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Section 1 – FMA LiPo Systems July 2005
This document is a work in progress. Latest revision:
Distributor for Kokam Lithium Polymer Cells 5716A Series/parallel connected packs How modular packs are manufactured Building a modular Kokam Li
Po “Super Pack” Balance Pro and Scorpion for the Two Cell
Packs BalancePro Application Examples Cell Pro Balancing
System (Coming mid-2005) What
goes in to design of FMA cells and packs Lithium Polymer batteries are a new generation
portable electric power source. They
are different from other batteries used for RC. In 1959, when Fred Marks became involved in RC, only carbon zinc
batteries were available to RC. Lead-acid batteries were used with a converter
to generate 180V for the tubes used in transmitters, but all else was done
with carbon zinc batteries. The first time anything other than carbon zinc
was used in RC was when the great Walt Good came to a meet in the early 1960s
with some extraordinary cells he had obtained from Johns Hopkins Applied Physics
Lab where he worked. The small Silver
Cadmium cells were of great interest, but far out of reach of the average
modeler. Surplus wet Nickel Cadmium cells began to appear
from the Nike missile program (they had to be replaced periodically) and found
good use as glow plug lighters. In
1962, Fred obtained his first NiCd button cells from the ABC Battery Company.
In due time, cylindrical NiCd cells came on the market with General
Electric and Gulton as the first mass producers.
It wasn’t long until the Japanese acquired the technology and rapidly
drove down the price of NiCds. NiCd technology has seen steady if slow growth
over the ensuing 40 years. NiMH became
a new technology only in the early nineties and has grown a bit faster than
NiCd. The primary attraction for NiMH
was lighter weight and better environmental characteristics. About 1980, Lithium Ion (Li Ion) cells began
to be used for light duty, lightweight applications. Li Ion cells began to be modified for RC from
retired cell phones and surplus sources only about four years ago. Li Ion cells can tolerate only modest discharge
rates but found some use in powering electric airplanes. Lithium Polymer (Li Po) cells began to see use
in 2001 in a small way. The “small
way” was primarily in the form of the Kokam Engineering Co., Ltd. 145 mAh
cell. A brief history of the development of Li Po
technology follows: Early in 1980, Motorola and Sony decided to apply lithium
ion technology to the mobile phone to reduce weight and improve energy density,
even though there were safety issues as there are now. They developed a safety module, the so-called
PCM (protection circuit module). Up
to now there have been few accidents from Li Ion. Meanwhile, the Bellcore Lab in San Diego announced
that they had developed the lithium polymer battery to increase energy density
and safety by using a plastic pouch packaging/stacking method (different than
Kokam’s system) using an ion conductive separator named PVDF (polyvinyldifluoride)
which has good binding characteristics at 100° C. Sony, Toshiba, Panasonic, Samsung, Saft, Varta, Kokam, too, evaluated Bellcore technology as an alternative,
but realized that it is not a practical technology for commercialization due
to the processing difficulty. Thus, Kokam decided to develop new technology
with assistance from the Korean government agency named KIST (Korea Institute
of Science and Technology). A new system
was invented system that permits Kokam to make the battery easier with significant
improvement over Li Ion and providing better safety. Kokam acquired patents world - wide and started
to design the full process and equipment suitable for mass producing Kokam cells. German and Chinese companies licensed Kokam
technologies. With the Kokam technology, we have successfully created
the first 20C discharge rate commercial Li Po battery In
June 2002, FMA, Inc. and Kokam Engineering Co., Ltd. signed an agreement for
FMA to serve as the agent for Kokam in North and At this time, FMA Direct has been actively promoting the use of Li Po cells and packs for three years with gratifying results. In the past three years, Li Po technology has advanced farther than NiCd technology advanced in nearly forty years. In 2002, the standard Kokam cell was capable of continuous operation at three to four times the multiple of capacity (3 to 4C) with 5C as the upper limit. In the past two years, FMA/Kokam has introduced, and FMA now has on the market, cells capable of sustaining up to 20C with loss of but a few percent capacity and with the capability to withstand pulses of current of < one second duration at up to 40C . Detailed performance data are available as Data Sheets in the FMA Li Po Compendium. During 2004, FMA/Kokam reduced Li Po cost by one-third.
