ABTS-LiIon-final-2.doc

Specifications for a 2 channel battery test system for Lithium Ion batteries
Battery division, ISAC Page 1 of 11
SPECIFICATIONS FOR A
TWO CHANNEL BATTERY TEST SYSTEM
FOR LI-ION BATTERIES

Contents
1 Introduction..................................................................................................................................... 3
2 Scope................................................................................................................................................. 3
3 Requirements specifications ......................................................................................................... 4
4 Acceptance test plan..................................................................................................................... 10
5 Deliverables................................................................................................................................... 10
6 General........................................................................................................................................... 10
7 Quotation....................................................................................................................................... 11

1 Introduction
ISRO Satellite Centre (ISAC), Bangalore, of the Indian Space Research Organization (ISRO),
Department of Space, Government of India, is responsible for making Satellites for
different missions.
Power generation in these satellites is typically by deployable sun tracking solar array and
energy storage is by rechargeable NiCd, NiH2 or Lithium Ion batteries.
Battery Division of the Power Systems Group, ISAC, is responsible for the design and
delivery of space qualified batteries for the different satellites. The batteries are subjected
to various tests at different temperatures and life cycle tests on ground to characterize and
assess their performance over the required mission duration.
For this purpose, Battery Division, ISAC requires an automated battery test system to
characterize two batteries simultaneously & independently. It should be possible to
expand to system to test four batteries.
The Automated Battery Test System will be used for testing of spacecraft batteries for time
periods ranging from a few minutes to several hours on a continuous, round the clock
basis. The system hardware must be configured to test two batteries (with a provision to
expand to four batteries), simultaneously in independent test domains. The system
software must be configured to handle up to four batteries simultaneously.
The batteries being tested are extremely expensive and safety of the batteries must be
assured under all circumstances.
2 Scope
This document establishes the specifications for the design, supply and commissioning of
an Automated Battery Test System as given in the specifications table below. It includes
the hardware and the software specifications & requirements, deliverables, documents
and other general conditions. The system shall be commissioned at Battery Division,
Power Systems Group, ISRO Satellite Centre, Bangalore.

3 Requirements specifications
Sl no Requirement / specification Vendor response
1. Automated battery test system (ABTS) to characterize two batteries simultaneously & independently
& function on a continuous, round the clock basis.
With provision to upgrade the number of test channels to 4.
2. The ABTS should have the capability to test and evaluate various types of Lithium-ion batteries
Supply Voltage: 100 V DC
Continuous charge current 40A,
Continuous discharge current 100A.
3. The overall system shall comprise of the following:
a) Test cabinet to house the system
b) Control computer System (PC)
c) Data Measurement & Acquisition system
d) Built-in charger & discharger
e) Application Software for configuring, controlling & testing batteries based on easy to use menu
driven build-test program & facility for real-time & offline data analysis
f) Printer, display, memory, cabling, interfacing hardware
g) Optional: audio alarm units
h) The system rack
Height: 6’6” including castor
Width: 19” or vendor std.
Optional: front & rear doors.
4. System shall have the following features:
a) To monitor, measure, record & display parameters like
 Battery voltages
 single cell voltages
 charge/discharge current (set & measured)
 temperature [measured by standard YSI Thermistor (10 KΩ at 25°C) & Type “T”
thermocouples].

b) To compute & display
 capacity (Ah)
 energy (Wh)
 time elapsed
 number of cycles completed.
 Any other parameters
c) To Control user defined operation steps which consist of open-charge – Rest – discharge-open.
d) To setup steps / operating modes of charge/discharge, which shall be user defined for the following
operating conditions:
 constant current
 constant voltage
 constant power
 constant resistance
 voltage limited taper current (CC-CV mode of charging).
e) Each test step shall have different end conditions & can be based on (but not limited to):
 measured values (voltage, current, time etc)
 integrated values (energy, capacity, half cycle data)
 calculated values (dV/dT, dT/dt & dV/dI).
f) Possible to branch to any step in the test based on the end step criteria met
g) Possible to Pause & Continue, Reset or Abort the test on any channel at any point of time,
independent of the other channel/s.
h) Setup for loop nesting for continuous cycles.
i) Real time & offline data analysis, viewing, plotting & printing of all the channels
j) The status of real time / present operation (such as charge/discharge & open/close) shall be
displayed on the system & also on PC
k) Have capability to programme a pulse to occur at any point of time during charge or discharge
operation. The minimum pulse width shall be of 100 milliseconds and its multiples up to 1 second. It
shall be possible to change the current during charge or discharge for a specified pulse width and
capture plot of the pulse (Voltage & Current Vs time in a scale of 50 millisecond steps).
l) Have capability to parallel the channels, if required to yield higher current.
m) The length of test cables from system to batteries under test shall be approximately 15 feet.
n) Separate lines shall be provided for Power and Monitor.
o) All the Power and Monitoring cables shall be extended up to battery under test and suitable plug in

