personnel, requiring the entire UPS
to be returned to the manufacturer.
Federal regulations also dictate that all equipment containing
high lithium content batteries be subjected to rigorous testing
prior to any equipment being shipped. The test plan requires
UPSs to be subjected to worst case tests. These tests are de-
signed to assure the UPS has protections designed-in to protect
the lithium batteries and assure proper safeguards are function-
ing to prevent a fire during transportation. A second tier of
testing is performed with the UPS packaged inside its shipping
carton including all associated packing materials. These tests
include vibration, shock and drop testing. All test results are
reviewed and if deemed acceptable, signed off by a DOT inspec-
tor. After receiving this approval all equipment shipments must
be shipped at Class 9 Hazardous Materials and clearly identified
as containing lithium batteries. Handling instructions must be
placed on the outside of the shipping container along with the
telephone number that can be contacted in case of an emergency.
The staff of both the shipper and recipient shipping departments
must be properly trained in the handling of hazardous materi-
als and lithium batteries. The proper fire suppressant equipment
must also be in place.
Lithium-Phosphate (LiFePO4) battery technology offers
the UPS manufacturer the best hope. The technology appears
to be one of the safest lithium battery chemistries due to its
improved thermal and chemical stability. It is much more
difficult to ignite a Lithium-phosphate battery in the event of
mishandling. They have a better cycle life than other Lithium-
ion chemistries and are more recyclable. Recycled phosphate
can be used as fertilizer. Further, there is presently one manu-
facturer of Lithium-phosphate batteries that has designed their
batteries with internal fusing, eliminating the need for BMS
protection circuits. Due to this they have received a waiver
from the DOT and can ship the batteries without a Class 9
hazardous materials declaration. However, only four 12 volt
batteries may be connected in series without a BMS to provide
equalization. Due to the characteristics of Lithium-Phosphate
type batteries, the VRLA battery chargers found in some UPS
designs can be used without modification.
At the present time, the costs, shipping and safety issues
associated with the proper implementation of high-capacity
Li-Ion batteries precludes their use in the majority of UPSs
and only viable in vertical markets willing to pay the extra
costs associated with Li-Ion batteries. Currently this consists
of the military and a limited number of scientific markets. The
Li-Ion batterys high power density and associated reduction in
battery pack size and weight are paramount to the higher costs
associated with the UPS.
For more information, please visit
Falcon Electric, Inc. at www.falconups.com.
www.BatteryPowerOnline.com
Meet Some of the Speakers

Vishal Sapru James Jackson Robin Tichy Kevin L. Gering Kevin See John Jung
Frost & Sullivan Siemens Electrochem Idaho National Lux Research, Inc. Greensmith
Solutions, Inc. Laboratory

Co-Located Conferences

Battery Power 2012 will be co-located with Advancements in Thermal Management

2012, Remote Monitoring & Control 2012 and Mobile Antenna Systems 2012.
Attendees of either event have access to the combined exhibit hall, networking
functions and luncheons.

For an upgrade fee of $300, attendees have access to all four co-located
conference programs.
FEATURE
Monitor Your Battery Cells for Superior Reliability
Chris Kaundart, Tech Writer
DPS Telecom
Do you know the status of your remote site battery plants?
Would you know if one individual cell was falling out of its
ideal voltage or temperature range? At a lot of companies, bat-
tery cell monitoring is a commonly overlooked opportunity to
reduce costs and improve reliability.
This creates a huge problem. If youve ever had battery fail-
ures in the past, you know just how painful they can be. A single
bad cell can dramatically affect an entire string of batteries if you
dont catch it early. An entire site could easily go dark if your
batteries arent working properly or become fully discharged.
Unfortunately, monitoring batteries isnt always as simple
as slapping a single voltage monitor on each string. To really
understand the big picture, you need to understand a lot of little
pictures of cell voltage and temperature.
Monitoring your battery power doesnt have to be a hassle.
Just follow this guide to learn more about effective battery volt-
age monitoring.
Monitor the health of individual battery cells
to improve the reliability of your batteries.
The Four Primary Benefits of Monitoring
Your Batteries
Leaving your battery cells unmonitored opens the door for
far too many problems that are easily avoidable. Here are four
of the main benefits youll see when you deploy your own bat-
tery monitoring system:
1. Prevent Outages
The first and biggest benefit of battery monitoring is the abil-
ity to prevent many power-related outages. When your battery
cells are left unmonitored, youre in the dark and constantly
guessing about their status. Creating a reliable network requires
continuous network monitoring, otherwise a small issue can
quickly turn into a serious problem.
10 Battery Power September/October 2012
What if your critical backup batteries are all discharged and
power fails at a site? This is a far too common disaster because
many companies dont take their backup power seriously, even
if they think they do. With a battery monitor in place, you
would have known your batteries were discharging long before
it became an issue. You might, for example, have dispatched a
portable generator that you might not have previously. These
kinds of simple outages and headaches arent hard to prevent;
the key is knowing theres a problem.
2. Detect Problems with Individual Bad Cells
Since a single bad battery cell can dramatically degrade the
performance of an entire string of batteries, its critical to deploy
a thorough battery monitoring system. Monitoring the entire
string is better than no monitoring at all, but its not the most
effective way to improve reliability.
A good battery monitor will have sensors to monitor each of
cells individually, looking not just for low voltages but a differ-
ence between the cells and the average of all the cells.
3. Avoid Complete Battery Discharges
Your batteries wont be very useful if theyre completely
drained. Whats worse is that a drained string can, in some
cases, delay or prevent the site from coming back up even after
power has been restored. With a monitoring device in place,
you can set thresholds for notification. This means if the battery
power drops below a certain percentage, youll receive a notifi-
cation and can quickly respond.
Lets face it, batteries are a part of your safety net and nothing
is worse than a false sense of security. If your primary power
goes down, thats precisely when youll need your batteries the
most. If your units are drained or otherwise impaired, then your
site will go completely dark long before they should; meaning
the critical network gear both you and your customers rely on
will be down. Had you known that your backup batteries were
low, you could have ensured they werent completely discharged.
4. Monitor Temperature Issues
Its not enough to only monitor voltage. Battery cells can get
abnormally hot when they are failing, so including temperature
monitoring can help detect battery issues long before they can
cause serious issues. Early notification gives the time needed to
respond to problems in a controlled manner. Including tem-
perature monitoring with voltage monitoring is the only way to
thoroughly and completely monitor your battery cells.
The 11 Features of a Quality Battery Voltage Monitor
A battery voltage monitor wont be truly effective without
the right features. Its far too common for a vendor to skimp
on hardware/software features and cut corners to reduce costs,
only to leave out the critical features needed for a truly effective
monitoring system.
www.BatteryPowerOnline.com
 A battery voltage monitoring system will
be able to monitor your critical backup
power supplies.

A limited and poorly designed battery monitor will end up

costing you big in the long-run. You think youre saving money
until your network goes down because the battery voltage moni-
tor wasnt up for the job. Dont settle for inadequate monitoring;
make sure the battery monitor has these 11 must-have features.

1. Adequate Capacity
Some battery voltage monitoring systems dont support the
capacity to handle large quantities of battery cells. Its abso-
lutely essential that you have the full support to monitor each
battery cell, otherwise youll find yourself vulnerable to the
weakest link in the battery string. Most critical sites will have
A/B power battery systems. Look for a single device that is
capable of monitoring both strings of batteries. Not all strings
are created equal; make sure the solution can monitor a 125
VDC string.

2. SNMP Support
What good is a battery voltage monitor if it has no way of
reporting problems to you? With a device that supports SNMP,
youll be able to receive SNMP traps to a central NOC or master
station to notify you if theres an issue with the batteries. This
means you can easily bring battery monitoring under the SNMP
monitoring umbrella. Notifications are the key to preventing
outages caused by issues with the batteries.

3. 24/7 Notifications
When it comes to monitoring batteries, and therefore protect-
ing your uptime, you want true flexibility. Having the capabil-
ity to receive 24/7 notifications (via SMS text message, email,
voice alerts, etc.) about the status of your batteries can be the
difference between an outage and keeping power to your gear.
Even if you have a 24/7 NOC (network operations center),
receiving on-the-fly and mobile notifications can provide an
edge in avoiding preventable outages. Look for a battery moni-
tor that can send alerts via emails, SMS text messages, paging,
etc. With flexible alerts that can notify you out of the office, you
can be assured you wont be left in the dark.