From the beginning of its involvement with Li Po technology, FMA has anticipated the need for a system of Li Po components. Several factors influenced this approach: ·
Li Po batteries require different chargers than other
chemistries. ·
The 3.7V cell output requires that packs and ESCs must
be designed and sized differently. ·
It was desired to make it as easy as possible for the
NiCd/NiMH user to make the transition to Li Po. ·
Li Po cells have unique safety and operating rules. · Over the past four years, FMA has addressed and optimized all aspects of successful use of Li Po batteries. By providing all the elements needed (below), FMA hopes that Li Po will continue the rapid rate of acceptance and success seen to date. We truly believe that glow engine power will be largely replaced by Li Po power over the next few years. See all products needed to make you
successful with Li Po batteries at www.fmadirect.com Balance charge packs (
Scorpion, BalancePro, CellPro ) Standard packs Car pack with built in cut -
off Scorpion car charger and pack
system Charge protection modules for use with any approved
Li Po charger protect against over voltage for 1 to 6S Discharge protection modules protect against unde
voltage for 1 to 6S. Can be daisy
chained in sets of six SKYVOLT 6S Cell balance charger maintains perfect
match in cells for packs up to 6S BalancePro
cell balancing charger for 2S.
Can charge parallel 2S packs up to 10 amps Economical 1S and 2S chargers for the smaller Li Pos LIPO 502:
Charge up to 4S packs with auto cell count that never misses AVC 1 AIR:
Salvage any ESC for use with Li Po packs
Getting interference from high current power systems? 4CH OPTOISOLATOR stops that. Need to drive big servos at up to 10 amps? 10 AMP REGULATOR Connector modules permit parallel or series
connection for maximum flexibility Microameter inserts in battery line to ESC so you
really know what the current drain is. No more guessing! Combine our on-board microammeter with our on-board recorder to measure up to 100
amps Servos in many sizes including the top digital servo
made All FMA receivers feature
dual conversion and Digital Signal Recognition From the tiniest to the BIGGEST,
FMA
Using Li Po cells was challenging for early users, and only the most persistent did what it took to use them. The first cells had only bare tabs that were thin and fragile, and one tab was aluminum that required special solder and techniques. The first improvement was to weld a nickel tab to the aluminum tab that, in turn, could be soldered. The next improvement was incorporating a small pc terminal board on each cell that made soldering as easy as for any cell with terminal lugs. Such cells are available still for certified pack builders who purchase in quantity. *
Some assemblers want to design custom modules using individual cells with the terminal blocks. This approach starts with the standard Kokam cells, identified by the “T” suffix; e.g., 145T.
In a series connected pack, the negative terminal of one cell connects to the positive terminal of the next cell. Output voltage is taken from the first and last cells in the chain. In this example, four cells are connected in series. This is called a 4s pack.
A series connected pack is used to supply more voltage than a single cell. The nominal output voltage from the example 4s pack is 4 x 3.7V = 14.8V.
In a parallel - connected pack, all the cells’ positive terminals are connected, and all the cells’ negative terminals are connected. In this example, four cells are connected in parallel. This is called a 4p pack.
A parallel - connected pack is used
to supply more current than a single cell.
The output capacity from the example 4p pack is four times the
individual cell capacity. If the pack
were made with KOK145 (145mAh capacity) cells, the pack’s capacity would be
Series/parallel connected packs
The drawing to the right shows a 2s4p pack. It starts with four pairs of cells connected in series. Those four pairs are then connected in parallel. The pack’s output voltage would be 2 x 3.7V = 7.4V. It’s capacity would be four times the capacity of the individual cells. The drawing below shows a 4s2p
pack. It starts with two sets of four
cells connected in series. Those two
sets are then connected in parallel. The
pack’s output voltage would be
How modular packs are manufactured Kokam modular packs are assembled as shown below. The pc boards work extremely well and stiffen up the end of the pack. The pc board and, thus, the cell terminals are accessible. If heat shrink has covered a connection, it can be accessed with a sharp tool or by careful removal of a small square of heat shrink material.
NOTE: ALL FMA/KOKAM PACKS HAVE
BEEN CONSTRUCTED AS SHOWN ABOVE UNTIL JULY 2005. STARTING IN JUNE 2005 UNITIZED PACKS ARE BEING
INTRODUCED AS ILLUSTRATED IN SECTIONS THAT FOLLOW. Two key types of components provide a foundation for the system approach to Li Po power: n Preassembled Li Po packs with attached wires and plugs. n Connector modules that enable packs to be connected in almost any configuration. With the Li Po pack system, users
can quickly and easily build custom power systems with increased voltage,
increased capacity or both. NOTE: It is the user’s choice to use FMA modular packs for
flexibility or to use FMA unitized packs for simplicity. The photo below shows four preassembled packs plugged into a Parallel Connector Module. The Module is then attached to an ESC for powering an RC model.
