WHO IS STACO ENERGY PRODUCTS
ldquoYour Tailored Power Solutions Providerrdquo
Staco Energy Products is an 82 year old manufacturer ofvoltage control power quality and emergency lightingproducts Staco utilizes power quality studies to correctlydiagnose the customerrsquos problem then provides the correctsolution for the application backed by a nationwide 24x7service organization
bull Uninterruptible Power Suppliesbull Harmonic Mitigationbull Emergency Lighting (UL924 OUST)bull Frequency Converters
bull Power Factor Correctionbull Power ConditioningRegulationbull Variable TransformersTest Setsbull Power QualityLoad Studies
Broadcast Products
VOLTAGE REGULATORS amp POWER CONDITIONERS
MODULAR POWER CONDITIONING SYSTEM VOLTAGE REGULATION
wwwstacoenergycom
bull 120-600VAC up to 2000kVA
bull 1 or better Continuous Voltage Regulation
bull 97-99 Efficient bull Flexible Design
Staco in the Broadcast Market
UPS PRODUCT PORTFOLIO
UNINTERRUPTIBLE POWER SUPPLIESSINGLE-PHASE | DOUBLE-CONVERSION | ON-LINE UPS
UNISTAR V1 ndash 3 KVA
wwwstacoenergycom
bull 120120 VAC amp 230230VACbull Standard and LB Extended Models Availablebull Universal TowerRack Mount
UNINTERRUPTIBLE POWER SUPPLIESSINGLE-PHASE | DOUBLE-CONVERSION | ON-LINE UPS
UNISTAR VP6 amp 10 KVA
wwwstacoenergycom
bull 09 Power Factorbull Continuous Digital Signal
Processor Controlbull LCDLED Mimic Panelbull Parallelable
UNINTERRUPTIBLE POWER SUPPLIESSINGLE-PHASE | LINE INTERACTIVE | NETWORK CAPABLE
UNISTAR SB-NET800VA - 3 KVA
wwwstacoenergycom
bull Pure Sine Wave Outputbull Battery Backup amp Programmable Outletsbull Multiple communication optionsbull Universal TowerRack Mountbull Hot Swappable battery designbull Automatic Voltage Regulation (AVR) to correct
brownouts and overvoltages without using battery power
UNINTERRUPTIBLE POWER SUPPLIESTHREE-PHASE | DOUBLE-CONVERSION | PARALLELABLE | ON-LINE UPS
FIRSTLINE XD10 ndash 40 KVA
wwwstacoenergycom
bull 208VACbull Available in 208 amp 480 Voltagesbull Single Phase or Three Phase Output
Configurations Availablebull Offers 50degC rating without derating UPS output bull Input friendly low reflected harmonic content bull 5 Year Warranty
INDUSTRIAL UPS
UNINTERRUPTIBLE POWER SUPPLIESTHREE-PHASE | DOUBLE-CONVERSION | PARALLELABLE | ON-LINE UPS
FIRSTLINE PLT10 ndash 60 KVA
wwwstacoenergycom
bull 208VACbull Available in 208 amp 480 Voltagesbull Parallel up to 4 Unitsbull Compact amp Reliable
UNINTERRUPTIBLE POWER SUPPLIESTHREE-PHASE | DOUBLE-CONVERSION | PARALLELABLE | ON-LINE UPS
FIRSTLINE PE80 - 200 KVA
wwwstacoenergycom
bull 480VACbull Unity Power Factor bull gt 965 Efficiency bull Up to 99 Efficiency in ECO Mode bull Lower initial cost and heat outputbull 5060 Hz Switching Capability bull 4 Year Warranty
ENERGY EFFICIENT UPS
UNINTERRUPTIBLE POWER SUPPLIESTHREE-PHASE | DOUBLE-CONVERSION | PARALLELABLE | ON-LINE UPS
FIRSTLINE P65 - 500 KVA
wwwstacoenergycom
bull 480VACbull Available in 208 amp 480 Voltages bull Up to 98 Efficiency in ECO Mode bull Reliablebull Flexiblebull Compact
EMERGENCY LIGHTING INVERTERSPARALLELABLE | DOUBLE-CONVERSION | ON-LINE UPS
100 LED COMPATIBLE
UNISTAR SCLI924350W - 21 KW
wwwstacoenergycom
bull Advanced Circuitry and Battery Protection
bull High AC to AC Efficiency
ENERGY EFFICIENT UPS
EMERGENCY LIGHTING INVERTERSPARALLELABLE | DOUBLE-CONVERSION | ON-LINE UPS