www.BatteryPowerOnline.com September/October 2012 Battery Power 11

FEATURE
4. Continuous Voltage Reading
Battery voltage monitoring equipment needs to provide con-
tinuous voltage readings. Without regular monitoring or at least
control over the sampling rate, a problem can linger for too long
before youre notified.
Thats why sampling batteries at too long of intervals can be
problematic. Battery cells can easily become fully discharged
between lengthy interval readings, which means the risk losing
power at your sites and not have any idea until the entire site
suddenly goes dark. With real-time monitoring and customiz-
able interval samples, you can be assured to know about these
kinds of emergencies before they bring down mission-critical
network equipment.
5. Accurate Voltage Measurement
If the battery voltage monitor cant accurately measure
voltage and temperature, then you may as well have no monitor-
ing at all. An effective battery monitor will be able to provide
accurate readings within 1 percent of the actual value. With an
accurate battery monitor, you can be assured to truly know the
status of the batteries.
6. Integrated Alarm Monitoring
Support for an integrated RTU (remote telemetry unit) can
provide additional value from the same rack unit of space. An
RTU can collect environmental alarms (about temperature, hu-
midity, smoke, power, etc.) and monitor critical network equip-
ment at remote sites and report these alarms back to you. This
means you can monitor additional pieces of equipment from the
same device thats monitoring the battery cells.
Having integrated alarm monitoring means you can get even
more ROI from the battery voltage monitor. You can monitor
other pieces of gear and environmental conditions to improve
service reliability at the remote sites. You can enjoy the peace
of mind knowing that youre fully monitoring all of the condi-
tions at the sites to avoid preventable outages.
7. Web Interface
A device with a Web interface will present you with powerful
network management tools. Instead of driving all the way out to
a site to configure or manage a device, you can do it right from
your desk. This can save on fuel costs and expensive man hours.
You may be a large company with an enterprise-grade SNMP
manager, but a Web interface lets you drill down when you need
to. An intuitive and easy-to-use Web interface is head-and-shoul-
ders above any other method to manage battery monitoring.
8. Historical Trending
A battery monitor with an analog logging feature will allow
you to graph historical trends of the battery monitoring data from
the Web page. With graphical data, youll be able to analyze bat-
tery voltage information and observe patterns with the batteries.
Or, if you ever need to reference past data about the battery volt-
age, youll have the historical graphs at your disposal.
You want this historical data stored both locally on the
12 Battery Power September/October 2012
device and within the network management system (NMS). In
case not all staff have access to the NMS, they will still have
local access to the history data.
Daisy chaining battery cells together is an easy
and simple way to manage your battery
voltage sensors.
9. Daisy-Chainable
You dont want sites to be a messy pile of cables and you
certainly dont want a device that is needlessly complicated to
set up. Having battery voltage sensors that are daisy-chainable
makes setup easy and clean. Just string the sensors along from
each other, rather than running long cables from the battery
monitor to each individual sensor.
Daisy chaining sensors improves accuracy, is a setup time-
saver and transmits data digitally. You can also keep high cur-
rent away from places you dont want it. Daisy chaining is the
easiest and best way to simplify monitoring setup.
10. Flexible Battery Support
Youll want a battery monitor to have the ability to work with
different battery types and voltages. All batteries are not the
same, they have different orientations, connectors and different
voltage ranges. For instance, you might have a standard string of
batteries or a string with four 12 V cells and propriety connec-
tors. You need a battery monitoring system that is very adaptable.
11. Local Voltage Isolation
You have to have sensors that isolate voltage locally. This
allows for more accurate battery readings and creates a safer
environment. Keeping the voltage reading local then transmit-
ting a digital signal back to headquarters equals having accurate
cell readings and you dont have to deal with the hazards of
transporting battery voltage.
Adequately Protecting Uptime
Monitoring battery cells doesnt have to be a struggle. Add-
ing a battery voltage monitor to a network is a simple solution
that can provide you with some serious value. Youll be able to
save time and money, not to mention greatly improve the reli-
ability of the network.
For more information, please contact
DPS Telecom at www.dpstele.com.
www.BatteryPowerOnline.com
 Juicing Up the Battery
Cutting Edge Research Delivers Battery Enhancements
Anu Cherian, Senior Industry Analyst
Frost & Sullivan
The battery market is currently entrenched with several
chemistries. Five decades ago, the lead acid battery was consid-
ered the most versatile, with manufacturers using it for nearly all
applications that needed energy storage. The advantages of long-
standing nickel metal hydride (NiMH) were later realized, as
it was replacing a very niche segment of the lead acid batterys
applications. Alongside the NiMH was the nickel cadmium
(NiCd), which was gradually slowing down as its counterpart
gained momentum due to its lighter weight and versatility of
use. However, the pace of development of the consumer elec-
tronics markets were rapidly changing and even the NiMH bat-
tery could not satisfy power requirements of new applications. It
was then that the years of research on lithium batteries paid off.
It became the appropriate fit for new electronic applications. The
main requirements were governed by a much smaller form fac-
tor and the lithium-ion (Li-Ion) battery delivered just as much, if
not more, power in a smaller architecture.
The well known characteristics of the lead acid battery are
high energy density, low cost, easy availability and versatility
of operation. However, the primary reason for the significant
growth of the lead acid battery was the ubiquity of its compo-
nent materials. Easy availability and market competition spurred
this technology forward. From an end-user standpoint, lead acid
was well known in the every corner of the world. The term bat-
tery was synchronous with the lead acid chemistry. Hence, its
success was attributed to its early entry into the market and its
low cost that made it easy for the common person to purchase
and use it.
Battery Markets
The energy storage and battery chemistry markets are cur-
rently worth billions of dollars. With the advent of Li-Ion, there
has been a complementary revolution with mobile power tech-
nology in cell phones and personal digital assistants (PDAs).
Mobile, on-the-go power has driven several generations of tech-
nology driven concepts. Beginning with Apples iPod, iPhone
and iPad, competition has picked up and the number of competi-
tors in this field has driven the application markets into billions
of dollars. However, as is the case every year, the smallest and
lightest weight device is just not sufficient enough, resulting in a
push for another device that is smaller and lighter than the previ-
ous generation.
A Key End User Market
Increase in the performance of battery chemistries is es-
sential for its application base to expand. The use of lead acid
www.BatteryPowerOnline.com
in a number of applications has driven the market to maturity
and intense price competition has made it a commodity product.
There are certain niche end user segments that always are ahead
of the game and a commodity product is just not their forte. For
example, the military is always a first responder to any cutting
edge technology. The Army has invested in the development of
in-house technology that is proprietary to their use. The military
is a key end user segment that always provides the initial impetus
towards the launch and commercialization of their technology.
Soldiers already carry immense weight on their backs for
basic necessities including food, first aid, as well as communi-
cation equipment, weapons and ammunition. Communication
equipment require batteries as well as back-up batteries, all of
which need to recharge quickly. These factors have triggered
the need for an increase in lighter weight systems and more
energy density of the batteries themselves.
Army Scientists and Their Cutting Edge Work
Scientists are looking for technology that needs to be easily
available in addition to satisfying the power needs of the ap-
plications in play. For example, in radios used by soldiers, the
time duration of the battery charge, recharge time, as well as the
level of degradation over extensive use are important factors
that require significant evaluation prior to use. With all of this in
mind, the military has funded millions of dollars toward battery
research. They have focused on intensifying the voltage per cell,
thereby increasing the overall energy density of the system. Fur-
thermore, additional research is being conducted on the use of
ubiquitous materials that enable the soldier to carry the battery
easily in rough terrain. Ongoing research into this area began
almost five years ago and is estimated to be about a year away
from production and mass deployment to soldiers.
In everyday life, batteries may not seem to be particularly
heavy or obtrusive. But to provide a better picture of a soldiers
load, battery weight constitutes nearly 20 percent of the weight
carried by a soldier. This is an average of 70 batteries per sol-
dier, or about 50 to 70 pounds. Even a reduction of five pounds
would be a huge step, although scientists are proposing reduc-
tions by 20 pounds per soldier.
R&D has not been able to increase the energy density dra-
matically. Current progress is only at a rate of about 1 percent
per year. Scientists are therefore trying to understand ways of
tweaking the energy density of cells by increasing the voltage
inside a single cell. Understanding micro level characteristics
of the cell, its functioning and means to increase voltage are
expected to create the necessary rectification to technology that
can push it further into the market. While taking an internal look
at battery technologies, the voltage per cell has been at a nomi-
nal 4 volts (V) in the Li-Ion battery chemistry. Army scientists
are now recognizing means to increase the single cell voltage.
September/October 2012 Battery Power 13
FEATURE
Even an increase within each cell by 1 V, making it 5 V, would
be considered a giant leap in the world of battery research.
These scientists have been able to accomplish this by using dif-
ferent kinds of materials in order to kick start the baseline cell
voltage. The correlation between such an increase in cell voltage
and energy density is remarkable. They have reported that it has
caused an increase of 30 percent in the energy density of a single
cell. Such a magnitude of change has the industry awestruck at
the cutting edge research that is proving to be useful to minimize
battery related weight to the soldier.
Where Does This Power Go?
In addition to reducing the weight of soldiers backpacks,
it also provides auxiliary power to necessary systems. In many
cases, these systems range from additional power for on-board
vehicles or even power for unmanned air and ground vehicles.
Power availability in these cases is uncertain and in the event
of an emergency, the option to use the battery reserve power
carried by the soldier would be life saving for an entire team
present in a war zone.
How is it Achieved?
Scientists are planning on achieving auxiliary power goals by
using the Li-Ion battery as the base material. However, infiltra-
tion with the right kind of additives, not yet released by Army
14 Battery Power September/October 2012
researchers, is the key. These are materials that military research
continues to fund so that it can be a forerunner in the space to
test out new tweaks to the Li-Ion battery. Although this material
is currently proprietary, there are a number of research laborato-
ries that continue to pursue research based on a nanoscale level.
It is not uncommon to use highly reactive dopants into the
electrode materials to enhance the life of the energy storage
system in total. Examples range from the use of polymer materi-
als to metal oxide infiltrates that increase the surface area in
addition to increasing the energy density. These are just a few
examples of various options that were considered by commer-
cial research organizations.
Indigenous Materials Research
Materials that are familiar and currently in use are not keep-
ing up with increasingly sophisticated end user demand. Hence,
there is a great deal of effort in driving innovations in materials
research. Some of the parameters to base this work on are envi-
sioned in the use of indigenous materials. If they can be freely
found and common in any part of the world, this provides a
greater flexibility for the soldier who is typically treading across
mostly unknown territory.
In May 2012, the Army released information and pictures re-
lating to this new battery system with half the footprint and half
the weight of existing systems without a reduction in the basic
parameters of operation of the battery. It is now half the size of
the traditionally used BA5590 battery. It is designed for compat-
ibility with existing electronic devices as well as potential future
inventions in electronics that could aid the soldier.
The material currently being extensively researched is a
lithium carbon-monoflouride battery. The battery is expected to
be deployed within a year and in a couple of years will also be
available for commercial production.
Availability of materials is the key factor while performing
such research and the Army continues to diligently pursue mean-
ingful analysis that has long term viability in the market. The
US military has been the pioneer in delivering enduring solu-
tions that, when commercialized, have caused significant leaps
in technological advancements.
Ease of Use and Flexibility
A common characteristic that brings familiarity in the world
of energy storage and, specifically, batteries is the rigidity
of construction. This has mostly been due to the fact that the
electrodes encompassing an electrolyte, either in liquid or gel
form, have been tightly contained only within an air tight box.
However, ongoing research is taking it a step further in devis-
ing ways and means to present a flexible material form of the
battery that the soldier can easily wear. In military jargon it is
called the polymer conformal battery. It fits the soldiers body
rather than protruding at different spots, making it difficult for
the individual to maneuver through tight spaces.
The total design is termed Solider Wearable Integrated Power
System, or SWIPES. It supplies a centralized battery power at
multiple nodes to energize different items. With a very smart
www.BatteryPowerOnline.com
design in place, the SWIPES won placement on the US Army is moving forward rapidly and new technologies are gradually
Greatest Inventions of 2010 list. Such cutting edge research is coming onto the main stage as end users are becoming aware of
expected to further enhance the design and the implementation the various options existing in the market. With design innova-
of the battery with an architecture that was only a fragment of tions and technology tweaks such as the one by the Army, there
ones imagination in the past. is great excitement in the world of energy storage technologies
on the unimaginable possibilities for battery technology and its
Other Market Possibilities evolution.
When this technology becomes available for commercializa-
tion, there are numerous possibilities for applications for the For more information, please contact Frost & Sullivan at
enhanced battery. When the form factor of the battery can be www.frost.com.
made to fit onto clothes of a soldier, the applica-
tion base in the commercial world could expand
in leaps and bounds. It could be used in athletic
gear to monitor the rate of use of energy in the
body for fitness purposes. Another great applica-
tion area would be for mountaineering purposes.
As mountaineers require emergency power
availability in case they are stranded in a storm