type connectors shall be provided for connecting batteries to test system. The vendor shall supply
the suitable mating connector s for power & monitor. Vendor shall specify the type of connectors.
p) In the event of a power failure to the complete system, it shall ensure that all the batteries under test
are open circuited.
q) In case of power failure, the test system shall go to ‘SAFE’ mode i.e. in safe mode, the system shall
first save the program, all the test settings and test data acquired and then allow itself for shutting
down, after confirming all connected batteries are open circuited. Further, if the system has gone to
safe mode, the test shall resume/restart either automatically or based on user-defined conditions.
r) The system shall work on 220/440 ± 10% VAC, 50 Hz.
s) The system shall be network compatible & operate in independent mode.
t) The test system should be delivered calibrated to traceable standards with relevant calibration
certificates valid for at least one year.
5. Protections: The safety of batteries shall be ensured under following conditions:
a) Against short circuit failure in each monitoring line
b) The first level software protection shall be based on pre set voltage/current/time/temperature
limits which are user settable.
c) A second level protection shall be available, in case of system failure, which includes mains supply
failure, PC hanging, PC failure, file writing errors, interface errors, memory overflows and
subsystem errors.
d) The system shall have an event log & a ‘WATCH DOG’ timer and warn the user by Audio and/or
Visual alarms in case of any emergency.
Vendor to specify the protection scheme.
6. Number of measurement parameters / channel (ie per battery)
All DC voltage monitoring lines should be differential with common mode voltage 100V.
a. DC voltage: 0 to 5V, 16 channels, accuracy: + 0.02% FSR or better (no. of channels expandable to 25).
b. DC voltage: 0 to 100V, 3 channels, accuracy: + 0.05% FSR or better.
c. 4 temperature parameters, 10k YSI; -50°C to +100°C; + 0.5°C or better
d. 4 thermocouples, “T” type; -50°C to +100°C; + 0.5°C or better
e. DC current: 100A + 0.05% full scale
7. Voltage Setting & Current Setting Resolution: In steps of 10 mV & 10 mA resp. &/or better
8. Time
Min step time: 100 milliseconds or better

Control/Measurement: Every 50 milliseconds
Pulse width for current: 100 milliseconds & its multiples up to 1sec
9. Calibration Device: Facility To calibrate each channel (voltage, temperature parameters and system
current)
10. PC controller system MS windows compatible:
Pentium IV or above
RAM 512 MB or better
Hard Disk160 GB or better
DVD Writer
TFT Flat Panel Monitor19” or better
Licensed OS
Color Laserjet Printer with connecting cables 1200 dpi or better
Ethernet / LAN adaptor card & cables
11. The software package shall consist of the following modules.
a) Windows based, easy to use, user friendly menu driven S/W system
b) File Manager or Configuration Editor
c) Data acquisition Module
d) Real time & Offline data Acquisition, display & control processing module
e) Data handling: presentation, data viewer, a graphical and statistical data analysis tool, automatic
data backup tool, etc
f) Historical storage (Database)
g) Off-line retrieval and analysis
h) EXCEL compatibility/portability of data
12. Windows based battery test software having the following features/menus:
a. Setup of test profile
b. Programming: which includes parameter & alarm specifications, Multiple end conditions for each
step allowing conditional branching, Insert or delete test steps, To call a test procedure as a
subroutine of another test, Edit the go-to (next step) for each end criteria etc
c. Start and stop single or groups of test parameters
d. Monitor & Control each Test step under progress
e. Check status of operation, measured parameters against setup alarm limits of each parameter
f. Periodic health checks of all measured & computed parameters