100 LED COMPATIBLE
FIRSTLINE PLT 924 9 - 54 KW
wwwstacoenergycom
bull Advanced Circuitry and Battery Protection bull High AC to AC Efficiency bull User-Friendly Mimic Panel bull Available in 208 amp 480 Voltages
THREE-PHASE
EMERGENCY LIGHTING INVERTERSPARALLELABLE | DOUBLE-CONVERSION | ON-LINE UPS
100 LED COMPATIBLE
FIRSTLINE P 924 585 - 225 KW
wwwstacoenergycom
bull Advanced Circuitry and Battery Protectionbull Cost Effective High Reliability Design bull Supports all connected lighting loads bull Monitoring and Communications bull Available in 208 amp 480 Voltages bull Customizable Battery Times
THREE-PHASE
Are Lithium Ion Batteries Ready for the Broadcast Market
Chuck Barry ndash Staco Energy Products
Agenda
Introduction
1 Current Lead Acid Battery Solutions
2 Lithium-Ion Batteries
3 Case Study
16
Saft proprietary information ndash Confidential17
CURRENT LEAD-ACID SOLUTIONS1
SBE Chapter Meeting ndash September 19th 2018
Why are batteries important for critical facilities
18
ndash Batteries play a critical role in each phase of power stability and they increase ability to operate autonomously
ndash Critical Loadsbull Loss of Revenue Uptime Business Ability Customer Satisfaction
Utility
Gen-set
UPS Critical Loads
3 Switchgear 1 Short Duration backup
2 Engine Starting
ldquoThe Weakest Link of Any Continuous Power System is the Lead Acid Batteryrdquo
19 SBE Chapter Meeting ndash September 19th 2018
Definitions ndash Battery terms
21
Ah ndash Ampere-hours
bull Batteryrsquos rating of capacity
bull 1 amp for 1 hour = 1Ah
Rated capacity of a battery
bull Amps available at a fixed time to a fixed end of discharge voltage at a standard temperature
bull Ni-Cd batteries rated capacity is measured at (per IEC60623)
o 5 hours to 100Volts per cell (VotlsCell) at 77degF at fully charged state Example 235Ah = 47A for 5 Hours
bull Lead-Acid Batteries rated at the 8hr rate to 175VPC 77F
Power = Instantaneous (V x I = Watts)
Energy = Power x Time (Watt-hours)
SBE Chapter Meeting ndash September 19th 2018
Standard UPS Lead Acid Battery Designs
1 10 Year Valve-Regulated (VRLA) Batteries
2 20 Year Sealed VRLA Batteries
3 20 Year Wet Cell Batteries
SBE Chapter Meeting ndash September 19th 2018 23
Battery Technologies
ndash10 Year ldquoVRLArdquo
bull Aka ldquoMaintenance Freerdquo ldquoGel Cellrdquo AGM
bull 3 to 5 year life on most UPSrsquos
bull Low cost most prevalent
bull Parallel Strings and Battery Monitoring System = Good Idea
Battery Technologiesndash20 Year Sealed (Stackable)
bull 9 to 12 year life (depending on number of outages environment)
bull Fails in ldquoshortedrdquo or open position
bull About 2x cost of 10 Year VRLA
Battery Technologiesndash 20 Year ldquoWetrdquo Cell
bull 15 to 20 year life
bull Very reliable
bull High maintenance large footprint eye wash stationhellip
bull About 3x cost of 10 Year VRLA
Battery Regulations Becoming Stricter
1 California Fire Code 2007ldquoIFC 6083 Thermal runaway VRLA battery systems shall be provided with a listed device or other approved method to preclude detect and control thermal runawayrdquo
2 This section applies to VRLA battery systems with an electrolyte content greater than 50-gallons
3 Spill containment dedicated rooms for VRLA
SBE Chapter Meeting ndash September 19th 2018 27