HIGH TECH.
or adverse climatic conditions, they require basic
necessities such as a torch for light, water puri-
fication, battery run communication equipment,
among others. The biggest advantage would be a

HIGH PRAISE.
versatile battery that can be used at low tempera-
tures. Temperatures in mountaineering signifi-
cantly decrease as the altitude of the explorer

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increases. Trekking, biking, car and bike racing,
and a plethora of areas in sports could change
radically in the event of a moldable battery that
becomes available for commercial use.
Other possible uses for malleable and higher
energy dense batteries are in the world of con-
sumer electronics where the size of laptops could Mid-Continent Instrument Company, a leading manufacturer
be further reduced if the battery material could of acclaimed aircraft instruments, avionics and power supplies
be made to encompass the basic framework of is taking aviation to new heights. The companys True Blue
the laptop design. Power division is harnessing the power of Nanophosphate
lithium-ion cell technology to design the next generation
The Future: Unimaginable Possibilities of aircraft power solutions. Interested?
For Energy Storage
The need for increasing energy density is
Join the challenge. Join our team.
driving technological innovation in the energy
storage market. From the dissatisfaction with
lead acid batteries, to the innovation of new
Were hiring Electrical Engineers Battery Systems
alternatives such as ultracapacitors and fuel
Electrical Engineers Power Electronics
cells, there is an increased push to enable these Mechanical Engineers
technologies to move forward in the market. Certification Engineers
Advancements in each competing technology

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www.BatteryPowerOnline.com September/October 2012 Battery Power 15