g. Real-time monitoring & display of all measured & computed parameters on screen
h. It shall oversee whether all tests are being conducted as per the procedure or not. It shall also check
whether the peripheral units like charger/discharger/data acquisition units are working properly
and shall caution in case of malfunction.
i. On-line help function shall be available for all menus and for setup of test procedures.
13. Data handling:
a. Monitor, measure, log, and print all parameters over the complete test regime
b. Create data file & store data, compatible with Excel format
c. View the test data recorded for each parameter in a single page
d. Provision to access and display / print the stored data for future applications / analysis.
e. Real time and offline graphics display
f. Search data file, save & print data records.
14. Real time/off-line data reporting shall include:
a. Facility to generate a report of summary of test results at the end of a cycle containing maximum,
minimum, average cell voltages, Ahin/Ahout, Whin/Whout etc. The report shall also include the
alarm conditions due to which a battery has stopped charge/discharge.
b. Customize charts/plots (like titles, axis formatting etc.) and save the same as templates.
c. Plot multiple test channels/data in a single plot/chart, to view multiple plots in a single window
and view multiple windows simultaneously side by side.
d. Capture chart for pulse (Voltage & Current Vs time in a scale of 10 to 1000 milliseconds)
e. Customize chart axis (scale, font, color, format, etc.)
f. Various chart options (header and/or footer, Zoom, Scroll, Add annotation, Add grids, Set grid
types, colors, and data markers, Save chart settings as a template for future charts etc)
15. Password Protection for the system
16. General:
a. System software and application software backup shall be given in CD’s and any improvement in
the software done at a later point (i.e., updated version), the vendor shall make it available.
b. The test setup menu, data viewing & graphics menu, samples of various data plots & charts & any
other relevant information shall be supplied (which is subject to discussions & customization before
finalization).

17. Calibration certificates, valid for 1 year, shall be provided.
18. Supply & commission system at ISAC, acceptance & burn-in tests for 168hrs on all units.
19. Train 2 persons from purchaser team
20. General:
a) Warranty of 1 year after commissioning of system
b) Attend to any problems with in two working days
c) Sales support for a period of 5 yrs after commissioning
d) Heritage and proven record of accomplishment in the manufacturing of cell/battery testing unit
only will be considered. List of customers to whom similar units were supplied shall be given
along with the offer.
e) Provide standard catalogues and leaflets along with make and model number
f) Provide details of cost breakup of H/W, S/W, spares, accessories etc
g) Information reg Auxiliary options Auxiliary inputs, reference voltage inputs, thermocouple
inputs, thermistor inputs, UPS, input controller board, input panel for voltage etc.
Any other supporting information can be provided.
21. Deliverables : as per item # 5
22. Optional: AMC (Annual Maintenance Contract). The Scope of the AMC shall include the following:-
a. Hardware:
 Preventive and breakdown maintenance of the system, ensuring that each of the channels
works independently.
 Preventive and breakdown maintenance of inter-connection between various hardware
equipments and the printer.
 All spare parts required for the system shall be maintained by VENDOR and shall be
replaced free of cost and only consumables like CDs, printer heads and stationery shall be
charged if replaced.
b. Software:
 Recommissioning and managing the operating system
 Recommissioning and managing the network software and the system monitoring & control
software.
 Taking corrective measures whenever some bugs/problems are found.

4 Acceptance test plan
ISRO reserves the right to participate in the Pre-shipment inspection & witness the
Acceptance tests.
The vendor shall supply and commission the system at ISAC and the system will
be accepted after acceptance tests and burn-in tests for 168 hours on the full system.
All units supplied shall conform to industry grade standards. The vendor shall be
solely responsible for carrying out all tests at ISRO.
Detailed acceptance tests to ensure compliance to each and every specification shall
be done before accepting the system
5 Deliverables
SL No ITEM DESCRIPTION
1 One ABTS system
(as specified to test 2 batteries, including controller, S/W & OS etc)
2 Necessary Cabling & interfacing connectors for two batteries
3 Documentation for software and hardware
4 Operating manual
5 Standard spares & Accessories
6 Calibration certificates for all measurable parameters valid for 1 year
7 Service manual (Optional)
8 Schematic showing all interfaces from battery to test system.
VENDOR shall deliver the complete system to ISAC within 6 months from the
date of order.
6 General
a. The vendors with excellent heritage and proven record of accomplishment in
the manufacturing of cell/battery testing unit only will be considered. List of
customers to whom similar units were supplied shall be given along with the offer.
b. The Vendor shall enclose a point to point compliance / deviation matrix with
respect to each of the specifications as given in the requirements specifications
table (item # 3), along with the offer without which the offer will not be considered.
c. Quotation shall consist of complete details with standard catalogues and leaflets
along with make and model number without which their offer will not be considered.
d. Vendor shall clearly indicate the power requirement of the system.
e. Vendor shall give the quotation in a two part bid: technical & commercial
separately.
f. Details of the cost break up shall be indicated in the commercial portion of the bid.
The cost of mainframe system, accessories, peripherals, software, cables, spares etc.
shall be specified separately.
g. The batteries are required to be placed in an Environmental Hot and Cold chamber
for testing. The mechanical housing scheme of electrical interface and connector
scheme between the batteries and the test system for Power/Monitor shall be
proposed and provided by the vendor.

7 Quotation
The vendor shall quote for the following:
1. Automated battery test system as specified in item # 5.
2. Optional Auxiliary modules
3. Essential Spares and accessories
4. Additional Documentation
5. Annual maintenance contract

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