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                                   BULLETIN
                         FSB-074 - BATTERY PACK UPDATE
                 DATE/REV:  01NOV93 / 0 (previously FSB 10-1)
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ABSTRACT:  Simultaneously using internal battery packs and external power in a
Self-Contained ADCP can damage the battery pack and the ADCP.

INSTRUMENT/PROGRAM AFFECTED:  All systems using battery packs.

SUMMARY:  Although LODYC followed RDI recommendations and precautions, a DD
lithium battery pack failed.  This is the second known failure of a DD lithium
battery pack.  This is the only known failure to have occurred in the ADCP
with the lithium battery cells that RDI has used or is using.

PREVIOUS HISTORY:  RDI has released three FSBs concerning battery packs.  FSB-
047 [old 6-6] (01FEB91), "Measuring Power Consumption in SC-ADCPs Having Alka-
line Batteries," FSB-058 [old 8-1] (01APR92), "Lithium Battery Pack Safety
Notice," and FSB-059 [old 8-2] (01APR92), "Discontinuing Distribution of Lith-
ium DD Battery Packs."

DESCRIPTION:  Battery pack safety update!  RDI has learned of a catastrophic
failure involving a DD Lithium Battery pack inside an SC-NBADCP.  The Labora-
toire D'Oceanographie Dynamique et de Climatologie (LODYC) in Paris, France,
deployed two identical narrowband SC-ADCPs in March 1992 using DD lithium
battery packs.  The ADCPs had the same setups.

After recovering the ADCPs (April 1993), LODYC checked the ADCPs and confirmed
they were still pinging.  LODYC began to retrieve data from the ADCPs using
RDI's procedures.  They left the lithium battery packs in the ADCP and con-
nected an external power supply.  LODYC set the external power supply to volt-
age levels higher than the internal lithium batteries.  This allows the exter-
nal power supply to override the internal batteries during data recovery.

The first ADCP data recovery was flawless.  LODYC followed the same procedure
for the second ADCP.  However, during data recovery a lithium battery pack
exploded, vented, and caught fire inside the ADCP.  No injuries occurred. 
After several hours, LODYC opened the ADCP and disposed of the battery packs.
The fire damaged boards, parts, and the pressure case.

SOLUTION/ACTION:  We recommend the following solutions, actions, and steps:

1. RDI urges you to use alkaline battery packs in SC-ADCPs.  We know some de-
   ployments need more alkaline battery packs then can fit inside the ADCP. 
   RDI has an external battery pressure case that holds additional alkaline
   battery packs.  We will help make this transition easier by offering these
   battery pressure cases at a special rate.

2. RDI has changed the procedure for pre-deployment testing and data recovery
   (see FSB-079a).  Our procedures now state that you must ALWAYS remove all
   types of battery packs BEFORE applying external power to the ADCP.

3. If you cannot use alkaline battery packs, and the ONLY alternative is lith-
   ium battery packs, we urge you NOT to use lithium "DD" cells.

4. In the interest of safety, RDI will stop selling lithium battery packs and
   their parts as of 31DEC93.  After that date, obtaining lithium battery
   packs will be left to the user.

WARRANTY:  RDI will not warranty ADCPs damaged by any battery, unless there is
proof the damage occurred due to a manufacturing default in the ADCP equip-
ment.  We assume no responsibility for the battery packs themselves.

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