FEATURE
PEM Fuel Cell Systems Reliable Backup Power Source for
Remote or Extended Run Power Outages
Kathy Fosberg
IdaTech
In todays world, on-demand communications is needed
24/7/365, businesses, individuals, emergency systems and gov-
ernments rely on their instant access to voice, data and/or video
through their wireless devices to be able to function effectively.
In order to provide customers with instant communications
anywhere in the world, wireless telecom companies have to con-
struct and maintain cell phone towers, radio relay stations, etc.,
at times in remote areas where the grid reliability is marginal.
Despite grid outages, telecommunications engineers
must keep these sites operating without interruption to retain
customer loyalty and avoid the high cost and potentially life-
threatening situations that would arise from a wireless commu-
nications failure.
In anticipation of grid outages, most wireless telecom sites
have backup power systems, traditionally consisting of valve-
regulated lead acid (VRLA) battery strings and/or gensets.
These traditional solutions arent always appropriate for
sites requiring extended run times (days vs. hours), and they
16 Battery Power September/October 2012
dont always work effectively. A battery string can be expected
to provide anywhere from one to four hours of backup power,
but battery functionality can be impacted by age, temperature,
deterioration of charge during down time and corrosion.
In addition, there are environmental problems with the
disposal of batteries. A diesel or propane generator, on its own
or in combination with batteries, provides longer backup. A
generators run time is based on how much fuel is available
for the generator and how much power is needed to replace the
electricity lost from the grid outage. The problem with genera-
tors is that they are noisy, produce noxious emissions and since
they have several moving parts, need a lot of maintenance,
repair and lubrication.
In recent years, an alternative to the traditional backup
electric power for telecom installations has become commer-
cially available. It is the fuel cell. A fuel cell produces electricity
through an electrochemical reaction. The science behind fuel
cells is not new. It was discovered by Welsh lawyer-turned-
scientist William Robert Grove in 1838, but it wasnt until the
mid 20th Century that the design and building of fuel cells with
commercial potential was explored.
The type of fuel cell commercially available today and most
appropriate for use with wireless telecommunications sites is
the Proton Exchange Membrane (PEM) fuel cell. These fuel
cells are compact, durable, reliable, quiet and operate at peak
efficiency in a wide range of climates (-40C to 50C) and
adverse weather conditions. In addition, they have few moving
parts (thus needing minimal maintenance), come in sizes rang-
ing from 250 W to 250 kW, can readily adjust their electronic
output to meet
shifting power
demands and of-
fer a high energy
density. Also,
fuel cells are fast
starting and can
begin deliver-
ing electricity
within seconds of
activation.
The typical
run time for one
of todays fuel cells operating on six bottles of hydrogen (one
bottle = 1 T-cylinder) is 10 hours at 5 kW of output power. For
longer run times, additional bottles of hydrogen can be hot-
swapped into the hydrogen storage cabinet. However, there can
be limitations as to how much extended backup run time can be
achieved by hot swapping bottles of hydrogen. The extended
backup run time can be limited by the amount of space for stor-
www.BatteryPowerOnline.com
age of additional bottles of hydrogen at a fuel cell installation
and/or the remoteness of a fuel cell installation, which makes
hot swapping unfeasible.
There is a new technology that has already been successfully
deployed commercially and can extend fuel cell backup runtime
not by hours, but by days. It is called a fuel processor.
A fuel processor uses a liquid fuel to make hydrogen on site
and on demand. Fuel processing is the act of converting hydro-
gen rich fuels into pure hydrogen gas as needed, then feeding
the pure hydrogen directly into a fuel cell stack. IdaTech has
developed fuel processors for a variety of common fuels includ-
ing methanol, a liquid found in windshield washer fluid and
many other common products. Again, fuel cell systems with liq-
uid fuel processors can provide backup power for days instead
of a few hours by using energy dense liquid fuel.
IdaTech sells complete fuel cell systems with integrated fuel
reformer and fuel tank. When the grid power fails at a wireless
telecom site, a small battery string takes over the sites load for
a couple of minutes while the fuel reformer starts up, produces
hydrogen, and then the fuel cell begins powering the sites load.
The system is powered by HydroPlus liquid fuel, a mix of
water and methanol (62 percent by weight methanol). The fuel
reformer is highly efficient, recycling the waste heat from the
fuel reforming process and directing it back to the reformers
combustion chamber where the waste heat takes over as the heat
supply to vaporize the liquid methanol/water fuel.
This system solves the problem of needed onsite on-demand
www.BatteryPowerOnline.com
electricity
during power
outages, and
yields imme-
diate savings
in footprint,
weight, regula-
tory setbacks
(clear space
requirements),
simplified refueling and, most importantly, extended run times.
It takes one 59-gallon fuel tank of methanol/water fuel with
a fuel reformer to produce 40 hours of 5 kW output power vs.
24 T-cylinders of hydrogen to produce the same amount of
output power. The fuel tank and reformer create a 72 percent re-
duction in footprint and 67 percent reduction in weight over the
amount of bottled hydrogen (and number of hot swaps needed)
to produce the same 5 kW power output.
The commercially available fuel cell with an integrated fuel
reformer and supply of HydroPlus methanol/water fuel is an
increasingly popular, highly reliable and cost-effective backup
power source for remote and/or extended run power outages for
the telecom industry.
For more information, please contact IdaTech at
www.idatech.com.
September/October 2012 Battery Power 17
FEATURE
Why Your Next Renewable System Should be Built
Around Energy Storage
Mark Cerasuolo, Senior Marketing Manager
OutBack Power
In the renewable energy industry, there has been much
discussion about how to convert variable resources such as
wind and solar into consistent and continuous energy similar to
the electricity consumers are accustomed to enjoying from the
utility. Meanwhile, more frequent instances of extreme weather
such as tsunamis, heat waves, hurricanes and ice storms are
causing sustained blackouts and giving residents and businesses
pause: what if the grid isnt as reliable as we once assumed? Or
consider another possibility: systems designed around installa-
tion and production incentives such as net metering (running the
meter backwards and selling back to the utility) can have their
entire economic rationale altered if those incentives change, and
policies invariably do change.
Finally, consider the fact that a grid-tied PV system is always
offline at night, but if surplus energy generated during the day-
time can be stored, it can be used at night when electricity costs
may be at their peak. These independent but related concerns,
grid stability, renewable system economic viability and consis-
tency, create opportunity for renewable energy systems that can
thrive when paired with an energy storage system to provide
electricity during power interruptions and peak use times.
Originally, many solar installations were off-grid entirely,
with users getting all their energy from solar panels, perhaps
with a diesel generator and battery system for backup power.
These consumers stayed completely off the grid, often because
they were located in remote areas where its too expensive for
a utility to build energy infrastructure. This off-grid technology
wasnt feasible for all geographies or appropriate for all needs,
which is why grid-tied systems came into the mainstream. To-
day, most commercial and residential solar system users in the
developed world use technology thats grid-tied where the utility
acts as energy storage, supplying power as needed when the
installation isnt producing enough electricity due to a week of
cloudy days or other disruptions in maximum solar exposure.
Developments in technology now offer a system choice
beyond black and white, either tied to the grid or completely
independent of it. Hybrids called grid-interactive photovoltaic
(PV) systems offer more of the best of both worlds: grid-tied
economics when the grids available or cost-effective, and
off-grid independence when its not. Grid-interactive systems
are based on grid-tied technology, and once they are combined
with proven energy storage technology, the comparable payback
expectations and greater capabilities will drive higher adoption
levels in the industry. While grid-interactive PV systems offer
users increased flexibility and reliability in installations, they
are not so different from the grid-tied systems integrators most
frequently recommend.
18 Battery Power September/October 2012
Grid-Tied and Grid-Interactive Systems -
The Similarities
For an analysis of the differences between grid-tied and grid-
interactive systems, one must first examine what both have in
common. Both types of systems deliver several similar benefits.
Lower Bills: Grid-tied and grid-interactive systems save
users money on utility bills in several ways. First, they simply
use less grid-produced electricity. Second, during times of
strong sunlight and relatively light load demand, surplus energy
can be sold back to the utility in many states and localities. Net
metering means that an owner can run the meter backwards and
potentially save a home or small business up to thousands of
dollars during the life of the system. Some states have a cap, but
between geographical amounts of sunlight, incentives and elec-
tricity costs, solar users stand to shave a big chunk off their bills.
Better Resell Value: According to recent statistics, solar
energy system owners can see a potential return of 97 percent of
their investment when its time to put their homes on the market.
This is higher than any other home improvements or amenities,
and its important to
keep in mind this is
on top of the money
owners save by reduc-
ing their energy bills
and taking advantage
of net metering. Addi-
tionally, a US Depart-
ment of Energy study
showed that homes
equipped with solar
energy systems are on
Photo courtesy of SolTerra the market for half the
time, even when you
factor in challenging
housing markets. If homeowners want the flexibility to move to
the next property, grid-tied and grid-interactive systems are both
attractive investments.
Decreased Carbon Footprint: After installing weather
sealing or efficient lighting, solar power can be the lowest-
hanging fruit toward attaining a greener lifestyle. Unlike wind
turbines and micro-hydro installations, solar does not have
prerequisites such as regular breezes or a running stream on
the owners property. Sunlight is accessible to everyone. Solar
power also has zero impact on the environment as a solid-state,
low-impact energy source with no moving parts compared to the
other methods, it requires no transmission paths past the roof
and it is used at the point of generation.
Incentives: Both grid-interactive and grid-tied systems
make their owners money by qualifying them for production
credits. Depending on the state, incentives pay owners per
www.BatteryPowerOnline.com
kilowatt-hour for producing electricity, even when the system In contrast, grid-interactive PV systems use bi-directional
owner consumes that electricity. Production credits vary by state energy transfer capability and smarter electronics to tie into the
and also by local utility, but they are a large contributor to the local energy utility when it most benefits users and be more in-
eventual payback for a renewable energy system. dependent when it does not. During emergencies when the grids
down, the interactive
Grid-Tied and Grid-Interactive Power - Where system switches to
They Differ stored power in batter-
The main difference between the two system options is not ies and uses the panels
what happens when the local power grid is operating normally, to help keep them
but what happens when the power is out, fluctuating or more charged. During nor-
expensive. Blackouts and brownouts that can damage equip- mal times when the
ment are occurring with increased frequency in many parts of user wants to lower
the country, and so-called storms of the century are regularly his energy costs and
in the headlines these days. This year started off with news of consumption, he can
rolling blackouts and extreme storms in many regions. chiefly rely on renew-
These types of conditions should worry those who operate able energy sources
to offset the utility, Photo courtesy of SolTerra
grid-tied systems, which are incapable of delivering power during
blackouts and emergencies. Per national and international indus- turning to the grid
try safety standards, grid-tied installations must disconnect for only when he needs to augment his clean, self-produced power
safety reasons (utility workers restoring power could be exposed or charge an energy storage system such as a battery bank. A
to potentially lethal backfeed AC if the system stayed online). smarter grid-interactive system prioritizes battery charging,
Also, the power fluctuations in solar panel-generated energy running loads and dealing with the utility in that order, offering
caused by cloud shadows, wind, trees and natural light variation total flexibility. In this way, grid-interaction lets consumer and
make it impossible to use this non-grid augmented raw power to commercial users get highly reliable, cost-effective energy while
operate home or office appliances from the panels alone. staying environmentally aware and responsible.
This is where the grid-interactive system takes a clear lead.

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www.BatteryPowerOnline.com September/October 2012 Battery Power 19

FEATURE
For an incremental extra investment during installation, a home
or business can get the best of both worlds: greener living plus
cost savings when the grid is online, and reliable backup power
when the grid is down or compromised, or when electricity is
expensive. The difference is not so much in the costliest part
of the solar energy system, the panels on the roof, but in the
balance-of-system components that convert electricity and
potentially the energy storage required to deliver power reliably
and independently of the grid.
The Grid-Interactive Way of Energy Conversion
And Storage
All renewable and solar energy systems use an inverter,
which is a device that converts the DC power generated by solar
panels (or by a wind or hydro turbine) into the AC power that
appliances, electronics and other everyday items need to oper-
ate. In a grid-interactive system, that inverter is a much smarter,
more agile device, capable of accomplishing multiple goals as
opposed to the one-trick grid-tied inverter.
For example, a grid-interactive inverter can perform as a
battery charger and store energy in a battery system designed
for residential and commercial applications. It can also convert
battery-produced DC during an outage into useable AC power
and charge those batteries during the day from the panels or a
generator. It can even turn a generator on as needed. Having bat-
tery backup taking care of power needs in the evening means the
generators runtime and fuel inefficiency can be greatly reduced
during an outage.
Investing in a grid-interactive system built around a smarter
inverter and backup batteries for energy storage is becoming
the norm in renewable energy systems. The benefits of having a
second system for clean, reliable backup power during outages
or peak use time are compelling.
Grid-Interactive Component Design and Cost
You can find grid-interactive and off-grid systems in places
where solar, wind or hydro may be the only source of power
aside from a generator, which includes field hospitals, Arctic
research stations and military outposts. For this reason, the reli-
ability and quality of grid-interactive inverters and components
based on off-grid technology is usually superior and well suited
for premium commercial and residential use.
While grid-interactive design effectively delivers twice the
system, it doesnt cost twice as much. The difference between
the cost of grid-tied and grid-interactive systems starts at 15
percent with essential backup capability (usually furnace, some
lighting, refrigerator, TV and Internet/PC). Larger homes and
small businesses may want to invest in greater backup capacity,
and thats another advantage of grid-interactive design topology;
its much more amenable to a building-block approach as well
as the addition of inverter and storage capability.
Making the Right Renewable Energy Decision
Regardless of the type of solar installation in use, electricity
users have experienced the setbacks of power outages. It can be
20 Battery Power September/October 2012
exasperating for a refrigerator full of groceries to fail or a busi-
ness to lose a day of productivity when the grid goes down, but
it also starts the conversation around alternative options.
Grid-interactive technology is a necessity in developing
countries where users only have access to the traditional power
grid for part of the day. A grid-interactive option delivers con-
tinuous access to electricity and enables augmenting the grid
with local renewable sources, instead of relying on more coal,
nuclear or other controversial forms of power generation to meet
local needs.
As the costs of greener systems become more competitive,
the industry is seeing a move
from renewable energy to renew-
able capacity. A large part of
the cost of solar, wind or hydro
systems comes from energy stor-
age, which can sway consumers
on price to implement a system
that relies on the grid for energy
storage or procurement. Lead
acid batteries are an inexpensive,
proven chemistry, plus the weight
of the batteries poses less of an
issue for stationary installations
in houses and buildings. How-
ever, users may see fewer charg- OutBack Power Energy Cell
ing cycles, which would require
upkeep of batteries over the total
life of a system. Lithium ion batteries provide high density and
efficiency, which leads to more charge cycles, but the economics
of this technology are still prohibitive for many installations.
The bottom line difference between grid-tied and grid-inter-
active is this: either type of system will save money when the
grid is operating according to the status quo. Investing up-front
in grid-interactive technology to take that next step in secure
energy storage gets owners twice the system and reliability. That
cost difference becomes slight over the systems payback period.
Today, users in grid-accessible areas can commit themselves
to a renewable energy future without taking the extreme step of
moving off-grid power or accepting the built-in limitations of
grid-tied systems. The option of having an independent method
of storage for energy with grid interactivity lets the spectrum of
users reap the financial and environmental benefits of cleaner so-
lar, wind or hydro power in ideal conditions, while keeping open
the option of going to the grid when practical for surplus energy
sellback. With the trend of extreme weather hitting geographies
all over the country, and with energy costs not getting any
cheaper, having a Plan B to tap into stored energy when the grid
goes down or gets expensive becomes top priority. The outcome
will be greater energy reliability, lower bills, smaller carbon
footprints and more satisfied customers.
For more information, please visit OutBack Power at
www.outbackpower.com.
www.BatteryPowerOnline.com

