Alpha Magnetic Spectrometer 02 Phase III Flight

Alpha Magnetic Spectrometer – 02 Phase III Flight Safety UPS Overview Jan 12 2010 John A. Heilig ESCG/Jacobs

Alpha Magnetic Spectrometer – 02 Uninterruptible Power Supply (UPS) • The UPS system consists of a redundant set of Lithium-Ion batteries (2 independent 8 cell units) • To ensure mission success during loss of ISS power or communication, the UPS battery provides control power to the payload for: – – – Watch-dog timer/control circuit Quench monitoring Initiation of quench heater 45 A pulse Nominal ramp-down at the end of the eight hours. CPVS Solenoid valve operations • Are sized for a minimum of 8 hours of operation, plus assisted quench operation / ramp down

Alpha Magnetic Spectrometer – 02 Uninterruptible Power Supply (UPS) • Battery is designed to meet: – NSTS 1700. 7 B, “Safety Policy and Requirements For Payloads Using the Space Transportation System” – NSTS 1700. 7 B ISS Addendum, “Safety Policy and Requirements For Payloads Using the International Space Station” – JSC 20793, “Manned Space Vehicle Battery Safety Handbook” • JSC EP 3 Battery Safety Form – Rev C

Alpha Magnetic Spectrometer – 02 CAB to UPS Block Diagram

Alpha Magnetic Spectrometer – 02 UPS Battery

Alpha Magnetic Spectrometer – 02 Uninterruptible Power Supply Components

Alpha Magnetic Spectrometer – 02 UPS Battery “Bricks” (old cells)

Alpha Magnetic Spectrometer – 02 UPS Battery Management System (BMS) • BMS is a radiation tolerant circuit that monitors and maintains a series string of eight Li-ion battery cells, with a nominal output voltage of 32 VDC. • The battery is monitored for unhealthy temperature and/or electrical conditions, upon which the system reacts to protect the cells. – – – Automatic Cell Balancing Thermal Monitoring Over-discharge Monitoring Short Circuit Protection Cell Over-voltage Monitoring • BMS consists of three PCBs: – Master Control Board – QTY 2 Monitor/Equalizer boards

Alpha Magnetic Spectrometer – 02 UPS BMS Electronics

Alpha Magnetic Spectrometer – 02 Current Status • While in testing by AMS-02 Collaboration personnel, the QM UPS suffered a catastrophic failure due to improper test setup and monitoring. • After a failure investigation with the AMS-02 collaboration testing partner, MIT pulled the contract for continued assembly and testing of the UPSs and awarded it to Yardney Technical Products, the original battery cell manufacturer and a leader in the field.

Alpha Magnetic Spectrometer – 02 Current Status • Upon receipt of the 4 remaining UPS units, an incoming inspection by Yardney noted that multiple cells in the units shows signs of decreased capacity. No obvious cause could be determined by observation or testing of the UPSs, BMSs, or cells. • It is strongly suggested the cause of the cell capacity issue was improper handling and storage before being received by Yardney.

Alpha Magnetic Spectrometer – 02 Current Status • Due to the low capacity, the decision was made to remanufacture identical cells to repopulate the entire set of flight and flight spare UPSs (8 cells x 4 units) and perform Protoflight testing on these cells. This cell design was Qual and Acceptance tested originally per L 1135 -05, Qualification Test Report for the Alpha Magnetic Spectrometer-02 (AMS 02) Uninterruptible Power Source (UPS) NCP 25 -3 Lithiumion Cells Per Li. TP-6208 Test Dates 1~05 to 2/17/05, Rev. -, Dated 3/11/2005 • The four (4) UPS units, 2 - FL, 2 - FS are being assembled now and will be fully flight certified. • During integrated testing of the Flight Spare units, issues were discovered with one FET and resistance drift on thin film resistors on the BMS circuits. Components replaced.

Alpha Magnetic Spectrometer – 02 Current Status 00592 NCP 25 -3 Rebuild Cell Capacity 38. 0 36. 0 Discharge Capacity (Ah) 34. 0 32. 0 30. 0 28. 0 26. 0 25 -3 -1233 4 25 -3 -1230 25 -3 -1223 25 -3 -1214 25 -3 -1193 25 -3 -1213 25 -3 -1236 25 -3 -1231 25 -3 -1224 25 -3 -1218 25 -3 -1212 25 -3 -1199 25 -3 -1238 25 -3 -1195 25 -3 -1211 25 -3 -1200 25 -3 -1203 25 -3 -1232 25 -3 -1225 25 -3 -1191 25 -3 -1204 25 -3 -1190 25 -3 -1235 25 -3 -1221 25 -3 -1217 25 -3 -1216 25 -3 -1209 25 -3 -1215 25 -3 -1192 25 -3 -1234 25 -3 -1201 25 -3 -1229 25 -3 -1210 25 -3 -1207 2 25 -3 -1239 25 -3 -1194 25 -3 -1205 0 25 -3 -1198 25 -3 -1208 25 -3 -1227 20. 0 25 -3 -1228 25 -3 -1237 25 -3 -1206 22. 0 25 -3 -1196 25 -3 -1226 25 -3 -1197 24. 0 25 -3 -1202 25 -3 -1222 25 -3 -1219 6 8 10 12 Cycle Number 14 16 18 20

Alpha Magnetic Spectrometer – 02 Current Status NCP 25 -3 AMS-02 Cell Score for Unit Grouping

Alpha Magnetic Spectrometer – 02 Current Status • Flight Spare and Flight Unit UPSs are currently in assembly and Test at Yardney. • Uncertified (partially) Flight Spare units will be used at ESTEC for TVT testing • FS units will be replaced with fully certified Flight units upon arrival at KSC. • FS units will be returned to Yardney to complete Flight certification • Delivery of two (2) FS units is expected Jan 15 and two (2) Flight units will be delivered to KSC by the end of Mar ‘ 10.

Alpha Magnetic Spectrometer – 02 Conclusion • Full details of the UPS are included in the Safety Data Package – Section 5. 12. 4. 2 Cryomagnet Control and Signal Conditioning (CCSC) – Section 5. 12. 4. 4 Cryomagnet Self Protection (CSP) – Section 5. 12. 4. 5 CSP Uninterruptible Power Source (UPS) – Hazard Report 13 –Battery Failure (Leakage/Rupture)