DOE – BCS TSD comme

BCS TSD comme

December 6, 2010

Wayne Morris AHAM

Larry Albert PTI
CSL s’

• For Appliances, each CSL represen

l l ft h l level of technology

– CSL 0 – “bad” NiCd– CSL 1 – “good” NiCd

• Better conversion efficiency, lower standb• B i etter maintenance power management 

• Still limited by inefficiency of chemistry itse

– CSL 2 – Li-ion

• Cell has no maintenance power and bette

acceptance
CSL s’

• Appliances have both NiCd and Li-ion in 

market

– NiCd still major proportion 

• C i 75% f t l Comprises 75% of pro tools

• Over 90% of small appliances• No market driver other than retailers

– Mi i l tilit d t Minimal utility advantage 

• For non-appliances (electronics), most ar• These share the same Product Classes These share the same Product Classes• We believe that there are some negative 

conseq g uences resulting from this combin
Example - Product Class 3 – 23,116K total shi

2

0

08 CSL (I 

C SL 1 CSL2 

A

pp1icadon Ship

m

e

nts 

(10001' ;) jIl') 

1 

P

orta

ble' Playe.rs 

7

J

40 

6,4 

3,6 0 

2 

C :.':lJ 1f'li!c .1 Ii I!...U;; . .l :':> 

4.2

06 (l ,8 0 

0.1 

3 

Tloy Ride-On \ l e

hicl es 3 

1

1.: 5.5 

_,0 

4 

R

C

Toys 

2,3 1.1 

0,4 

- DIY 

P

o' el' Too]:; 1 

53 10.7 

5,4 

_

J 

(E x tell

ul1) 

6 

H

a

ndh

e]d '\ 1,3,7 

3

8.8 

2 1.:" ') -, '-; 

7 DIY 

P

ov -er Too]:; 

2

0.0 ] 1. 1 1 ,] (Illte21'al) 

8 

Stick 

V 'a CUl1JllS 

8

63 

3

8.S 1 1. ... _.2 

9 

Aim- MaUres . Ptnnp 250 ... ,3 1.1 

0,4 

10 Dniv

er .al Battery 240 28.1 

5.4 1,6 

C

h

argers. 

11 

WiJreles:;.. Sp

e

a'kel's ' 6 

2 ,,3 1.1 

0,4 

12 R eMS (H

obby 125 J' ,. 1.1 

0,4 

G

um.d

e) -",) 

13 Blenders 6] 

2,3 1.1 

0,4 

14 Mixers 

58 J: .3 1.1 

0,4 

l I?iglt

ed 

A

Vf'ra ge 10.0 

5.4 LO 
Example – PC 3

• Roughly half the shipments are from DVD 

players and camcorders players and camcorders

– Virtually all Li-ion – low UEC

• These should only be considered in CSL 2

– But these are included in CSL 0 and CSL 1 

• Distorts CSL 1 because this mixes good NiCd App

with Li with Li

-ion consumer electronics ion consumer electronics

• No energy savings in going to CSL 1 for these prod

– But shipments of these products are included – G d NiCd li Goo

d NiCd appliances compare agai t Li ns -ion cons

electronics

– Li-ion based consumer electronics should be 

excl d d f CSL 1 lu

d

e

d

from CSL

1
Scaling

• Scaling proposed at public meeting 

i th li bilit f CSL improves the applicability of CSL ov

wide range of power levels

– Appropriate for Eb levels higher the rep

• High correlation of data to regression 

– I it f l l l Inappropriate for lower levels

• Effect of fixed losses dominate at lower lev• Evidenced by lower correlation Evidenced by lower correlation

• Propose “break” at rep. unit for lowe
Original Regression Analys

Area of 

Concern

24-hour Energy vs. Battery Energy 

Product Classes 2 - 6 

2,500.00 ,---------------------------------

200.00 600 .00 800 .00 1,000.00 

B

att

ery 

En

ergy (Wh) 
Proposed – “break” at representative unit 

40 .00 

- PU 

35.00 

_ PC4 

30 .00 

U

nit En

ergy Con

sumption 

v

s. B

att

ery 

En

ergy 

Pro

d

uct 

Classes 

2, 3 & 4 

'" 

B

att

ery 

E

n

ergy (Wh) 

y

= 1.4364XY 

y 0 .9655)(+ 

Kl 

y ' 0 .39.2.2 )(+ K 
LCC – benefit overstateme

benefit overstateme

Usage and life in PC 3&4

• Usage in PC 3&4 – power tools not accur

– Pro - is: 2.70 should: 1.