Connector Module Wires from ESC ESC Wires preattached to packs Four preassembled packs
Connector Modules are available in three sizes, with corresponding connectors, to handle a variety of power requirements: n For high power applications:
n For moderate power applications:
n For low power applications:
The Connector Modules are made in series and parallel configurations with five connectors. Lines of tiny holes allow you to cut or snap off sections you don’t need (removed sections are fully functional). Modules can be cascaded; that is, several modules can be plugged into another module, which can be plugged into another module, and so on. These examples show how various configurations can be built very quickly: n Needed: a 2s3p pack (three parallel-connected packs of 2 cells in series). Solution: plug three preassembled 2s packs into a Parallel Connector Module. n Needed: a 4s3p pack (three parallel-connected packs of 4 cells in series). Solution: plug two 2s packs into a Series Module; create two more assemblies just like it; plug the three assemblies into a Parallel Module. Here’s a real-life example: Greg Covey built a 3s4p pack for his Wipa
Firecat using the Kokam USA Connector Modules.
Says Greg: “The 3s4p Kokam
1200HC pack tripled my flight time while being 5oz lighter than the 10-cell
CP1700 NiCd pack.” Four 3s packs plug
into a Parallel Module to make the 3s4p pack.
You can even change pack configurations between flights. The CP1700 pack is 1700 mAh and weighs 19
oz. The total capacity of the Li Po pack
is 4800 mAh and weight is 14 oz. The
NiCd provides about 7 minutes flight time and the Li Po pack delivers about 21
minutes. Building a modular Kokam Li Po “Super Pack”
This section describes one way to create a 4s5p “Super Pack” of Kokam 1500HD cells that provides awesome power and duration! The 7500mAh capacity pack can deliver 50 to 60amps continuous and up to 75amps peak in short bursts. A 2s5p or 3s5p configuration would be a simple plug-together assembly, as explained earlier in “The Li Po modular pack connection system.” The 4s5p configuration, on the other hand, requires a little re-wiring that can be done safely without disturbing the factory assembled pack. One application for such a pack is to power the AXI 4120 External Rotor brushless motor... for very long flight times. Put two of these packs in series and you can power an AXI 5330 or Hacker B50XL motor.
1. Start with two Kokam 2-cell 1500HD packs, in the same orientation, with the Kokam labels facing you.
2. Remove the labels securing the output leads (see above). 3. Stick the two packs together: a. Place a strip of 1" wide servo tape over the label on one pack (see below). We’ll call this the rear pack.
b. Lift the front pack, align it over the rear pack, and press it into position. 4. With the front pack toward you, cut three wires as shown below. 5. Remove the Deans connector and its leads from the front pack. 6. Make the first solder connection, which connects the two packs: a. Slide a piece of heat-shrink tubing over the short red wire on the rear pack. b. Solder the black wire on the front pack to the short red wire on the rear pack, as shown here.
7. Make the second solder connection, which completes the circuit to the connector: a. Slide a piece of heat-shrink tubing onto the red wire on the rear pack. b. Solder the red wire on the front pack to the long red wire on the rear pack, as shown here:
8. You now have a 4s pack. Check the voltage at the connector; it should be about 14.8V if the cells are charged. 9. If the voltage is correct, slide the heat-shrink tubings over your solder connections and shrink them down. 10. Cover the pack with a piece of large heat-shrink tubing. or Wrap the pack with tape (for example, filament tape or packing tape). 11. Repeat steps 1 through 10 to build a total of five packs. 12. Plug the packs into a Kokam CMP-HC 5 (parallel) Connector Module. 13. Wrap duct tape around the Connector Module to prevent it from shorting. 14. You can tape the packs together. However, it is often advantageous to keep the packs separate so they can be inserted and arranged in the fuselage.
