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PERFORMANCE SPECIFICATION FOR B354 BATTERY TEST SYSTEM

1.1 OVERALL SYSTEM REQUIREMENTS


This battery test system must be composed of a PC-type (Windows based) computer, a user
data/control/interface program, and multi-channel, microprocessor-based, modular hardware; and
be capable of collecting voltage, current, and temperature data on a battery for a particular test
channel. A test channel is defined here as a positional port where the battery being tested is
installed, and battery data (voltage/current/temperature) is collected in response to software-
controlled test scenarios (profiles such as charge/discharge/rest).

The battery test system must be complete when it arrives with all needed cables, hardware, and
software to function as described in this performance specification document. The system will
need to arrive pre-calibrated and ready to use immediately.

Charge/Discharge channels:
This test system must consist of 32 independent channels. Each channel is to be software
configured, capable of providing charge/discharge/rest cycles with a +/- 10 Amp current range,
adjustable for constant-current mode to within +/- 0.1% full scale for both ranges, and have a 0 to
10 VDC voltage range adjustable for constant-voltage mode to within +/- 0.1% full scale for both
ranges.

Temperature monitoring channels:


This test system must consist of 32 independent type K thermocouple temperature monitoring
channels. Each channel is to be software configured, capable of providing temperature
monitoring with a -200 to 500°C temperature range within +/- 1% full scale.

Auxiliary cell voltage monitoring channels:


This test system must consist of 16 independent cell monitoring channels. Each channel is to be
software configured, capable of providing voltage monitoring with a +/- 10VDC voltage range, to
within +/- 0.1% full scale. Common mode voltage shall be greater that 20VDC with a minimum
of 1Mega Ohm input impedance.

Thermal Chamber Control:


This test system must consist of a RS485 interface and software control feature to allow control
of Cincinnati Sub Zero thermal/humidity chamber that has F4 Watlow controller. The software
must be able to change the temperature and humidity levels during any cycle step as required by
the user.

Connections/Cables:
The test system will be provided with 10A lug cables 6 ft (2m) in length for all 4 channels. The
test system will provide mating connections for the 32 temperature and 16 auxiliary
measurements to allow the NASA end user to add wire as needed.

This system must be capable of supporting charge/discharge test scenarios on each channel
simultaneously, such as the reverse pulse charge waveform shown below. A rise time typical of
1ms is acceptable.

Current [Amps]
4.0 |_______________ 30 ___________
| | mSec |
| | _____| Period => 1 Sec.
0 | | |
| |__|
-10 | 5 mSec
|___________________________________ Time
1.2 DATA/CONTROL/INTERFACE SOFTWARE REQUIREMENTS

1.2.1 The software must be capable of independently configuring each test channel with different
charge/discharge/rest test run profiles, which can be saved and recalled for subsequent test runs.

1.2.2 The software must have the capability to provide complex charge/discharge/rest cycles on per
channel basis. “Complex” cases follow below.

1.2.3 The software must be capable of providing up to 100 step (“staircase”) functions as part of a
test run profile.

1.2.4 The software must be capable of concatenating several test run profiles, with each profile capable
of being initiated by another profile or step function, based on any combination of battery
voltage, current, temperature, capacity (Amp-hrs), time, and derivative related criteria.

1.2.5 The software must be capable of contiguously mixing adjustable high sample rate (down to 1
millisecond) test segments with adjustable low sample rate segments (i.e. switch on high sample
data acquisition rate on any or all voltage, current, temperature test channel parameters during
pulse discharge periods).

1.2.6 The software must have the capability to configure each test channel’s profile(s) for “stop-test”,
based on logical “And” / “Or” criteria of voltage, current, temperature, capacity (Amp-hrs), time
and derivative related condition(s) battery parameters.

Example (1): “Stop channel test if battery voltage is …., OR temperature is ….”
Example (2): “Stop channel test if capacity is …. AND time is …. hours”

1.2.7 The software must provide the capability to terminate a particular channel’s test and force an
open circuit condition at the battery under test terminals, based on same logical criteria basis as
mentioned above (1.2.6).

1.2.8 The software must provide the capability to terminate a particular channel’s test and force an
open circuit condition at the battery under test terminals, as a “manual abort” on the program’s
runtime screen.

1.2.9 The software must be capable of recovering test data in case of PC program failure (computer
crash) and continue to test upon PC re-boot.

1.2.10 The software must have the capability to graph and simultaneously display the voltage, current,
temperature, capacity, and derivative related acquired data from each test channel while the test is
in progress.

1.2.11 The software must provide data analysis tools.

1.2.13 The software must be capable of conducting internal resistance battery measurements.
1.2.14 The software must have the capability to export acquired data to Microsoft Excel.

1.2.15 The software must have the capability to perform system tests.

1.3 TEST SYSTEM HARDWARE REQUIREMENTS

1.3.1 The test system hardware must be composed of micro-controller based battery test stand,
whereby the PC station downloads the test profile and if PC communication is lost, the micro-
controller will shut down the test to a fail-safe condition.

1.3.2 Each test system channel must have test active/inactive status LED(s).

1.3.3 Test system hardware must have detailed channel calibration procedures (state if the channels
support auto-calibration), and easily accessible calibration posts.

1.3.5 Test system hardware must have field-upgradeable expansion capability for the temperature
measurement and/or auxiliary voltage measurements of 8 channels (minimum).
[Note: Positive discrimination may be given towards manufacturers providing additional future
expansion capability.]

1.4 OPERATIONS REQUIREMENTS

1.4.1 START-UP SUPPORT:


Vendor must provide technical support for software/hardware installation and system start-up at
NASA JSC B354 facility with a US citizen within 2 weeks of delivery of the system. Any system
level hardware or software corrections needed at this time will be provided by the test system
manufacture at no additional cost to NASA.
[Note: Positive discrimination may be given towards manufacturers providing free training.]

1.4.2 DOCUMENTATION:
Required submittal of two sets of hardware/software operation manual, hardware/software user’s
manual, and circuit diagrams/component lists.
[Note: Non-disclosure statement may be signed if necessary.]