• Why: 2 charges/ workday, 10 charges/7 days= 1.4

– DIY detachable - is: 0.64 should: 0.

• Why: 2 charges/week 2charges/7days = 0 29 Why: 2 charges/week, 2charges/7days = 0.29

• Life – some lifespans are overstated

– Wearout based on usage Wearout based on usage – at old usages life 

at old usages, life 

curtailed

– Market life at “normal” usage is no more than 
LCC – benefit overstateme

U fil i PC 2 Usage profiles in PC

2

• Usage of MADB appliances in PC2 is 

dramatically distorted by inclusion of con

electronics in PC electronics in PC

– Currently 0.55 charges/day

• Most MADB appliances see only 

 a few c

a month (0.1 charges/day at the most)

• Many electronics in the product class are 

ch d l ti k harge

d several times a wee

k

• Consider segregating MADB’s from non-

for this PC for this PC
LCC – cost understatemen

Cost of conversion to CSL 2 – Lith

• Holding Safety and utility constant 

– Charging Safety –

• analy y sis may not have considered uniform safety a

CSL 2 products and associated costs

• UL 2575 should correct this in time

– Drives redundant, cell-by-cell monitoring and contro

• Energy savings should not be an incentive to lowe

Energy savings should not be an incentive to lowe

– Utility

• Same performance: use of power cells rather than 

cells -

– Eb lower for power cells – more cells for same capa

• Same Cycle life – requires discharge control 

– Analysis does not consider cost impact of discharge 
Safety - Charge contro

Charge contro

• Specified in UL2575 Specified in UL2575

– While standard is not design proscriptiv

state of the art usually requires: state of the art usually requires:

• Independent, redundant control• Cell-by-cell monitoring

• Some manufacturers follow this alre

– Unclear if cost analysis was sensitive t

Unclear if cost analysis was sensitive t

differences between products
Utility - Cycle Life Cycle Life

• Pro tool users expect long cycle life Pro tool users expect long cycle life

• Typically 800 – 1000 cycles from NiC

• Li-i ith t di h t l 250 ion without discharge control: 250

• Equivalent cycle life can be achieved 

discharge control

– Requires circuitry on load side– Not included in analysis as focus was 

charging
Typical Ni-Cd System

N di h l No disc

harge control

MOT
10A Cycle Life test 18V NiCd with 6V cut-off

2.5 ,--_______________________

" 515 • " " 

5 Channel problem at 

, 

startup 

< I • 

05 

0 

0 200 400 600 

800 

CYCLE NUMBER 

1·

'

1.

'2 

"I 
18V 1.5Ahr Pack 

10A life with 5V cutoff 
Li-ion System

Electronic Discharge control turns off Electronic Discharge control turns off 

cell voltage – extends life

Hi current 

solid state 

device

Control MOT

Electronics
10A Cycle Life – 18V Li-ion with tool cut-off

3 

2.5 

-

• 

2 

• 

05 

o 

o I 00 200 

300 

• 

• 

400 

-

500 

CYCLE NUMBER 

& 

600 

It IP100 223.566Ah I IP1 00 223·570 Ah I 

-

• • • • - 

• 

700 

800 
Multi-voltage Chargers voltage Chargers

• Common in power tools Common in power tools

• Supported in TP

• H t h dl i St d d ? How to handle in Standard ?

– Especially when voltage range crosses 

b di oun aries

• We made suggestions in supplemen

comments 

– Scaling helps