CAUTION: The modular pack is a viable, safe way to use Li Po cells. It is very important to arrange access to the terminals of each cell so that cell balance can be checked occasionally using a Digital Voltmeter (DVM). A “Unitized Pack” consists of cells interconnected permanently in series and parallel to fill a given application in the lightest, most reliable configuration. Not until proper charge and discharge control modules were developed by FMA has it been deemed safe to operate unitized packs of Li Po cells because there was no access to cell voltage for control of charge and discharge of an individual cell as there is with a modular pack. In May 2005, for the first time, FMA Direct has introduced the Scorpion race - car pack and charger that control charge and discharge of individual cells in a pack. The control system is described later in this manual. The concept for the unitized pack itself is straightforward. A multi-wire cable brings out not only the end terminals to power the ESC but also a sense wire from each individual cell in a pack. By stacking Li Po cells and interconnecting them with a pc board, a pack of any configuration can be designed. However, this is a fixed pack, not as flexible or modular. It has fewer connectors, perhaps even none (if you wire directly to the ESC) or a single female connector. The concept of control is equally simple, although implementation is very sophisticated. That is, the voltage for each cell is monitored continuously during charge and during discharge. No cell is ever allowed to exceed 4.2V during charge. No cell is ever permitted to go below 3 V during discharge. The pack illustrated below is a 6AH 3S configuration in which three 2AH cells per “cell” are connected in series using gold plated copper bar. The unitized package is convenient. However, some models either have a battery bay already fixed or may require a slim-line, stick pack. The square pack offers easy access to the cell terminals, but a stick pack can be stuffed in a bit more easily. A 1s, 2s, 3s, 4s, 5s, 6s, etc pack can be formed and as many parallel as desired formed using a pc board. Because Li Po packs and the new brushless motors are so lightweight, it is generally necessary to get the pack mounted as far forward as possible in the model
. 1. The SKYVOLT system is designed to power aircraft demanding from 250 watts to over 10Kw. The concept is virtually unlimited. FMA presently has packs up to 31AH 7S operating military UAVs. A full scale German sailplane is powered by a 200 AH Kokam pack. Methods for sizing a propulsion system are discussed in a later section. SKYVOLT is a total system design, not just cells/packs.
3. UltraRC 2-meter FAI Pattern Plane
The new SKYVOLT packs were used in an UltraRC Icepoint e-conversion. The 4-cell 3.2AH Kokam packs
are pre-wired to a special connector so that each cell can be monitored during
charge and discharge for optimal safety, longevity, and investment security.
The SKYVOLT packs are used in conjunction with Protection Modules, one for
charge and one for discharge. This new approach in Lithium cell safety and
protection will be available around August/September 2005 from FMA Direct.
Here is the SKYVOLT system installed
in the Icepoint. The packs are mounted as before but they now connect to the
Cell Pro 6s Discharge Protection Module (DPM) instead of directly to the ESC.
The ESC control line is then routed through the DPM to control the
motor shutoff. Since everything is
mounted with Velcro, I can easily swap back to my non-SKYVOLT packs and continue
flying. The ESC simply reconnects as normal to the receiver. 4. Fun World
EP 3D Plane The Fun World EP 50"
3D plane from World Models was recently retrofitted with a new 3-cell SKYVOLT
3.2AH pack and Cell Pro Discharge Protection Module (DPM). The SKYVOLT pack provides a 20C discharge rate
and 3C (20 minute) charge rate using the highest technology Lithium cell protection
ever seen in the R/C market. The SKYVOLT
cell balancing charger (available in August/September 2005) and discharge
protection circuitry combined with Kokam SHD type cells deliver the highest
rates ever seen in R/C to provide more power and more flying time than any
other Lithium technology system. Balance Pro and Scorpion for the Two Cell Packs 1. Balance Pro is a logical spin-off from the popular Scorpion electric car racing system. Scorpion was used to develop the cell balance concept and has been in development for two years. Balance Pro is the airplane version that applies to every two-cell pack in use today. The function and use is the same as for SKYVOLT.
2. The accessory items
for Balance Pro are simpler than for
SKYVOLT. The charger is for two cells.
The AVC 1 AIR can be used as the cut-off although any of our FMA speed
controls can be set to use as the cut-off.
Cell unbalance is less likely with two cells. Having the two cells
charged to exact balance each charge suffices.
Tthere is no need for a balancing cut-off device except for AVC 1 AIR.
FMA’s Balance Pro 2s Charger is
part of a revolutionary new Li Po battery and charge system for R/C aircraft.
In essence, it is very similar to the 2s Scorpion system for R/C cars.
With a variable charge rate of 0.5amps to 10amps, the charger brings Balance
Pro 2s packs to 90% of capacity in as little as 20 minutes.
FMA’s Safe Charge Connector is a key part of the system.
The connector enables the charger to monitor individual cells and independently
charge each cell to its optimum level. Charge protection dramatically improves pack
performance, pack life and charging safety.
All Balance Pro packs from FMA come standard with the Safe Charge Connector.
The Balance Pro charger may be used to charge only FMA's new Balance
Pro 2S (7.4V) Li BalancePro Application Examples 1. Space
Scooter Hop-up with BalancePro As a performance hop-up, the new
BalancePro technology from FMA Direct will super- charge the Multiplex Space Scooter
by providing more power, less flying weight, and tripling the flight time!
