A123 Systems APR18650M1-A User manual

USER DOCUMENTATION
Date: March 6, 2014
Document #: 493005-002
Rev 02
Battery Pack Design, Validation, and
Assembly Guide using A123 Systems
Nanophosphate®Cells
Including:
APR18650M1-A
ANR26650M1-B
AHR32113M1Ultra-B
AMP20M1HD-A

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Copyright © 2014 A123 Systems, LLC.
All rights reserved.
DOCUMENT NOTICE AND DISCLAIMER: This document is the property of A123 Systems, LLC. ("A123"). The
information in this document is subject to change without notice. A123 is under no obligation to update the
information in this document. A123 reserves the right to make changes in the design of its products or
components as progress in engineering and manufacturing may warrant. It is the user’s responsibility to satisfy
itself as to whether the information contained herein is adequate and sufficient for any particular purpose.
Nothing in this document modifies the terms of sale or the rights, obligations and warranties of A123 pursuant to
any agreement that may exist between the user and A123. This document does not create any additional
obligation for A123 and does not add to any warranty set forth in such agreement. The user is responsible for
ensuring that all applications of A123's products are appropriate and safe based on conditions anticipated or
encountered during use. In making this document available, A123 is not rendering professional or other services
on behalf of any entity, or undertaking to perform any duty owed by any person or entity to someone else. The
user of this document should rely on his or her own independent judgment in the use of the information herein or,
as appropriate, seek the advice of a competent professional in determining the exercise of reasonable care in the
specific circumstances. While A123 has used reasonable endeavors to indicate the application of certain legal
requirements, this document is not legal advice and should not be relied upon as such. It is the user’s responsibility
at all times to ensure its use of this document, and any activities relating thereto, is in compliance with all legal
requirements applicable to the user and the user’s application(s).
A123 SYSTEMS, NANOPHOSPHATE and the A123 LOGO are registered trademarks of A123 Systems, LLC. All other marks
are trademarks or registered trademarks of their respective owners.

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Contents
Preface...........................................................................................................................................................................1
About this Document ................................................................................................................................................1
Purpose of this Document ....................................................................................................................................1
How to Use this Guide ..........................................................................................................................................2
Conventions Used in this Guide............................................................................................................................2
Related Documents and Resources ......................................................................................................................3
Chapter 1 .......................................................................................................................................................................4
Possible Dangers Involved With Handling Cells and Battery Packs...........................................................................4
Thermal Events .....................................................................................................................................................5
Short Circuits.........................................................................................................................................................5
Arc Flashes ............................................................................................................................................................5
High Voltage..........................................................................................................................................................5
Chapter 2 .......................................................................................................................................................................6
Transportation, Storage and Disposal .......................................................................................................................6
Transporting Batteries ..........................................................................................................................................7
Storing Batteries .................................................................................................................................................16
Battery Disposal ..................................................................................................................................................16
Chapter 3 .....................................................................................................................................................................17
Nanophosphate®Technology and Cell Characteristics............................................................................................17
Nanophosphate Technology ...............................................................................................................................17
Power ..................................................................................................................................................................18
Safety ..................................................................................................................................................................20
Life ......................................................................................................................................................................21
Chapter 4 .....................................................................................................................................................................22
Battery Pack Design.................................................................................................................................................22
Design Overview .................................................................................................................................................23
Configuration of Cells in a Battery Pack..............................................................................................................24
Battery Pack Structural Design ...........................................................................................................................27
Cell Protection.....................................................................................................................................................35
Battery Pack Control (Monitoring and Management) ........................................................................................39
Battery Pack Use .................................................................................................................................................48

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Chapter 5 .....................................................................................................................................................................53
Summary of Battery Pack Validation.......................................................................................................................53
Performance Testing...........................................................................................................................................54
Abuse Testing......................................................................................................................................................55
Compliance Testing.............................................................................................................................................56
Chapter 6 .....................................................................................................................................................................57
Battery Pack Assembly ............................................................................................................................................57
Incoming Cell Inspection.....................................................................................................................................57
Material Handling and Storage ...........................................................................................................................57
Cell Welding ........................................................................................................................................................58
Appendix A...................................................................................................................................................................61
Cell Specifications....................................................................................................................................................61
AMP20M1HD-A..................................................................................................................................................62
ANR26650M1-B.................................................................................................................................................72
APR18650M1-A.................................................................................................................................................79
AHR32113M1Ultra-B .........................................................................................................................................83
Appendix B...................................................................................................................................................................90
Acronyms and Terminology ....................................................................................................................................90