Lead Acid Battery
ndash Widely Adopted
ndash A Known Entity (good or bad)
ndash Almost 100 recyclable
ndash Scrap Value for Lead
28
Benefits of Lead-Acid
ndash Unpredictable Performance
ndash Lack of Affordable Accurate Battery Monitoring System
ndash Temperature-Sensitive
ndash Slow Recharge Time
ndash Heavy Cumbersome to Replace
ndash Requires Frequent Maintenance
Cons of Lead-Acid
SBE Chapter Meeting ndash September 19th 2018
Typical Lead Acid Battery Construction
29
Exploded View
2 VoltsCell Nominal
SBE Chapter Meeting ndash September 19th 2018
30
Lithium Battery Construction (Cylindrical Cell vs Pouch Cell)
Cylindrical Cells
IFR26650
IFR18650
Battery Module Design
Pouch Cells
Cathode Powder
Nominal Cell Voltage 23V - 38V (Based on cathode chemistry)
Copyright 2006 Toshiba Corporation
Flywheel Energy Storage System
Saft proprietary information ndash Confidential35
LI-ION BATTERIES2
SBE Chapter Meeting ndash September 19th 2018
Battery BasicsHistory
ndash 1991 Sony introduced the first Li-ion cell (18650 format)
ndash 1992 Saft introduced its commercially available Li-ion cell
ndash 1976 Exxon researcher ndash Whittingham described lithium-ion concept in Science publication entitled ldquoElectrical Energy Storage and Intercalation Chemistryrdquo
36
The future of batteries ndash Lithium-ion
1792 1802 1836 1859 1868 1888 1899 1901 1932 1947 1960 1970 1990
SBE Chapter Meeting ndash September 19th 2018
Overview of Battery Types
37
Global Market of Batteries
SBE Chapter Meeting ndash September 19th 2018
Li-ion Many Flavors
39
ndash Currently Used Cathodesbull LiCoO2 = LCO ndash Cell Phones Tablets Camerasbull LiNiCoAlO2 = NCA ndash Industrial EVrsquos bull LiNiMnCoO2 = NMC ndash E-bikes Medical Devices EVrsquosbull LiMn2O4 = LMO ndash Power Tools Medical Devicesbull LiFePO4 = LFP ndash Portable and Stationary high load
applicationsndash Currently Used Anodes
bull Graphite = Carbon (C)ndash Emerging Anodes
bull Li4Ti5O12 = Lithium Titanate Oxide (LTO)
bull Alloy anodes = Si and Sn based (Silicon and Tin)
bull Mainly improving safety
195 Ahkg145 Ahkg125 Ahkg
162 Ahkg
300
320
340
360
380
400
420
440
000 5000 10000 15000 20000 25000
CAPACITY (Ahkg)
VO
LTA
GE
(V)
LiNiO2
LiCoO2
LiMn2O4
LiFePO4
SBE Chapter Meeting ndash September 19th 2018
Major Lithium Ion Chemistries
Tradeoffs among the four principal lithium ion battery technologies
The furthered colored shape extends along a given axis the better the performance along that dimension
Source Battcon Paper JMcDowall
40 SBE Chapter Meeting ndash September 19th 2018
Cell Formats
41
ndash Cylindricalbull Provides best support for expansion and contraction of
electrodes during cycling
bull Suitable for higher capacity levels per cell
bull Less factory handling required
ndash Prismaticbull Better energy density with thermal barriers
ndash Pouchbull Difficult to seal for long life
ndash Capacities determined by geometry (up to 80Ah per cell)
ndash Varying the winding process results in different battery performance (Energy vs High Power)
SBE Chapter Meeting ndash September 19th 2018
From Cells to Modules
42
Lithium-Ion Modulesndash 12V 24V 36V 48V common Voltages- Packs of Lithium-ion cells- Typically contains
- Li-ion Cells
- Bus Bars
- Electronics
- Monitoring
- Communications
SBE Chapter Meeting ndash September 19th 2018