2.
Multiplex Easystar Hop - up with BalancePro The Multiplex Easystar from Hobby Lobby was easily upgraded to double the flight time over the stock 7-cell, 1100mAh NiMH pack using the BalancePro 2-cell, 2AH Lithium pack. The BalancePro provided slightly greater power than the stock pack and fit perfectly into the Easystar nose. The battery pack was held in place with a foam wedge. Cell Pro Balancing System (Coming mid-2005) 1. Cell Pro has been developed so that any FMA/Kokam pack in future, or retrofitted to packs sold the past three years, can benefit from cell balance control. 2. The Cell Pro pack can be any pack distributed by FMA/Kokam and equipped with the CellPro connector. 3. The system will include packs up to 4S. 4. Customer service for modification of FMA packs to the Cell Pro connector system may be offered at a modest charge depending on interest. 5. The block diagram and flow chart for Cell Pro closely parallels SKYVOLT and is not repeated here. The pack is defined by the CellPro connector. The RUN connector may be any of the standard FMA connectors or the connector of your choice. The CellPro connectors are very small and light - weight.
This beautiful giant scale model is powered by Li Po packs. It was entered in the 2003 U.S. Scale Masters meet and earned first place in Team Scale.
Chinese
Turboprop Tu-4 AEW built by George Maiorana and flown by Dave Pinegar won
first place in Team Scale at the 2003 George Maiorana, the builder, reports: “WOW says it all! Everything went excellent with the 4s3p 1500HC packs. The plane wowed Dave [Pinegar, the pilot], myself and everyone with its performance. Dave never had to use full throttle. 7.5 - minute flights took the packs to 15.4V with plenty to spare. It took 3.5 hours to recharge at that level (1/3 C). Without the Li Po packs, we would not have been able to compete with the plane. The flight schedule would have been too long for the NiMH 3000.” One convenience of the modular system is that the connectors carry only a proportionate share of the current. In the 4s3p packs that George built, the total current delivered is an average of 27 to 30 amps. However, the individual 3p legs carry only 10 amps, so lighter connectors could be used until the collection point is reached (the connector at the left and right ends). Bear in mind that George’s four packs drive four brushless motors turning 16 inch, four-bladed carbon fiber props. What a project! Kokam Li Po packs are exceptionally flexible. They are equally at home in a giant scale airplane, a helicopter, a 3D aerobat, a park flyer or an indoor model. Please open the Li Po Gallery Section of the FMA web site to see a wide range of applications. For starters, a whole series of conversions of a variety of models that normally are glow engine powered appear at the following links: Hangar 9 33% Edge 540 uses a large 10s3p Kokam
6.3AH pack made from 30 Kokam 2.1AH cells. Ultra RC Icepoint 2-meter FAI pattern plane uses a Skyvolt 8s 3.2AH system. Vmar Easy 3D conversion uses a 4-cell Kokam (20C) 3.2AH pack Graupner Extra 300S uses a 4s2p configuration of Kokam (15C) 2AH cells Hangar 9 Corsair F4U uses a 6s4p pack of Kokam 1500mAh cells Below are other examples of Kokam cells used in smaller electric planes. Fliton Flubber uses Kokam 3-cell 1500mAh
pack Multiplex Magister uses a 3-cell Kokam (20C) 3.2AH pack for more power What goes in to design
of FMA cells and packs 2. Experience at FMA/Kokam is that the user should have the best data that can be made available so that he can make an intelligent choice. 3. The stumbling block is that many do not want to spend the time to educate themselves about the cells or develop an understanding of cell technology. 4. The result often is that the buyer looks for the lowest price and often buys something that can never do the job he wants. Hence the caveat: Buy cheap, buy twice. Worse yet, the buyer is scared away from Li Po technology because of a bad experience. That, we want to prevent. 5. Accordingly, please be patients and try to get as much out of this handbook as you can. 6. The battery products and accessories covered here are truly superior because they are based in true need as learned over the past three years of concentrated activity. 7. The basic characteristics of Li Po cells are charted on the next page. The key points to review are: · Low internal resistance means less voltage depression, lower operating temperature and higher capacity retention under load. · Lower temperature means longer life. · Basic chemistry and cell design contribute greatly to longevity. · The chemistry for 4th generation Li Po cells provides much better safety than was available two years ago. · New charge and discharge control technology makes FMA packs safer than any other factor. ·
Notwithstanding, one must observe proper safety precautions
since lithium can ignite under circumstances
of abuse.
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