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Figures
Figure 1 – AMP20 cells discharge curves*...................................................................................................................18
Figure 2 – AMP20 cells discharge curves at various temperatures* ...........................................................................19
Figure 3 – AMP20 cells cycle life (1C charge / 1C discharge rates) *...........................................................................21
Figure 4 – AMP20 cells capacity loss due to calendar aging *.....................................................................................21
Figure 5 – Example of AMP20 cells connected in series..............................................................................................25
Figure 6 – Example of AMP20 cells connected in parallel ...........................................................................................26
Figure 7 – Effect of AMP20 cell life with respect to surface pressure .........................................................................28
Figure 8 – AMP20 cell thickness variation wrt SOC for three representative AMP20 cells.........................................29
Figure 9 – Graph of the pressure vs. deflection of an example compliant pad for AMP20 Cells ................................30
Figure 10 – Pressure on AMP20 cell face without compliant pad (left) and with compliant pad (right) ....................31
Figure 11 – Pressure map across the surfaces of each cell in a representative stack of cells .....................................31
Figure 12 – AMP20 cell corner that will vent under extreme internal pressure .........................................................32
Figure 13 – ANR26650 end-to-end cell spacing...........................................................................................................32
Figure 14 – APR18650 cell vents..................................................................................................................................33
Figure 15 – Diagram of optional AMP20 cell cooling concept.....................................................................................34
Figure 16 – Individual cell fusing strategy ...................................................................................................................35
Figure 17 – Example AMP20 cell fuse pattern in cell terminals ..................................................................................36
Figure 18 – Example of a necked-down connection to the cell which can act as a fuse .............................................36
Figure 19 – Example of total system fusing strategy ...................................................................................................37
Figure 20 – Battery pack with representative short circuit faults ...............................................................................38
Figure 21 – AMP20 cell voltage vs. SOC at 23 °C .........................................................................................................45
Figure 22 – AMP20 cell vSOC sensitivity to OCV error ................................................................................................45
Figure 23 – AMP20 cell temperature effects on OCV with respect to (wrt) SOC ........................................................46
Figure 24 – AMP20 cell 60s, 20A DCR measurements wrt SOC at various temperatures ...........................................47
Figure 25 – Battery voltage and current during recharge ...........................................................................................49
Figure 26 – AMP20 cell* capacity degradation vs. time for various recharge rates**................................................50
Figure 27 – Bus bar concept diagram and resulting welded cross sections ................................................................58
Figure 28 – Two types of bus bars ultrasonically bonded in the center to each other ...............................................59
Figure 29 – Schematic of cylindrical cell welding process ...........................................................................................59
Figure 30 – AMP20M1HD-A cell dimensions ..............................................................................................................70
Figure 31 – Notes for AMP20M1HD-A cell dimensions drawing ................................................................................71
Figure 32 – ANR26650M1-Bcell diagram and dimensions........................................................................................78
Figure 33 – APR18650M1-A cell diagram and dimensions .........................................................................................82
Figure 34 – AHR32113M1Ultra-B cell diagram and dimensions.................................................................................89

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Tables
Table 1 – A123 Systems cell model numbers ................................................................................................................2
Table 2 – Steps required to transport a lithium ion battery..........................................................................................8
Table 3 – Nominal energy and ELC of A123 cells .........................................................................................................10
Table 4 – US transportation classification of cells .......................................................................................................11
Table 5 – US transportation classification of batteries................................................................................................11
Table 6 – International transportation classification of cells ......................................................................................12
Table 7 – International transportation classification of batteries ...............................................................................12
Table 8 – International Air Transport Association (IATA) packaging and quantity restrictions (PI-965) .....................13
Table 9 – International Air Transport Association (IATA) packaging and quantity restrictions (PI-966 & PI-967) ......15
Table 10 – Example of histogram data of temperature ranges and durations...........................................................42
Table 11 – Charge current and voltage calculation examples .....................................................................................49
Table 12 – Performance tests......................................................................................................................................54
Table 13 – Abuse tests.................................................................................................................................................55
Table 14 – Useful battery pack standards and their relevant applications .................................................................56
Table 15 – AMP20M1HD-A cell specifications............................................................................................................62
Table 16 – AMP20M1HD-A Max continuous charge currents wrt temperature and SOC..........................................65
Table 17 – AMP20M1HD-AMax 10s pulse charge currents wrt temperature and SOC.............................................65
Table 18 – AMP20M1HD-A Max continuous discharge currents wrt temperature and SOC .....................................65
Table 19 – AMP20M1HD-A Max 10s pulse discharge currents wrt temperature and SOC ........................................65
Table 20 – ANR26650M1-Bcell specifications...........................................................................................................72
Table 21 – ANR26650M1-BMax continuous charge currents wrt temperature and SOC.........................................74
Table 22 – ANR26650M1-BMax 10s pulse charge currents wrt temperature and SOC............................................74
Table 23 – ANR26650M1-BMax continuous discharge currents wrt temperature and SOC ....................................74
Table 24 – ANR26650M1-BMax 10s pulse discharge currents wrt temperature and SOC .......................................74
Table 25 – APR18650M1-A cell specifications ............................................................................................................79
Table 26 – APR18650M1-AMax continuous charge currents wrt temperature and SOC..........................................81
Table 27 – APR18650M1-AMax 10s pulse charge currents wrt temperature and SOC.............................................81
Table 28 – APR18650M1-AMax continuous discharge currents wrt temperature and SOC .....................................81
Table 29 – APR18650M1-AMax 10s pulse discharge currents wrt temperature and SOC ........................................81
Table 30 – AHR32113M1Ultra-B cell specifications ...................................................................................................83
Table 31 – AHR32113M1Ultra-B Max continuous charge currents wrt temperature and SOC .................................85
Table 32 – AHR32113M1Ultra-B Max 10s pulse charge currents wrt temperature and SOC ....................................85
Table 33 – AHR32113M1Ultra-B Max continuous discharge currents wrt temperature and SOC.............................85
Table 34 – AHR32113M1Ultra-B Max 10s pulse discharge currents wrt temperature and SOC................................85
Table 35 – Acronyms and terminology descriptions ...................................................................................................90