Battery Management System
Ensures safe operation and Real-Time Status of the batteryIt also contains battery protection and safety devices with CircuitBreakers andor contactors to control string connectivity which keeps thebattery in optimal operating condition
During operation the BMS (battery management system) offers real-timeinformation from the battery through various protocolcommunication inindustrial format
43 SBE Chapter Meeting ndash September 19th 2018
VCellMin
VCellMax
Tmax
Tmin
Current for Discharge
Recharge Current
SOH
SOC
Ibat
Vbat
Warnings
Faults
Battery mode
MBMM watchdog
of BMM in parallel
of BMM connected
of BMM disconnected
Remaining capacity
Remaining energy
To full charge energy
VMD
VMR
SBE Chapter Meeting ndash September 19th 2018 44
(Various protocols)
Power
Volta
geLi-Ion Systems Scalability
Example profile 500kW for 5 min at 480Vnom
4 strings at 506V consisting of 11xmodules
45 SBE Chapter Meeting ndash September 19th 2018
BMM
Flexrsquoion 46 PFe
506 Vnom
Intelli-Connectreg
Flexrsquoion 46 PFe
Flexrsquoion 46 PFe
Flexrsquoion 46 PFe
Flexrsquoion 46 PFe
Flexrsquoion 46 PFe
Flexrsquoion 46 PFe
Flexrsquoion 46 PFe
Flexrsquoion 46 PFe
Flexrsquoion 46 PFe
Flexrsquoion 46 PFe
BMM
Flexrsquoion 46 PFe
506 Vnom
Intelli-Connectreg
Flexrsquoion 46 PFe
Flexrsquoion 46 PFe
Flexrsquoion 46 PFe
Flexrsquoion 46 PFe
Flexrsquoion 46 PFe
Flexrsquoion 46 PFe
Flexrsquoion 46 PFe
Flexrsquoion 46 PFe
Flexrsquoion 46 PFe
Flexrsquoion 46 PFe
BMM
Flexrsquoion 46 PFe
506 Vnom
Intelli-Connectreg
Flexrsquoion 46 PFe
Flexrsquoion 46 PFe
Flexrsquoion 46 PFe
Flexrsquoion 46 PFe
Flexrsquoion 46 PFe
Flexrsquoion 46 PFe
Flexrsquoion 46 PFe
Flexrsquoion 46 PFe
Flexrsquoion 46 PFe
Flexrsquoion 46 PFe
BMM
Flexrsquoion 46 PFe
506 Vnom
Intelli-Connectreg
MBMM wPLC
Flexrsquoion 46 PFe
Flexrsquoion 46 PFe
Flexrsquoion 46 PFe
Flexrsquoion 46 PFe
Flexrsquoion 46 PFe
Flexrsquoion 46 PFe
Flexrsquoion 46 PFe
Flexrsquoion 46 PFe
Flexrsquoion 46 PFe
Flexrsquoion 46 PFe
Related Standards for Emerging Technologies
46
ndash IEEE Std 1679-2010bull IEEE Recommended Practice for the Characterization and Evaluation of Emerging Energy
Storage Technologies in Stationary Applications
bull Recommended information for an objective evaluation of an emerging energy storage device or system for any stationary application
bull The storage medium may be electrochemical (eg batteries) kinetic (eg flywheels) electrostatic (eg electric double-layer capacitors) thermal or some other medium
- Devices recharged by non-electrical means such as fuel cells are beyond the scope of this document
- The document provides a common basis for the expression of performance characteristics and the treatment of life-testing data
ndash IEEE Std 16791 ndash draft format
ndash UL1642 UL1778 UL1973 UL9540a
ndash NFPA 1 NFPA 855 IFC
SBE Chapter Meeting ndash September 19th 2018
SBE Chapter Meeting ndash September 19th 2018 47
C100
C10
C
10C
100C
1
10
100
1 000
10 000
100 000
0 20 40 60 80 100 120 140 160 180 200
Energy [Whkg]
Pow
er [W
kg]
Super capacitor
Ni-MH
Ni-Cd
High Power Li-ion (VLP)
Medium Power Li-ion (VLM)
High energy Li-ion (VLE)
Very-high power Li-ion (VLV)
AgO-Zn
Ultra-high power (VLU)
Li-Ion Flexibility
48
Ragone diagram
Standard Lead-Acid
SBE Chapter Meeting ndash September 19th 2018