RRC Standard Smart Batteries with Optimized
Energy Density
RRC has three new standard Li-Ion SMBus battery packs
RRC2040, RRC2024 and RRC2040. The energy content for
two of the battery packs: the RRC2020 and RRC2024, are now
optimally rated close to the 100 watt limit that exists in terms of
the Dangerous Goods Ordinance. The batteries are SMBus v1.1
compliant and meet the JEITA standards (required for export to
Japan). The temperature-dependent load profiles of the batter-
ies increase safety and also lead to a maximized cycle life of
the batteries. Used in combination with RRCs battery chargers,
they can be optimized and accelerate charging. By using the
PROVIDING POWER SOLUTIONS SINCE 1915
SBS-2002 or (2002C) Digital Hydrometer
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Batteries
Impedance Track technology, it is not necessary to manually
calibrate the battery. The use of Cell Balancing leads to maxi-
mum available capacity and to longer life. The battery packs
have comprehensive charge/discharge safety systems as well as
passive safety electronics, and worldwide agency certification
approvals, and international recycling support.
New Zinc-Air Battery System Surpasses Industry
Benchmark for Off-Grid Energy Source
QuantumSphere, Inc. has released the MetAir Ranger series
for on-demand back-up power in off-grid and emergency ap-
plications. QSIs MetAir Ranger portable power system has
received independent validation that it surpasses the industrys
72-hour emergency preparedness benchmark. The system
achieved 108 hours of instantly accessible emergency power.
The MetAir Ranger, a 3.2 kilowatt hour battery system
weighing less than 25 pounds, yields energy densities of 352 Wh
/ Kg and costs per kilowatt hour of less than $200. The MetAir
portable power systems utilize QSIs proprietary cathode tech-
nology. While one MetAir Ranger system is about the size of a
single deep cycle lead acid battery, it is roughly half the weight
and has 11 times the equivalent energy per kilogram. It is also
designed to accept replaceable power cartridges once the initial
system is air activated and used. The MetAir Ranger series is
essentially a plug and play box of portable energy and requires
no external energy sources to stay charged. The MetAir Ranger
INNOVATIVE TECHNOLOGY FOR
BATTERY DIAGNOSIS & MONITORING
EXCLUSIVELY FROM SBS
1-800-554-2243
Call Monday-Friday, 8a.m.-5p.m. CST
BCT-5000 Battery Capacity Tester
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www.BatteryPowerOnline.com September/October 2012 Battery Power 21

NEW PRODUCTS Batteries
has an optional 150 inches by 16 inches by 12 inches) and competitively priced, the
watt 110 volt AC Newcastle Systems Portable Power package comes standard
inverter with two with an inverter, battery status meter, wire harness and smart
outlets and a USB charger. It is available with four different battery/inverter/char-
charging port. ger configurations: Models PP8, PP12, PP22 and PP25. Weight
In comparison to ranges from 65 to 170 lbs.
the commonly avail-
able battery types Balqon Corp. Introduces HIQAP Lithium Battery for
used today, such as Solar Energy Storage Applications
Lithium-ion, Nickel Balqon Corp. has introduced a low cost high capacity
metal hydride and lithium batteries as an alternative to the current industrial deep
Lead acid, QSIs cycle lead acid batteries. The HIQAP batteries are available
technology is based in 12, 24 and 48 volt configurations with an amp hour capac-
on a safe and proven ity ranging between 700 Ah to 1,000 Ah. HIQAP battery packs
zinc-air battery chemistry that is cost effective to manufacture include Balqon proprietary battery management system (BMS)
and easy to use. Zinc-air batteries are electro-chemical batteries and related power electronics components for direct replacement
powered by oxidizing zinc metal powder (a non-combustible, of current lead acid battery packs. HIQAP lithium battery packs
non-toxic and abundant domestic material) with oxygen from are designed to support large daily loads requiring deep depth of
the air to generate an electrical current. In addition, Zinc-air discharge and high energy transfer efficiency for solar, micro-
batteries have very high energy densities and an unprecedented grids, off-grid storage and telecom applications.
shelf life of up to 10 years before initial use. Sizes range from HIQAP batteries include large format 1,000 Ah and 700 Ah,
small button cells for hearing aids, mid-size for remote por- 3.25 VDC folded prismatic cells connected in a series, available
table power applications, to very large systems used for electric in 12 V, 24 V and 48 V configurations. Life cycles of HIQAP
vehicle propulsion. batteries vary from 2,500 cycles to 5,000 cycles based on depth
of discharge. Low internal resistance allows for over 95 percent
Power Pack Offers Quiet, Convenient Alternative to efficiency during energy transfer compared to 80 percent ef-
Generators, Extension Cords ficiency of equivalent deep cycle lead acid batteries.
For virtually any application requiring portable electric
power, the Portable Power package from Newcastle Systems K2 Energy Solutions, Inc. Launches of HT Technology
offers many advantages over extension cords or generators. That Extends Battery Life
Quiet, reliable and compact, it provides AC power for indoor or K2 Energy Solutions, Inc. commercially launched the HT
outdoor use. Technology in its energy optimized cells in the first quarter of
Generators are noisy, emit exhaust fumes and cannot be used 2012. This technology extends the effective operating tempera-
indoors. They also can be unwieldy, and in most situations they ture range of its batteries, consequently extending the overall
require the storage of extra fuel. Extension cords are incon- life of the batteries utilizing it. The company expects to fully
venient and unsightly and can trip people or be accidentally implement the technology in its power optimized cells by the
unplugged. Cords also reduce voltage if too long, and can even third quarter of 2012.
cause short circuits HT technology solves one of the primary challenges in
in damp surround- the commercialization of rechargeable lithium ion batteries,
ings. In contrast, the rapid degradation of battery capacity at elevated tempera-
the Portable Power tures. The operating life of a battery, with HT technology,
Package draws on improves by as much as six times when compared to conven-
a rechargeable bat- tional lithium ion technology measured at 60C (140F). High
tery to provide in- temperature performance has limited the use of lithium ion
tegrated, seamless batteries in some transportation, energy storage and military
power for virtually applications where battery systems must frequently operate in
any use. Outdoors, extreme environments. K2 Energy Solutions, Inc. believes that
it is well suited its HT technology will greatly accelerate the commercializa-
for mobile conces- tion of its battery systems.
sions, remote LED
signage, trailers,
etc. It is also well suited for indoor use wherever a powered
device needs to be used in more than one location and/or where
power may not be otherwise available.
Housed in a sealed but fully ventilated steel cabinet (16

22 Battery Power September/October 2012 www.BatteryPowerOnline.com

 Components

Polarized, CR2 and CR123A Lithium Battery Holders
A broad selection of polarized
SMT and THM CR2 and CR123A
lithium battery holders has joined
the Keystone Electronics roster.
With polarized contacts, a princi-
pal design feature, the advanced
design holders accommodate all
CR2 or CR123A batteries from
major manufacturers.
Equipped with heat resistant
Nylon housings, the entries are
suited for traditional soldering and reflow processing. Surface
mount types feature gold-plated phosphor bronze contacts as-
suring low contact resistance and solder joints where lead-free
soldering or reflow processes are employed. Thru-hole mount
versions are equipped with tin-plated phosphor bronze contacts.
A wide range of applications includes OEM photographic, medi-
cal, consumer and industrial electronics.
Advancements Made to Millennium Plus+
Flow-Rite has announced advancements to the Millennium
Plus+ single point battery watering system. The latest features
include a debris resistant shroud, lower shut off level, improved
versatility and a new ergonomic installation tool.
Large pass through holes on the sides and bottom of the new
shroud allow debris to freely flow through the shroud. This
minimizes the chance of large debris being caught between the
shroud and displacer, while still protecting the internal com-
ponents from impact. Improved shroud and displacer designs
achieve a 0.20 inch lower shut off level while maintaining the
same overall valve length. This provides more room for electro-
lyte expansion inside the cell.
The non-mechanical optical level indicator allows the opera-
tor to verify that each cell has been properly filled after water-
ing. Millennium Plus+ features a built-in indicator that is inde-
pendent from the valve function, giving a true reading even if
the valve is damaged. The indicator simply signals the presence
of liquid, with black for full and white for water needed.
Flip tops are now color coded to match valves for quick
valve length identification. These user-friendly access ports
eliminate drilling cell covers and removing the watering system
to check specific gravity levels.
A 35P (DIN) adapter for the standard bayonet style valve
is now available. The latest valve for GNB works on all GNB
batteries including Flooded Classic, Liberator and Titan. These
improvements in versatility can save hundreds of dollars in in-
ventory costs. In addition, valves are faster and easier to install
with the new ergonomic spanner tool.