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Preface
About this Document
Purpose of this Document
This guide provides information that may be useful for designing, validating, and assembling battery packs with
A123 Nanophosphate®cells. Creating a well designed battery pack requires many considerations. The scope of this
guide is to outline the unique aspects of designing battery packs with A123 Nanophosphate cells. A123 Energy
Solutions recommends the study of additional relevant documentation from appropriate sources before designing
validating, and assembling battery packs with A123 Nanophosphate cells.This document may not be applicable to
any cells not provided by A123.
Anyone involved in the design, use, or assembly of products that use A123 cells should read and understand this
document.
Designing, validating and assembling battery packs is potentially dangerous to personnel
and property. Therefore, these activities should only be attempted with a complete
understanding of all aspects of proper battery pack design and construction. A123 is not
responsible for any battery pack designed by any party other than A123. Anyone involved
in building a battery pack with A123 cells must have the training and experience necessary
to safely handle the cells and prevent accidental short circuits and arc flashes.

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How to Use this Guide
The chapters in this guide are organized sequentially as they relate to design requirements that must be
considered and understood before and during designing, validating, and assembling battery packs with A123
Nanophosphate cells. This guide contains the following information:
•Chapter 1, Possible Dangers Involved With Handling Cells and Battery Packs – describes dangers
involved with handling cells and battery packs.
•Chapter 2, Transportation, Storage and Disposal – describes regulations and laws required for
transporting lithium-ion batteries or products containing them.
•Chapter 3, Nanophosphate® Technology and Cell Characteristics – describes how Nanophosphate
electrode technology influences power, safety, and cycle life performance.
•Chapter 4, Battery Pack Design – describes the various stages of battery pack design, covering aspects of
A123 Energy cells, which may be different from other cells.
•Chapter 5, Summary of Battery Pack – describes performance, abuse, and compliance testing.
•Chapter 6, Battery Pack Assembly – describes the processes for cell incoming inspections, material
handling and storage, and cell welding.
•Appendix A, Cell Specifications – describes electrical, physical, and environmental specifications and
maximum charge and discharge currents per cell.
•Appendix B, Acronyms and Terminology – describes terms and acronyms used in this guide.
Conventions Used in this Guide
This document uses the following conventions for notes, cautions, warnings, and danger notices.
A notice presents information that is important, but not hazard-related.
A notice presents information that is important, and may be hazard-related.
A warning contains information essential to avoid a hazard that can cause severe personal
injury, death, or substantial property damage if the warnings are ignored.
A danger contains information essential to avoid a hazard that will cause severe personal
injury, death, or substantial property damage if the warnings are ignored.
Table 1 – A123 Systems cell model numbers
A123 Systems Cell Model Numbers
Abbreviated Cell Model Numbers
Used in this Guide
APR18650M1 - AAPR18650
ANR26650M1 - BANR26650
AHR32113M1Ultra-B AHR32113
AMP20M1HD-A AMP20

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Related Documents and Resources
•A123 Product Documentation:
oA123 Energy web site: http://a123energy.com/resources-overview.htm
oA123 Systems web site: http://www.a123systems.com/resources-overview.htm
•http://www.iata.org/whatwedo/cargo/dgr/Pages/lithium-batteries.aspx
•http://www.ups.com/media/news/en/intl_lithium_battery_regulations.pdf
•http://www.welding-consultant.com
•http://www.ccl.fraunhofer.org/
•Sandia Report SAND20053123 “FreedomCar Electric Energy Storage System Abuse Test Manual for
Electric and Hybrid Electric Vehicle Applications”

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Chapter 1
Possible Dangers Involved With Handling Cells and
Battery Packs
A123’s cells are highly stable and abuse-tolerant; however, handling a battery pack remains potentially dangerous
to personnel and property; therefore, anyone attempting to design or handle battery packs must first completely
understand all aspects of proper battery pack design and construction. The dangers involved in building a battery
pack include those described in the following sections.
•Thermal Events
•Short Circuits
•Arc Flashes
•High Voltage