In addition to our complete line of larger test equipment

Maccor offers a wide range of desktop test systems
and support equipment, including...

Secondary Cell
Test System
32 Test Positions
per Desktop
Cabinet
High Capabilities
for Single-Cell
Testing at a Very
Economical Price

Desktop Battery Frequency

Test System Response
Rack Mount Analyzer
1 to 8 test positions
or Desktop
makes this the Powerful AC
perfect mid-range High Performance impedence
desktop tester Temperature measurement
Chamber system

www.BatteryPowerOnline.com September/October 2012 Battery Power 23

NEW PRODUCTS ICs & Semiconductors
Integrated 600-mA MicroSiP Power Module Achieves
9-mm2 Solution Size and Extends Battery Life
Texas Instruments, Inc. (TI) has introduced a small, inte-
grated step-up (boost) DC/DC power module for smartphones,
tablets and other portable electronics. The TPS81256 MicroSiP
converter integrates the inductor and input/output capacitors to
achieve a solution less than 9-mm2 and sub-1 mm height, sim-
plifying design and saving up to 50 percent more board space
versus competing solutions.
Smartphone and tablet designers continue to require smaller
point-of-load converters, while maintaining long battery
run-time with high power conversion efficiency. The 4-MHz,
600-mA TPS81256 module supports a 5 V output with a power
density of 400 mW/mm3. The device extends battery life by
reducing the supply current to 43 uA during light load operation.
The TPS81256 also achieves power efficiency of greater than
90 percent from an input voltage of 2.5 V to 5.5 V, enabling it to
efficiently manage 3 W over a full Li-Ion battery voltage range.
The TPS81256 is available now in a nine-bump, 2.6 mm by
2.9 mm by 1 mm MicroSiP package suited for automated assem-
bly by standard surface mount equipment, and is priced at $1.70
in quantities of 1,000.
Synchronous Step-Down Regulator Features Input
And Output Current Limiting and Current Monitoring
The LTC3626 from Linear Technology is a high efficiency,
3 MHz synchronous buck regulator that offers both input
and output current limiting and monitoring. It incorporates a
unique constant frequency/controlled on-time, current-mode
architecture that delivers up to 2.5 A of continuous output cur-
rent at output voltages as low as 0.6 V from a 3 mm by 4 mm
QFN package. Its current-mode operation offers improved line
and load transient response even with high step-down ratios.
The LTC3626 operates from an input voltage range of 3.6 V
to 20 V, making it suitable for a wide range of applications,
including dual/multiple-cell Li-Ion battery stacks and 5 V to
18 V intermediate bus systems. Its average input current and
output current limiting are pin-programmable, making it well
suited for applications such as USB power. The LTC3626s
switching frequency is user programmable and synchronizable
from 500 kHz to 3 MHz, enabling the use of tiny, low cost
capacitors and inductors.
The LTC3626 uses internal switches with RDS(ON) of 115
mOhms and 70 mOhms to deliver efficiencies as high as 95
24 Battery Power September/October 2012
percent. Its unique control architecture enables it to achieve duty
cycles as low as 5 percent, while maintaining switching frequen-
cies up to 2.25 MHz, making it well suited for high step-down
ratio applications, such as 12 VIN to 1.2 VOUT conversions.
Burst mode operation is used to maximize light load efficiency,
requiring 300 A (at no load), important for applications de-
manding maximum battery run time. For applications requiring
the lowest possible noise, the LTC3626 can be configured to run
in forced continuous mode, for minimum noise and potential RF
interference. Furthermore, an internal die temperature monitor
provides a voltage proportional to temperature, which can be
programmed to limit maximum die temperatures. Additional
features include a power good voltage monitor, output voltage
tracking capability and short circuit protection.
The LTC3626EUDC is available in a 3 mm by 4 mm QFN-
20. Pricing starts at $3.45 each in 1,000-piece quantities. An
industrial grade version, the LTC3626IUDC offers guaranteed
performance over the -40C to 125C operating junction temper-
ature range, priced at $3.97 each in 1,000-piece quantities. Both
versions are available from stock.
Fairchild Semiconductors Load Switches Provide
Power Efficiency, Advanced Protection Features for
Mobile and Consumer Applications
High-complexity mobile devices, such as smart phones,
tablets, digital cameras and other consumer goods require
seamless power management and battery switching in order to
provide greater flexibility and better reliability. Fairchild Semi-
conductors IntelliMAX family of advanced load management
switches help designers increase system protection and reduce
complexity in their designs while achieving greater system
power and reliability.
With features such as slew rate control to prevent inrush
currents, over-current limit and thermal shutdown protection,
reverse current blocking and low operating input voltage,
Fairchilds comprehensive portfolio of IntelliMAX smart load
switches are capable of handling a wide range of applications
with multi-channel configurations and high-voltage and current
loads. The expansion of the IntelliMAX series addresses the
dynamic power challenges of light industrial applications with
one-chip solutions that provide designers off-the-shelf capa-
bility for their design needs, reduced component counts and
increased efficiency.
For smart devices and portable storage devices that require
a high current capability and low ON-resistance solution for
power path management, the FPF1039 and FPF1048 switches
offer an ON-resistance of 20 m and 23 m, and an input volt-
age range of 1.2 V to 5.5 V and 1.5 V to 5.5 V, demonstrating
low shutdown current drain to help facilitate compliance in low-
standby power applications. The optimized slew rate controlled
turn-on characteristics with TR = 2.7 mS prevents voltage droop
on supply rails with bulk capacitances as large as 200 F. The
FPF1048 product also offers true reverse current block to avoid
unwanted reverse power regardless of the device being on or off.
Full-function load switches with adjustable current limits,
www.BatteryPowerOnline.com
 ICs & Semiconductors

such as the FPF2165R and FPF2195, are well suited for applica-
tions with physical connectors like USB and HDMI devices that
may encounter large current conditions. Input power budget con-
trol can be easily adjusted with a current limit with an external
resistor that offers reverse current blocking to prevent unwanted
reverse current when the device is turned off. The devices oper-
ate in a constant-current mode to help protect against current
damage and maintain limited current after a current limit fault.
Power Integrations ICs Introduce Primary-Side
Regulation to Power Supplies Up to 90 Watts
Power Integrations has released the LinkSwitch-HP, a family
of energy-efficient, off-line switcher ICs that can deliver up to
90 W output power with accurate primary-side regulation (PSR).
LinkSwitch-HP ICs utilize innovative control algorithms and
the properties of the main power transformer and output diode,
instead of optocouplers and related feedback circuitry, to de-
termine the amount of power to deliver from the primary to the
isolated secondary side. This method reduces component count,
saving space and cost while enhancing reliability. Popularized
more than a decade ago with the advent of Power Integrations
LinkSwitch line, PSR is now standard in many low-power
applications such as mobile-phone chargers but until now has
lacked the constant-voltage accuracy required in higher-power
products. LinkSwitch-HP devices feature a multi-mode control
architecture that radically advances the PSR, making it a viable
approach for power-supply applications from 9 W to 90 W.
LinkSwitch-HP devices automatically select their con-
trol mode according to prevailing line and load conditions to
optimize conversion efficiency and response to transient load
demands, while minimizing output ripple and audible noise.
Continuous-conduc-
tion-mode (CCM)
operation results in
reduced RMS currents,
leading to higher ef-
ficiency and less heat
dissipation, while 132
kHz, full-load operat-
ing frequency enables
the use of smaller
magnetics and LC post-
filter components. LinkSwitch-HP ICs are capable of no-load
power consumption of less than 30 mW at 230 VAC and are
more than 50 percent efficient at 0.1 W input power, meeting all
global energy efficiency regulations such as ErP (EuP), EN-
ERGY STAR EPS V2.0 and EC Ecodesign Directive Tier 2 for
external power supplies.
LinkSwitch-HP ICs feature a comprehensive protection suite,
including selectable current limit, programmable shutdown
delay-time extension, brown-out, brown-in, overvoltage, over-
current and over-temperature protections.

NEGOTIATED SALE
on behalf of our client
MTU FRIEDRICHSHAFEN GmbH
FUEL CELL SYSTEMS
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Characterization & Performance Testing Abuse Testing
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Customized Data Acquisition & Control Temperature
Overcharge / Overdischarge Vibration
Abnormal Charging Impact & Crush
Mechanical Shock Projectile
Nail Penetration IP Code
The line has been designed for the production of nickel elektrodes,
used in fuell cells, coating speed 1-10 m/min, cap. in 3 shifts
approx. 500.000 boards per year, nickel foam coil length approx. 80-
300 m, foam thickness approx. 1,6 mm, working width 700 mm, roller Detroit Testing Laboratories
width 800 mm, total dim. (L/W/H) approx. 44x4,2 (top area) x 5,8 m, is now Element Materials
The line is consisting of the following components: double decoiler, Technology!
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www.TroostwijkAuctions.com info.warren@element.com www.element.com

www.BatteryPowerOnline.com September/October 2012 Battery Power 25

NEW PRODUCTS Charging, Testing & Monitoring
Eltek Expands DC Power System Monitoring
Capabilities with CAN Modules
Eltek has announced a family of five new controller-area
network (CAN) modules that enable its Smartpack and Smart-
pack2 controllers to monitor a complete range of power-related
systems from a single controller.
The Battery Monitor has four voltage measurement inputs
used for battery symmetry monitoring based on midpoint or
block measurements. The Battery Monitor also has inputs for
monitoring one battery shunt and battery breaker.
The Load Monitor Module lets site operators monitor indi-
vidual distribution breakers. It can connect up to eight current
shunts and can monitor up to eight fuses. It can also be used for
both positive and negative distributions.
The I/O Monitor Module expands the standard monitor
and alarm capabilities of the Smartpack controllers. Each I/O
Monitor Module has six configurable inputs for fuse sensing and
feeding external signals into the control system and six con-
figurable relay outputs for connecting external alarms including
tank-level measurements or climate control sensors.
The AC Mains Monitor provides inputs for measuring
voltage and current on up to three phases of the systems AC
mains and enables monitoring of mains availability, quality and
consumed energy.
All nodes are powered by the distributed power supplied on
the CAN bus from the Smartpack and Smartpack2. The CAN
Power Module can be added to supplement the available power,
if the CAN bus needs to be isolated or additional CAN bus
power is needed. Configuration of the CAN nodes is plug and
play and can then be done via the user display on the Smartpack
controller or by using Elteks WebPower and PowerSuite soft-
ware tools. The modules are powered by the CAN bus, so only
a RJ45 patch cable is required for connecting the node to the
control system. This enables greater flexibility in positioning the
nodes close to their measuring connections reducing the amount
of wiring needed.
Victron Energy B.V. Introduces the Skylla-i 24 Volt
Battery Chargers
Victron Energy has added two battery chargers to its product
range: the Skylla-i 24/80 and 24/100. These two battery chargers
are Victrons answer to the growing demand for modern, power-
ful battery chargers. The Skylla-i 24 V battery chargers are
light and small, allow remote control, enable to set a maximum
amount of shore side current and are NMEA 2000-certified.
The Skylla-i 24 V battery chargers are significantly lighter
and smaller than their predecessors. The Skylla-i 24 V models
are 30 percent lighter and 35 percent smaller in volume.
With the Skylla-i Control GX control panel, the Skylla-i 24
V charge process is easy to monitor and to control. The panel
indicates the state of charge by means of energy efficient LEDs.
The battery chargers can be connected to self designed
SCADA systems by means of the NMEA 2000 canbus. This new
development is completely in line with Victrons open network
philosophy, an operative network in which all components
26 Battery Power September/October 2012
seamlessly interact; regardless of the manufacturer. The Skylla-i
24 V battery chargers will be NMEA 2000 certified shortly.
Battery Monitor Makes Monitoring Affordable,
Efficient and Reliable
Factor Power, Inc. has launched the Extreme Battery Monitor
(XBM). The XBM uses the latest methods in communication,
features a stylish and modular design, and with its simple plug
and play installation, it will afford customers savings in time and
money upon integration.
The XBM uses Split Core Technology, which allows the cus-
tomer to install the product without having to take their system
offline, which is an extremely important advantage. The SNMP
and wireless functionalities allow the customer to observe their
systems from wherever they are, whenever they want, from a
laptop or mobile device.
The XBM allows users to monitor up to four strings and 250
cells at a time with one unit, with nine different alarm types and
eight different types of measurements.
Midtronics Develops New GRX-5100 Hybrid/EV
Battery Service Tool
Midtronics, Inc. has completed the initial field testing for the
GRX-5100 Hybrid/EV Battery Station, the high-voltage Hybrid/
EV vehicle battery service and de-power tool for various hybrid
and electric vehicles. The GRX-5100 safely de-powers high-
voltage batteries and also enables service for the battery system
at the module level, reducing manufacturer warranty costs and
repair time and expense for customers.
Currently completing field testing at General Motors, the
GRX-5100 was developed to perform full battery pack service,
including balancing, charging in no-start situations and full
de-powering. The de-power capability enables packs in vehicles
that have been involved in severe collisions to be de-powered to
a safe level for storage, recycling or shipment. Beyond service
providers, the GRX-5100 is also targeted for reclamation yards
where it can be used to perform critical safety checks and de-
powering with the battery pack either in or out of the vehicle.
The GRX-5100 features a versatile electrical harness be-
tween vehicle batteries and communication systems via unique
adapters for each vehicle model. Simple menu prompts guide
verification that the battery and communication systems are
properly connected and balancing or de-powering operations
can safely begin. The station also utilizes USB-based memory,
which will support system updates for future vehicle battery
systems without a hardware upgrade.
The GRX-5100 is the latest in Midtronics products for the
hybrid/electric vehicle market. Previous product releases have
included the HYB-1000 Hybrid Battery System Analyzer,
designed for the aftermarket, and the GRX-5000 EV Battery
Module Diagnostic Station, which performs both battery module
balancing and diagnostics and was initially created in support of
the Nissan LEAF program.
www.BatteryPowerOnline.com
 Power Supplies

(larger than 1 W multiples) allowing the singles to meet the ErP

requirement of 87 percent and 500 mW. Designed for convec-
tion and cooled applications, the GRN series operates from 0C
to 70C with suitable derating above 50C.

40-Watt DC/DC Converter with a 2:1 Input

ConTech, a Division of Calex, has released the TMH series
GRN Series of Green Power Supplies of DC/DC converters. The TMH series offers up to 40 watts of
Power Sources Unlimited, Inc. has released the new GRN
fully regulated output
series of green power supplies. Available in both single and
power with an industry
multiple output versions, these energy efficient component
standard 2 inch by 1 inch
power supplies cover the 45, 60, 80, and 110 watt power levels.
footprint. The series of-
Complying with the energy saving requirements of the ErP
fers a 2:1 input range with
(Energy Related Products) Directive, the single output ver-
nominal input voltages
sions offer high efficiency, high power density and low standby
of 12 VDC, 24 VDC and
power. The multiple output versions are available with up to
48 VDC. Single outputs
four outputs and also offer high efficiency and low no-load input
offered are 3.3, 5, 12, and 15 VDC. Dual outputs are +/-12 and
power in a compact, low profile package. The GRN series is
+/-15 VDC.
well suited to a broad range of medical, information technology,
The TMH series operates with efficiencies as high as 92 per-
and industrial applications and is designed for those seeking to
cent. Features include Remote On/Off, Output Trim and Short
reduce standby and overall power consumption.
Circuit Protection. The operating ambient temperature range of
Offering 17 standard models at each power level, the GRN
the TMH is -40C to 55C with no de-rating. The non de-rated
series offers a flat efficiency curve from 25 percent to a 100
temperature range can be extended to 65C ambient with an
percent load. The use of innovative design techniques result in
optional heat sink. The unit is encapsulated with a thermally
more than 87 percent average efficiency for the singles (12 V to
conductive potting compound in a six-sided metal case for im-
48 V) and 85 percent for the multiples (3.3 V and 5 V outputs
proved thermal performance in still air environments. The TMH
also available) while featuring less than 300 mW standby power
series is RoHS compliant.

www.BatteryPowerOnline.com September/October 2012 Battery Power 27

INDUSTRY NEWS
Orbital Sciences Corp. Awards GS Yuasa Lithium
Power Follow-On Order for Additional Cygnus
Satellite Batteries
GS Yuasa Lithium Power, Inc. has been awarded a follow-on
order by Orbital Sciences Corp. to deliver batteries to be used
aboard the Cygnus cargo logistics spacecraft supporting NASAs
Commercial Resupply Services (CRS) program for the Interna-
tional Space Station. The order from Orbital is for battery sets
for Cygnus spacecraft that will carry out missions four through
eight of the CRS contract. In 2011 GYLP successfully complet-
ed deliveries of batteries in support of the initial demonstration
mission and CRS missions one to three.
GS Yuasa has successfully completed the deliveries for the
demonstration mission and the first three CRS missions. This
follow-on award demonstrates Orbitals confidence in our ability
to deliver highly reliable battery systems, meet program mile-
stones and support a long-term program, said William Moll,
GYLP president. GYLP looks forward to continuing to work
with Orbital in support of the CRS program.
GS Yuasas lithium ion batteries provide a low mass and
highly reliable solution to power Orbitals Cygnus advanced
maneuvering space vehicle.
The batteries will be assembled and tested at GYLPs Ro-
swell, GA facility and use GS Yuasas space qualified LSE190
rechargeable lithium ion cells. The initial battery delivery for
this order will be in the fourth quarter of this year with addi-
tional deliveries through 2014.
BMW and Toyota Join Hands to Develop Fuel Cells
In a Decade in Which Battery Driven Vehicles are
Expected to Dominate
BMW and Toyota have announced a joint development for
a fuel cell sports car in extension of the research partnership of
lithium ion batteries established last year. With this step, both
companies are keeping their options wide open. While BMW
has proactively been developing a hydrogen engine vehicle,
Toyotas interest would rest with designing and engineering the
sports car with an ultra-light CFRP body, which is one of the
core competencies of BMW.
Partnerships between vehicle manufacturers are the key for
development and commercialisation of future expensive tech-
nologies such as fuel cell and battery electric vehicles. At least
five electrification related joint ventures between manufactures
can be observed for 2011. BMW joined hands with PSA last
year to produce and share hybrid components for mass produced
electric vehicles. The key advantage lies in the manufacturer
reducing development expenses and accelerating the time for
commercialization in such a conjoint effort. Sharing components
between manufacturers for new technologies helps achieve
economies of scale.
If the fuel cell is the ultimatum of a sustainable vehicle, it is
the lithium ion driven battery vehicle however, which has oc-
cupied the market today. More than 25,000 electric vehicles (in-
cluding plug-in hybrid vehicles) have been sold in the first five
months of 2012 in North America and Europe alone. The global
28 Battery Power September/October 2012
tally of electric vehicles sold last year was 43,200 cars. Fuel cell
cars are expected to be mass produced only post 2014. The fuel
cell vehicles are still on the test bench with only a hand full of
vehicles such as the Mercedes Benz F-cell, Toyota FCHV-adv
and Chevrolet Equinox running diversified trails. Honda FCX
Clarity leases for $600 a month for a period of three years.
Mid-Continent Instrument Company Signs Agreement
Supply Advanced Nanophosphate Lithium-Ion Battery
Technology for Aviation Applications
Mid-Continent Instrument Co., Inc. has strengthened its
True Blue Power division by signing a distribution and supply
agreement with A123 Systems, Inc. by which Mid-Continent
will offer A123s advanced Nanophosphate lithium-ion battery
technology for aviation applications.
True Blue Power, which was announced in March 2011, ini-
tially began by offering two inverters and the TS835 Emergency
Power Supply (EPS), the industrys first FAA TSO-approved
EPS to feature A123 technology. Under the agreement with
A123, True Blue Power will provide lithium-ion cells, modules
and custom power solutions to the aviation community.
ABSL Space Products Lithium-Ion Battery Outlasts
Satellite Mission Goal
EnerSys and its Longmont, Colo.-based ABSL Space Prod-
ucts (ABSL) business has announced that the lithium-ion battery
built for the Tactical Satellite-3 (TacSat-3) performed nearly
three times its planned mission life before the satellite de-orbited
on April 30th,, 2012.
ABSL was selected by ATK to design, fabricate, test and
deliver a lithium-ion battery for the TacSat-3 spacecraft bus that
was designed and built by ATK. ABSLs battery was responsible
for powering the satellite during eclipse and peak mission load
conditions. The TacSat-3 spacecraft bus was designed for one
year of operational goal but the satellite exceeded that goal by
nearly two years.
TacSat-3 is a forerunner to the Operationally Responsive
Space program (ORS). ABSL also provided the lithium-ion
space battery to ATK for the ORS-1 mission. TacSat-3 was
designed to meet the various needs of the US military forces.
ABSLs lithium-ion battery was a key component in the success
of the onboard satellite operations, which exceeded the original
mission life goal.
ANSYS Making Electric Vehicle Batteries More
Practical and Efficient
One year into a US Department of Energy (DOE) funded
project, ANSYS, General Motors LLC, the National Renewable
Energy Laboratory (NREL) and ESim are leveraging engi-
neering simulation technology to optimize electric and hybrid
vehicle battery performance. The team achieved significant
milestones during the past year in support of the DOEs Com-
puter Aided Engineering for Electric Drive Vehicle Batteries
(CAEBAT) project.
Industry News continued on page 30
www.BatteryPowerOnline.com
 MARKETPLACE
Index of Advertisers
Arbin Instruments. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Maccor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
www.arbin.com www.maccor.com

Battery Solutions, Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Mid-Continent Instruments. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

www.batteryrecycling.com www.mcico.com

Eagle Eye Power Solutions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19 Reed Exhibitions Japan Ltd. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

www.eepowersolutions.com www.batteryjapan.jp/en/ex

Element Materials Technology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Samsung Sdi America Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32

www.element.com www.samsungsdi.com

EPEC Engineering Technologies. . . . . . . . . . . . . . . . . .. . . . . . . . . . . .17 Storage Battery Systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

www.epectec.com www.sbsbattery.com

Hioki. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 Troostwijk Auktionen GmbH & Co. KG. . . . . . . . . . . . . . . . . . . . . . . 25

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Intellibatt, LLC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 UL International Ltd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31

www.intellibatt.com www.ul.com

Calendar of Events

September
18-19 - Battery Power 2012, Denver, Colo.

25-28 - 13th European Lead Battery Conference,

Paris, France

October
23-25 - Advanced Energy Solutions Conference,
San Diego, Calif.

24-26 - Batteries 2012, Nice, France

November
13-15 - The Battery Show, Novi, Mich.

December
4-5 - Lithium Battery Power 2012, Las Vegas, Nev.

6-7 - Battery Safety 2012, Las Vegas, Nev.

Send Calendar of Event listings to

Shannon Given at shannong@infowebcom.com.

www.BatteryPowerOnline.com September/October 2012 Battery Power 29

INDUSTRY NEWS
GM awarded ANSYS a subcontract to develop battery
software tools that will help accelerate development of next-
generation electric vehicles (EV). The project is a result of a
competitive procurement through the DOEs NREL that was
presented to GM last year.
The main goal of the CAEBAT project is to incorporate
existing and new battery models into engineering simulation
software to shorten design cycles and optimize batteries for in-
creased performance, safety and life span. The project is driving
EV innovation.
The GM-ANSYS-ESim teams achievements over the past
year include prototyping and validating three electrochemistry
modeling approaches. The partners also prototyped a co-sim-
ulation feature, which blends battery multiphysics and system
simulation technologies that enable engineers to shed unneces-
sary details and increase simulation efficiency without compro-
mising the accuracy of the model.
Traditionally, the EV battery industry depends mostly on
the expensive and time-consuming process of design-build-test-
break for prototyping and manufacturing these batteries, said
Jan Aase, director of the vehicle development research lab at
GM Global R&D. However, the virtual development of engi-
neered products has proven to be an effective way of evaluat-
ing many design alternatives. This specific team was selected
because of their individual track records of success in their
respective fields for providing reliable technologies that lead to
efficient products.
NREL expects that the resulting systems will become com-
mercial offerings in about two years. This initiative is funded by
DOEs Vehicle Technologies Program in the Office of Energy
Efficiency and Renewable Energy.
BASF Broadens its Technology Base and Global
Market Access for Battery Materials
Over the last few months, BASF has taken several strategic
decisions to strengthen its position in materials for high-per-
formance batteries. Through acquisition of the US companies
Ovonic Battery Company and Novolyte Technologies, purchase
of Mercks electrolyte activities, conclusion of a license agree-
ment to acquire the lithium iron phosphate technology (LFP)
with the LiFePO4+C Licensing AG and participation in Sion
Power, BASF has further improved its technology base and
global market access for battery materials. Research and devel-
opment activities have also been stepped up.
Most materials in lithium-ion batteries of the kind currently
used in electric or hybrid cars are based on innovations from
chemistry, said Dr. Andreas Fischer, vice president Battery Re-
search and Electrochemistry at BASF, in Ludwigshafen/Germany.
Especially cathodes, anodes and electrolytes are important
for battery performance. A battery is a chemical power plant
in which all the materials have to be optimally matched to each
other, added Fischer. We have therefore initiated numerous
research and development projects for these key components in
recent years, with the aim of developing innovative materials for
high-performance batteries that will significantly increase the
30 Battery Power September/October 2012
range of electric cars while reducing the cost of the battery.
In these activities, BASF researchers are also cooperat-
ing with numerous national and international universities and
research institutes as well as industry partners. One example
is the Innovation Alliance HE-Lion (High Energy Lithium-ion
Battery) sponsored by the German Federal Ministry for Educa-
tion and Research and headed by BASF. In HE-Lion we are
collaborating with other companies such as Bosch and VW and
numerous universities and research institutes in developing the
next generation of lithium-ion batteries, explained Fischer.
Besides materials for lithium-ion batteries, BASF is also
researching future battery concepts such as lithium sulfur and
lithium air. These new technologies promise much higher
energy densities and have the potential to further reduce the
weight and cost of the batteries, said Fischer. Here too, BASF
is cooperating with external partners from science and industry.
We are working on basic questions relating to new materials
and functional components, for example in the research network
Electrochemistry and Batteries, with scientific partners from
Germany, Switzerland, Israel, the USA and Canada. To increase
the service life and energy density of lithium-sulfur batteries,
BASF is also cooperating with the US company Sion Power.
Cymbet EnerChip Bare Die Solid State Batteries
Verified Non-Cytotoxic
Cymbet Corp. has announced the successful results of in
vitro biocompatibility feasibility studies that were conducted to
evaluate the cytotoxicity potential of the EnerChip Recharge-
able Solid State Battery. EnerChip bare die battery samples were
gamma sterilized and evaluated using two in vitro test methods
for cytotoxicity: a) Medium Eluate Method (MEM) -1X CMEM
Cell Growth Medium Extract, and b) Agar Diffusion Solid
Sample. These in vitro cell culture assays are considered to be
excellent screening assays for biocompatibility.
The gamma sterilized Cymbet EnerChip bare die batter-
ies were found to be non-cytotoxic (0 percent cell lysis) using
both the Medium Eluate Method Eluation Test and Agar Dif-
fusion Test feasibility screening procedures. The lack of any
adverse biological responses in these very sensitive in vitro
cell culture assays is indicative (although not a guarantee) of
biocompatible test results in the other in vitro and in vivo as-
pects of biocompatibility as suggested by the ISO 10993-1 and
FDA G95-1 guidelines.
Cymbet EnerChip solid state batteries are fabricated using
standard semiconductor integrated circuit processes with pat-
ented construction techniques. EnerChip batteries are REACH
compliant as they contain no hazardous substances as shown
on the Substances of Very High Concern (SVHC) candidate list
published on the European Chemicals Agency (ECHA) web site.
Additionally, EnerChip rechargeable solid state batteries have
been fully tested as RoHS compliant.
www.BatteryPowerOnline.com
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